Nissan 200SX

S14 and S14a

Workshop Manual

V1.11

SXOC

October 2010

QUICK REFERENCE INDEX

III
III

III

GENERAL INFORMATION
MAINTENANCE

.' . ~ .

ENGINE MECHANICAL
ENGINE lUBRICATION &
COOLING SYSTEMS

ENGINE CONTROL SYSTEM

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS

CLUTCH

NISSAN
MODEL 814 SERRES

MANUAL TRANSMISSION
AUTOMATIC TRANSMISSION - - - - PROPELLER SHAFT &
DIFFERENTIAL CARRIER

FRONT AXLE & FRONT SUSPENSION - - REAR AXLE & REAR SUSPENSION - - BRAKE SYSTEM
STEERING SYSTEM
RESTRAINT SYSTEM
BODY & TRIM
HEATER & AIR CONDITIONER - - - ELECTRICAL SYSTEM
ALPHABETICAL INDEX

1994 NISSAi\' MOTOR CO., LTD.

Printed in Japan
Nollo be rcprcxiuced in whole Dr in rart WIthOut the prior written pennissloJ] of Nissan Motor Company Ltd., Tokyo, Japan.

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:AII 'Information -:Iif'thl(~~n~.r '~~b8sed q~.:t"(I,atesl product Informs-

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-:~:~:.~~. -~~J~AN~,.M01'~~~~~Q;~t LTD.
,'?""."

. ~.~~ -, ~ oVe~

Service Department

~ ",..Tokyo. Japan

GENERAL INFORMATION

SECTION
~ l

-~

~~

_ : : ....-.

'"

} " 1

G I !:'

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. , , ! _~

CONTE,NTS

~ ... ; ~
'Precautions for Supplemental Restraint
, System' AIR BAG" and SEAT BELT PRE
TENSIONER"
~~
,
General Precautions
'". '" '

PRECA,UTIONS

:.. u:-'.~

, Function and System Application

2 ~--'-{lt~l~m Battery Replacement
Check~ng Equipment
"
~ .. ~ .. 4~'
IDENTIFICATION INFORMATION
Model Varia.ion
~ ... 4
Idenli(icatton Numbe r
,
4
Di mensions
,
5
:' 6
Wheels and Tires
" .. _., .. ,
:: ~7
LIFTING POINTS AND TOW TRUCK TOWING
Garage Jack and Safely S'and
2~pOle Lift.
,

.:.7

.- .... :~'. ;~:

~,~;~~'12~1~grd:;~~:~~R:::~~L:~:::::::::'::i::i,~,:
.. ,

Oescrrpt!O,~ 2' ...-,.. ,.!~ ~

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',.~'~' -~

Wiring Diagram Codes [Cell Codes)

17

HOW TO PERFORM EFFICiENT DIAGNOSIS FOR

AN ELECTRICAL INCIDENT
Work Flow
Incident Simulation Tests

Circuit Inspection

~ J~ 1

,
,.
H

18
16
19
23

,Pr~pafaUon

0< -

TO'

32 IMI~
32
32
33 ~1
33
34 [J}[Q}
37
37
38 fj-$l.
38

.,.39
39

Board-on Lift

~UJ

39

Tow Truck Towing

"
TlGHTEN1NG TORQUE OF STANDARD BOLTS
SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology Ust..

Cl

32

/:2

Pf~ca.u~ior)? for Multipart Fuel Injection

" Precautioqs Jor Turbocharger

Engi ne Oils
: :'Pre'caulr6ns' for Fuel .!.;.. ~_~
HOW TO US'E' tHIS' MAN'UAL::.~~.:

29

CONSULT CHECKING SYSTEM .. "

II

.~YS~te.rr{or EG9S En'g;ne ~

:
;-Pre~~~tions .lor Thr,ee, Way Ca.talysl

HOW TO FOLLOW FLOW CHART IN TROUBLE

, DIAGNOSES .. .,_
~
:
-

,.H

40
41
42
,,42

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PRECAUTIONS

Observe the folfowing precautions to ensure safe and proper

servicing.

Precautions for Supplemental Restraint System

"AIR BAG" and "SEAT BELT PRE-TENSIONER"
The Supplemental Restraint System "Air Bag" and "Seat belt
pre-tensioner", used along w!th a seat belt. help to reduce the
risk or severity of injury to the driver and front passenger in a
frontal co~Usion. The Supplemental Restraint System consists
of a~r bag modules (located in the center of the steering wheel
and on the instrument panel on the passenger side), a seat
belt pre-tensioner, a d~agnosis sensor unit. warning lamp, wiring harness and spiral cable. Information necessary to service
the system safely is included in lhe AS seclion of this Service
Manual
WARNING;

To avoid rendering the SRS inopera1ive. which could

increase the rtsk of personaJ injury or death in the event
of a collision which would resul1 in air bag intration, aU
maintenance must be performed bV ali authorb:ed NISSAN
dealer.

Improper maintenance. including incorrect removar and

installation 01 the SRS, can lead to personal injury caused
by unintentional activatton of the system.

AU SRS electrical wiring harnesses and connectors are

covered with yellow outer insulation. 00 not use electrical
test equipment on any circuit related 1o the SRS.

General Precautions

Do not operate the engine ror an extended period of tIme

without proper exhaust ventHatJon.
Keep Ihe work area well venldated and free of any Hammabfe materials. Special care should be taken when handling any flammable or po~sonous n1aterials. such as
gasoline. refrigerant gas. etc. When working in a pit or
albe! enclosed area. be sure 10 properly ventilate the area
before working with hazardous materials
Do nol smoke while working on the vehide

Gt-2

PAECAUTlONS
General Precautions (Cont'd)

--I

Before jacking up the vehicle, app~y wheel chocks or other

lire blocks to the wheels to prevent the vehicle from moving After jacking up the vehicle, SUo pporl the vehicle W e i g h t .
with safety stands aL the points designated ror proper lifting before worKing on the vehicle
These operations should be done on a levej surface
When removing a heavy component such as the engine or j:I~"jk.
transaxle/transmission, be careful not to iose your balance
and drop them. Also, do not allow them to striKe adJacent ~~~:~,~I
parts, especially the brake tubes and master cylinder
Before starling repairs which do not requ~re battery power,
always turn off the ignition switch, then disconnect the
ground cable from the battery to prevent accidental short
circuit.

To prevent serious burns, avoid contact with hot metal

parls such as the radialor, exhaust manifold. tail pipe and
muf1ler. Do not remove the radiator cap when the engine
is hot.

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,ofT

SGI2.lJ

Before servicing the vehicle, protect fenders, upholstery

and carpeting with appropriate covers
Take caution that keys, bucktes or buttons on your person
do not scratch the paint

.,VI

SGI2~~

Clean all disassembled parts in the designated I iquid or

solvent prior to inspection or assembly
Replace oil seals, gaskets, packings, O-rings. locking
washers. cotter pins. sel1~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
assemb~ed locations and sequence
Do not touch the terminals 01 electr~cal components which
use microcomputers (such as ECMs).
Static electricity may damage interna~ electronic component"i

GI-3

.f.:0

r~:,.s,

Ii:

PRECAUTIONS
Generaf Precautions (Confd)

After disconnecting vacuum or air hoses, attach a tag to

indicate the proper connection,
Use onty the flu~ds and the lubricants specified in MA section and HA section or their equivalents.
Use approved bonding agent, sealants or their equivalents
when required
Use tools and recommended special toots where specified
for safe and efficient service repairs.
When repairing the fuel. oi', water, vacuum or exhaust
systems, check alj aHected lines tor leaks.
Dispose of drained oil or the solven1 used for cleaning
parts in an appropriate manner

Precautions for Multiport Fuel Injection System

or ECCS Engine

8e1ore connecting or d~sconnecting multiport fuel injection

system or EeM (EGeS control module) harness connector,
be Sure to turn the ignition swi1ch to the "OFF" position
and disconnect the negative battery terminal
Otherwise, there may be damage to ECM.
Before dIsconnecting pressurized fuel line 1rom fuel pump
to injectors, be sure (0 release fuel pressure to eliminaLe

danger

Be careful not to jar components such as ECM and mass

air flow sensor,

Precautions for Three Way Catalyst

If a large amount of unburned fuel (jaws into the converter, the
converter temperature win be excessively high To prevent
this. fOllow the procedure below:
1, Use un~eaded gasoline only. Leaded gasoline wi/( serlously damage the three way catalyst.
2. When checking for ignition spark or measuring engine
compression, make tests quickly and only when neces~
sary
3. Do not run engine when the fuel tank level j:s low. otherwise the engine may misfire causing damage to the converter.
Do not place the vehicfe on flammable materiaL Keep flammable material otf the exhaust pipe and the three way catalyst.

Precautions for Turbocharger

The turbocharger turbine revotves at exlremely high speed~
and becomes very hot. Therefore, it is essential to maintain a
clean supply of oil flowing through the turbocharger and to
follow aH required maintenance fnstruc1ions and operating
procedures.
For proper operation of lhe system, follow the procedure
belOw.
1, Always use 1he recomm8nded oil. Follow the Instructions
for proper time to change tt1e 0" and proper oi~ level
2. Avoid accelerating engine to a high rpm imrnedintely after
starting.
3. 11 engine had been operating at high rpm for an extended
period of lime, let it idle for a few minutes prior lo shutting
it off.

GI-4

PRECAUTIONS
Engine Oils
Prolonged and repeated contact wilh used engine oil may
cause skin cancer, Try to avoid direct skin contact with used
oil 11 skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.

\':'1,',

HEALTH PROTECr'ON PRECAUTIONS

Avojd 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, particularjy underpants, wtth
oil.
Heavily soiled clothing and oil-impregrlated footwear
should not be worn, Overalls must be cleaned regularly,
Flrst 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 oH from the skin
Wash with soap and water to ensure all oil is removed
(skin cleansers and nail brushes will hefp). Preparations
conta;nmg lanolin rep1ace the naturall skin oHs which have
been removed.
Do not use gasoline, kerosine, diesel fuel', gas oil. thinners
or solvents for cleaning skin,
If skin disorders develop, obtain medical advice wilhout
delay
Where practicable. degrease components prior to handling
Where there is a risk of eye contact, eye protection should
be worn, for example, chemica~ goggles or face shields; in
addition an eye wash facility should be provided.

"

,: .. 1.

',.1.

":.'1":'

ENVIRONMENTAL PROTECTION PRECAUTIONS

Burning lIsed engine oil in small space heaters or boilers can

be recommended only for units of approved design The healing system must meet the requirements of HM Inspectorate of
Pollution for small burners 01 less than 0.4 MVv. H 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 disposa1 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 ilIegai 10 pour used oil on to the ground. down sewers or
drains, or Into wflter coursos.
The regulations concerning 1he pollution of the er1\ftronment
will vary 'rom country 10 country.
::1

Gr-5

"'1

PRECAUTIONS

'"

~. I

Precautions tor Fuel

Un~eaded

premium gasoline with an octane rating of at least

95 AKJ {Anti-Knock Indexl number (Research octane number
96).
CAUTION~

Using a fuel other than that specified cOllJd adversely aflect

'he emission conlroi de.,ices and systems, and could also
affect the warranty cOl/erage vartdity.
Under no circumstances shoutd a teaded gasoline be used
since this will damage the three way catarvst.
1

GI-6

HOW TO USE THIS MANUAL

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 OU~CK REFERENCE INDEX, a black tab (e,g, I:ITiI } 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 sect jon.
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-S"),
THE LARGE ILLUSTRATIONS are exploded views {See below) and contain tightening torques, lubrication points, section number of the PARTS CATALOG {e.g. SEC.440J and other tnformation necessary to perform repairs.
The illustrations should be used in reference to service matters only, When ordering parts. refer to
the appropriate PARTS CATALOG.
IIExample"
SEC. 440
Pad rE>lainer

(U\>per side)

1m'Que
member

/-p..

lJ\

t./."

54 U [5.5.6.5.40 - 47)

~~~ /@'~>

"/~........

)-p~n

boot /
//

I~'.~'?l~ //~/

~
ll.....

Pad

rets.cner

(Low., sid_I

.. ainPin
!II to

slH:ling ponlon

Inner shim

rCOPP",W.Sher

~
'l;' /~~))J

1/
1

m--~

P ~
,

Outer Slum

/ \

I ./'

Pad

J/

Dust seal

~W

J'

'.

-~ 1720

[1.7 _ 2.0, 12 _ 14)

~~

~" ~------_-A::~:e:::

t\
I
\
\

l /

\
\. Piston

'\..

Cylinder body
PIston seal

f)

to)

7 - 9 (0.7 - 0.9,5.1 .6.5)

Pin boll

tc:l 22 - 31 (U - 3.2, 16 - 23.

1!ii!I.~

toJ : Nm (k~m. Itlbl

SBR364AA

THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special lools,
knacks of work and hfdden or tricky steps which are not shown in the previous large illustrationsAssembly, inspection and adjustment procedures ror the complicated un,ts such as the automatic
transaxle or transm!ssion, etc. are presented in a step-by-step format where necessary.

GI-7

L/

HOW TO USE THIS MANUAL

The followfng SYMBOLS AND ABBREVIATIONS are used:

T{ghtening torque
MIT
Should be lubricated with grease.
AfT
Unless otherwise indicated, use
recommended mu'ti-purpose
Ale
grease_
PiS
Should be lubricated wIth oil.
Tool
SeaHng point
SAE
Checkjng point
Always repjace after every disas-

m
@

-.t(

5DS
LH,RH
FR,RR

sembly.
Apply petroleurr jeHyApply ATF
Select with proper thickness.
Adjustment is requiredService Data and Specifications
Left-Hand, Rjght~Hand
Front, Rear

Manual TranSax.le/Transmiss(or
Automatic Transaxle/
Transmission
Arr Conditloner
Power Steering
Spec,al Service Tools
Society of Automotive Engrneers.
Inc_
A.utomatic Transm,sston Fluid
Drive range 1st gear
Drive range 2nd gear
Drive range 3rd gear
Drive range 4th gear
Overdrive
2nd range 2nd gear
2nd range 1st gear
1st range 2nd gear
~st ranqe 1st gear

The UNITS given in thIs rnanual are primarily expressed as the Sl UNIT (International System of UniU,
and a~ternative[y expressed in the n1etric system and in the yard/pound system.
"Example tl
Tjghtening torque:
59 - 78 N'm (6.0 - 8.0 kg-m 1 43 - 58 ft-Ib)
TROUBLE DIAGNOSES are included in sections dealing w~th compncated components_
SERVICE DATA AND SPECrFFCAT~ONS arc contained at the end of each section for qu'ck reference
of data
The captions WARNING and CAUT'ON warn you of steps that must be followed to prevent persona~
injury and/Ot damage to some part o~ the vehicle.
WARNING indicates the possibility of personal injury if instructions are not fo'lowedCAUTION indicates the possibility 8f component damage if instructions are not followed
BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information_

GI-8

HOW TO READ WIRING DIAGRAMS

Sample/Wiring Diagram -

EXAMPL -

GI-EXAMPL-02

~UG~'P'9'

UG
1

:-~
,

..

BR

~TO

GI EXAMPl04

::

13

:
~
I
I
I

\:.--...
I
I

I
,

POWER POSIT'ON
A

GND

POSITION

Mfr models

S~GNAl

11

B
GND

UNlT~

~B
- .....
I (32)

fl
..
I

~-

B~

_---.
I

L..~

R('I~r I~

last rag(l (FOldout D~9Cl

@D.@)
@)

HOW TO READ WIRING DIAGRAMS ,,",.'

Sample/Wiring Diagram -

EXAMPL -

(Cont'd)

OPTIONAL SPLICE

MIT models

Ali models

lOA

[li\
L

I
~ L-e
I

GlF\

._GiR~
I
@

L~

ffi-~~-m
'-if-I@~
l

GIR

!'

l~._.

ch1J
U

FlE.LA.V

.__sd

GI-10

HOW TO READ WIRING DIAGRAMS

DescripHon
-,

Item

Nurnber

1
-'-'-'-'--

'"

This shows tne condition when the system receives ballery positive voltage

Power condition

-'

Oeser iplio n

...

(can be operated}
,

_.

- -r - - - - .

.-

The double line shows that 1his IS a fusible link

Fusible IU1k

The open circle shows curren I flow in and the shaded Clrcle shows current
flow out

This shows the location of the fusible hnk or fuse in the lus~b!e link or lusa

Fusible linklruse location

bo;r See "POWER SUPPLY ROUTING" In EL section lor arrangement.

~Fuse

The single line shows that thj5 is a fuse

The open circle st,ows current flow in and the st1aded circle shows Cu(renl
flow out

Current rating

Connectors

System branch

Optional spnce

Splice

This shows the current rating af the fusiole fink or fuse

This shows that connector

CID

is lemaie and connector (~ is

Terminal No wilh an alphabet (A1, 85, e1cl indicates ttla~ the connector is
SMJ connedor" ReIer to Gt-16.
This showS Ihal the system branches to anolher sysLem idenLilied by cell
c<:lde (section and system)
.__ ...

.-.

10

Page crossing

11

OpUon abbreviation

--.-

The open circle shows that the splice is optional depending on \leh~c1e applicallan,

-------_.--,-

The shaded circle shows that the sp~ice

,

._-_ ....

m~le,

The G/A wire is ~Dcated in the A 1 terminal 01 both connectors

.. Tilis arrow shows lnat lhe

15

always on the vehicle.

c~rcuif continues

to an adjacenl page

.. Ttle A will maid., with the A on the precedmg or next page

ThiS shows that the ctrcuit is optional depending on vehicle appllcalion
_--.-"",--

This shows thai continuity elCisfs between le(r(linals I and 2 when the swilch

12

Switch

is In the A position. Continuity exists between terminals 1 and 3 when the

switch is in the 8 position.
Thrs arrOw shows that the circuit continues to anolher page idenlHlad

13

Page Crossi ng

oy

cel1

The C will match with the C on another page within the system other thatl tile
next or preceding

pages-

Relay

i5

Conoeclors

RELAY" in El seclHm for delaBs.

--

-y

~--------~

16

.-

--------~_.,--

Component name

18

._-

ThiS shows that the connector is connecled to the body or a terminal with
bolt or nut.
,..-------.~,

.. "

-"-------------

ThiS shows the name 01 a component.

1"-

---~

17

This shows an internal representation 01 the relay See 'STANDARDIZED

14

Component boX' In wave

"_._---

--.~------

This shows thai another pari 01 the component is also shown on another
page !indicated by wave line) wit",in the system

line
Assembly paris
_c-

CannectQi terminal in componen, shows thaI It is a harness inc::orporaled

assembly
_._--~-

------

......

----

This shOwS n,e connec!or number

\9

Connector number

u"

The leller shows which harness the CUlmector

is localed

Example'M main harfless_ See "HARNESS LAYOUT" m EL sechon 10 locale

lhe connector A coordinate grid is included lor complex harnesses to aid In

locating connector'S

GI-l1

I~

r',,:.

code,

HOW TO READ WIRrNG DIAGRAMS

Description (Cont'd)
Number

Description

Hem

-----~--------

This shews a code 10r IhE'.: c.olor oi the wire

SR -= Brown

B -- Brack
W

20

Wire cofar

= White
= Red

OR .- Orange

Pin k

G ~< Green

PU

L = Blue

GY =--' Gray

Yellow

58 .:

LG = Ught Green

Purple
S~y

Blue

CH;;,. Dark Brown

DG -

Dark Green
~he

When the wi,..e colof IS s!r',ped.

base color is gillen firsl, IO'llowp.d by the

stripe color as shown below,

Example' LlW "'- Bhle With Wh'le_S_lr_ip_e_ _~_ _ ,~

21

Common component

ponent
The dotted nnes between terminals show thai these termrnats are pari of the

Common connecto!

22

Connectors enclDsed in broken line show that lhose belong 10 the same com-

same connector.
Arrow Ind~cates electrIc curren! Itow. especialfy where lhe d',rection

or

stan-

dard How (verllcal'IY downward or hori2ontally from lell to r'ight) is dHncu't to

Current flow arrow

23

follow

A. double arrow" . . . " shows 1hal current can flow in

ei~her

direction

depending Oil circuit Dperation

-.~._-

-1----------~i~~~~~,~~~,~---~. shows ~ ~_:::-~.'_~_~. of lhe option abbrev I allon LJ,~.:"d on (he, pag~

'.-I---'.~------.--,

:'>4

?5

Gmund
"

26
.-._--

This S,",,0""5 (he 'groul,d connection

o. _ _ _

'

This area shows the connector (aces 01 the- components In lhe wIfing dia-

Conneclor' views

~~am

~"-I------._---------~.,

0\'1

Ihe pAge

~ ,.

? __ ,

This shows the arrangement of fusfble l'rnk(s) and luse(s), used for connector
vfews of POWER SUPPLY ROUTING In "EL'" sec hal') ,

27

Fusible lInk and fuse box

The open sQuare shows currer)t flow in, and the

~haded

square shows cur-

rent flow oul- Same rneanings as the open and shaded circles in Number 2
and 4 abovo.
28

This shows thaI mOr'e inlormalion Dn the Super MUltiple Junction (SMJ) and

Reference

joint connectors eXlsls See Foldout Page in EL section for details.

~.-'.----r--------.------,.------+--~---------

29

30

This shows the code fOr the color of !he GonneCLof For code meaning, refer

C0nnector color

--_._-31

The line enclosed by broker, lIf'1e GlrCI,e shows shield Wlre.

Shielded line

,~.

,-

Cell code

._-'---------+-------32

Ground

--_.-

__

to wire cO~Qr codes above (20).

_ - - - -_._.

~----_._
..

." - - -

---_._-

. _ - - - _ . _ , ..

_._.

This identities each page 01 Ihe wiring diagram by section, system and wiring
diagram page number .

- - - ---------,-------~-- The line spliced and grounded under wire colOr shows thaI ground line is

----+----~------_.-

spliced at the ground09d connector.

GI-12

HOW TO READ WIRING DIAGRAMS

Description (Cont'd)

~,(e;:~rl:m' t:rminBI

~
_.~_.; :;~

'. -'~ .

C{Jnnec~o~

CONNECTOR SYMBOLS

.--J

S,vmbOI I

;Hffi

-,.,~

Conn.ct~'

,,--

sld-e-----

Most of connecLor symbols in wiring d~agrams are shown from

the terminal side.
Connector symbo~s shown trom the terminal side are

enclosed by a single line.

Single line

DI:ii

Connector symbols shown from the harness side are

enclosed by a double line and foHowed by the direction

mark~

View from harness side

COI1r'lector symbol
~

jplll!IU

~ Dou~e line

~k

Conneow

~sW

l_.
Example

Male terminal

Male and female termina's

Connector guides for male terminals are shown in black
and female term~nals in white in wiring diagrams

GU~'-{~
COMeclor

Connector symbol

Female termJnal

GUide

Conn~lar
1.........-

symbol

-~I
~
Connector

SGf363

-~_.

GI .. 13

HOW TO READ WIRJNG DIAGRAMS

Description (Cont'd)
SWITCH POSITIONS
~witches

Normally open

are shown in wiring diagrams as if the vehicle is in

the "normal" conditfon.
A vehicle is in the "normal" condition when:

ignition switch is "OFF",

doors, hood and trunk l.id/back door are closed,

pedafs are not depressed. and

parking brake is released.

Normally closed

SGI~M

DETECTABLE LINES AND NON-DETECTABLE LINES

In some wiring diagrams. two kinds of lines representing
with different weight are used.

A line with regular weight (wider tine) represents a

'Idetectable line for DlG (D(agnostic Troubte Code)", A
"detectable line for DTC" ~s a circuit in which ECM (ECCS
control module) can detect its malfunctions with the
on-board diagnostic system.

A fine with less weight (thinner line) represents a "nondetectable line for OTC", A "non~detectable line for DTC"
is a circuit in which ECM cannot detect tts mal1unctions
with the on-board diagnostic system,
l

w~res,

VEHICLE

SPEED
SENSOR

(@

l~G_G~
1@-G-R~
I~I

SPEED

=r-' OMETER
Y/G

@)

--

' fiG

. Delectable liM
fCir OTC
Non-delectable
line lor DTC

2Ei
,

VSP

ECtA
(feeS CONTROL MODULEl

[ ]

@)

- - - - _ . __ ~

SGIB62 f

GI-14

HOW TO READ WIRING DIAGRAMS

Description (Cont'd)
MULTIPLE SWITCH
The continuity of multiple switch is described in two ways as
shown be~ow_

The switch chart is used in schematic diagrams.

The swftch diagram is used in wiring diagrams.

r~8mp,e

(SWITCH

~:R~J--~---~----

(SWITCH

DIAGRAM)---~

:~ ;,

wlPfR SWITCH

OFF !NT LO H1 WASH

2
3

WIPER
SWITCH

~T'~T-------J

4
5

-(i.

Bolt"! sWITches are turned il"1

combinalion

r~

ConlirlUity CirCUIt of wiper ~wlk.h

S~T-~-~-P-O-S-ITI-O~N--~

i~'

CONTINUITY CIRCUIT

OFF

3-4

3-4,5-6
LO

3-6

HI

2-6

WASH

1- 6
SG18/~

GI-15

r:..

HOW TO READ WIRING DIAGRAMS

Description (Confd)
FOLDOUT PAGE
The foldout shoutd be spread to read the entire wjring diagram.

Super mulliple lunction (SMJ)

in widng diagram. connectors consisting of terminals having terminal numbers with an alphabet (81.
DO, etc) are SMJ connectors,
If connector numbers are shown rn Reference Area, these connector symbols are not shown in Connector Area. For terminal arrangement of these connectors. refer to the fold-out page at the end of this
manual.

Joint connector
Joint connector symbols are shown in Connector Area in the wiring diagram concerned. Fold-out page
also carries inside wiring layout together with such joint connector symbols.

Example

Super Ml,Illlple JuncliOf1

(SMJ\

~R-----.

L----S

I ~~:~~SSl I
~

SR

~CMD~
lran~ - _. - ~ffOOll

--r <mY ,...

L (Engine 6R

rOOm

harness)

r---

or---

il

\i

II

! L'
Irl\I

JOlNT CONNECTOR

c(illJillJJ r'Mi'
[TI!ill!] ~

Ghoc'

'@IDL--J

~ctm~@

room harnEISsl

Terminal Ammgemenl

I:i

IJ

(EI"Il)mB

oSTART:.~TEM

IL

8 R-----~M-a-in---'harn~SS)

~~

~~

i~~
@

~r~-

'f__
l@
! ~~-~_.~ ~Connec.o, Ar..

),'

-~

- - - - - - - - - - - -.................- , - - - - - - . . . . . : . , . - - " " - - - - - - - -.......

AefBrence Area'
Refer to the loldollt page for the lerm~nal ammgement
01 the Connectors shown here in thf;l "Reference Are,t"

t ,

._"

SGI8S9-J!,

GI-16

HOW TO READ WIRING DIAGRAMS

Wiring Diagram Codes (Cell Codes)
Use the chart below to find out what each wiring diagram
stands for,
Code

Wiring Diagram Name

Section

AACIV

EC

IACVAAC Valve

ABS

SR

Antilock Brake System

A/C. A

HA

Auto Air Condilioner

A/C. M

HA

Manual Air Conditioner

All

AT

Code

Di agram Name

EC

Mass Air Flow Sensor

MAIN

EC

Main Power Supply and GrOUlld

Circuit

METER

EL

MAFS

W~r~ n 9

Section

--

---------+-..-

--

..

and fuel Gauges

Automatic Transmis.sion

tEL

Headlamp System

AT/e

EC

A/T Control

AUDIO

EL

AudIO

BACK/L

El

Backup lamp

------------

~,---

Speedometer. Tachomeler, Temp

_----.-.

- - 1-----------,

AIM

COde.

...

_--

MIL. Data link C<:lonector For Con-

MIL

EC

MIRROR

EL

Door Mirror

MULTI

EL

Multi-remote Control System

PlANT

EL

PNP/SW

EC

Park/Neutral Position Switch

POWER

EL

Power Supply Routing

suIt

~--

800ST

EC

Boost Pressure Sensor

CHARGE

EL

Cnarging System

CHIME

EL

Warning Chime

CMPS

EC

Camshaft Position Sensor'

COOl/F

EC

Cooling Fan Control

--------

PST/SW

EC

R/FOG

EL

Power Antenna

i,'l,

Power Steering 011 Pfessu re

Switch
Rear Fog Lamp

OEF

El

Rear Window Defogger

SAOOF

EL

Sun Roof

DEFIS

EC

Rear Window Defogger Signal

SRS

RS

Supplemental Restraint System

D1FF

PO

Dilferential Oil Cooler

S/S~G

EC

Start Signat

DJLOCK

EL

Power

STAAT

EL

Starling System

DTRL

EL

STOP/L

EL

---EeTS
EGRCfV

_.-.,

Door Lock

Head~,amp

- Wi1h Daylime Light

System

EC

Sensor

THEFT

EL

EGR an-d canister Control Solenoid

TPS

EG

TURN

EL

VSS

EC

VTC

EC

VTC Solenoid Valve

EL

Warn rng La mps

------~-----

EL

Front FOg Lamp

FleD

EC

IACV-FICD Solenoid Valve

F/PUMP

EC

Fuel Pump

H/LAMP

El

Headlamp----Withoul DaytIme LIght

System

H/SEAT

EL

Healed Seat

HEAT

HA

Heater'

EL

Headlamp Was her

HQ2$

EC

Heated Oxygen Sensor

IGN/SG

EC

Igmtion Signal

~
EL

lNTIL

EL

KS

E.C

Lamps

Theft Warning System

ThrotUe Position Sensor

---

WARN
-----f---

ll1uminalmn

..- -

__

lamps

. ~ _ - r - - _

I,njector

.--- r----

Interior. Spot and Trunk Room

Lamps
Knock Senso r

GI-17

Vehide Speed Sensor

-Waslegate Valve Control Solenoid

WG/V

EG

WINDOW

EL

Power Window

WIPER

EL

Ffont Wiper and Washer

WIP/R

EL

Rear Wiper 8r'\d Washer

----,

Horn, Cigarette lighter, Clock

---~---

Turn Signal and Hazard Warning

---~

HLC

EC

--

Valve

F/FOG

ILL

Stop Lamp

EL

......

INJECT

-_._--

Clearance, license, and Tail

TAlllL

Engme Coolant Tempera'ure

EC

.-_. ------

Valve

~-

---

--

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELI::'CTRICAL INCIDENT

Work Flow

- -

- -

-- - - -

- - -

--- --

--

-'

- -

- - - -

- - - -

_w

- -- - --- - - - - -- -- -

- - -

~ ~

STEP 1

- - - - - - - - - - - -- - - - STEP 2

STEP 3

STEP 4

- - - STEP 5

- - - - - - - - - - - - - - - - - - - - - STEP

SGt838

STEP
STEP 1

DESCRIPTION

Gel detailed ~nformation about the conditions and the environment when the ~ncidenl occurred.
The following are key pieces of information
WHAT

STEP 2

reqt.J~red

to make a good anafysis

Vehicle Model, Engine. Transmission and the System (i.e. Radio).

WHEN

Date, Time of Day, Weather CondJlions. Frequency,

WHERE

Road COfldHio(\$, Altitude and Traltic Situation.

HOW

System Symptoms, Operat~ng Conditions tOther Components lnleraclion}.

Servke History and if any After Market Accessories have been installed.

Operate the system, road 1est If necessary.

Verify the parameter of the incident.
11 the problem can not be duplicated, refer to "Incident Simulation Tests" nex1 page,

STEP 3

Get the proper diagnosts materials together includlng:

POWER SUPPLY ROUTING

System Operation Descriptions

Applicable Service Manuar Sections

Identify where to begin diagnOSIS based upon your knowledge of the system operation and the customer Comments.
STEP 4

Inspect the system tor 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
STEP 6

Repair Or replace the incidenl circuil or component

Operate the system

in

all modes, Verity the system works property under all conditions, Make Sure you have

not inadvertently created a new incident during your diagnosis or repair steps

GI-18

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Incident Simulation Tests

INTRODUCTION

sometimes the symptom is not present when the vehicle is brought in 10r service. Therefore, it is necessary to simulate the conditions and environment when the incident occurred. Otherw;se, only a No
Troubte Found Diagnosis may be found. The foUowing section Hlustrates ways to simulate the conditionsl
environment under which the owner experiences an electrical incident.

iM1~

The section is broken into the six following topics~

1. Vehicle vibration
2. Heat sensitive
3. Freezjng
4. Water intrusion
5. Electrical load
6. Cold or hot start up
Gel a thorough description of the incident from the customer. It is important for simulating the conditions of the problem.
~rL
The problem may occur or become worse while driving on a rough road or when engine is vibrating
(idle with Ale on). In such a case, you wiU want to check for a vibration related condition. Refer to the
illustration below.
.1'411

VEHICLE VIBRATiON

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, ThlS test may indicate a loose or poor e'ectrical connection.

Hint

&/f

.5

Connectors can be ex.posed to moisture. It

posSible to get a thin film of corrosion on the connector :?~
terminals. A visual inspection may not reveal thrs without disconnecting the connector. It the problem
occurs intermittently, perhaps the problem tS caused by corrosion. It is a good idea to disconnect, inspect
and clean the terminals on related connectors in the system.
~~

Sensors & relays

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

Tap gently,

Bend gently

SGl8J9

G I 19
- ._ _-

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Incident Simulation Tests (Cont'd)
Possible cause

Anv probe entering. the

le(m~,.,a' may enlarge

the contact spring

opening crea.ting an
intermittent signal.
Inte... rni11~nt

signals
lhrough
pIerced
Insul,Uion

Prop~r

Normal

fnlarged

crimp

Insuration n01
removed

DEFORMED (ENLARGEDI FE::MALE Te~M'NALS

Wire strands
missing

DEFECTIVE lNSULAnON STRIPPIf'lG

Seal

,loose

Sea.'~

IUn!OCk~d t~~~l
(HIc:Jden by wire seal)

L -__ ~

-....-J

Intermnlenl
contact

Check lor unlocked terminats by

pu1hng each wire at the end of
the cQnneC~"i,

TEAM1NAL NOT PAOPRU' SEATED

----

---.

l
ILI_l/~_in

~----------'
SGI."

SGlB40

T ester probe
When probing a connector it is possible to enlarge the cOntact
spring opening, H this occurs it may create an intermittent
signaj in the circuit. When prob;ng a connector, use care not
10 enlarge the opening_ The probe of the Digital Multimeter
(DMM) may not fit into the connector cavity. in such cases
make an extensfon of a "T" pin and probe it from the harness
side of the connector. Most DMMs have accessory alligator
dips, Slide these over the probe to alJow clipping the "T" pin
for a better contact. If you have any diff;culty probing a

terminal, inspect the termina'. Ensure you have not accidentally opened the contact spring or pulled a wire loose

GI-20

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Incident SimulaUon Tests (Cont'd)
Engine compartment
There are several reasons a vehicle or engine vibration could
cause an electdcal complaint Some of the things to check for

are:

Connectors which are inaccessible for diagnosis probing

Connectors which may not tully be seated.
Wiring harness whtch are not long enough and are being
stressed during engine vibraHons or rocking.
Wires taying across brackets or moving components.
Loose. dirty or corroded ground w~res.
Wires routed too close to hot components.

To inspect components under the hood, start by verifying the

integrity of ground connections. (Refer to GROUND INSPEC.
TION described later.) First check that the system is properly
grounded Then check for loose connection by genlly shaking
the wtdng or components as previously explained. Us~ng the
wiring diagrams inspect the widng for continuity.

Fie;
-::>.?

Behind the instrument panel

jmproperly routed or improperly clamped harness. can
becorne pinched during accessory insta!lahon. Vehicle vibration can aggravate a harness which is routed along a bracket
or near a screw behind or below the dash.

_(:~j}':f

Under sealing areas

An unclamped or loose harness can cause wIring to be
pinched by seat components (such as slide gU.des) during

vehicle vibration. If the wiring runs under seating areas

inspect wire routing for possible damage Of pinching,

~:~"

HEAT SENSITIVE

Heeling lesl

Do not hea1 above BODe ~ 140Fi

f::r.;:

The owner's problem may occur during hot weather or after f1l~
car has sat for a short time. In such cases you witl want to
check for a heat sensitive condition.
To determine if an electrical component is heat sensihve. heat ~~~I
ttle component with a heat gun or equivalent.
Do not heat components above 60C (140F). If incident occurs
while heating the unit, either replace or properly insulate the ~.\~~~
component
SG~842

r( .

GI-21

Incident Simutation Tests (Cont'd)

FREEZING

Freezing test

The customer may indicate the incident goes away after the
car w~rms up (winter time) In such cases the cause could be

Water in

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 hI the morning, do a quick and thor-

Connector

ough diagnosis of those electrical components which could be

Solenoid
Sc)1843

affected,
The second method is to put the suspect component Into a
freezer long enough for any w~ter to freeze. Reinstall the part
~nto the car and check for the reoccurrence of the incident. If
it occurs, repair or replace the component.

WATER INTRUSION

Weter 'ntruslo/\ tut

The incident may occur only during high humidity or in rainyl

snowy weather. In such cases the incident cou~d be caused by
water intrusion on an electrical part. This can be simula1ed by
soaking the car or running it through a car wash.
Do not spf'a'i watnr directly on any electrica I components.

SG)Jl.~

ELECTRICAL LOAD

E'f'ct,'ca' Joad fleet

The incident may be electricaJ load sensitiv8_ Perform diagnosis with all accessories (including AIC, rear window defogger.
radio, fog Jamps} turned on.

88 C'V..O/~
"ON~~
Ale

COLD OR HOT START UP

Rear

wifldow"
defogger

\)

Ugh1 switCh'
.

sGla.sl

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 shortty after being turned off. In these cases you
may have to keep the car overnight to make a proper diagnosis.

GI-22

HOW TO PERFO'~,.~". EFFtCfENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Circuit Inspection
INTRODUCTION

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 al1 available information on the system to be tested. Also, get
a thorough understanding 01 system operation. Then you will be able to use the appropriate equlpment
and follow the correcf test procedure.
~~/J.\
You may have to simulate vehicle vibrations while testing electrical components. GenUy shake the wir..
irlg harness or electrical component to do this.

OPEN

A circuit is open when there ,s no continuity through a section oJ the circuit

SHORT

There are two types of shorts.

1. SHORT CIRCU1T
2. SHORT TO GROUND

When a circuit contacts another circuit and causes the

normal resistance to change.

When a circuit contacts a ground source and grounds the

,~,~

circuit.

TESTING FOR "OPENS" IN THE CIRCUIT

Before you beg.n 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 wilt also reinforce '~,l
your working knowledge of the system.
(nspectJoli for Dpens

~S! ~L.9~K

L1

B+ SIDE

...._1

I
I

-oJ

SG1846

Continuity check method

The continuity check is used to find an open in the circuit. The Digital Multimeter (DMM) set on the
resistance function wilt indicate an open circui' as over limit {OL. no beep tone or no ohms symbol}. Make
sure lo 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.

gy'~

Oisconnect the battery negative cable.

Start at one end of the circuit and work your way to the other end. (At the fuse block in this exam- .~~
pIe)
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 ~r(
that portion of ~he circuit has good continuity_ If there were an open in the circuit, the DMM wou'd
indicate an over limit or infinite res;stance condition. (point A)
5. Connect the probes between SWl and the relay. little or no resistance wiH indicate that portion of r~,:._
the circuit has good continuity. If there were an open in the circoit, the DMM wou!d indicate an over
limit or infinite resistance condition. (po.nt B)
6. Connect the probes between the relay and the solenoid. Little or no resistance will indicate that por- rL
tion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate
an over IimH or ~nfjnite resistance condHion. (point C)
Any circuit can be diagnosed using the approach 10 the above example.
1.

2.

rrx,

GI-23

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Circuit Inspection (Cont'd)
Voltage check method
To help in understanding the dlagnosis of open circuits please refer to the previous schematic.
In any powered circuit, an open can be found by methodically check~ng the system for the presence of
voltage. Th;s is done by switching the DMM to the voltage function.
1. Connect one probe or the DMM to a known good ground.
2. Begin probing at one end of the circuit and work your way to the other end.
3. With SW1 open, probe at SW1 to check for voltage.
voltage:
open is further down the circuit than SW1.
no voltage; open is between fuse block and SW1 (point A),
4. Close SW1 and probe at relay.
voltage;
open is. further down the circuit than the relay
no voltage; open is between SW1 and relay (point B).
5 Crose the relay and probe at the solenoid.
voltage;
open is further down the ckcuit 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

To simplify the discussion of shorts in the system please refer to the schematic below.
Inspection for shorts
1GN "ON"

t OR "S~:RT'

, --'

B + SIDE

~.~_
~

_ SWI

~~----r--

SHORT

SKORT

I\7l

lJLJ
+ -

iELAa

SOLENOID

- - :=-------rB-1
1)

OMM
IVoltag e check)

SHORT

!
-::;-

SW2

C
SGI847

Resistance check method

1.
2.
3.

4_

5.

6.

Disconnect the battery negative cable and remove the btown fuse.
Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered 1hrough the

fuse.
Connect one probe of the ohmmeter to the load side of the fuse terminal. Connect the other probe
to a known good ground.
With SW1 open check for continuity.
continUity;
short is between fuse terminal and SW1 (point A).
l

no continuity, short is further down the drcuit than SW1.

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 circuH than the relay.
Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse termfnat and a known good ground. Then, check for continuity.

continuHy;

short is between relay and solenoid (point C).

no continuity;

check solenoid. retrace steps.

Voltage check method

1.
2.
3-

Remove the blown fuse and disconnect all loads (Le. SWl open, relay disconnected and solenoid
disconnected) powered through the fuseTurn 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)
With SW1 open and the DMM leads across both fuse terminals. check for voltage.
voltage,
shorl tS between (use block and SW1 (point Al

GI-24

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Circuit Inspection (Cont'd)
4.

5.

no voltage; short is further down the circuit than SW1.

With SW1 closed. relay and solenoid disconnected and the DMM )eads across both fuse terminals,
check for voltage.

voltage;
short is between SW1 and the relay (point B).
no vollage; short is further down the C'fCUit 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 sole- l\',~:~,
noid (point C),
no voltage; retrace steps and check power to fuse block.

GROUND 1NSPECT10N
Ground connections are very important to the proper operation of electrical and electronic circuits
Ground connections are often exposed to moistLlre, dirt and other corrosive elements. The corrosion
(rust) can become an unwanted resistance. This unwanted resistance can change the way a circu;t
works.
Electronically controlled circuLts are very sensitive to proper grounding. A loose or corroded ground can
drastically affect an electron,eal1y controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks c1ean, there can be a th~n film of rust on the surface.
,~?
When inspecting a ground connection follow these rules:
1. Remove the ground bolt screw or dip,
2, tnspect all mating surfaces for tarnish, dirt, rust, etc.
3. Clean as required 10 assure good contact
4. Reinstall bolt or screw securely.
5. Inspect tor "add-Do" accessories which may be interfering with the ground drcuit.
6- If several wires are crimped into one ground eyelet term'nal. check for proper crimps. MaKe sure
all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are .~.~ 1
cased in one eyelet make sure no ground wires have excess wire insulation.
Ground Inspection

/.--~/
Inspecl mallilg $ut1acf!s
for tarnish, oir1, rust, etc
Clean as requIred 10

Remolle bolt lSCfewl.

a~$ur~

good contact

--~
/

:~:~~~

R."install bolt (screwl

securely

:-g':ii

j ,

1(: ':',

GI-25

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Circuit Inspection (Cont'd)
VOLTAGE DROP TESTS
Vortage drop tests are often used to find components or circuits which have excessfve resistance. A
voltage drop jn 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
singfe strand of wire is not able to carry the current. The single strand will have a high resistance to the
current. This will be picked up as a slight voltage drop.
Unwanted resistance can be caused by many situations as follows:
Undersized wiring (single strand example)
Corrosion on switch contacts
Loose wire connections or splices.
11 repairs are needed always use wire that is of the same or larger gauge.

Measuring voltage drop 1.

2.
3.

Accumulated method

Connect the voHmeter across the connector or part of the circuit you want to check. The positive lead
of the voJtmeter should be closer to power and the negaHve lead closer to ground.
Operate the circuit.
The voltmeter will indicate how many volts are being used to "push" current through that part of the
circuit.

Note In the illustration thai there is an e:ccessit/e 4.1 voU drop between the battery and Ihe bulb.
Symptom; Dim bulb or no operat~on
o (zetoi ohm
resl~1ance

between switch
.and bulb

,
I

mil

I
Load I

--

Connection wi1h
high resjsta.nce

Ground

__

Ground
SGI845

Measuring voltage drop -

S1ep 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 fhe IIComputer Controlfed System~t operate on very low amperage.
The (Computer Cont(olted) system operations can be adversely affected by any variation in resistance
in the system. Such resistance variation may be caused by poor connection, improper instarfation,
improper wire gauge or corrosion.
The step by step voltage drop test can identify a component or wire with too much resistance.

GI-26

Circuit Inspection (Conl'd)

L C<;UlriAct the \lollme1er as snowr'I, starting at the battsl)' and
wor~ing yoU1 way Ilround the circuit
2. An unusually 'arge voltage drop will indIcate a componen1 Dr
~re tha~ needs to be repaired As you can seft the IIIv5lr.tlon
above. the poor connection causes a 4 volt drop,

~.~

.1

~~l I
It

The char1 that follows IHlJsln"les some maximum aflowabre vohage drops, These values are gwen as a guideline. thl!l exact value for eaen
component may vaIY.
COMPONENT
Wire
Ground Connections
Swltch Contacts

rr~

VOLTAGE DROP
negligible
,001 volts
Approlil. 0,' volts
Appro)(, 0,3 vollS

<

5G1654

~~l

~I

~1

~iQ;

~r.~

~,~

c~r~1

$1
~Ri~

~J

[{&\

~l.

fJJI~(

GI-27

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Circuit Inspection (Cont'd)
Re4ationship between open/short (high resistance) circuit and the ECU pin control
System Description: When the swrtch is ON, the ECU lights up the lamp.
Case 1

TRMINAL: 2
Power supply
to light up
the lamp

TERMINAL 1
Monitor~ng

Swi1ch

of the switch
operation ION/OFF)

Lamp

(;'I
~

1-----------,--

"--y--J
Short:

Open:

'------v-------

L-~

FUSE blows.
Inoperati\le lamp

(;;;CU

Short: FUSE blows

when switch ~5 ON
Open, Inoperative ~amp

Short & Open'

Inoperative ri'1mp

,,-.,~

Short:
Open:

No problem
'noperallV~

lamp

Hrgh resistance:
(Sjngle strand) See below'

Input-output vortage chart

Pin

-~

Item

Condition

I n case of high resistance

such as $ingle strand (V) ..

Vo'tilge

No.

value rV]

~~-

Sw,tch

Switch
ON

OFF

lamp

Battery

Lower than

voltage

Approx. 8 {Examplel

Appro){.O

SWitch

Batterv

ON

voltage

OFF

Approx.O

battery vo ltage

,.~---~
Approx.O
Approx..O

_~_ti"e lamp~

-,---"

Approx.O

The voltage value is basad on the body ground.

: II higl"l re~iSlam;e e)(ists in the sw~1ch side circuit (caused by a single strand). termmal 1 does not delect bat1eIY vollage, ECM
does not detAct the switch is ON el,lQn if 1M switch does turn ON. Therefore. the ECM does nor supply power to light up the 'amp

Case 2

TERMINAL: 2
Monitoring
of 1he switch
oparalkln (ON/OFF)

TERMINAL: 1

Lamp

Ground control
lo tight lip the lamp

~-J

'----~
Short _ FUSE blows
Open _ Inoptil..-ative lamp

Inpu1~output

Pin

Item

ECU

Short:

Lamp stays ON
Inopera~ive lamp

St1or1:.
OpQn~

Lamp stays ON,

(Same as the switch ON,

Open: liloperative lamp

\.~
Short
Open:

No problem
l",operar~B

lamp

High resistance- See below

(SIngle strandl'

voJtage chart
Condi~ICr'1

Voltage

No.

\fa~ue

l n case 0 f h ~9h rest stance

!VI

such a'i s.ingle strand

IVI
.~

lamp

Swirch
ON

Approx.O

Battery voltage
(Inoper;;ltiv6 lampl

--

~----

OFF

Battery

Bartery \/'oltage

vojtage

Switch

Switch
ON
OFF

Approx, 5
--,--,,---The vollagQ value IS based an the bodlj ground
__0

_ _ _ ' - - - - - - ___

----

Approx.O

-._---~

Higher than 0
App r ox.4 lEl<amplel

f---------.----Approx, 5

---~,_

<-----,~

, If high resistance S)lcisl,s in the switch s~de C1r(;U1t ~caused by a s,ngle slr8lndL terminal 2 does not detect approx. av. ECM does
not detect the 5wttch is ON even it t"e switch does turn ON Therelore. the ECM does not canUol ground to lighl up Ihe lamp_

GI-28

HOW TO FOllOW FLOW CHART IN rROUBLE DIAGNOSES

NOTICE
The flow chart indkates work procedures required to diagnose
problems effectively< Observe the following instructions before.
diagnosing.
1) Use the flow chart after locating probable causes of a
problem foUowing the "Preliminary Check or lhe "SympH

~1:t0:~

10m Cha rl" .

After repairs, re-check Ihal Ihe problem has been completelyellmlnated.

Reter to Component Parts and Harness Conneclor localion tor the Syslems described in each section tor
identification/location of components and harness connectors.
Refer to the Circuit Diagram for Quick Pinpoint Check.

2)
3)

4)

~ I,.,:'j

;/~

If you must check circuit continuity between harness connectors in more detail t such as when a sub-harness is ~IG
used, refer 10 Wiring Diagram in each individual secUon
and Harness layout in EL seclion for Identification of har
ness connectors.
When checking circuit continuilY1 ignition switch should be

5)

~;'~

uOFF".
6)

Before checking voltage at connectors l check battery volt-

:;~:l

age.
After accomplishing the Diagnostic Procedures and E1ec..
trical Components Inspection, make sure that all harness
connectors are reconnected as they were.

7)

Exampfe
a"--~-------------I

'1
r=='--------~------L.----------<::'------,

CHECK POWER SUPPLY.

NG

Check the followi ng

t} Turn ignilion switch "ON"

ltems.

2) Check vollage between terminal @

1)

Batlerv voltage should exist.

posiUon sensor and

batlery

OK

SGI561

Harness continuity
between camsh aft

and ground .

2) EGGS relay-1 (See

page EC-106.)

3) "BR" fusible link

4) Power source lor

ECM (See page

EC-104_)
5) Ig n i lion

CHECK GROUND CIRCUIT.

11
SGI562

T urn ~ 9" ili on switch "OFF",

2) Oi scor'lnect camshaft posHion se nsor

harness connector,

3J Check resislance between terminal

@ and ground.
Reslstance:

ApPfodmalely 00
-~-~-1'--O-K-~'~----'

NG

sw~tch

Check the (ollowing

Hems.
1) Harness continuity
between

~"rnshafl

position sensor and

ground
:?) Ground circuIt for

ECM (See page

EC-104 )

.... _--------~----------

'----------------~~---~

GI...29

SG1800-B

\,~:rr

HOW TO FOLLOW THIS FLOW CHART

ill

Work and diagnostic procedure

Start to diagnose a problem using procedures indicated in
enclosed blocks. as shown in the following example.

CHECK POWER SUPPLY.

~...-.. Check item be~ng per1) Turn ignition switch "ON",
tormed.
2) Check vollage between terminal @
}
Procedure. steps or mea1
and ground.
surement resuJts
I
BaUel)' vollage snould exist
.
I

~ Measurement results

Required results are indicated in bold type in the corresponding block. as shown below:
These have the following meanings:
Battery voltage -+ 11 - 14V or approximately 12V
Voltage: ApproxImately OV -+ less than 1V
[J] Cross reference of work symbols in the text and
illustrations
Illustrations are provided as visual aids for work procedures. For example, symbol
indjcated in the left upper

portion of each illustration corresponds with the symbol in

the ffow chart for easy rdentification. More precisely. the
procedure under the "CHECK POWER SUPPLY" outlined
previously is indicated by an illustration

@J Symbols used in illustra1ions

Symbols included in illustrations refer to measurements or
procedures. Before diagnosing a probfem, familtari2e
yourself with each symbol.

Direction mark
Refer to 'CONNECTOR SYMBOLS" on GI-11.

GI-30

Key to symbols signifying measuremenls or procedures

Symbol

Symbol explanation

i5
)

Check after connectmg the connector'

I'.. ~

Insert key inlo ignition swHch,

discon(\~cting the

conneC-

tor to be measured.

~
~

Turn ignlliDn switch to "OFF"

position.
Turn Ignition switch to "ON" position.
Turn ignition switch to "START" pas!lion,

~~

Turn ignilion switch from

c&a~

Turn ignll~on switch from "ACe" to

"OFF" position.

~
@a,

Turn

~gnitiDn-

~
~

10

"ON"

...

VENT switch is "ON",

Fan switch IS "OFF".

ei<cept for "OFF" positionJ

41

~11

Apply fused OBtlery posilive voHage

directly to components

--

> -

engine slopped.

'@/.

Start engine, or check with. engine

runn~ng_

Apply parking brake

Re lease pa rkl n g brake,

Voltage should be measured With a

--

Depress brake peda1

Release brake pedal

..
~

Depress

i!J

Release accelerator pedal,

_._- .

~'\

~'

1q::::IE~

Current should be measured with an

~65
~~

am meier
Procedure wil~ CONSULT

GI-31

~----

acce~eralor

pedal .

Pin terminal check for SMJ Iype ECM

01

sured with an oh mmeter

vehicle,

Disconnect battery negative cable.

[~.u~.r_~

resistance should be mea-

Ori~e

.,'

sufficiently _

lIoltmeter_

.s::~

@-

---------------..,

-'-

Check alter engine is warmed up

OEF swHch is "ON",

@,~

00 not start engine. or cheCK with

C~rcuit

REC switch is "OFf",

h1

"OFF" position

C-r~H

leJ
19J
lBJ

~.-

REG switch is < 'ON".

Turn ignition switch from "ON" 10

Ale swHch is "ON".

Fan 6witch is "ON" (AI any position

POS~IIO(),

Ale switch is "OFF",

0,
/~

swllch from "OFF" to

8
ID

"OF~"

"ACC" position.

--

Procedure without CONSULT

~
~
~
~
~
~

to be measu red.

---'----

&J

Symbo~ e~planation

Symbol

Check after

and AIT control unit connectors,

For detaUa regarding the (ermlnal
arrangement. refer to the roldoUI

page.

~i5
~~
t 0 ,.,,

H.,'~:"

CONSULT CHECKING SYSTEM

Function and System Application

Function

Diagnostic test mode

EeeS

All

ArR BAG a

~-

1----

Th~5

mode enables a technician to

adjust some devices ~asler and more

Work support

accurately by following the indications

on CONSULT.

Selfdiagncstic results can be read

Self-diagnostic results

and erased qu Ickly,

Input/Output data in the ECM can be

Data monitor

read.

Diagnostic Test Mode in which CON-SULT drives some actuators apart

Active test

trom the ECMs and also shifts some

para meters in a specified range.

1------

ECM part number

ECM part nu mber can be read,

Conducted by CONSULT instead at a

technician to determine whether each

system is "OK" or "NG",

Function lest

X: AppHcable
., The e",isting program card (EE922) is applicable only

t~

driver's side air bag system on vehicles

outs~de

Europe.

Lithium Battery Replacement

CONSULT contains a lithium battery. When replacing the battery obey the foltowing:

WARNING:
Replace the lithium batfery with SANYO EJectric CO' l ltd., CR2032 only. Use of another battery may
present a risk of fire or explosion, The battery may presen1 a fire or chemica1 burn hazard if mistreated.
Do not recharge, disassemble 01 dispose 01 In fire.
Keep the battery out of reach of children and discard used ballery conforming to the local regulations.

Checking Equipment
When ordering the below equipme-n', con1acl your N ISSAN dLsttlbulor.

Oeseri ption

Tool name

N'SSAN CONSULT

CD

CONSULT unit

ProQram card lEE 922)

and accessories

IAE930}"

"TOO'

For Australia

GI ..32

brnr

IDENTIFICATION INFORMATION
Model Variation
Applied monel
.. ...
~

Destination

Engine

Body type

Axle

Transmission

Righi-hand
drive

-----~--

Left-hand drlve

5-speed MIT

GBYARRF,UE4

G8Y ALRF-UG4

4-speed AJT

GBYAARAUE4

GBY ALRA-UG4

Europe
I--._---~

_.

5~speed

SR20DET

Coupe

Australia

2WD

MIT

G8YARRF-UM4

4speed A/T

GBY ARRA-UM4

Except Europe

5-speed MIT

G8Y ARTF-UH4

GBYAlRFUG4

and Auslra\ia

4-speed AIT

GBVARTA-UH4

GBYALRA-UG4

Prefix and suffix designations:

G

BY

.:,,--.
'?,~

514

I I

(;l,

O thers

4 : 4 passengers
Destination

G : LHD
M : Australia
E : RHD lor Europe
H : RHO ekcept for Europe and Australia
Fuel supply

U : Turbocharged
Model
Transmission
F : S-speed manual
A . 4-speed automatic

Grade
R , Base

T: SE
Steering side
L : Left-hand dri\le

Right~hand

drive-

Axle

A 2-wheel drive models

Engine type

BY . SR200ET
Body 1ype

G ~ Coupe

I:i-'.:

GI-33

IDENTIFICATION INFORMATIO.~
Idenlificat'on Number

Ve-hir.;le Identification numbElr

{Chassis number)

Tire placard (on the consQle lid}

(For AlJsCrallal
(

SGlbBl

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

For Europe

JN~

S14

XXXXXX.

T T ~e

serial number

Stopgap {no meaning)

Desll"lation

U . Europe
MOnel

Axle
A : 2-wheel drive models
Eng1ne type

B : SA2QOET
Body type
G . Coupe

Man u1acturer
JN1 : Nissan. Passenaer vehicle

GI..34

IDENTIFICATION INFORMATION
Identification Number (Cont'd)
For Australia and New Zealand
JN1

S14

T
T
T

XXXXXX

~e <erial number

Oestinat~~~pgap

A : Australia and New Zealand

Model

Axle
A : 2-wheel drive models
Engine type
B ~ SR20DET

Body type
G: Coupe
M(:I(fu'acturer

IN 1 . Nissan, Passenger vetlfcle

Except Europe s Australia and New Zealand

G

T TT
B

S14

;XI;_WhB::~~:e

XXXXXX

~e serial number
models

Engine type

B: SR20DET
Body type
G: Coupe

GI35

IDENTIFICATION INFORMATION
Identification Number (Cont'd)
IDENTIFICATION PLATE

NISSAN MOTOR CO, l TO JAPAN

~ it

!,-,.;-~.uill

.,." ~ I~

TMIf$

(I

~i~

6'\

1
:2
3
4

TvP4!

Vehicle tdentifiCCItior'l number (Chassi~ numbtul

Model
Bodv color eode
S Trim color code

&.!i::.

6 Engine mode'

Li:.

Iii

B ~ Q Ih .. ~ ~ ~

~:~
-ot.

Engine di'Placement
trBJ'smiuion mod!!1
A)(le model

J~U!o

SGlJ1S

MANUAL TRANSMISSION NUMBER

ENGINE SERrAL NUMBER

r-------------------

FS5W71C

Front

SGiB82

e - - - - - - -_ _

AUTOMATIC TRANSMISSION NUMBER

RE4R01A

SGIBn

GI-36

~ ~ ~

MGIOJ2A
_..J

Dimensions
Overall length

mm {in)

Overall width

mm(in)

1,730 (68

Overall height

mm lin)

1,295 (51.0j

4,520 (178.0)
~l

Front Iread

mm (in)

1,480 (58.3)

Rear 'read

mm (in)

1,470 (579)

Wheelbase

mm (in)

2.525 (99,4)

Wheels and Tires

Road wheel

16 x 6-1/2JJ
16 x 4T-.2

Steel'1

16 )( 6-1/2JJ

Aluminum

mm {in) 40 P,S?), 30 (1.18r2

Offset
Tire size

(Convenliona~1

Spare tire (T-type)'2

:205/55R1689V
T12Sf9D016

'1. For Spare tlre

"2. For Spare tire (T -type) for Australia

I~I.

GI-37

::.:

LIFTING POINTS AND TOW TRUCK TOWING

Garage Jack and Safety Stand

WARNfNG:

Never get under the vehicle while n Is supported only by the jack. Always use safety stands 10 sup..
port the frame when you have to get under the vehicle.

Place wheel chocks at the front wheels when 1he rear wheels are raised and place wheel chocks at

the rear wheels when the front wheels are ratsed.

CAUTION:

Place a wooden or rubber block between safety sland and vehicle body when the supporting body
Is flat.
Never place salely stand at the side member.
Garallga jack

po~nts

Fit the lower side

Use salety sland adapler

~
as shown for ,table suppert. ~

e:?

Attachment
SST NrL LM4519-OOOO

Safely stand

sill into grOO'ffl-

SOlan

GI-38

LIFTING POINTS AND TOW TRUCK TOWING

2-pole Lift

WARNING:

When lifting the vehicle, open the tift arms as wide as possible and ensure thai the front and rear of the
veh iele are wen balanced.
When setting the 11ft arm, do not allow the arm to contact the brake lubes and fuel lines.
Put the sill In the groove of the /itt pad to prevent
the sHi from daf<Jrmlng. If the pad does not helle
a groove. prepare a 5uilQble attachment l/Ir'Ilh ono.

Note:
Ltfl-up points

.... the lime

p8ntovraph
point.

l.-ck

Cl

SGIB74

Preparation
SPECIAL SERVlCE TOOLS
Tool number
(Kenl-Moore No.)
Toor name

DescrIption

LM4086~0200
(~

Board-on lift attach-menl

~TOOI

LM4519-0000

( -

Safety stand attachment

NTOO2

Board-on Lift
CAUTION:
Make sure vehicle Is empty when 1I"lng~
The board-on 11ft attachment (LM40860200) set at front end
of vehicle shOUld be set on the fronl of the sUI under the
fronl door opening.
Po&llIon attachments al front and rear ends or boa rd.,on 11ft.

AGI016

GI-39

:e'l

LIFTING POINTS AND TOW TRUCK TOWING

Tow Truck Towing

CAUTION:
All applicable loeaJ laws regarding IhEt towing operation

must be

beyed.

It.s 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.
When towfng with the rear whee's on the ground, release
the parking brake and move the gearshift lever 10 neutral
position (UN 1 position).

NISSAN recommends that vehicle be towed with the driving

(rear) wheels off the ground as illustrated.

TOWING AN AUTOMATIC TRANSMISSION MODEL

WITH FOUR WHEELS ON GROUND OR TOWING WITH
FRONT WHEELS RAISED (With rear wheels on ground)
Observe the following restricted towing speeds and distancesSpeed:
Below 50 km/h (30 MPH)
Distance:
Less than 65 km (40 miles)
If the speed or distance must necessarily be greater, remove
the propeller shaft betorehand to prevent damage to the transmission.

TOWING POINT
Always pUll the cable straight out from the vehicle. Never pull
on the hook at 8 sideways angle.

Tow~ng

hook
SG'B66

GI-40

TIGHTENING TORQUE OF STANDARD BOLTS

Tightening torque (Wi1houl Iubdca"l)

Bolt dtame-

Pilch

ter'

Bolt size

Grade

mm
6.0

M5

1.0

'.25

80

M8

1.0

4T

M10

HeltQgon head bolt

mm

Hexagon tlanQe bolt

"'

'-,-~,---

N'm

IoIg-m

Ulb

N'm

kgm

fllb

S1

0.52

3.8

6.1

a,6:?

4.5

13

13

15

15

11

13

1.3

16

1,6

12

29

3,0

22

30

31

22

51

52

:is

~_.--

1.5

25

2.5

18

125

25

26

19

100
~~.

M12

12.0

M14

14.0

M6

6.0

Me

Ml0

M12

1,75

42

4,3

31

1.25

46

4,7

34

56

5.1

41

1.5

74

7.5

54

B8

9.0

65

1.0

8,4

0.66

62

10

1.0

1.25-

2f

2. f

15

25

2.5

16

B.O
1,0

22

2.2

'6

26

27

20

, 5

41

4.2

30

.48

4.9

3S

3e

100

'.25

43

4.4

32

5'

5.2

1]5

71

7')

52

64

8.6

62

125

77

7,9

57

92

9.4

66

1.5

127

13.0

94

147

l~.O

108

12

1.2

15

1,5

1,25

29

3.0

22

35

3,6

1.0

31

3.2

23

31

3,8

27

1,5

S9

6.0

43

70

'.1

51

120

M14

14,0

M6

6.0

11
-~~-

M8

9T

M10

8.0

100

26

1.25

62

6.3

46

74

7.5

175

98-

10.0

12

118

12.0

87

M12

12.0

M14

1.....0

......

54
-._~-

1.25

108

n.O

80

137

l4.0

101

1.5

177

16.0

130

206

21.0

152

1. Special parts lire excluded.

2. This standard Is appltcab1e to bolls having the following
marks emb()ssed on the boll head.
Grade

4T
7T
9T

'; Nominal diameler

Mark
M

I
Nom inal d iameler 01 bolt threads (Un it: mm)

Melric screw lhreads

rTp

GI-41

SAE J1930 TERMINOLOGY LIST

SAE J1930 Terminology list

All emission retated terms used in this publication in accordance with SAE J1930 are listed. Accordingly,
new terms, new acronyms/abbrevtations and old terms are listed in the following chart.
.": Not applicable
NEW ACRONYM f

NEW TERM

OLD TERM

ABBREVIAnON
Air cleaner

Air cleaner

ACL

Barome1rlc press u re

BARD

...

Barometric pressure sensor-SCOD

BAROS-BCDD

BCDo

Cams hart positIon

CMP

...

Camshaft pas ilion sensor

CMPS

Crank angle sensor

Carburetor

CARB

Carburetor

Charge ai r cooler

CAe

Intercooler

Closed loop

CL

Closed loop

Closed throWe position sw{lch

erp

Clutch pedal posttlon switch

Continuous fuel in)ecHon

sY5~em

switch

cpp switch

Clutch swltch

...

CFj system

Continuous 1rap oxidizer system

CTOX system

Cranksha1t posi1ion

CKP

Idle switch

..
...
~

...

Crankshaft position senSOr

CKPS

Data link connector

OLe

...

Da~a

Dle for CONSULT

Diagnostic connector for CONSUL T

link connector 10r CONSULT

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic lest mode seloctOf

DTM selector

Diagnostic mode selector

Diagnoslic test mode'

aTM f

Mode 1

Di agnostic test mode II

DTM II

Mode II

DiagnosUc

trovb~e

code

Ole

Malfunction code

...

Direct fuel injection system

OFI system

Distributor rgn it lon system

01 system

19n~tion

EFEmixture heater

Mixture healer

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmabie read ooty

memory

EEPROM

Early fuel

evaporation~mixture healer"

timing control

...
.-

r--.---~-------_.

Eleclror,ic ignition system

EI system

ErlQH\e control modufe

ECM

Ignition timing controj

ECCS control unIt

EngIne cootant tempera1ure

EeT

Engine temperature

Engine coolant temperature senSDr

EelS

Engine modification

EM

...

Engine speed

RPM

Engine speed

Erasable programmabfe read only memory

EPROM

...

Evaporatrve emission system

EVAP system

Evaporatil/e emission control system

El(nausl gas recirculation valve

EGR valve

EGA valve

--

Engjne 1emperature sensor

.-

------_.--~

GI-42

SAE J1930 TERMINOLOGY LIST

SAE J1930 Terminology List (Conttd)
Not appllcab le

NEW ACRONYM I

NEW TERM

OLD TERM

ABBREVIATION

ExhauSt gas recirCLItation contro~-BPT valve

Exhaust gas reClrculaHon controlsolenoid

EGRC-BPT valve

aPT valve

EGRC-solenoid valve

EGR control solenoid valve

EGR temperature senSQr

Exhaust gas temperature sensor

FEEPROM

...

FEPROM

...

valve
Exhaust gas recirculation lemperature sensor
Flash electrically erasable programmable
read only memory
Flash erasable programmable read only
memory

Flexible 'uel sensor

FFS

..

Fle"ible fue. system

FF system

'0

Exhaust gas sensor

-~ ~ -

........ .-.._._.

Heated Oxygen sensor

H02S
lAC

fdre air control valve-air regulator

IACV-a'r regulalor

Air regulator

IACV-AAC valve

Auxiliary air control (AAC) valva

IACV- FiCO solenoid valve

FICO solenoid valve

valve

IACV-idle up control $olet'Joid valve

ldle up cool(Ol solenoid valve

Idle speed controlFI pol

ISC-FI pot

Idle aTr control valve-auxiliary air control

vat yEt

Idle air control valve-F~CD solenoid valve

=~
-'c:.

Idle speed control

'~

_ _ _ _ _ _ _ _ _ --....L.L._

Idle air control

valve-~dle

up control solenoid

Ft

Idle speed control system

ISC system

Ignilion control module

lCM

tndijrect fuel injechon system

IFI svslem

Intake air temperature sensor

...

...
.~

pO~

i~,,~r

--

Ai,.. temperalure sensor

KS

Oeloflation se nsor

Malfu nctfol'\ i ndicalor lamp

MIL

Check engine light

Manifold absolute pressure

MAP

Manifold absolute pressure sensor

MAPS

Manifold differential pressure

MOP

ManifOld differential pressure sensor

MDPS

Manltold surface temperalure

MST

Manifo~d surface lemperature sensor

MSTS

Manifold 'Vacuum z.one

MVZ

Manifold vacuum zone sensDr

MVZS

...

- - ..

...
...

.... - - -

...

..........

, ..

~.

'-

- - - - - - - - - -. ---'-

..
...

------

Air flow meter

MAFS
-

~--

Mixture control solenojd valve

Me

MullipOrl tuel injection System

MFl system

Neulral position switcl1

-~

., ...-

Oe\onallon

Knock sensor

Mass air flow se ....sor

-----"

...

IATS

Knock

Idle ai., control system

~ystem

solenoid 'Vatve

...

-----

Air-fuel fatio cOrllrol solenoid valve

... - . , . . . . . - -

Fuel Injec,ion control

Neutral switch

...

NOf\-volaWe random access memory

NVRAM

On-board d iagnos\)<:; system

080 syslem

Selfdi egnosi s

Open loop

OL

Open loop

O)(idation catalyst

OC

Catalysl

GI-43

---------" -

--

SAE J1930 TERMINOLOGY LIST ."

SAE J1930 Terminology List (Cont'd)
0: Not applicable
NEW ACRONYM I

NEW TERM

Ox idation catalytic converter system

Oxygen sensor

ABBREVIATION

OLD TERM

OC system

....

025

...

Exhaust gas sensor

Park position switch

Park/neutral position switch

PNP switch

Park/neutral switch

Period ic trap oxi dizer system

PTOX system

Powertr8lin control module

PCM

Programmabte read only memory

PROM

...
...

Pulsed secondary ai r injection control sofe

noid vahle

PAfRC solenoid va}ve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Ai,. induction valve(AIV) controi

Pulsed secondary air injection valve

PAIR vaFve

Air induction val ....e

Random access memoty

RAM

Read only memory

ROM

.....

Scan tool

ST

Secondary air injechon pump

AfR pump

Park switch

....

..

....

Secondary air injection system

AIR system

...
...

Sequential multiport fuel injection system

SF~

Sequential fuel injection

Service reminder ;ndicator

SRt

system

5i multaneous m uItiport fue I injection system

...

Smoke puff limiter system

SPL system

Supercharge..

SeB

System readjness test

SRT

....

SC

Supercharger bypass

.*.

Simu Ilaneous fuel injection

..

...
...

Thermal vacuum valve

TW

Thermal ....acuum v81~e

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

...

Three way + oxidation catalyst

lWC+OC

Catalyst

Three way + oxidation catalytic converter systern

TWe

Throttle body

TS

Throttle chamber

Th rottle body fuel j niectfon system

TBI system

Fuel injection control

Throttle position

+ DC

system

..

SPI body

Throttle position

TP

Throltle position sensor

TPS

Throttle sensor

Throttle position. swHch

TP switch

Throttle switch

Torque convefler clutch solenoid velve

Tee

Lock-up cancel

solenoid valve

soteno~d

Lock-up solenoid
Turbocharger

TC

Turbocharger

Ve h ide speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAfS

Air How meter

GI-44

SAE J1930 Terminology List (Conttd)

.... Not appl icable
NEW TERM

NEW ACRONYM I

---

Warm up olJ.:idation cats Iyst

WU-OC

Warm up o)(idation catalytic converter system

WU-OC system

Warm up three-way catalyst

WU-TWC

Warm up three-way catalytic converler system WU-TWC system

Wide open throttle posilion switch

OLD TERM

ABBREVlATION

WOTP swHch

Cata~yst

..
...
~

Catalyst

Full 6witch

i
i

L.__--

.G.I.-4.5

MAINTENANCE

SECTION

CONTENTS
PRECAUTIONS AND PREPARATION

Supplemental Restrainl System (SRSJ "AlA

BAGo, and "SEAT BELT PRE-TENSIONER
Special Service Tools .. __
Commercial Service Tool
PRE~DELIVERY INSPECTION ITEMS
GENERAL MAINTENANCE
_
PERIODIC MAINTENANCE (EJrcept for Europe)
PERIODIC MAINTENANCE (For Europe)
RECOMMENDED FLUIDS AND LUBRiCANTS
Fluids and lubricants
SAE Vlscosity Number
"
ENGINE MAINTENANCE _ _
Checking Drive Belts
Changing Engine Coolant..
Checking Cooling System
-- .. - __ ._
Checking Fuel Lines
Changing Fuel FUter
Changrng Air Cleaner Filter
Changing Engine Oil
Changing Oil FiHer
Changing Spark Plugs
_
Checking PosHive Crankcase Ventilation
{PCV) System
_._
CheCking Vacuum Hoses and GonnecUons
Checking Vapor lines
Checking Heated Oxygen Sensor lH02S)

CHASSIS AND BODY MAINTENANCE

Checking Exhaust System
,.. ,.. ,.. ,

Checking Clutch Fluid level and Leaks

Checking Clutch System
Checking MIT au
-.. ---19
Changing MfT QU
_,
,.. 19
Checking A/T Fluid
,
_
,
20 !1
Changing AfT Fluid
-.
,
20
Checking Propeller Shart..
- - 20 ~lQl
Checking O.fferential Gear OU
,
_ 21
Changing Differential Gear Oil.
21
Balancing Wheels
"
,.21 rr~
Tire Rotation
,
21
Checking Brake Fluid Level and leaks
.21
Checking S,ake Lines and Cables

21
Changing Brake F'uid
,22
Checking Brake Booster. Vacuum Hoses,
Connections and Check Va1ve
22
Checktng Disc Brake
22
Checking Steering Gear and Unkage
23 @'1f
Checking Power Steering Fluid and lines
23
lubricattng locks, H,nges and Hood Latches
24 JXt5
Checking Seat Belts. Buckles, Retractors,
Anchors and Adjusters
24
SERVICE DATA AND SPECIFICATIONS (SDS}
25 1ID7
Engine Maintenance
,.. ,
,.. 25
Chas$ts and Body Maintenance
25

2
0< . . - .

2
3
4
5
7

, 10

10
11
12
12
12
13
14
14
15
15
16
16
17
17
17
18

-" 19
19
'9
, 19

PRECAU1IONS AND PREPARATION

Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER t ,
The SUPP'emental Restraint System HAir Bag" and "Seat belt pre-tensioner

l
'.

used along with a seat

belt help to reduce the risk or severity of injury to the driver and front passenger in a frontal coflision.
The Supplemental Restraint System cons.sts of air bag moduJes (located in the center of the steering
whee~ and on the instrument panel on the passenger side}. seat belt pre-tensioner, a diagnosis sensor
unitt warning lamp, wiring harness and spiral cabfe. Information necessary to service the system safely
is 'neluded in the RS section of this Service Manual.

WARNJNG:

To avoid rendering the SRS inoperalive~ which CQuid increase the risk of personal injury or death
In the event ot a collision which would result fn air bag rnflalion, aU maintenance must be performed
by an authorized N1SSAN dealer.
Improper maintenance, Including incorrect removal and InstaUatlon of the SRS. can lead 10 personal
Injury caused by unintentional activation of the system.
All SRS electrical wiring harnesses and conneclors are covered with yellow outer insulation. 00 not
use electrfcal test equipment on any' circuit related to the SRS.

Special Service Tools

Tool number

Description

Toof name
EG17650301

Radiator cap tester

adapler

NT053

KV1D115800

Oil filter wrench

85 nlm (2.56 in) dia.

NTOO6

Commercial Service Tool

Tool name

Description
Wrench with a magnet to hold spark plug

Spark plug wrench

NT~'

16 mm
(0.83 ~n)

MA-2

PRE-DELIVERY INSPECTION ITEMS

Shown below are Pre-delivery Inspection Items required for the new vehicle. It Is recommended that
necessary Items other than those listed here be added, paying due regard to the conditions in each
country.
Petiorm appllcable items on each model. Consult text of this section for specifications.
'~f

UNDER HOOD -

engtne off

UNDER BODY

o
o
o
o

Radiator coo'ant level and coolant hose connections for leaks

Battery Uuid leve'. specific gravity and conditions of battery terminals
Drive belts tens~on
Fuel hlter for water or dusts, and fuel Unes
and connections for leaks
o Engine oil level and oil leaks
o Clutch and brake reservoir fluid level and
fluid Hnes for leaks
~ Windshield and rear window washer and
headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose
connections for leaks

ON INSIDE AND OUTSIDE

Remove front spring/strut spacer (H applicable)

Operation of an instruments, gauges. lights
and accessories
Operation of horn{s), wLper and washer
Steering lock for operation
o Check air conditioner 'or gas leaks
o Front and rear seats. and seat belts for operaHon
AU rno~dings, trims and fittings for fit and
alignment
All windows for operation and alignment
Hood, trunk Jid, door panels for fit and alignment
Latches, keys and locks for operation
Wealherstrips for adhesion and fit
Headlamp aim;ng
o Tighten wheel nuts (Inc. inner nuts 1f applicable)
Tire pressure (inc. spare tire)
Check front wheels for toe-in
Instatf clock/voltmeter/room 'amp fuse (If
applicable)
~ Install deodorizing filter to air purifier (If
applicable)
~ Remove wiper blade protectors {If applicable~

Manual transm,ssion/lransaxle and differenI

tial gear oil level
Brake and fuef lines and oil/fluid reservoirs iEfM.!
for leaks
Tighten bolts and nuts of steering linkage and
gear box. suspension. propeller shafts and It
drive shafts
~ Tighten rear body bolts and nuts (Models with ~~
wooden bed only)

o
o

ROAD TEST
o Clutch operati on
n Parking brake operation
o Service brake operaHon
o Automatic transmisston/transaxle sh1ft timing
and kickdown

Steering control and returnability

Engine performance
Squeaks and rattles

o
o

ENGINE OPERATING AND HOT

o
o
o
o
o
o

o
o

o
o

Adjust idle mixture and speed (and ignition J:~

Urning1)
Automatic trsnsmLssion/transaxle fluid level
~ Englne idling and stop knob operation (Diesel ~~
only)

FINAL INSPECTION
IJ Install necessary parts (outs;de mirror, wheel
covers, seat belts. mat, carpet or mud naps)
o Inspect for interior and exterior metal and
paint damage
o Check for spare tire, jack, tools (wheel chock), ~1
and literature
o Wash, clean interior and exterior
"1: Not required on models with a direct ignition
system
~: Not applicable on this modef

MA-3

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 operaUng properly. The owners
can perform the checks and inspections themselves or they can have their NtSSAN dea'ers do them for
a nominal charge.
Item

Reference pages

OUTSIDE THE VEHICLE

The maintenance items listed here shoutd be performed from time to time, unless otherwise
specified.
Tires Check the pressure with a gauge periDdically when at a service statiol'r. including the
spare. and adjust to the specifjed pressure if necessary. Check carefully for damage, culs or
eKcessive wear.

WIndshield wiper blades Check for cracks or wear it they do not wipe properly.
Doon end en'llne hGOd Check that all doors, the engFne hood, the trunk lid and back door operate property. Also ensure that all latches IDCk secure.y. Lubricate .1 necessary. Make sure that
the secondary latch keeps the hood from opaning when the primary latch is released. When driving in areas using road salt or other corrosive materials, check for lubrication frequenUy.
T'fe relation Tires shoujd be rotated every 10,000 km (6,000 miles).

MA-21

INSIDE THE VEHfCLE

The maintenance items listed here shouFd be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle etc.

lights Make sure that the headlights, stop lights, ta" lights, lu(n signal lights. and other lights
are aU operaling properly and installed securely. Also check headlighl aim.
Warning lights and ch'mes Make sure that all warning lights and chimes are operating properly.
Steering wheel Check for change in the steering conditions, such as excessi..,e free play, hard
stee ring or strange noises,
Free

play~

Les. than 35 mm (1.38 In)

Seat belts Check that all paris of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operale propefly and smoothly, and Bre installed securely, Check the belt webbing for
cuts, frayjrlg, wear or damage.

MA-24

UNDER THE HOOD AND VEHICLE

The maintenance items lisled here sholJtd be checked periodically e.g. each time you check the
engine oil or refuel.
Windshield washer fluid Check that there is adequate 11urd 1n the lank.
Engine coalant level Check the coolant level when the 9ngine is cold.

MA-12

Engine 011 level Check the level arter parking the vehicle on a level spol and turning off the
engine.

MA-1S

Brake and clu'ch fluid level Make sure that the brake and clutch fluid level is between the
"MAX" and "MIN" lines on Ihe reservoir.
Ballery Ch.eck the nuid level in each cell. tt should be between 1he "MAX" and "MIN" lines.

MA-4

MA-19,21

PERIODIC MAINTENANCE (Except for Europe)

The following tables show the normal maintenance schedule. Depending upon weather and atmospheric
varying road surfaces, individual driving habits and vehicle usage, additional or more freQuent maintenance may be required.
PerlodJc maintenance beyond the last period shown on the tables requires similar maintenance.
conditions~

MAINTENANCI:

OP~RAT10N

MAIN,ENANCE tPnERVAL
hm x 1,000

Perform eltt"1er at number of kilometers

(miles) or montt1s. whichever comes first

(Miles )( 1.000)

(0.61

Months

ENGINE AND EMISSION CONTROL

10

20

30

40

SO

6(}

70

(6)

(12)

PSI

(24)

(30)

(36}

(-'2)

(46)

12

'8

24

30

36

42

48

80

Reference page

Check drlve belts. lor cracks. haying. wear & lension

Change engine anti-freeze coolant (Ethyllme glycof base) (LLC)

MAt2

.x

MA13

ChBf;k '\lei lines

l{

MA-14

Replace air cleaner filler (ViSCOU9 p&p&r lype)*

MA-15

MA-16

Every 5,000 km (3,000 miles) or 6 months

Change engine oil (Use API SE. SF, SG or SH 011)*

Change engine oil riner. (Use Part No. 15208.oSFOO)
A~pl9ce

)(

luel filter.

Replace 6~8rk pfugs- (Use PLA T1NUMTIPflEO type)

CHASSIS AND BODY

MA-17.18

MAl9, 20.21

Underhood

Ct'leck brake, clul<.;h & aUlomatic trans.miSSion ft.uid level &

leaks.

Chsflge brake 110.d*

MA-22

MA22

)(

MA23

Check brake. clutch & exhaust systems for proper sachmenl.

leaks. cracks, chaling. abfasion. deleriora1lan. etc.

Check oil level in manual transmission & diftarenltsl gear.

fFi~

ell

!Ai
IP'~

Under vehicle

Check Bteerlng gear & linkage. 8'de & suspension P811~ & prlr
peller shaft & dr~ve shan for damaged, loose & missing parts &
lubrication*

~C

~
X

Check br&ke booster lIacuum hoses. connections & et'leck vafve

Check power steer,og lIuid & lines

!L~

MA.15

MA16

Check vapor lines and heated oxygen sen.sor

MA-12

MA-15

Elf'ery 100.000 km (60.000 mllosl

~M

Underhood and under yehlcle

Check cooling system

@~

MA-19.21

MA.19.21

I?~

MA-20,23

FA-5, RA5, 7

~!

MA-21
FA-6

IPJ~

Outside and Inslde

Check whee-l al ignment " necessary. rotate & balance wheels
Check brake pads. discs & olher brake componenls
deterioration a leaks*

fOf W~Ull',

lubricate lock:s. hinges &. hood latch*

Check foot brake, parking brake & clutch fOr free play. slrOke &
operation

MA-22

MA~.24

X.

CL-4. 6R-7, 23

X
X

Check seat belts. buckles. ret(actors. anchors & adjuster

)(

S&e NOTE (1)-

Air bB9 svstem

MA-24

Check: Checx_ Correct or replace if necessary

IRIS

RS-5

NOTE: (1) Inspect al the f4rst 10 years and Ihen every 2 years.
(2) Maintenance items with
should be performed more frequently acccrding to "Maln'en.nce undel severe drivIng
eondltlons".

U.'.

~'iI

~l

~~
~IL

m~~

MA-S

PERIODIC MAINTENANCE (Except for Europe)

MAINTENANCE UNDER SEVERE DRIVING COND'TIONS
The maintenance intervals shown on the preceding pages are for normal operating conditions_ If the
vehicle is mainly operated under severe driving conditions as shown below. more frequent maintenance
must be performed on the following items as shown in the tabre.
Severe driving conditions
A ~ Driving under dusty conditions
B - Driv;ng repeatedly short distances
C - Tow;ng a trailer
Extensive idHng
E - Driving in extremety adverse weather conditions or in areas where ambient temperatures are
either extremely low or extremely high
F ~ Driving in high humidity areas or in mountainous areas
G - Driving in areas uSing sart or other corrosive materials
H - Driving on rough and/or mUddy roads or fn the desert
I - Driving with frequent use of braking or in mountainous areas

o -

DrivIng condition

MaintenBI....ce
operalion

Maintenance item

Air cleaner litter

Reprace
Replace

Malr'llena."1ce
ir\lervat
More trequenlly

Engine oil

Engine oil 'filter

E

Fuel filti:!r

Replace

Brake rruid

Replace

Av10malic & manual transmissian oil & diUerential gear oil

Replace

Steering gear & linkage. aide &

suspension pa.rts & ptoPE"t!er

~ha11

G
G

Replace

Check

So ddve shafts

Bn~ke pads. eHscs a, other brake

components

Checlt;

Lock, "",:nge'S & hood latch

lubricate

Mail'lten8nce operation: Chec~ = Check. Correct or replace " necessary_

, MA-6

Reference page
MA~15
---~--

MA-15
Every 5.000 km
(3.000 miles) Dr 3 months

Every 20,000 km
<12,000 miles) or 12 mooltls
Every 40,000 km

(24.000 miles) or 24 months

Every 10.000 km

i6,OOO mites.) or 6 months

Ellery 5.000 km
{3.000 mires) or ~ months

MA16
MA16
MA-~'

MA-19.:2'O.21
MA-20,23
FAS, RA-S, 7

MA-22

MA-24

PERIODIC MAINTENANCE (For Europe)

The following tables show the normat maintenance schedule. Depending upon weather and atmospheric
conditions, varying road surfaces t 'ndividual drjv~ng habits and vehicle usage, addihonal or more frequent maintenance may be reQuired.
Periodic maintenance beyond the last perIod shown on the tables requires slmlJar maintenance.
@~

ENGINE OIL SERVICE

Abbreviations: R

= Replace.

MAINTENANCE OPERATION

MAtNTENANCf. INTERVAL

P&t1orm on kllornuter baSils or on month

basIs tI not driver'! 10,000 km (8,000
miles) within tl year.

[Engine 011 service]

Engina oil (Usa API

km

Jl

1,000

(Miles

l(

Months

1,000)

10

20

30

40

50

60

70

80

Refer
ence

(6)

(12)

(181

(24)

(30)

(36)

(42}

(48)

page

12

24

36

48

60

72

1M

96

Engine compartment and under vehicle

sa or SH Oil

onl~)*

Engine oU tHter fUse Part No. 152Q.8...65FOOI*

HOTE: (1) M81nlenance Items with

MA~15

MA-16

"*" should be performed more frequently KCardlng to uMa'ntenance under aeV8fe driving
[F~

conditions".

MAJOR SERVICE (Engine)

f I~

Abbreviations: R = Replace. I :: rnspect. Correct or replace II neceSSElry.

A~ the ~pecifiQd

mileage Dnly

MAINTENA.NCE .NTERVAl

MAINTENANCE OPERA nON

Months

12

24

36

48

30

60

90

120-

(18)

(36)

(54)

(72)

Re!ttfe-nce page

Perform on month basis or on kilometer basis

U di"i'ven 30.000 km (18,OOO miles) within BI year,

(Miles

lC

1,000)

Underhoad and under vehJc'e

Drive bells

See NOTE (1).

MA-12

Engine ant!-rrooze coolant (Ethylene glycol base}

SEta NOTE (2).

MA12

GooHng system

MA-U

Fuellina3

MA-14

Air cleaner Wter (Viscous

pa~r

Spark plug (Use PlATINUM.T,PPEO type)

MA1S

P.AA-15

IRJ

MA~16

MA-18

Heated o:llygen sensor <EliCcept lor Sweden}

See NOTE (3).

Vapor lines

ft

type)*

Fuel ri iter*

MA-l1

NOTE: (1) After 24 months Dr &0,000 km (36,OOG mites), eheck every 12 months or J().OOO km (18,000 miles).
(2) Change at 60 months Dr 90,000 If;m (54,000 mUes), then eY~ry 24 monlhs Of 60 1000 II;m (36,000 miles).
(3) For Sweden periorm at the Uul 90,000 km t54,OOO mite's), and IRen every 60,000 km (36.000 miles) or 24 manlns,
whichever comes Orst.
(4) Malntooance Items with
should be performed more frequenUy according to ~IMalntenance under 5evere driving
conditions".

*H

MA-7

~'iJ'
;xl~

MAJOR SERVICE (Chassis and Body)

Abbreviations: R

Replace. I

Inspect. Co(rec\ or replace it necessary.

MAIN'TENANCE INTERVAL

MAiNTENANCE OPERATION

Perform on monlh basis or 011 kjlome~er basis

j1 dnven 30.000 '<m (18.000 miles) withlr'l a year.

Monlht.

'2

24

36

48

km)i\ 1,000

30

60

90

120

(18,

(36'

(54)

(72)

(Miles

)It

1.lOOJ

Underhood and under

Rele(ence page

vehfc~e

MA-19.21

Brake & clutch ojl 'evel & leak*

MA-.20

Automatic transRlis$rc.HI r1u,C (level & leakage)*

Brake fluid*

MA22

arake booster vacuum hoses. c;onneclu:ms &. chec}( ... alve

MA~22

Power steerin9 f!vid & lines

MA2J

Brake & clutctl system

MA-19.21

M8r1wd rransmlss ron & standard diHerenUal ge~r o~1 (For ~eak9g9J

MA.19.21

SlecrJng gea,r & linkage, aide &. suspension pads. propeller 9"afl & drive
shalt, exhaust system

MA 20. 23

*'

RA-S. 7, FA.5

Oulside and Inside

MA-21

Wheel alignment (it necessary. rotate & balance Wheels)

Bn~lle

FA-fj

pads, disC5 & ot~er brake componen15*

MA-22

Headlamp a.iming

EL-64

Seat ber1~. buckles. r'e~r8clors & adjuster

MA-24

CL-4
BR-7.23

Fool bra~e. pa(king brake & clutch (For free play. stroke & operation)
Body Corrosron

Annually

Air bag system

SHe NOTE

Pl.

RS5

NOTE: {1) Inspect at th& flnt 10 years SInd then every 2 years.
(2) Maintenance l1ems wllh ~l*" should be performed mote 'requenUy accotdll'Q io HMa'n1enBn~e und~r sev-e-l'e driving
conditions".

IIIb

MA-8
~t.,

...

PERIODJC MAINTENANCE (For Europe)

MAINTENANCE UNDER SEVERE DRIViNG CONDITIONS

The maintenance intervals shown on the preceding pages are for normal operating conditions_ If the
vehicle is mainty operated under severe driving conditions as shown below, more frequent maintenance
must be performed on the foHowing items as shown in the table,

Severe driving conditions

A ~ Driving under dusty conditions
- Driving repeated'y short distances
C ~ Towing a trailer
o ~ Extensive idling
E - Driving in extremely adverse weather con.
B

- Drtving in high humidity areas or in moun-

tai~~lIS ~reas
.
~ D,rlvlng m ~reas usmg salt or other carro-

th~ ~eser~

ditions or in areas where ambient temperextremely low or

ature are either

extremely high
Drlvino condition

sl~e. mat9r1a~s
Driving on rough and/or muddy roads or in

Dnvmg .wlth freQuent use

mountamous areas

Maintenance

Mail'\terlance item

cparaiion

Ma~ntenar'lce

or

in1erval

.
braking or in

Re1etence
paQe

Engine 011 servIce

A

Engll'ie oil

EngIne oil 1iI1e-r

Replace

AepJ8ca

EV'ttry 5.000 km (3.000

miles> or 6 months

Every Oil Cha;n!JA

MA-'S
MA-16

Melor lervlce
A
E

G H

Air cle-aner' filler

Replace

MA15

fU&1 liner

Replace

MA-1S

Brake lluid

Repiac:::e

Sleertng gear 0& linkage, alCle & suspension parts. propeller shaft & drive
sha1t. ex"avs1_s_ys~te_m

c
A

Every 12 mont~s or 30.000

-I
'if

n~l !

1.~ I
~,r, I

" I
'~l I
~l I

MA-2t

km t~8.000 miles'
MA20. 23
FA-S. RA-5. 7

Chec~

Automatif; & manual transmIssion &

differential gear 01'

Replace

H I

Brake pads, discs 8. Olher brake

cOMponents

C"'eck

Every 24 months or 60.000

km (36,000 mite",)

Every 6 months Of 15.000

km ('9.000 miles)

I
I

MA22

i~,:g:

f I.~ "

RECOMMENDED FLUIDS AND lUBRICANTS

Fluids and lubricants
Capactly (Approximate)

Recommended fluids and

Lit~r

~mp

tubric.a.nt~

measure

Engine oil (Refill}

With oil Hlter

3.7

3-1!4 ql

Without oi I fi Iter

3.5

3-1/8 qt

Cooling system (with reservoir tank)

6,2

5-1i2 ql

Manual transmission oil

2.4

4-1/4 pt

Differential carrier gear oil

loB

3,1/6 pl

API SF/ee, SF/CD, SE, SG or SH1

Automatic transmission fluid

7.9

7 qt

Power steering fluid

0.9

3/4 QI

Anti-freeze coolant (Ethylene glycol

base) or soft water

API GL-4

Genuine Nissan ATF or equhJaleot-2

Type DEXAON
For Europ~

0013 or DOT4 (US FMVSS No. 1'6r3

Except for Eu rope
DOT3 (US FMVSS No. 116)

8rake and clutch flu fd

Ml.Ilti~purp()se

NLGI No, 2 (Lithium soap base)

grease

'i: For fUrther details, see "SAC Viscosity NUriIIJer'>.

"2', For mor~ inlormatlon regarding su'~able fhJir;is, 'Contac\ a Ni~s~n dealership
3: N"ver mix differant type fluids (DOT3 and DOH.)

MA-10

tr

RECOMMENDED FLUIDS AND LUBRICANTS

SAE Viscosity Number

Oul$fde Temperature R8nge

ilnllclpated

ee'o"~

Nert 011

Outside
c~an9~e_

GASOLINE ENGINE Olt

+4\i

Befora N.lft

on

Change

GEAR OIL

+1l)4

NO" recommended
10f lustelned hlgn

75W

&peed drl""'''9

SW-30 or 10W30 Is preferable regardless

driving conditions.

SOW 75W-90

~l.

8OW-90

TiOOO3

Tl0005

Tel'l\~rature RSl'lQe

An'lcfp~ted

0'

MA-11

For warm and cold areas: 75W-90 for trans- ;~\~r

mlsston and SOW-90 for differential carrier
are preferable.
~:'f;.
For hot areas: 90 is suitable for ambient temperatures below 40~C (104"F).

ENGINE MAINTENANCE
LocI( nut",
Power steering
oH pump ~uUey
Water pump

Checking Drive Belts

'. \
"'fi\nl,

f Adjusting

puHe)'

nut

Idler j:lulley

,/ Ale compreSSQr
pulley

lO:k:'~
0

Adjusting bort
.. .' CheckIng polnl

fnspect for cracks, iraying. wear or ofl adhesjon, it

necessa ry repl ace with a new one.
2. Inspect drive belt deflections by pushing on the bert midway between pulleys.
Adjust if belt deffections exceed the limit.
1.

Adjust

Befl deflecUon:

Unit mm (inl
Used be11 deflection

Adjus1
SMA 77tlC

Dellection of

Alternator
Air conditioner
compressor

Power steering
oi~

pump

Appned pushing
force

Limit

Deflection after
adjustment

new berl

11 10.431

7 - 8 (0.2B - 0.31)

4 - 5 (0,16 - 0.2D)

7 (0.28)

5 - 6 (0 20 - 0.24)

6 - 7 (0.24 - O.2B}

15 (O,59}

11 - 12

9 - 10

(0.43 - 0.47)

(0.35 - 0.39)

98 N (10 kg, 22 Ib)

Inspect drive belt deflections when engine is cold.

Changing Engine Coolant

WARNING:
To avoid being scalded, never change the coolant when 'he
engine is hoI.
On thjs model ft is unnecessary to move heater "TEMP" controt lever or switch before changing the coolant. This is
because air mix door is in "HOT" position when ignHion switch
is "OFF". (This applies to both automatic and manual air conditioners.)
SMA771C

1.
2.

Remove radiator drain plug and radiator cap_

Remove reservoir tank. drain coolant, then clean reservoir
tank.
Install it temporarily.
Be careful nol to allow coo~an' to contact drive belts.

Radialor deai" plug

3.
4.
5.

Remove cylinder block drain plug, air (eHet plug and air
bleeder cap,
lnstall radiator drain plug and tighten cylinder block drain
plug securely.
Fill radiator and reservoir lank with water.
Air relie1 piug is relnstalled once coolant spills from the air
relief hole during refill.
Then fill radiator and reservoir Lank with water.

Air relief plug:

tDJ; 10 N-m (1.0 kg-m, 7 ft-fb)

SMA.778C

6,

Reinstall radiator cap and air bleeder cap.

MA-12

...

ENGINE MAINTENANCE
Changing Engine Coolant (Cont'd)
7.

Warm up engine until cooling fan operates, then race

engine 2 or 3 times under no-load.

Make sure that air conditioner switch Is "OFF".

8. Stop engine and wait until it cools down.
@[i
9. Repeat step 1 through step 8 until clear water begins to
drain from radiator.

10. Ora'n water~

Apply sealant to the thread of drain plug.
~:

8 12 N'm (0.8 - 1.2 kgm, 5.8 - 8.7 ft"lb)

11, ReinstaH reservoir tank,

12. FiH radiator and reservoir tank with coolant up to specified
level following step 5 through step 8.
Follow instructions attached to antifreeze container for
mixing ratio of anti-freeze to water.
Coolant capacIty (With reservoir tank):
6.2 (51/2 Imp qt}

!lJ~

fl{;

(Reservoir tank capacity for "H" level is 1-8 C (1-5/8 Imp qt)./
Pour coolant through coolant filter neck slowly to allow air in
system
escape.
13. n necessary, add coolant.
14. Start and warm up engine, then increase engine speed to
4,000 rpm. Check that radiator coolant level is not lowered,~;~O)
and that no water noise is heard in heater core. If water
noise is heard, bteed air by referring to "Refilling Engine
Coolant" in section Le.
~;~

'0

'!i~~;~11
~

MAX,
MIN.

S"Amej
Checking Cooling System
CHECKING HOSES
Check hoses for improper attachment and for leaks, cracks.
damage, loose connections, chaHng and deterioration.

CHECKING RAD'ATOR CAP

Apply pressure to radiator cap with cap tester to see if it is
satisfactory.
Radiator cap rettef pressure:
78 - 98 kPa

~
\-EG1165D301

/r.//~--'-~'---

(0.78 0.98 bar. 0.8 1.0 kg/cm 2 , 11 . 14 pSi)

SLCl"3A

MA..13

[~Ik\

:~a.

Checking Cooling System (Cont'd)

Pull the negative-pressure vaive to open it. Check that it closes
completely when released.

SMA871g

CHECKING COOLING SYSTEM FOR LEAKS

Apply pressure to the cooHng system with cap tester to check
for leakage.
Testing pressure:

157 kPa {1.57 bar, 1.6 kg/cm 2 , 23 psi)

CAUTION:
Higher pressure than the specified value may cause damage
to radiator.

SMA99{JA

Checking Fuel Lines

Inspect fuel nnes and tank for improper attachment and tor
leaks, cracks t damage~ loose connections, chafing and deterioration.
If necessary,

repa~(

or replace fauHy parts,

CAUTION:
Tighten highpressure rubber hose clamp so that clamp end

3 mm 10.12 in}

---

-~rr-1

........ ..J... _~ __ .J

toJ

.-

Foel hose Clcm1p$

1.0-1.5Nm
10.10 ~ 0.15 kg-m,

0.7 1.1 ft.lb~

Is 3 mm (O~12 In) from hose end.

Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.

h
SMM04A

Changing Fuel Filter

WARNING:
Before removing fuel filler, release fuel pressure from fuel
rlne to eliminate danger.

MA..14

b_--------~

Changing Fuel Filter (Cont'd)

4.

Remove fuse for fuel pump.

Start engine.
After engine stalls, crank engine two or three times to
make sure that fuel pressure is released.
Turn ignition switch off and install fuse for fuel pump .

5.
6.

Loosen fuel hose clamps.

Replace fuel H1ter',
Be careful not to spilt fuel over engine compartment. Place

1.
2.
3.

!l~~

:[t

a shop towel to absorb fuel.

Use a high-pressure type fuellil1er, Do not use a synthetic

resinous fuel filter.
iFi~
When tightening fue' hose clamps, refer to "Checking Fuel
Lines",
I~l

Changing Air Cleaner Filler

Viscous paper type
The viscous paper type filter does not need clea ning between
renewals.

Changing Engine Oil

WARNING:

1.

2.
3.

Be careful not to burn yourself, as the engine oil Is hot.

Prolonged and repealed contact with used engine oil may
cause skin cancer; try 10 avoid direct skin contact with ~lf
used 011. If skin contact 15 made t wash thoroughly with
soap or hand cleaner as soon as possibre.
Warm up engine, and check for oil leakage from engine :~H~
components.
Remove drain plug and aU filler cap.
Drain oil and refill with new engine oil.
Refill oil capacity (Approximate):
Wrth 011 finer change
3.7 f (3-1/4 Imp qt)
Wl1hout 011 filter change
3.5 t (3-1/8 Imp ql)

CAUTION:
Be sure to clean drain plug and Install with new washer.
Drain plug:
~: 29 - 39 Nm (3.0 4.0 kg-m l 22 .. 29 ft-Ib)

Use recommended engine 011.

MA-15

ENGINE MAINTENANCE
Changing Engine Oil (Conl'd)
4.
5.
6.

Check oU lever.
Start engine and check area around drain plug and oil filter for oil leakage.
Run engjne for a few minutes, then turn it off. After several
minutes. check oil level.

AefW oll to "H" level

00 not ovarlin
SMA/"S9C

Changing Oil Filter

1. Remove oil filter.

WARNING:
Be careful not to burn yourself, as the engine and the engine
are hoI.
The oi1 filter is a small full-How cartridge type and is provided
with a retief valve.
Refer to LC section f'Oll FIL TERtI).

on

2.

Before installing new oil filter, clean the oil fifter mounting
surface on cylinder block, and coat the lubber seal of 0;1
tilter with a litHe engine oil.

SMA010

3.

Screw in the oil fiJter until a slight resistance is felt, then

tighten additionally more than 2/3 turn.
4. Add engine oil.
Refer to "Changing Engine 011".

Changing Spark Plugs

1.
2.

Disconnect ignition wires from spark plugs at boot.

Do not puU on the wire.
Remove spark pJugs with 16 mm (0.63 in) spark plug

wrench.
Spark plug:
Standard type PFR6B-9
Hot type
PFR5B-9
Cold type
PFR7B-9
(OJ: 20 .. 29 Nm
(2.0 - 3.0 kg~m, 14 22 ft-Ib)

MA-16

ENGINE MAINTENANCE
Changing Spark Plugs (Cont'd)

g
16mm

Wrench with ii magnet

10 hold spiJrk plug

Checking and adj usting plug gap are not requi red between
renewals.
Do not use a wire brush for cleaning.
If plug Up Is covered with carbon, spark plug cleaner may

be used.

Cleaner air pressure:

Less than 588 kPa (5.9 bar, 6 kg/em:!t 95 psi)

(D1"I~_~y

Cleaning time:
Less 'han 20 seconds

SEM294A

}I'

Checking Positive Crankcase Ventilation (PCV)

System
Checking PCV valve
With engine running at idle. remove ventilation hose from PCV
valve; i1 valve is working properly, a hissing no~se will be
heard as air passes through it and a strong vacuum should be
felt immediately when a finger is p\aced over valve inlet.

1f.;J1'

Checking Vacuum Hoses and Connections

Check vacuum hoses for improper attachment and for ~eaks, i~r~:,
cracks, damage, foose connections, chafing and deterioration-

Checking Vapor Lines

1.

2.

Visually inspect vapor lines for improper attachment and

for cracks, damage, loose connections, chafing and deteriorationInspect vacuum relief valve of fuel tank filler cap (or"
clogging, stick'ng, etc.
Refer to 'EVAPORATIVE EMISSION SYSTEM" in EC section.

MA-17

~{,'~~:"
~t

ENGINE MAINTENANCE

tl MONITOA

CAS. RPM (REF'

MJR FIC MNT

NO FAll

Checking Healed Oxygen Sensor (H02S)

CI

200'Jrpm

Checking procedure

R~CH

INSPECTION START ,

Start engine and warm il up until water

~emperature indicator

RECORD

points to Ihe mid-

dle 01 gauge
SEF8t8K

~L~

,=-f!_[;]_r!1
fa\ 1. See
~

"M/R FIC MNT" in "Data

monitof" mode
2. Run eng lne at about 2.000 rpm
for about 2 minutes under
no-load

3 Maintaining engine at 2,000

rpm under noIDad {engine is

warmed up sulficfenlly,),
check (hat the monitor fluctuales between "LEAN" and

"RICH" more than 5

'e/
,
\

t /

1 lime

RICH

---->

LEAN -.

RICH
2 limes

CHECK-

tim~s

during 10 seconds,

"-

1--------

tm
~

Malfunction indicator
lamp

RICH .... LEAN

-0

RICH -lEAN AJCH ....

OR ~--~

1_ Set .. Heated oxygen sensor

monitor" in the Diagnostic test

mode \I

SEFOS1PA

{Rete r to EC section,)

2. Run engine at about 2,000 (pm

for about 2 minutes under

no-load.
3, Maintaining engine at 2,000
rpm under

no~ load.

check to

make sure 1ha1 malfunction

jndicator lamp on the instrumen1 panel goes ON and OFF
mOte than 5 times during 1D

seconds_

C--I'---*"I
NG

I,

INSPECTiON END

MA..18

---.J

Check and adjustmenl

should be made by re'er~
ring to ~DLE SPEEDI
IGNITION Tl MfNGIIDLE
MIXTURE RATIO INSPEC
TlON in EC section,

CHASSIS AND BODY MAINTENANCE

Checking Exhaust System

SMA2 1

Check exhaust pipes, muffler and mounting for improper

attachment, leaks, cracks, damage, loose connections.
chafing and deterioration.

'Al

Checking Clutch Fluid Level and Leaks

If fluid level fS extremely low. check clutch system for

leaks.

t:'i~:

Min.

<l
SMA9418

Checking Clulch System

Check fluid lines and operating cylinder for improper
attachment. cracks damage. ~oose connections. chafing and
deterioration.
4

~I"T

~,_~II,

~/~ l

~-6~1
l7-~ /

0~lIer plug

Checking MIT Oil

Check oil fevel and for oil leakage.
NeV'er slarl engine while checking 011 level.
Firler plug:
34 N'm (2.5 .. 3.5 kg-m. 18 - 25 fttb)

(OJ: 25

Changing MIT Oil

~FiIIID lhis lelJel

1.
2.
SMA 103

Drain oil from drain plug and refill with new gear oil.
Check oil level.

Oi' grade: API Gl-4

Viscosity:
See uRECOMMENDED FLUIDS AND LUBRICANTS".
Capacity; 2.5 { (4-3/8 Imp pt)
Drain plug:
~: 25 - 34 N'm (2.5 - 3.5 kg-rn, 18 - 25 ft-Ib)
After refining oU, leave MIT unattended for about two mtnutes.
Then check oil level again loUowing the above procedure. Add
oil it necessa ry.

MA-19

r-~'

f:l

,.:-,

CHASSIS AND BODY MAINTENANCE

Checking AfT Fluid

HOT [SO BOOC (122 - 17&I)FII

1.
2.
3.

a.
b.
COLD [30 . SOQC (86 122Fl)
SATQ19EA

c.
d.

e.
f.
4.
5.

6.

Warm up engine.
Check for fluid leakage.
Before driving, fluid leve! can be checked at fluid temperatures of 30 to 50C (86 Lo 122F) using "COLD" range on
dipstick.
Park vehicle on level surface and set parking brake.
Start engine and move selector lever through each gear
position. Leave selector lever ~n "p" position.
Check fluid level with engine idling.
Remove dipstick and note reading. If level is at low side of
either range, add fluid to the charging pipe.
Re..insert dipstick into charging pipe as far as it will go.
Remove dipstick and note reading. It reading is at law side
of range, add fluid to the charging pipe. Do not overfill.
Drive vehicle for approximately 5 minutes in urban areas.
Re..check fluid 1evel at flUid temperatures of SO to BOoe (122
to 177"F) using "HOT" range on dipstick.
Check f~uid condition. If fluid is very dark or smells burned,
or contains friction materia! (clutches. band, etc,). check
operation of AlT. Refer to AT section for checking operation of AlT.

Changing AfT Fluid

Check fluid far contamInation,

SMA65J6

1. Warm up AIT fluid.

2. Stop engine.
3. Drain AfT fluid from drain plug and refill with new AfT flutd.
Always refill same volume with drained fluid,
011 grade:
Genuine Nissan ATF or equivalent.
011 capacity (With torque converter):
7.9 t (7 Imp qt)
Drain plug~
~: 29 - 39 N'm (3.0 4.0 kg-m, 22 - 29 ft-lb)
4. Run engine at idle speed for five minutes.
5. Check fluid level and condition,
Refer to "Checking AfT Fluid".
If fluid rs sUII dirty, repeat step 2. through 5.

Checking Propeller Shaft

Check propeller shaft and center bearing for damage. looseness or grease leakage. If greasing points are provided. supply grease as necessary.
Refer 10 PO sectjon~

~'i//

Check tIghtening torque,

- - - - - - - - _ .__

SMA922B
._~~-

MA-20

CHASSIS AND BODY MAINTENANCE

Checking Differential Gear Oil

Check

0"

level and for oi\ leakage.

Filler plug:

toJ: 39 - 59 N'm (4 - 6 kg-m, 29 - 43 ft-Ib)

SMMI2C

Changing Differential Gear Oil

1, Drain oil from drain plug and refill with new gear oiL
2. Check oil \eveL
011 grade: APt GL-S
Viscosity:
See "RECOMMENDED FLUIDS AND LUBRICANTSl'.

Capacity:
1.2 - 1.4

FBle'PIU@

r (2..1/8 - 2-112 Imp pt)

DraIn plug:
[OJ: 39 .. 59 Nm (4 - 6 kg .. m, 29 - 43 ft-Ib)
SMA2'57A

Balancing Wheels

Adjust wheel balance using road wheel center.

Whee' balance (Madmurrt allowable unbalance):
Refer 10 SDS (MA-25).

Tire Rotation

Right front

RiQht rear

Spare
~, tlre

r=====--..
Radial
tlre

-------...

~fQ\

Do not Include the T-Iype spare tire when rotating the tires.
Wheel nuts:
~: 99 .. 117 N'm (10,1 11.9 kg-m, 73.0 - 86.3 It-lb)

mw;,

c:::J~L::)

left front

left rear

SMA8008

Checking Brake Fluid Level and leaks

If fluid level is extremely tow, check brake system for r-i'

leaks,

Checking Brake Lines and Cables

Check brake fluid lines and parkfng brake cables for

improper attachment leaks, chafing, abrasions and
deterioration, etc.

SBAJ69C

MA-21

rI

CHASSIS AND BODY MAINTENANCE

Changing Brake Fluid
1.
2.

Drain brake fluid from each ai,- bleeder valve.

Refill until new brake fluid comes out from each air bleeder
valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to SR section.
RefUi with recommended brake flutd.
Never reuse drained brake fluid.
Never mix different type fluids (0013 and DOT4).
Be carelul not 10 splash brake fluid on painted areas.

SBR419C

Checking Brake Booster, Vacuum

Connections and Check Valve

Hoses~

Check vacuum Hnes connections and check valve for

lmproper attachment, air t1ghlness. chafing and deterioration.
1

Checking Disc Brake

ROTOR

Check condition and thickness.

Unit" mm (In)
Rear

FfOn.t
--~---

OPF25V

CL11H

Sta ndard Ihjckness

Disc: brake type

(l 181)
_r_.300
. ______

9.0 (0,354)

Minimum thickness

280 (' 102)

80(0,315)

SMA2lS0A

CALIPER

Check for leakage.

SMA922A

PAD

Check for wear or damage.

Unit mm (lnl

Rear

Franl

OPF25V

Cl11 H

100 {O 3941

9.5 {O.374)

Disc brake 1ype

Sta ndard th ~ckness

__._.._._._....

~-------t----_.

Minimum thlckness

SMM418

MA-22

------,---~--~~

20 (O.079)

CHASSIS AND BODY MAINTENANCE

Checking Steering Gear and linkage
STEERING GEAR

Q : Check grease le.akag&

Check gear housing and boots for looseness, damage or

grease leakage,
Check connection with steering column for looseness.

STEERING LINKAGE
Check baH jorflt. dust cover and other component parts for
looseness, wear, damage or grease leakage.
.

: Check lightenIng forQue.

~ : Aefer 10 ST section.
SMI\&54C

:'0~

.-?,~

Checking Power Steering Fluid and Lines

CHECKING FLUID LEVEL
Check fluid level with dipstick on reservoir cap. Use "HOr" .EC
range at fluid temperatures of 50 to 80"C (122 to 176 F)_ Use
"COLD" range at ftuid temperatures of 0 to 30C (32 to B6"F].
CAUTLON:
~I~
IJ

Do not overfilL
Recommended fluid Is Automatic Transmisslon Fluid type
'iOEXRONn or equivalent.

'.e'l

SST457C

CHECKING LINES
Check lines for improper attachment, leaks, cracks, damage.
loose connections, chafing and deterioration.

l\1

SST4.58C

r"

L~

MA-23

Lubricatln
9 Locks, Hinges and Hood Latches

L."

Seal Be Its , Buckles, Retractors,

Checkmg d Adjusters
Anchors an
11 seat
Inl~orw
andbelt

A""'";;.I
Including '" ~" . gulda
lI. .emllttll eh.d h~. to

CAUTION:

colllllon,

Check anct10rs for loo!.8

mounting.

I) NI..ln
mbU.a In .11
rl" : . ". . _
-::..::: ..... dlmaged

~"II colli....... _
:~d properly ~

minor

not

emIll:;""" "

colIlion, t _
bell ...
Also lnspec 8 colll.lon, .nd r

In Ull durlng
p4Ifl)' --'Ing. bly
dlmaged or ':"01 . _ "":' . . . . .
If any compo
do not rep. r.

I.

qUOOU"':"':::' _ "'-:;;"aaed,

Replacll II
cut. fr8yed. or
If webb4ng I.
embty,
epl..-ce beU SA hd bvc-kle.

~..... 011 tanll'"

"t

Un. 08nulrMl

For I t

refer to

11<1" numbly.

ten.klner,
be~::c;;s.

He

A.nchor bolt

:g-m,

~43
- 55 N
{44 - 56

32 - 41

.
of buckles
Cl'1ec.k 'I.Jnctl~en Duckl&d
and tongues
and released

tt-lb)

MA-24

S'ERVICE DATA AND SPECIFICATIONS (50S)

Engine Maintenance
Spark plug

INSPECTION AND ADJUSTMENT

PlaUnumwtlpped type

Drive belt deflection

Unit mrn (in)

P_FR_6_8_-9

afler

PfASB-9

-~---~~----~--------

Oellechon ol
new belt

Derleclion
Limit

SlandElrd~ty~p~e_ _~
Hot type

Used belt dellection

COld type

PFR7B-9

adjustment
Alternator

11 (0.4:3)

Ai r condaior.e r
compressor

POWEll'

{O.28)

7-8

4 -5

(0.20 . 0-31)

(0.16 0.20)

5-6

6 7

(0,20 - D.24)

(024 . (128)

Cooting system
Unit kPa (bar.
78

Radiator cap reliel pressl)re

steering oi I

15 (0_59)

pump
Applied pus.hing

11 . '2

9 HI

(0.43 - O.47)

(0.35 - 0.39)

(0.78 - 0.98, 0.8

Cooling system leakage lesUng

pressure

kgJcm~. psi)

'.>~:

98
L

1.0. 11 14l

~:~~

157 (1.5T. U3. 23)

98 N {10 kg. <2 tb}

force

TIGHTENING TORQUE
Coolant and oil capacity

Unit
Unit { (Imp qt)

Coolant (with rf!se rvoir lank)

Approx. 7,0 (6--1 fEl)

1.8 (15/6)

Reservoir lank

Engine oil

N'''''

kg-m

fl-lb

29 - 39

3.0 - 4_0

2229

Spark plug

2{}29

20- 3.0

14 . 22

Camshaft position s.ensor

7-B

0.7

515-.8

142 -

ad

pan drain

P' ug

With oil Wter change

Approx 3 7 13-1/4\

Crankshatt pulley

Wilhou\ oil lilter change

Approx_ 3.5 (3- 1/8)

Timing bell
pUilev nut

1en~ioner

\5~

2229

0.8

14.5 - 155

105" 112

2.2 - 3.0

16 . 22

Chassis and Body Maintenance

Brake

INSPECTION AND ADJUSTMENT

Un.l. mm (in)

Wheel balance
Oynamic
M<liKimum allowable

~l.~"

Disc brake

Standard thickness

g {o.z)

unbalance
Static

9 loz)

rmfl

Pad

10 (0,35)
(OM side)

(81 rim lIange)

20 (0.71)

OPF25V

10.0 {O.394}

CL\IH

9.5 (0.374)

i>tl

Minimum lhickness
OPF2SV

20 {O.O79)

CL11H

2.0 (0.079)

;.fr

Roto(
S1~ndard

thIckness

OPF25V

300'1.181)

ClIlH

9.0 (0.354)

Minimum thic:kne-ss

MA-25

;R~~l

FM'.
Fl,

QPF25V

280 <I 1021

CLlIH

B.O (0315)

I'rt .~:~ "

'.'--,.---

ENGINE MECHANICAL

--------~---~-----------~

EM
l~/j,
.

'i

SECTION

-~~--_

L(;

elj"":'
S''''~

CONTENTS
2

P RECAur'ONS.
Supplemeotal Restraint System (SRSI "AIR
BAG" and "SEAT BELT PRE-TENSIONER"

~~

Installation _..

Parts Requiring Angulal Tightening

Disassembly

tnspection
Assembly

",. 2
,.... " .... 2
Special Cautions to Ensure the Safe Disposal
___ ." 3
of Sodium-fHled Exhaust Valves .. ,.,
5
PREPARATION
- ,_
".,,-__ ,_ ...... " 5
Special Service Toots, .,,,Commercial Service Tools _.
" .. 8
_9
OUTE R COMPONENT PARTS., ..
_______ 12
CO MPRESS ION PRESSURE .. ,.". -

Oil PAN ."

" __ ._ "
", ..
Removal "..
.
'.. -,-Installation __ .. ""
,
TIMING CHAIN
"
".,,-,.
..
Removal. _
Inspection"
Installation. ,

,-.
__

OIL SEAL REPLACEMENT

INTAKE MANIFOLD ..
Removal ..... __

... 12
.13
, .. 13
...... 16
....,,_, 19
,.. 20
______ .. 23

... 24
"" ... ,,32

-35
...... 35

" .. 36

38
39

.._"

Removal and Instalfation..

Liquid Gasket Application Procedure

Mco$urement 01 Compression Pressure"

C"UNDER HEAD..
"

,,-

__ ."

39

_._._

.40
" 46
_. _.49

TURBOCHARGER
RemovaL. ... _...

".".....

"

"

- ,_."

,,_ "

"

50
,.51

,."..

..

,.. ,.. ,53

Installation.......

. - .-53

ENG'NE REMOVAL." ....... " , RemovaL

. ." .. 56

.... ....

..

56

CYLINDER BLOCK.",,-

,1~.~r

"....
-- _

~:~:

:;/',

'Rti~

57

Disas$emb~y

Inspection
Assembly,

-- ... " .. 55

._ .. "..

Jnstallafio n

~rr

, _.".49

Disassembly
Inspection
AssernlJ'y .. ,

.. _

'~l

"." .58

..
, -_

-- 59
,.. 67

SERV'CE DATA AND SPECIF1CATIONS {5DS}. '"

72

,._..

. " .. ,.. ,.-,

General Specifications......
Inspection and Adjustment. ...

~rR\

~~n

]')

..

.73

,}~~

-~.. {

Ii >~.
~l.

r(~':~;

'1

PRECAUTIONS

Supplemental Restraint System (SRS) '4AIR

BAG" and ((SEAT BELT PRE-TENSIONER"
The Supplemental Restraint System "Air Bag" and "Seat Belt Pre-tensioner", used along with a seat
bel\~ help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The Supplemental Resfrajnt System consjsts of air bag modules (located in the center of the steering
wheel and on the instrument panel on the passenger s;de). seat belt pre-1ensioners, a diagnosis sensor unit, warning lamp. wiring harness and spiral cable, Information nece~sary to service the system
safely is included fn the RS seclion of this Service Manual.

WARNING:

To avoid rendering (he SRS inoperative, which could Increase the risk of personal Injury or death
in the event of a collision which would result in air bag intlation, aU maintenance must be pertormod
by an authorized NISSAN dealer.
Improper maintenance. including incorrect removal and installation of the SRS, can lead 10 personal
Injury caused by unintentional activation
the system.
All SRS air bag electrical wlrrng harnesses and connectors are covered with yellow outer Insula..
tlon. Do nol use electrical tesl equipment on any clrcutt related to the SRS.

0'

Parts Requiring Angular Tightening

Use an angle wrench for the hnal tightening of the following
engine parts:
Cylinder head bolts
Main bearjng cap bolts
Connecting rod bearing cap nuts
Do not use a torque value for final tightening.
The torque values for these parts are for a preUminary step.
Ensure thread and seat surfaces are clean and coated with
engine 011.

Liquid Gasket Application Procedure

a.

Bolt J'lole

SEMJ71C

Use a scraper to remove aU traces of old liquJd gasket

from maUng surfaces and grooves. Also, completely clean
any oil from these areas.
b. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Uquid Gasket or equivalent.)
Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197
jn) wide (for oil pan).
Be sure Jlquid gasket is 2.0 to 3.0 mm (O.019 to 0.118
in) wide (in areas except oil pan).
c. Apply liquId gasket to Inner surface around hole perimeter area.
(Assembly should be done within 5 minutes after coaUng.)
d. Wail at least 30 minutes before refilling engine oU and
engine

coolant.

EM-2

PRECAUTIONS

Special Cautions to Ensure the Safe Disposal of

Sodium-filled Exhaust Valves
The handling and disposal or sodium-filled exhaust valves @f
requires special care and consideration Under conditions
such as breakage with subsequent exposure to water. the
sodium metal will react vio'ently~ The sodium meta', which
lines the inner portion of the exhaust valve, forms sodium
hydro}(ide. A~SO, it releases hydrogen gas wh~ch may result in
an explosion or fire.

A sodiumfjlled exhaust valve is identified on the top of its

stem as shown in illustration.

t~

111enlificafi011 mark of
sodium-tilled exhaust valve

OEALER DISPOSAL INSTRUCTIONS

CAUTION:

Use approved shatter-resistant eye protection when per.. !Alf

forming thIs procedure.
Perform th's and aU subsequent disposal work procedures ~ij!
In an open room, away from flammable liquids. Keep a fir~
extinguisher, rated at least 10 ABC, in close proximity to
the wOfk a r e a . ; f t : .
Be sure to wear rubber groves when performing the folloWing operations.
1. Clamp valve stem in a vIce,

Unit: ITlm (inl

2.

The valve has a speclaHy-hardened surfat:e- To cut

through iI, first remove a half-round section, approximately
30 mm (1.18 in) long. Use an air-powered grinder until the
b'ack iron color is removed and the silver-catored metal
appears,

3.

Use a hacksaw to cut through approximately half the diam~

eter afthe valve stem, Make the serration at a point 40 mm [RtF.I,
(1.57 in) from the end of the stem.

SEM95QC

--------~--------

110 mm (1.57 io)

. . . . I--..~. . 1

S~M96(JC

EM-3

PRECAUTIONS
Special Cautions to Ensure the Safe Disposal of
Sodium-filled Exhaust Valves (Cont'd)
4.

Cover the serrated end of the valve with a large shop

towel. Strike the valve face end with a hammer, separaling it into two pieces.

Fill a bucket (such as a 20 oil can) with at least 10 C {2-1/4

1mp gal} of water. Using a pair ot Jarge tweez.ers. carefully
place the already-cut (serrated) va1ves into the water one
at a time. Quickly move away at feast 2,7 m {9 ft}. Place the
valves in a standing position as shown in the figure. This
allows comp'ete reaction of the sodium with the water. The
rna/Dr portion of the resultant chemical reaction lasts 1 to
2 minutes. After the bubbling action has subsided. additional valves can be placed into the water. Wait until each
subsequenl chemical reaction sUbsides before placing
add,t,onal valves into the water However, no more than 8
valves should be placed in the same 10 f (2-1/4 Imp gal)
amount of water. The complete chemical reaction may take
as long as 4 to 5 hours. Remove the valves using a set of
large tweezers aHer the chemkal reaction has stopped.
AiterwBrds, the valves can be mixed with ordinary scrap
metal.
CAUTION:

Make sure the resuUant (high alkalinity) wasle water does

nol contact your skin. If the wasle water does contact you,
wash the contacted area immediately with large quantities
of water.
Check country and local regulations concerning any chemical treatment or waste water discharge permits. These
may be required to dispose of the resultant (high alkalinity) waste w~ter_
5.

~~==~ ITl~:':- - -

aueke!

{Sut:h as 20

l! oil

cal1)~

SEM5WD
--~------

EM-4

PREPARATION
Special Service Tools

~To<ll number
Tool name

Description
Disassembling ar"ld assembling

ST05015000
E.ngine stand assembty

G) ST05011000
Engine sland

@ 5105012000
Base

uc

NT042

KV10106500

Engine stand shaft

NTD:/!8

KV10115300

Engi ne sUbattachment

NTOO8

ST10120000

~
Loosening and tightening cylinder head

fj

Cyl,inder head boll

w/eneh

NT583

~~~
c

KV10116200

boll
8:

13 (0.51) dla.

b: 12

~O.47)

c: 10 (0.39)
Un~1:

Disassembling valve mechanism

Val\l9 spring
compressor

CD

KV101159DO
Attachment

NT[l22

KV101092SD

Disassembling valve mechanism

Valve spring

compressor
G) KV10109210

Compressor

l;v~

"'1) KV101D9220
Adapter
~) KV10111200

Adapter (Useless)

NT5B6

EM-5

rnf1l (inl

PREPARATION
Special Service Tools (Cont'd)
": Speciaf 1001 or commercial equivalent

Tool number
Tool name

Descriplion

KV10115600

InslaUing valve oil seal

Valve oil seal drift

Inlake

Exhaust

Side A

Side

Side A

Side B

p: 20 (0.79) dla.

b: 13 (0.51)

a
8:

cU~.

20 (0.191 d:la.

b: 14.2 (0.559) dla.

c: 10.3 (0.40&) dla.

~:

d; 8 (O.3t) die.

d: 8 (0.31) eU8.

11 (0.43) d18.

e; 10.7 (0.421)

e: 10.1

I: 5 (0.20)

r:

(OA~1)

dla.

5 (0.20)
Unit. mm (ifl)

NT603

KV10115700

Adjusting shims,

Dial gauge sland

NT012
------------I-------,--~---

EM0347000Q

Installing piston assembly into cylinder

Piston ring compressor

bore

NT044

KV10107400

Disassembling

Piston pin press stand

pin

CD

and

KV10107310

Cenler shaft

IJ) ST13040020
Stand

@ ST13040030
Spring

@ KV10107320
Cap
(]) ST13040050
Drift

NTO'J

E019600000'
Compression gauge set

NT626

KV10l11100

RemOVl ng oil pan

Seal cutter

NT046

EM-6

assembling piston

PREPARATION
Special Service Toots (Conttd)
ToOl number
Tool name

Description
Pressing the tube of liquId gasket

WS39930000
Tube presser

KV10112100

--+---Nl-O-52-----~~-~.------,~-------~-------Tightening bolls for beahng cap, cyHnder

Angle wrench

hearl, etc.

ST166~0001

Removing pilot bushing

Pilot bushing puller

NTCH5

EM..7

PREPARATION

Commercial Service Tools

Tool name

Description

Spark plug wrench

g
16mm
(0.83 In)

Removing and installing spark plug

NTQ47

Finishing valve seal dimensions

Valve seal cutter set

NT048

Removing and installing piston dog

Piston ring expander

~--_

..

"--

NTOJO

-~-----

Removing and installing valve guide

Valve guide drift

.~

Intake

9.5 mm (0.374 In) die..

mm (0.191 In) dill.

b == 5.0
E.hausl

NT015

00::

10,50 mm (0 .... 13 In) d~l!I.

6.0 mm to,2'36 In) die.

Reaming valve guide CD

o\fersize valve guide @

Valve guide reamer

d~

Of

hole for

Unit: mm (In)

c:i,

In1Bke-

6.0

(O.236~

Exha.u'9t

70 {O.276)

d~

10.175
{O.4006J
11.175
{C ,4400)

"IT016
---------------+---~-----~-----------------_._~---~-

Installing fro...,t oil seal

Front oil seal dritl

7S n\m (2.95 In) dla.

b "" 45 mm (1.77 In) dill.

8 -NTOll9

Installing rear oil seal

Rear oil seal drilt

NTD49

a
b

= 110 mm (4.33 In} dis.

=<

80 rnm (3.15 in)

d~a.

OUTER CO MPONENT PARTS

SEC.
111118140 147148150-163164
SEC. 220.223.226

(0.52 - 0.66 3. 8 - 4 .8)

II

SEM970E

CD

Ignition coil

Spark plug
Intake
manifold collector support

0'1~ pressure switch

011 filter
Oil fi Iter bracket
Alternator adjusting bar

EGRC-BPT va Ive
Intake manifold s
Oil cooler
upporl

Alternator bracket
Water outlet

_______.:EM~-9~

@
@
@

~n

Thermostat
Thermoslat housing
Knock sensor
Blow-by control valve
VTC solenoid valve

OUTER COMPONENT PARTS

SEC. 118140223

2.9 - 3.8 (0.30 0.39, 2.2 2.8)

Uf;IS(ID*
o

G)

.,

Throttle body
bolts
. Tighten all bolls
to 181022 N.m
1) (18 to 2.2 kgm.

Tighten in
numerical order

1310 16 f!-fbl

-~--------

: N'm (kg-m. ft-fb)

SEM971E

G)
@
@
@

Throttle body
IACV-FICD valve
IACV-AAC valve
Intake manifold collector

Air pipe

(J)

EGR valve
Intake manifold
Engine coolant temperature
sensor
Thermal transmilter

EM-10

Injector

Fuel tube assembly

Injector harness

OUTER COMPONENT PARTS

..

~ 20 - 31
~ 13 . 16 (1.3 - 1.6, 9 12)

tc!l . Nm (kg-m,

ft-Ib)

~ : Apply liquid gasket

SEM972E

G)

@
@

Blow-by hose
Oil level gauge
Camshaft position sensor
Exhaust manifold
Turbocharger

Water outlet

(J)

Air inlet

Oil tube
Water tube
Oil return pipe

EM-11

@
@

@
@
@

E)(haust manifold cover

Air outlet
Exhaust manifold outlet
EGR pipe
Heated o)(ygen sensor

!8J1

COMPRESSION PRESSURE
Measurement of Compression Pressure
1.
2.
3.
4.
5.

Warm up engine.
Turn ignition switch off.
Release fuel pressure.
Refer to "Releasing Fuel Pressure" in EC section.
Remove all spark plugs.
Disconnect distributor center cable.

6.
7.

Attach a compression tester to No.1 cylinder.

Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown
above.
Always use a fully-charged battery to obtain specified
engine revolution.
Compression pressure:
Unit: kPa (bar, kglcm 2 , psi)1300 rpm
Standard

1,079 (1079,11.0,156)

Minimum

883 (8.83, 9.0 128)

Difference limit bel ween cylinders

20 mm (0.79 In) dla.

Use compressor tester whose end (rubber

portion) is less than 20 mm (0.79 in) dia.
Otherwise, it may be caught by cylinder
head during removal.
SEM387C

98 (0.98, 10, 14)

10. If compression in one or more cylinders is low:

a. Pour a small amount of engine oil into cylinders through
spark plug holes.
b. Re-test compression.
If adding oil helps compression, piston rings may be worn
or damaged. If so, replace piston rings after checking pislon for wear or damage.
If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve sea1. (Refer
to 50S.) If valve or valve seat is damaged excessively,
replace them.
If compression stays low in two cylinder 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_

EM-12

Oil PAN

SEC. 110

16 - 19 11.6 1.9, 12 14)

~ . Apply liquid gasket.

~ : N.m (kg-m, ft-Ib)

Removal
1. Remove engine under cover.
2. Drain engine oil.

CD

3.

Remove steel oil pan bolts.

4.
(1)

Remove steel oil pan.

Insert Tool between aluminum oil pan and steel oil pan.
Hi!~\
Be careful not to damage aluminum mating surface.
Do not insert screwdriver, or oil pan flange will be
~iL
deformed.

SEM975E

OIL PAN
Removal (Cont'd)
(2) Slide Tool by tapping on the side of the Tool with a hammer.

(3) Remove steel oil pan.

(4) Remove baffle plate.

5.
6.
7.

8.

Install engine slingers to cylinder head. Refer to "ENGINE

REMOVAL" (EM-55).
Set a suitable hoist on engine slinger and hold the engine.
Remove the following parts.
Tension rod bolts at transverse links
Front stabilizer bar securing bolts and nuts from side
member.
Both left and right side engine mounting bolts. Refer to
"ENGINE REMOVAL" (EM-55).
Disconnect steering shaft lower joint.

Remove power steering tube bracket securing bolts at left

tension rod bracket.
10. Remove front suspension member securing bolts while
supporting with a jack.
11. Lower front suspension member by around 60 mm (2.36
in)

9.

12. Remove alternator support.

EM-14

OIL PAN
Removal (Cont'd)

13. Remove rear cover plate.

14. Remove aluminum oil pan bolts.

l.. '?"'
\S'

loosen in numericaf order.

SEM979E

15. Remove four oil pan-to-transmission bolts.

16. Remove two engine-to-transmission bolts and install them
into open bolt holes shown. Tighten the two bolts to
release aluminum oil pan from cylinder block.

17. Remove aluminum oil pan.

(1) Insert Tool between cylinder block and aluminum oil pan.

Be careful not to damage aluminum mating surface.

Do not insert screwdriver, or oil pan flange will be
deformed.

(2) Slide Tool by tapping on the side of the Tool with a ham-

mer.

KV10111100

SEM047D

EM-15

I~\T

EiRl

OIL PAN
Removal (Cont'd)
18. Remove the two oil pan-to-transmission bolts previously
installed in aluminum oil pan.

Installation
1. Install aluminum oil pan.
(1) Before installing aluminum oil pan, remove all traces of
liquid gasket from mating surfaces using a scraper.
Also remove traces of liquid gasket from mating surface of
cyl inder block and front cover.

SEM050D

(2) Apply a continuous bead of liquid gasket to mating surface

of aluminum oil pan.
Use Genuine Uquid Gasket or equivalent.

-l ,

7 mm (0.28 In)

0
Groove

i
Borl hole
SEM067D

4.05.0 mm
(0:157 - 0.197 In)

For areas marked with "*", apply liquid gasket to the

outer side of Ihe bolt hole.

Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in)

wide.
Attaching should be done within 5 minutes after coating.

SEM981E

Cut here.

liquid gasket

SLCII06

EM-16

OIL PAN
Installation (Cont'd)
(3) Install aluminum oil pan.

Tighten bolts in numerical order shown.

<D - @ bolts:
(OJ: 16 - 19 N'm (1.6 1.9 kg-m, 12 - 14 ftlb)
@,-@ bolts:
~: 6.4 - 7.5 N'm (0.65 - 0.76 kg-m, 4.7 5.5 ft-Ib)

Tighten in numerical order.

SEM982E

2.

3.
4.
5.

6.

Install the four oil pan-to-transmission bolts.

Install rear cover plate.
Install alternator support.
Tighten front suspension member securing bolts.
Install all removed parts after removing steel oil pan.

7. Install steel oil pan.

(1) Before installing steel oil pan, remove all traces of liquid
gasket from mating surfaces using a scraper.

Also remove traces of liquid gasket from mating surface of

aluminum oil pan.

SEM051D

7 mm (0.28 In)

--l
Groove

(2) Apply a continuous bead of liquid gasket to mating surface

of steel oil pan.
Use Genuine Liquid Gasket or equivalent.

Inner
side

Boll hole

r~nr

SEM909B

4.05.0 mm
(0.157 0.197 In)

~ Liquid gasket

,'glig"{

SEM983E

EM-17

OIL PAN
Installation (Cont'd)

Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in)

wide.
AUaching should be done within 5 minutes after coating.

Cut here.

~--------=J
Liquid gasket

SLC906

(3) Install steel oil pan.

Install bolts in numerical order shown.

Wait at least 30 minutes before refilling engine oil.

~o=o~

o/Jj_~J\o

n ~I

:1 11 n

CD~ 'l,~rl ~
Engine
n~ J
J n

front

I] l

I I') ~ @

~~J
CD

nghten in numerical order.

al

SEM984E

EM-18
&&R"
.. ,

TIMING CHAIN

SEC. 120-130135-210

Sf::M985E

G)
@
@
@

>

Cylinder block

Chain guide

Crankshafl sprockel

Chain guide
RH camshaft
Chain
. sprocket
tensloner

Front cover

Chain guide

(J)

Crank pulle
Oil pump s pacer
Y

@
@

Timing chain
LH camshaft sprocket

ii\l1

TIMING CHAIN
CAUTION:

After removing timing chain, do not turn crankshaft and

camshaft separately, or valves will strike piston heads.

When installing rocker arms, camshafts, chain lensioner,

oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.

Apply new engine oil to boll threads and seat surfaces

when installing cylinder head, camshaft sprocket, crankshaft pulley, and camshaft brackets.

Removal
1.

Release fuel pressure.

Refer to "Releasing Fuel Pressure" in EC section.
2. Remove engine under covers.
3. Drain coolant.
4. Remove radiator.
5. Remove air duct to intake manifold and air recirculation
duct.
6. Remove PCV hoses from rocker cover.
7. Remove drive belts and water pump pulley.
8. Remove alternator.
9. Remove power steering oil pump.
10. Remove the following parts from cylinder head and intake
manifold: vacuum hoses, fuel hoses, water hoses, wires,
harness, connectors and so on.
11. Remove ignition coils and all spark plugs.

12. Remove rocker cover.

Engine front

Loosen in numerical ordeL

SEM986E

13. Remove intake manifold supports.

..

SEM987E

EM-20

TIMING CHAIN
Removal (Coot'd)

14. Set No 1 .
.
strake by
TDC on th e compres sian
rotati n '
piston at
g crankshaft.

III

crankshaft u .
ca tating
ed in f Igure
camshaft sprocket Il.JG
s set at position in~:llm
mark at
on left.

~otate

.
15. Rem ave chain t enslOner

16. Remove camshaft position sensor.

17. Remove tim'Ing chain guide.

_~_S_EM991E

EM-21

TIMING CHAIN
Removal (Cont'd)
18. Remove camshaft sprockets.

19. Remove camshafts, camshaft brackets, oil tubes and bat

fie plate.

Loosen in numerical order.

SEM993E

I
20. Remove exhaust manifold with turbocharger. Refer to
"Removal" ;n "TURBOCHARGER" (EM-49).

21. Remove cylinder head outside bolls and inside sub bolls.

22. Remove cylinder head bolts.

A warped or cracked cylinder head may result from removing in incorrect order.

Bolts should be loosened in two or lhree steps.

23. Remove cylinder head with intake manifold.

J Engine front

0
0

a
0

ill

@l
0

tID

Loosen in numerical order.

CD
SEM996E

EM-22

TIMING CHAIN
Remo
24
va I (Cont'd)
. Remove oil
Refer to "R pans.
25. Rem ave oil emaval"
in. "0baH
strain er and
IL PAN"
(E M-13).
I
e plate.

26. Romov e crankshaft pulley.

27, Remove f ront cover.

. chain
28. Remo ve timing
.
ch am
. 9 Ul'd es and rImlng

.
c=P

Inspection

'.

I
U

Check for cr.ells

s. Replace
chain if necess ary.
and excessive w ear at roller link

~\;

SEM984C

EM-23

~y

r~l~

TIMING CHAIN

Installation

r
r

Engine
front

1.

Install crankshaft sprocket on crankshaft.

2.

Position crankshaft so that NO.1 piston is set at TOG an

key way is at 12 o'clock. Fit timing chain on cranksha
sprocket, aligning the mating marks.

Mating mark color on timing chain.

eD
: Gold
@, @: Silver

3.

Install timing chain and timing chain guides.

4.

Before installing front cover, remove all traces of liquid

gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
cylinder block.

~ Crankshaft
L....y'side

"-r-----J

Crankshaft sprocket
SEM470E

CV
. 2~ _'? '";;;,
Moti,. m
Mating mark -tr=.
-',
\~

I
~ t"'",,

56'~~

Mating mark
SEM213DA

t_--------------E-M-~2-4---------

TIMING CHAIN
Installation (C

contin~~t'd)

5.

Apply a
of front cover
us bead of liquid
Use Ge nume
.
'Liquid Gask t
gasket to matIng
'
surface
e or eq U1valent.
.

6,

Install oil
Mak e surepump
drive spacer and fro
that 0-.
g IS inslalled onntoIl pump
ock.
sage 01 cylinder b;on

SLC492A!

~ove,

0 u tl et

pas-

:[;1,

Wipe off ex cesslve

.
liq UI'd gasket.

7.

Install cran
Set No 1 ~shaft pulley
. pIston at TOG' on Its
, co mpression stroke

8.

~--..
EM-25

bnz

TIMING CHAIN
Installation (Cont'd)
9.

Install oil strainer and baffle plate.

10. Install oil pan.

Refer to "Installation" in "OIL PAN" (EM-13).

11. Before installing cylinder head gasket, apply a continuous

bead of liquid gasket to mating surface of cylinder block.

Cylinder head bolt

L-"AIIIIIIIIIIIIIIIIIIIIIIIIIIII']

12. Install cylinder head with intake manifold.

CAUTION:
The cylinder head bolts can be reused providing dimension
"A" is not exceeded.
Dimension "A":
158.2 mm (6.23 in)

SEM020D

n CD
0

a.

Cylinder head bolls tighlening procedure:

Tighten all bolts to 39 Nm (4.0 kg-m, 29 ft-Ib).
b. Tighten all bolts to 78 Nm (8.0 kg-m, 58 fl-Ib).
c. loosen all bolls completely.
d. Tighten all bolts to 34 to 44 Nm (3.5 to 4.5 kg-m, 25 10 33
ft-Ib).

Engine fronl

CD
0

LJ
Tighten in numerical order.
SEM998E

EM-26

TIMING CHAIN
Installation (Cont'd)

e. Method A: Turn all bolts 90 to 95 degrees clockwise with

Tool or suitable angle wrench.
Method B: If an angle wrench is not available, mark all
cylinder head bolts on the side facing engine
front. Then, turn each cylinder head bolt 90 to
95 degrees clockwise.
1. Turn all bolts 90 to 95 degrees clockwise.
g. Ensure that paint mark on each bolt faces the rear of the
engine. (Method B only)
Do not turn any bolt 180 to 190 degrees clockwise all at once.
L..--

,~

__'

II
NIL\,

-----~----------,

Method B
90 - 95 degrees

I~\.~;

~:S~

fGu.
Engine
front

Paint mark

~J
Tightening torque N-m (kg-m, ft-lb)

118
(12, 87)

h>

78
18,58)

2S

39 (4.0. 29)

$;,1]'

@
0)IQ)

@
-------I----~-------------_.----

39
(4,29)

iJ&,

90 +-Z degrees
SEMD74DA

~~

13. Install cylinder head outside bolts and inner sub-bolts.

14. Install exhaust manifold with turbocharger. Refer to
"Installation" in "TURBOCHARGER" (EM-53).

~}~

~If
~~
1~lf

15. Install camshafts, camshaft brackets, oil tubes and baffle

plate.
Position camshaft.
a. LH camshaft key at about 12 o'clock
b. RH camshaft key at about 10 o'clock

EM-27

rc{:I~,

r~l

Installation (Cont'd)
~End bracket

Rli camshaft

bra~.
0 .....
,

PosiHon camshaft bracket.

Camshaft bracket bolts lightening procedure

STEP 1:
Tighten bolts . @ In that order then
tighten bolts CD - in that order.
~: 2 Nm (0.2 kg-m, 1.4 ft-Ib)
STEP 2:
Tighten bolts in the specified order.
rp;J: 6 Nm (0.6 kg-m, 4.3 ft-Ib)
STEP 3:
Tighten bolts in the specified order.
~: 9.0 - 11.8 Nm
(0.92 - 1.2 kg-m, 6.7 - 8.7 ft-Ib)

End bracket

Engine

~.

'ronb
NO.1 to 4
brackets
No. t to 4
bre.ckets

~~~a~:;t

2:mshatt

SEMOOIF

Intake side

--~
.--./

ut

J!

::Il-/(
u

(...)

(( ' ) -

~J~~

l~J
Exhaust side

:J

Engine front

Tighten in numerical order.

SFMO02F

16. Install camshaft sprockets.

line up mating marks on timing chain with mating marks on
camshaft sprockets.

Mating
mark
SEM98BE

Lock camshafts as shown in figure and tighten to specified

torque.
~: 127 - 137 Nm
(13 . 14 kg-m, 94 - 101 ft-Ib)

EM-28

TIMING CHAIN
Installation (Cont'd)
17. Install timing chain guide.

III
18. Install camshaft position sensor.
a. Make sure that No.1 piston is at TOC on its compression
stroke.
b. Set mating marks on rotor shaft of camshaft position sensor as shown.

c.

Install camshaft position sensor aligning the center of fixing bolt hole.
After installing, confirm that mating marks on rotor shaft of
camshaft position sensor are as shown.
d. Tighten fixing bolts.

19. Install chain tensioner.

Press cam stopper down and "press-in" sleeve until hook can
be engaged on pin. When tensioner is bolted in position the
hook will release au'omatically. Ensure arrow "A" faces the
front of the engine.

SEM990C

SEM991C

EM-29

~~

Installation (Cont'd)

If hook does not release automatically, turn crankshaft

counterclockwise until it does release.

Turn

20. Install cylinder head front cover.

Before installing, remove all traces of liquid gasket from

mating surface of cylinder head and the cover using a
scraper.

Apply a continuous bead of liquid gasket to mating surface

of cylinder head front cover.

Use Genuine liquid Gaskel or equivalent.

2,03.0 mm
{O,OT9 0.118 In}

,..-------------------,

21. Install intake manifold supports.

SEM987E

22. Remove all old liquid gasket from mating surfaces of

rocker cover and cylinder head.
23. Apply a continuous bead of liquid gasket to mating surface
of rocker cover gasket and cylinder head.

Use Genuine Liquid Gasket or equivalent.

24, Install rocker cover,

Rocker cover tightening procedure:

(1) Tighten nuts CD - @ - @ - @ in that order to 4 Nm
(0.4 kg-m, 2.9 ft-Ib).
(2) Tighten nuts CD 10 '~ as indicated in figure to 8 to 10 Nm
(0.8 10 1.0 kg-m, 5.8 to 7.2 f1-Ib).

Engine fronl
Tighlen in numerical order,

Q
SEM009F

EM-30

TIMING CHAIN
Installation (Cont'd)
25. Reinstall any parts removed in reverse order of removal.
When refilling engine coolant, refer to "Engine
Maintenance" in MA section.

IIII
ILl:

EM-31

VALVE Oil SEAL

1.
2.
3.

4.

5.

Air

Remove
Remove
Refer to
Remove

rocker cover.
camshafts and sprockets.
"Removal" in "TIMING CHAIN" (EM-20).
ignition coils on spark plugs.

Install air hose adapter into spark plug hole and apply air
pressure to hold valves in place. Apply a pressure of 490
kPa (4.9 bar, 5 kg/cm 2 , 71 psi).
Remove rocker arm, rocker arm guide and shim.

SEM077D

6. Remove valve spring with Tool.

Piston concerned should be set at TOC to prevent valve from
falling.

7.

Remove valve oil seal.

8.

Apply engine oil to new valve oil seal and install it with
Tool.

EM-32

OIL SEAL REPLACEMENT

SEM6930

FRONT OIL SEAL

1. Remove the following parts:
Engine under cover

Drive belts
Crankshaft pulley

2. Remove front oil seal.

Be careful not to scratch front cover.

SEM997C

Engine
inside

/'i

~ Engine

Y --+',------4-- LV

Oil seal lip ~

ou1side

Dust seal lip

~~
~

SEM715A

3.

Apply engine oil to new oil seal and install it using a suitable tool.

EM-33

IIII
lie

OIL SEAL REPLACEMENT

REAR OIL SEAL
1.
2.
3.
Be

Remove transmission. (Refer to MT or AT section.)

Remove flywheel or drive plate.
Remove rear oil seal.
careful not to scratch rear oil seal re1alner.

4.

Apply engine oil to new oil seal and install it using a suitable tool.

SEM999G

r
Engine /'--0
r.l\. Engine
inside y--+~-y outside
Oil seal lip ~

r- Dust

~~'
=d

seal lip

SEM71SA

SEM0010

EM-34

INTAKE MANIFOLD
Removal
1.
2.
3.

4.
5.

Release fuel pressure.

Refer to "Releasing Fuel Pressure" in EC section.
Drain coolant.
Remove air duct from intake manifold.
Remove PCV hoses from rocker cover.
Remove vacuum hoses, fuel hoses, water hoses, wires,
harnesses, connectors, etc. from intake manifold.

6.

Remove intake manifold collector supports.

7.

Remove intake manifold collector.

8.

Remove harness connectors of engine coolant temperature sensor and thermal transmitter.
Remove fuel tube assembly.
!R:[~j

'M/ll

Engine fran!

Loosen in numerical order.

SEM011F

9.

10. Remove EGR tube.

11. Remove hose and tube between EGR valve and EGRC-BPT

valve.

EM-35

INTAKE MANIFOLD
Removal (Cont'd)
12. Remove intake manifold supports.

SEM9B7E

13. Remove intake manifold.

Engine front

Loosen in numerical order.

SEM014F

Installation

Engine front

1.
2.
3.
4.

Install
Install
Install
Install
valve.

intake manifold.
intake manifold supports.
EGR tube.
hose and tube between EGR valve and EGRC-8PT

5.

Install fuel tube assembly.

Tighten bolts in two steps.
1st: 9.3 . 10.8 N'm (0.95 - 1.1 kg-m, 6.9 - 8.0 tt-Ib)
2nd: 21 - 26 N'm (2.1 - 2.7 kg-m, 15 - 20 ft-Ib)
Connect harness connectors of engine coolant temperature sensor and thermal transmitter.

Tighten in numerical order.

SEM015F

6.

7.

Install intake manifold collector.

Engine front

Tighten in numerical order.

SEM017F

EM-36

Installation (Cont'd)
8.

Reinstall any parts removed in reverse order of removal.

@[

II
l~ I
~f(;

EM-37

SEC. 111-130
~ Reier to "Installation" In
/

_v,

"TIMING CHAIN",

~waSher~

---J

Rocker cover gasket

to.J

Refer to "Installetlan" In
"TIMING CHAIN".

r---..........-C bhausl side

~~

~ /?~~

to.J 4.5 - 8.3

(0.46 - 0.85, 3.3 - 6.1)

'~

~~j

~~r"-A~, .. I I ,~
..

1~i~I~~ j

f,,-E:-~-r. . ...,c..:>,,,,,

1I~.r"'A:""~

r.

~~~:::.1S-~'il ,-.-~~

"",n~Y~~~ ~~

I.~~alve

~ ~

oil seal

.~~

9.0 - 11.8

'11.92 - 1.2,

'.1 - 'n

9
(k9~m, ft-lb)
: Apply liquid gasket

COJ : Nm
~

SEM01BF

CD

Oil filler cap

(~)

Rocker cover

@
@

Rocker arm guide

rJJ

Shim

Rocker arm
Hydraulic lash adjusler
Chain tensioner

Camshaft sprocket

@J
@
@
@
@

Camshaft bracket

Oil tube

@
@
@l

Camshaft

Chain guide
Cylinder head

@l
@

Valve spring seat

Valve spring
Valve spring retainer
Valve collet
Spark plug
Cylinder head bolt

Valve

EM-38

'-'.,?~------------

CAUTION:
When installing rocker arms, camshaft and oil seal, lubricate contacting surfaces with new engine oil.
When tightening cylinder head bolts, camshaft sprocket
bolts and camshaft bracket bolts, lubricate thread portions
and seat surfaces of bolls with new engine oil.

III
OK

1\

~@
;,'

If a hydraulic lash adjuster is kept on its side, there is a

risk of air entering it. When hydraulic lash adjusters are
removed, stand them straight up or soak them in new
engine oil.
Do not disassemble hydraUlic lash adjusters.
Attach lags to lash adjusters so as not to mix them up.

~,r;~

:':,

SEM878CA

Removal and Installation

Removal and installation procedures are the same as those
for timing chain. Refer to "Removal" and "Installation" in
"TIMING CHAIN" (EM-20, EM-24).

Disassembly

Rocker arm guide

ROCk~rarm

Remove rocker arms, shims, rocker arm guides and 8jgJ

hydraulic lash adjusters from cylinder head.
CAUTION:
Keep parts in order so that they can be installed in their O ri 9- i,~']
inal positions during assembly. (Install parts in their original
positions.)
1.

Shim
Hydraulic
lash adjuster

\,i, \ \

.&If

~' ~

1~1

SEM202D

2.
3.

Remove intake manifold. Refer to "Removal" in "INTAKE

MANIFOLD" (EM-35).
[~:['.\
Remove water outlet.

CYLINDER HEAD
Disassembly (Cont'd)
4.

Remove valve components with Tool.

5.

Remove valve oil seal with a suitable tool.

Inspection
CYLINDER HEAD DISTORTION
Measure the distorsion in the directions as shown.
Head surface distorsion:
Standard
Less than 0.03 mm (0.0012 in)

limit

SEM925C

0.1 mm (0.004 in)

If beyond the specified limit, replace or resurface.
Resurfacing limit:
The resurfacing limit of cylinder head is determined by the
cylinder block resurfacing in an engine.
Amount of cylinder head resurfacing is "A".
Amount of cylinder block resurfacing is liB".
The maximum limit is as follows:
A + B = 0.2 rnm (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:
136.9 - 137.1 mm (5.390 - 5.398 in)

CAMSHAFT VISUAL CHECK

Check camshaft for scratches, seizure and wear.

EM-40

CYLINDER HEAD
Inspection (Cont'd)
CAMSHAFT RUNOUT
1

Measure camshaft runout at the center journal.

Runout (Total indicator reading):
Standard
Less than 0.02 mm (0.0008 in)

limit
0.1 mm (0.004 in)
2.

,,".~,I

If it exceeds the limit. replace camshaft.

CAMSHAFT CAM HEIGHT

1.

Measure camshaft cam height.

Standard cam height:
Intake & Exhaust
37.920 - 38.110 mm (1.4929 - 1.5004 in)
Cam wear limit:
Intake & Exhaust
0.20 mm (0.0079 in)

2.

If wear is beyond the limit. replace camshaft.

III
l~

SEM549A

CAMSHAFT JOURNAL CLEARANCE

1.
2.

Install camshaft bracket and tighten bolts to the specified

torque.
Measure inner diameter of camshaft bearing.
Standard inner diameter:
28.000 - 28.021 mm (1.1024 1.1032 in)

!~J

SEM927C

3.

4.

Measure outer diameter of camshaft journal.

Standard outer diameter:
27.935 27.955 mm (1.0998 1.1006 in)
If clearance exceeds the limit, replace camshaft and/or
cyl inder head
Camshaft journal clearance:
Standard
0.045 0.086 mm (0.0018 - 0.0034 in)
Limit
0.15 mm (0.0059 in)

CAMSHAFT END PLAY

1.
2.

Install camshaft in cylinder head.

Measure camshaft end play.
Camshaft end play:
Standard
0.092 - 0.173 mm (0.0036 0.0068 in)
Limit
0.20 mm (0.0079 in)

[-{!~,

81.

EM-41

CYLINDER HEAD
Inspection (Cont'd)
CAMSHAFT SPROCKET RUNOUT
1.
2.

Install sprocket on camshaft.

Measure camshaft sprocket runout.
Runout (Total indicator reading):
limit 0.25 mm (0.0098 in)
If it exceeds the limit, replace camshaft sprocket.

3.

SEM929C

VALVE GUIDE CLEARANCE

1. Measure valve deflection in a parallel direction with rocker
arm. (Valve and valve guide mostly wear in this direction.)
Valve deflection limit (Dial gauge reading):
Intake & Exhaust
0.2 mm (0.008 in)

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

a. Measure valve stem diameter and valve guide inner diameter.
b. Check that clearance is within specification.
Valve to valve guide clearance:

2.

Unit: mm (in)

Standard
Intake
SEM938C

Exhausl

c.

0.020 - 0.053
\0-0008 - 0.0021)
0.040 - 0.073
(00016 - 0.0029)

Limit
0.08 (0 .0031)

0.1 (0.004)

If it exceeds the limit, replace valve or valve guide.

VALVE GUIDE REPLACEMENT

1.

To remove valve guide, heat cylinder head to 110 to 130C

(230 to 266F).

SEMOOBA

.._-------------------------------

CYLINDER HEAD
Inspection (Cont'd)

2.

Press out valve guide or use a hammer and suitable tool

3.

Ream cylinder head valve guide hole.

Valve guide hole diameter
(for service parts):
Intake
10.17510.196 mm (0.4006 - 0.4014 in)
Exhaust
11.175 - 11.196 mm (0.4400 - 0.4408 in)

4.

Heat cyl inder head to 110 to 130C (230 to 266F) and press
service valve guide onto cylinder head.
Projection "L":
14.0 - 14.2 mm (0.551 . 0.559 in)

-I
'\"r,

Mllf
/f:l:],

SEMOB3D

5.

Ream valve guide.

Valve guide inner diameter:
Intake
6.0006.018 mm (0.2362 - 0.2369 in)
Exhaust
7.000 - 7.018 mm (0.2756 - 0.2763 in)

VALVE SEATS
Check valve seats for pitting at contact surface. Resurface or [{~
replace if excessively worn.
Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct iE!l,
vafve seat.
Cut with both hands to uniform the cutting surface.

EM-43

CYLINDER HEAD
Inspection (Cont'd)
REPLACING VALVE SEAT FOR SERVICE PARTS
1.

Bore out old seat until it collapses Set machine depth stop
so that boring cannot contact bottom face of seat recess in
cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Intake
35.500 - 35.516 mm (1.3976 - 1.3983 in)
Exhaust
31.500 - 31.516 mm (1.2402 - 1.2408 in)
Use the valve gUide center for reaming to ensure valve seat
will have the correct fit.

SEM795A

3.
4.

Heat cylinder head to 110 to 130"C (230 to 266F).

Press fit valve seat until it seals on the bottom.

5.

CuI or grind valve seat using a suitable 1001 at the specified dimensions as shown in SOS.
After cutting, lap valve seat with abrasive compound.
Check valve seating condition.
Seat face angle "a":
44"53' - 45"07' deg.
Contacting width "W":
Intake
1.4 1.7 mm (0.055 - 0.067 in)
Exhaust
1.7 - 2.0 mm (0.067 0.079 in)

SFM008A

6.
7.

SEM8928

VALVE DIMENSIONS

T (Margin thickness)

IT

[Waf~

Check dimensions in each valve. For dimensions, refer to

SDS.
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.

-r---+-:r------c----o-1
d

-L~-~

SEM188A

EM-44
u

CYLINDER HEAD
Inspection (Cont'd)
VALVE SPRING
Squareness
1.

2.

Measure "S" dimension.

Out-of-square:
Less than 2.2 mm (0.08l In)
If it exceeds the limit, replace spring.

SEM288A

Pressure
Check valve spring pressure.
Standard:

578.02 - 641.57 N
(58.94 - 65.42 kg, 129.96 - 144.25 Ib)
at 30.0 mm (1.181 in)
Limit:
More 'han 549.2 N (56.0 kg, 123.5 Ib)
at 30.0 mm (1.181 In)
EM113

If it exceeds the limit, replace spring.

HYDRAULIC LASH ADJUSTER

1.

Check contact and sliding surfaces for wear or scratches.

2.

Check diameter of lash adjuster.

Outer diameter:

SEM935C

16.980 - 16.993 mm (0.6685 - 0.6690 in)

3.

Check lash adjuster gUide inner diameter.

Inner diameter:
17.000 - 17.020 mm (0.6693 - 0.6701 in)
Standard clearance between lash adjuster and
adjuster guide:
0.007 - 0.040 mm (0.0003 - 0.0016 in)

EM-45

~ll

CYLINDER HEAD
Inspection (Cont'd)
ROCKER ARM, SHIM AND ROCKER ARM GUIDE
Check contact and sliding surfaces of rocker arms, shims and
rocker arm guides for wear or scratches.

Assembly
1.

Install valve component parts.

Install valves, noting their identification marks as indicated
in the table below.
Valve

Identificalion mark

Identification mark

Intake valve

53J

Exhaust valve

5J

SEM595D

Wide pilch

Narrow pilch

Cylinder head side

Always use new valve oil seal.

Refer to OIL SEAL REPLACEMENT.
Before installing valve oil seal, install valve spring seat.
Install valve spring (uneven pitch type) with its narrow
pitched side toward cylinder head side (paint mark).
Atter installing valve components, tap valve stem tip wilh
a plastic hammer to assure a proper fit

SEMOB5D

2.
a.

Check hydraulic lash adjusters.

Push on the rocker arm above the hydraulic lash adjuster.
If it moves 1 mm (0.04 in) or more, there is air in the high
pressure chamber.
Noise will be emitted from hydraulic rash adjuster if engine
is started without bleeding air.

SEM093D

b.

Proper rod

rEngine oil

-~~ ~-{-

Remove hydraulic lash adjuster and dip in a container

filled with engine all. While pushing plunger as shown in
figure, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves.
Air cannot be bled from this type of lash adjuster by running
the engine.

SEM772C

EM-46

CYLINDER HEAD
Assembly (Cont'd)
3,

ROCker~arm
guide
Rocker arm
Shim

HYdrauUc
lash adjUster" i

Install rocker arms, shims, rocker arm guides and hydraulic lash adjusters.

CAUTION:
Inslall all parts in their original positions.

l\:l[

Valve shim clearance adjustment

ilt

\ \

t ' .'
SEM2020

l.-_----~--------J

/~shim

~ Rocker arm guide

Ifil

~ ----..... Valve collet

I!J ~ Valve spring

retainer
'Valve spring

p ~[':l...

4. Determine proper shim size when replacing valve, cylinder head, shim, rocker arm gUide, or valve seat
l~t
a. Install valve component parts to cylinder head (Except
shim).
rF~
Always replace rocker arm guide with a new one.

"'-Valve spring seal

Valve all seal ~

Valve
SEM3640

Dial gauge

b.
c.

Remove hydraulic lash adjuster.

Install Tool" into hydraulic lash adjuster fixing hole.
Tool (KV10115700) is screwed into magnetic stand rod
used with dial gauge.

lAY

SEM365DA

Rocker arm guide

Valve

Valve

----~----------------------------

SEMB99D

Before measuring, make sure the following parts are

installed in the cylinder head: valve, valve spring, collet,
retainer, and rocker arm guide (excepl shim). On shim
side, measure difference (T 1 ) between contact surfaces of
rocker arm guide and valve stem end.
When measuring, lightly pull dial indicator rod toward you to
eliminate play in Tool (KV10115700).

~If

d.

EM-47

IX)~

I~l

CYLINDER HEAD
Assembly (Cont'd)
e. Select proper shim.
Shim thickness (T): T1 0.025 mm (0.0010 In)
Shims are available in thicknesses from 2.800 mm (0.1102
in) to 3.200 mm (0.1260 in) in steps of 0.025 mm (0.0010 in).

Indicate

= 2.800 mm

(0.1102 In)
SEM096D

2.0 - 3.0 mm
(D.079 D.11 Bin)

5. Install water outlet.

(1) Before installing water outlet, remove all traces of liquid
gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
cylinder head.
(2) Applya continuous bead of liquid gasket to mating surface
of water outl et.
Use Genuine liquid Gasket or equivalent.

~ Liquid gasket
SEM019F

6.

k
1

Install intake manifold.

Refer to "Installation" in "INTAKE MANIFOLD" (EM-36).

EM-48

TURBOCHARGER

Removal
1. Drain coolant from radiator and cylinder block.
2, Remove engine under cover.
3. Remove front exhaust tube.
4. Remove air ducts for turbocharger unit.
5. Remove air cleaner case.
6. Remove wastegate valve control solenoid and its hoses.

7.
8,
g,
10,

Remove
Remove
Remove
Remove

~[,

exhaust manifold cover.

heat insulator.
heated oxygen sensor.
EGR tube.

11. Remove connector bolts for water inlet and return tubes
and oil inlet tube,

12. Remove oil return hose from cylinder block.

13. Remove exhaust manifold fixing nuts.

Loosen in numerical order.

SEM023F

EM-49

~"T

TURBOCHARGER
Removal (Cont'd)
14. Remove steering column shaft lower joint (LHD model
only).
15. Remove exhaust manifold with turbocharger unit.

SEM994E

Disassembly

Locking plates

1.

Remove oil tubes and water tubes. Before removing tubes,

put mating marks on tube connectors and turbocharger-

2.

Unbend locking plates for turbocharger unit fastening nuts.

3.

Remove exhaust manifold.

SEM817D

SEM025F

4. Remove exhaust outlet, air outlet and heat insulator brackets.

Air outlet

Exhaust outlet

Heat insulator
bracket
SEM026F

EM-50

.----------------1

TURBOCHARGER

Inspection
Perform the following checks. If NG. replace turbocharger unit.

Oil Inlet
Turbine housing

TurbIne wheel

Wastegate valve

Check for leaks.

0'1 outlet
SEM028F

OIL AND WATER TUBES

Check tubes for clogging.

SEM029F

ROTOR SHAFT
1.

Check rotor shaft for smooth rotation.

SEM030F

EM-51

TURBOCHARGER
Inspection (Cont'd)
~

2.

Check rotor shaft for carbon deposits.

3.

Measure rotor shaft runout.

Runout (Total indicator reading):
Standard
0.056 - 0.127 mm (0.0022 - 0.0050 in)

4.

Measure rotor shaft end play.

End play:
Standard
0.013 . 0.097 mm (0.0005 - 0.0038 in)
Do not allow wheels to turn when axial play is being measured.

Rotor shaft

)
SEM031F

SEM827D

TURBINE WHEEL
Check turbine wheel for the following.

Oil
Carbon deposits
Deformed fins
Contact with turbine housing

SEM828D

COMPRESSOR WHEEL
Check compressor wheel for the following.

Oil
Deformed fins
Contact with compressor housing

SEM829D

EM-52

Inspection (Cont'd)
WASTEGATE VALVE
Remove rod pin and check wastegate valve for cracks, deformation and smooth movement. Check valve seat surface for
,f;J[
smoothness.

III

SEM830D

WASTEGATE VALVE ACTUATOR

Apply compressed air to wastegate valve actuator and check
it for smooth movement.
:e:;
Do not applying compressed air to the actuator continuously.
The air pressure should be in the range of 38.7 to 44.0 kPa if,;
(387 to 440 mbar, 290 to 330 mmHg, 11.42 to 12.99 inHg).

Assembly
Assembly is the reverse order of disassembly.
Install gasket between exhaust manifold and turbocharger
with lappet side facing exhaust manifold.

Bend locking plates along the side of turbocharger fastening nuts.

SEM832D

Installation
1. Install exhaust manifold fixing nuts.

@@

Tighten in numerical order.

SEM033F

I~l~r

TURBOCHARGER
Installation (Cont'd)
2.

Installation is the reverse order of removal.

Install oil tubes and water tubes in the following order,
aligning the mating marks.
a. Ojl feed tube
b. Water return tube
c. Water feed tube
d. Oil return tube

EM-54

ENGINE REMOVAL

MIT model

CC!l

-------,

13 - 16 (1.3 . 1.6, 9 . 12)

.-I

l' .~

~ l~~~~':V

..

'"

.;,~.

~5"
-....."

43-55
(4.4 - 5.6, 32 - (1)

t(

dI

----~

;;,..

4355
'\

(4.4 - 5.6, 32 - 41)

22 - 28 (2.2 - 2.9, 16 21J

@rt~ ,-..

f'!'11 43 - 55 (4.4 - 5.6, 32 - 41)

~\

f'~.

~~_
~/
\;

~./"'~

13 - 16 (1.3 . 1.6, 9 . 12)

;---."

_/

" - 78 f7 - 8, 51 - 58)

toj

'~~

---J
toJ

l' .:

L.

22 _ 28
22 _ 28 (2.2 _ 2.9, 16 - 21)
(2.2 - 2.9, 1621)

J-'~"'. ~
_/

~ 43 - 55 (4.4 . 5.6, 32 - (1)

: N.m (kg-m. tf.lb)

69 78 (7 - 8, 51 - 58)

SEM034F

EM-55

ENGINE REMOVAL

...

WARNING:

Situate vehicle on a flat and solid surface.

Place chocks at front and back of rear wheels.
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.
For safety during subsequent steps, the tension of wires
should be slackened against the engine.

Before disconnecting fuel hose, release fuel pressure from

fuel line.
Refer to "Releasing Fuel Pressure" in EC section.

Be sure to hoist engine and transmission in a safe manner.

For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:

When lifting engine, be sure to clear surrounding parts.

Take special care for accelerator wire casing, brake lines
and brake master cylinder.

In hoisting the engine, always use engine slingers in a

safe manner.

Removal
1. Remove transmission.
Refer to AT or MT section.
2. Remove engine under cover and hood.
3. Drain coolant from both cylinder block drain plug, and radiator drain cock.
4. Drain engine oil from drain plug of oil pan.
5. Remove vacuum hoses, fuel tubes, wires, harness and
connectors and so on.
6. Remove front exhaust tubes.
7. Remove radiator and shroud.
8. Remove drive belts.
9. Remove Ale compressor and power steering oil pump
from engine.
10. Install engine slingers to cylinder head.
11. Set a suitable hoist on engine slinger.
12. Remove engine mounting bolts from both sides and then
slowly raise engine.

13. Remove engine as shown.

Installation
Installation is in the reverse order of removal.

CYLINDER BLOCK

SEC.110.120

III
I
~ 127 - 137

,p;I

~~It

(13.0 14.0. 94 - lOll

/'

Refer to "Assembly". ~

. Apply liquid gasket

N-m (kg-m. ft-Ib)

SEM036F

CD

Rear oil seal retainer

Cylinder block
Water pump
Fron! cover with oil pump

@
@
@

Oil strainer
Thrust bearing
Crankshaft

@
@

CD

Connecting rod bushing

Piston rings

Piston
Piston pin
Connecting rod
Connecting rod bearing
Baffle plate
Main bearing beam
Main bearing cap
Pilo! converter

EM-57

@)
@
@
@

Drive plate
Reinforcement plate
Flywheel
Pilot bushing
Rear plate
Main bearing
Qiljet
Battle plate

CYLINDER BLOCK

CAUTION:

When installing bearings, pistons, or other sliding parts,

lubricate contacting surfaces with new engine oil.

Place removed parts such as bearings and bearing caps

in their proper order and direction.
When installing connecting rod nuts, and main bearing cap
bolts, apply new engine oil to threads and seating Surfaces.

Disassembly
PISTON AND CRANKSHAFT
1.
2.
3.
4.
5.

6.

7.

Remove engine.
Refer to "ENGINE REMOVAL" (EM-55).
Remove compressor bracket and engine mounting
bracket, then install engine on engine stand (ST0501S000).
Remove cylinder head.
Refer to "Removal" in "TIMING CHAIN" (EM-20).
Remove oil pan.
Refer to "Removal" in "OIL PAN" (EM-13).
Remove timing chain.
Refer to "Removal" in "TIMING CHAIN" (EM-20).

Remove pistons with connecting rods.

When disassembling piston and connecting rod, remove
snap ring first. Then heat piston to 60 to 70C (140 to 158F),
or use piston pin press stand at room temperature.
Remove rear oil seal retainer.

SEMB778

~~-c--~'-"~-;;-o

8.

J
0

Remove bearing beam, bearing cap and crankshaft.

Before removing bearing cap, measure crankshaft end
play.
Bolls should be loosened in two or three steps.

i
SEMOOml

EM-58

CYLINDER BLOCK
Disassembly (Cont'd)
9.

Remove baffle plate.

10. Remove oil jets.

SEM8100A

Inspection
PISTON AND PISTON PIN CLEARANCE

l- -

1.

Measure inner diameter of piston pin hole "dp".

Standard diameter "dp":
21.987 - 21.999 mm (0.8656 0.8661 in)

2.

Measure outer diameter of piston pin "Dp".

Standard diameter "Op":
21.989 - 22.001 mm (0.8657 - 0.8662 in)
Calculate piston pin clearance.
dp - Dp = -0.004 to 0 mm (-0.0002 to 0 in)
If it exceeds the above value, replace piston assembly with
pin.

AEM023

3.

AEMOJO

PISTON RING SIDE CLEARANCE

Side clearance:
Top ring

NG

0.045 - 0.080 mm (0.0018 - 0.0031 in)

2nd ring

--'---

R_in~g_Fe_e_le_rs~g:_~

0.030 - 0.065 mm (0.0012 - 0.0026 in)

Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston and/or piston ring assembly.

_::_4A___JA
_

EM-59

Pi~

CYLINDER BLOCK
Inspection (Coot'd)
PISTON RING END GAP
Feeler
gauge

Top ring:
Standard

0.20 - 0.30 mm (0.0079 - 0.0118 in)

Limit

0.39 mm (0.0154 in)

2nd ring:
Standard
0.35 - 0.50 mm (0.0138 - 0.0197 in)

Ring

Measuring point
SEM8228

Limit
0.59 mm (0.0232 in)
Oil ring:
Standard
0.20 - 0.60 mm (0.0079 - 0.0236 in)
limit
0.60 mm (0.0272 in)
If out of specification, replace piston ring. If gap exceeds maximum limit with new ring, rebore cylinder and use oversize
piston and piston rings.
Refer to 50S (EM-78).

CONNECTING ROD BEND AND TORSION

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.

SEM003F

EM-60

Inspection (Cont'd)
CYLINDER BLOCK DISTORTION AND WEAR
1.

SEM123C

E-

e=

~~

...:e,

~~
~,

Clean upper face of cylinder block and measure the distortion in the directions as shown.
Standard:
Less than 0.03 mm (0.0012 in)
Limit:
0.10 mm (0.0039 in)
2. If out of specification, resurface it.
The resurfacing limit is determined by cylinder head resurfacing in engine.
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:
211.25 - 211.35 mm (8.3169 - 8.3208 In)
3. If necessary, replace cylinder block.

III

'lJ~'

",'!!

SEM008D

PISTON-TO-BORE CLEARANCE

1.

Unit: mm (in)

SEM363E

2.

Using a bore gauge, measure cylinder bore for wear, outof-round and taper.
Standard inner diameter:
86.000 - 86.030 mm (3.3858 - 3.3870 in)
Wear limit:
0.20 mm (0.0079 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.
Out-of-round (X - Y) standard:
0.015 mm (0.0006 in)
Taper (A - B and A - C) standard:
0.010 mm (0.0004 In)

!~iJ

~$.\

Check for scratches and seizure. If seizure is found, hone

~!k

it.

SEM010D

EM-61

CYLINDER BLOCK
Inspection (Cont'd)

Front mark

11 /~/~I';j==

Engine
Iront

If cylinder block or piston is replaced, match piston grade

with grade number on cylinder block upper surface.

Cylinder grade number

(each cylinder)

Cylinder grade number

~\~

):u:(
-::? 0

<:::::>

CI

0 0 c:::

~CI~Q)r

L...-

----'--.

AEngine
frool

SEM~

3.

Measure piston skirt diameter.

Piston diameter "A":
Refer to 50S (EM-78).
Measuring point "a" (Distance from the bottom):
10.5 mm (0.413 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
0.010 - 0.030 mm (0.0004 - 0.0012 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to 5DS (EM.

78).
6.

Cylinder bore size is determined by adding piston-to-bore

clearance to piston diameter" A".
Rebored size calculation:

D=A+B-C
where,
0: Bored diameler
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores.
8. Cut cylinder bores.

When any cylinder needs boring, all other cylinders must

also be bored.

Do n01 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-at-round and taper.

Measurement should be done after cylinder bore cools

down.

CRANKSHAFT

A B

1.
2.

Check crankshaft main and pin journals tor score, wear or

cracks.
With a micrometer, measure journals for taper and outof-round.
Unit mm (in)

Out of-round (X - Y) and

Taper (A - B}
Taper' A - B
Out-aI-round X - y
SEM316A

EM-62

f-M_a_in~jo_\)_rn_a_'~_~~~_Le_S_S_lh~a_n_O_O_05_(O_.O_OO_2_)_
Pin journal

Less than 000;:>5 (0000'1)

CYLINDER BLOCK
Inspection (Cont'd)
3.

Measure crankshaft runout.

Runout (Total indicator reading):
Less than 0.05 mm (0.0020 in)

II
BEARING CLEARANCE

uc

Use Method A or Method B. Method A is preferred because

it is more accurate.
Method A (Using bore gauge & micrometer)

Main bearing
1. Set main bearings in their proper positions on cylinder
block and main bearing cap.

SEM685D

2.

Install main bearing cap and main bearing beam to cylinder block.
Tighten all bolts in specified procedure. Refer to
"CRANKSHAFT" in "Cylinder Block Assembly" (EM~68).
3. Measure inner diameter "A" of each main bearing.

4.
5.

6.
7.

Measure outer diameter "Om" of each crankshaft main

journal.
Calculate main bearing clearance.
Main bearing clearance = A - Dm
Standard: 0.004 - 0.022 mm (0.0002 - 0.0009 in)
Limit: 0.050 mm (0.0020 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.

a.

When grinding crankshaft journal, confirm that "L" dimension in fillet roll is more than the specified limit.
"L": 0.1 mm (0.004 in)
b. Refer to 80S for grinding crankshaft and available service
parts (EM-BO).

EM-63

&7

,H~

Inspection (Cont'd)
8.

No.5

a.

If crankshaft is reused, measure main bearing clearances

and select thickness of main bearings.
If crankshaft is replaced, 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 Roman numerals.

SEM313D

Type I

Main journal grade number

b.

Grade number of each crankshaft main journal is punched

on the respective crankshaft. These numbers are punched
in either Arabic or Roman numerals.

C.

Select main bearing with suitable thickness according to

the following table.

No.5

No.1

Crankshaft
fronl view

No. 4

SEM013D

Type II

Crankshaft
fronl view
SEM203D

How to select main bearings

(Identification mark and color)
Crankshaft

Main journal grade number

journal grade
number

0
(A, Black)
1

2
3

(B, Brown)

(C, Green)

3
(0, Yellow)
(E, Blue)

(B. Brown)

(C, Green)

3
(0, Yellow)

3
(0, Yellow)

(E, Blue)

5
(F, Pink)

4
(E, Blue)

5
(F, Pink)

(G, No color)

(C, Green)
3
(0, Yellow)

For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number
1 + 2
= 3 (0, Yellow)

EM-54

CYLINDER BLOCK
Inspection (Cont'd)
Connecting rod bearing (Big end)

1. Install connecting rod bearing to connecting rod and cap.

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

III

AEM027

-------------=--,

4.
5.

6.
7.

Measure outer diameter "Dp" of each crankshaft pin jour- l~

nal.
Calculate connecting rod bearing clearance.
Connecting rod bearing clearance (C - Dp):
Standard
0.020 . 0.045 mm (0.0008 - 0.0018 in)
Limit
0.65 mm (0.00256 in)
If it exceeds the limit, replace bearing.
If cjearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
Main
Refer to step 7 of "BEARING CLEARANCE bearing" (EM-63).

f.ll..()
Type I

8.

Main journal grade number

No.5

If crankshaft is replaced with a new one, select connecting

rod bearing according to the folloWing table.
Connecting rod bearing grade number:
These numbers are punched in either Arabic or Roman
numerals.

No. 4

No.1

Crankshalt
front view

Crank pin journal grade number

Connecting rod bearing grade

number

SEMQ13D

'ype II
No.3

No

4 cylinder
~

W---'>.~

Grade 0
Grade 1

Grade 2

Identification colors of connecting rod bearing:

Grade 0; No color
Grade 1; Black
Grade 2; Brown

Crankshaft

rear view

SEM204D

EM-55

Inspection (Conl'd)
/'

/'

Method B (Using plastigage)

CAUTION:

Do not turn crankshaft or connecting rod while plastigage

is being inserted.
When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. If clear.
ance cannot be adjusted using any standard bearing
grade, grind crankshaft journal and use undersized bear.
ing.

EM142

CONNECTING ROD BUSHING CLEARANCE (Small end)

1.

Measure inner diameter "C" of bushing.

2.
3.

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:
0.023 mm (0.0009 in)
If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston set with pin.

AEM029

L-

AEM030

REPLACEMENT OF CONNECTING ROD BUSHING

(Small end)
1.

Drive in small end bushing until it is flush with end surface

of rod.
Be sure to align the oil holes.
2. Ream the bushing so that clearance with piston pin is
within specification.
Clearance between connecting rod bushing and piston
pin:
0.005 . 0.017 mm (0.0002 - 0.0007 in)
SEM062A

REPLACEMENT OF PILOT BUSHING (MIT) OR PILOT

CONVERTER (All)

ST1661 0001

or suitable tool

1.

Remove pilot bushing or pilot converter using Tool or suitable tool.

SEM916A

EM-56

Inspection (Confd)
2.

Install pilot bushing or pilot converter as shown.

Crankshaft side

III

AIT
SEM1638

FLYWHEEL/DRIVE PLATE RUNOUT

Runout (Total indicator reading):
Flywheel (MIT model)
less than 0.15 mm (0.0059 in)
Drive plate (A/T model)
less than 0.20 mm (0.0079 in)

Dial gauge

Assembly
1. Install timing chain oil jet.
Drive oil jet into cylinder block with punchmark facing up.

SEM865D

2.
3.

:J
line front

Install piston oil jets.

Install baffle plate.

I
I

SEM810DA

PISTON
1.

Install new snap ring on one side of piston pin hole.

EM-67

Assembly (Cont'd)
2.
~

Front mark

Piston grade
number

Oil hole

Engine
front

Heat piston to 60 to 70 e (140 to 158F) 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.
D

Cylinder
number
SEM946C

s p e r side
Top

?-

Q.t

Punchmark side

2nd
'?91~

3. Set piston rings as shown.

CAUTION:

When piston rings are not replaced, make sure that piston
rings are mounted in their original posiHons.

When replacing piston rings, If there is no punch mark,

install with either side up.

011

SEM601D

Oil ring

til ?

expander

lit'

;(

Engine
front

Top ring
Oil ring
uppe r rail

4.

Locate the ring gap as shown.

'0
.

2nd ring

,.~

IJ

../)
Oil ring
- ; / ... lower rail
SEM160B

CRANKSHAFT

#5
#4

'#1~~
S;
il hole

#2

c2
Engine

#3

~~ \ )

~~,

front~

\\

~~

~~
SEM6B5D

1.

Set main bearings and thrust bearings in their proper positions on cylinder block and main bearing cap.
Confirm that correc1 main bearings are used. Refer to
"Inspeclion" of this section.
Direct the oil grooved side of thrust bearing to crankshaft
arm side.

Assembly (Conl'd)

,...-------------~------,

2.

a.
b.

Tighten in numerical order.

SEM015D

c.
d.

e4

Install crankshaft, main bearing caps and beam and

tighten bolts to the specified torque.
Prior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat 1he bearing cap.
Tightening procedure
Tighten all bolts to 26 to 32 N'm (2.7 to 3.3 kg-m, 20 to 24
tt-lb).
Turn all bolts 75 to 80 degrees clockwise with Tool or suitable angle wrench.
Loosen all bolts completely.
Tighten all bolts to 32 to 38 N'm (3.3 to 3.9 kg-m, 24 to 28
ft-Ib).
Vi"
Turn all bolts 45 to 50 degrees clockwise with Tool or suit'~
able angle wrench.
If an angle wrench is not available, mark all bearing cap !~~
bolts on the side facing engine rear. Then, turn each bolt
specified degrees clockwise. Confirm angle of degrees
with a graduator, not by eye-measurement.
After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.

III
I

3. Measure crankshaft end play.

Crankshaft end play:
Standard
0.10 - 0.26 mm (0.0039 - 0.0102 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace thrust bearings with new ones .

.-,

Feeler gauge r,
"\I
~D

4.

Align oil hole.

~~

JJ
rd

Install connecting rod bearings in connecting rods and

connecting rod bearing caps.
Confirm that correct bearings are used. Refer to
"Inspection".
Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.

.~[}i1

SEM159B

5.
a.

Install pistons with connecting rods.

Install them into corresponding cylinders with Tool.
Be careful not to scratch cylinder wall by connecting rod.
Arrange so that front mark on piston head faces toward
engine front
Be careful not
hit oil jet with connecting rod.

'0

EM-59

t{!A\
!R

Assembly (Cont'd)
b.

Install connecting rod bearing caps.

Tighten connecting rod bearing cap nuts in the following
two steps.
Step 1
Tighten nuts to 14 to 16 N'm (1.4 to 1.6 kg-m, 10 to

12 ft-Ib).
Step 2

Turn nuts 60 to 65 degrees clockwise with angle

Connecting rod bearing cap n lIt
SEM017DA
'--------~---~-

Baffle plate

,----------------_.---=

wrench. If angle wrench is nol available, tighten

nuts to 38 to 44 N'm (3.9 10 4.5 kg-m, 28 to 33 ft-Ib).
After securing connecting rod cap nuts, make sure crankshaft turns smoothly by hand.

6.

Measure connecting rod side clearance.

Connecting rod side clearance:
Standard
0.20 - 0.35 mm (0.0079 0.0138 in)
Limit
0.50 mm (0.0197 in)
If beyond the limit, replace connecting rod and/or crankshaft.

7.

Install baffle plate.

8. Install rear oil seal retainer.

(1) Before Installing rear oil seal retainer, remove all traces
of liquid gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
cylinder block.
(2) Install rear oil seal. Refer to "REAR OIL SEAL" in "Oil Seal
Replacement" (EM-34)

SEM2180

EM-70

Assembly (Cont'd)
~

Liquid
gasket

(3) Apply a continuous bead of liquid gasket to mating surface

of rear oil seal retainer.

Use Genuine Liquid Gasket or equivalent.

II

SEM219D

C,,'
L,\';-)

EM-71

SERVICE DATA AND SPECIFICATIONS (50S)

General Specifications
In-line 4

Cylinder arrangement

COMPRESSION PRESSURE
Unit: kPa (bar, kg/em', psi)/300 rpm

DIsplacement

em' (cu in)

Bore and stroke

mm (in)

1,998 (121.92)

86 x 86 (3.39 x 3.39)

Valve arrangement

DOHC

Firing order

1-3-4-2

Standard

1,079 (10.79,11.0,156)

Minimum

883 (6.63, 90, 128)

Differential limit between cylinders

98 (0.98, 1.0, 14)

Number of piston rings

Compression

Oil
Number at main bearings
Compression ratio

8.5

EM-72

SERVICE DATA AND SPECIFICATIONS (50S)

Inspection and Adjustment
VALVE

CYLINDER HEAD

Head surface distortion

Unit: mm (in)

Unit: mm (in)

'Gu

Standard
less than
0.03 (0.0012)

0.1 (0.004)

II
I
II:

H
~---l---

SEM188-B
Valve head diameter "0"

SEM043F
Nominal cylinder head height

"H"
Resurfacing limit

136.9 - 137.1 (5.390 - 5.398)

Intake

34.0 - 34.2 (1.339 - 1.346)

Exhaust

30.0 - 30.2 (1.181 - 1.189)

Valve length "l"

0.2 (0.008)"

Intake

101.19 - 101.61
(3.9839 - 4.00041

Exhaust

102.11 - 102.53
(4.0201 - 4.0366)

Sum of resurfacing cylinder head and cylinder block

Valve stem diameter "d"

5.965 - 5.980 (0.2348 - 0.2354)

Intake

6.945 - 6.960 (0.2734 - 02740)

Exhaust
Valve seat angle

"0;"

Intake
45 15' - 4545'
Exhaust
Valve margin 'T'
Intake

1.1 (0.043)

Exhaust

13 (0.051)

Valve margIn 'T' l<mil

More than 05 (0.020)

Valve stem end surface grinding

limil

Less than 0.2 (0.008)

.---------------

EM-73

SERVICE DATA AND SPECIFICATIONS (50S)

Inspection and Adjustment (Cont'd)

Valve guide

Valve spring

Uni!: mm (inl

Free height

49.36 (19433)

mm (in)

Pressure
N (kg, lb) at height mm (in)
578.02 - 64157
(58.94 - 65.42, 129.96 - 14425)
at 30.0 (1.181)

Standard

5492 (56.0, 1235)

at 300 (1.181)

Limit
Out-ai-square

mm (in)

Less than 2.2 (0.087)

Hydraulic lash adjuster (HLA)

Unit mm (in)
HLA outer diameter

16.980 - 16993
(0.6685 - 06690)

HLA guide inner diameter

17.000 - 17.020
(0.6693 - 0.6701)

SEMOB30

Standard

Service

Intake

10.023 - 10.034
(0.3946 - 0.3950)

10.223 - 10.234
(0.4025 - 0.4029)

Exhaust

11.02311.034
(0.4340 - 0.4344)

11,223 - 11.234
(0.4418 0.4423)

Valve guide

Clearance between HLA and HlA guide

0.007 0.040
(0.0003 - 0.0016)

Outer
diameter

Valve guide
Inner
diameter
(Finished
size)
Cylinder head
valve guide
hole diameter

Intake

6.000 - 6.018 (0.2362 - 0.2369)

Exhaust

7.000 - 7.018 (0.2756 0.2763)

Intake

9.975 - 9.996
(0.3927 - 0.3935)

10.175 - 10.196
(0.4006 - 0.4014)

Exhaust

10.975 - 10.996
(0.4321 - 0.4329)

11.175 - 11.196
(0.4400 - 0.4408)

Interference fit of valve

guide

Standard

Limit

Intake

0.020 - 0.053
(0.0008 - 0.0021)

0.08 (0.0031)

Exhaust

0.040 - 0073
(0.0016 - 0.0029)

0.1 (0.004)

Stem to guide
clearance

d"

0.027 - 0.059 (00011 - 0.0023)

Valve deflection limit

02 (0.008)

Projection length "L"

14.0 - 14.2 (0.551 - 0.559)

SERVICE DATA AND SPECIFICATIONS (50S)

Inspection and Adjustment (Cont'd)

Valve seat

Unit: mm (in)

Cylinder head

EXHAUST

II
I

--.------- D

--------0

Standard

Standard

'23

!:~X/7-l.-==- '29.35
:}f----

. 29.65
(11555 _ 11673):

'31.4 - 31.6 11 236 - 12441

'4453' - 4507'
'33.6 - 33.8
f4----- d
(1.323 - 1.3311
Contacting width (W): 1.4 1.7

......
'26.8 - 27.0 (1.055 - 1063)
'4453' 4507'
'29.4 - 29.6 (US? - 1.165)
----d
Contacting width (WI: 1.7 2.0 (0.067 - 0.079)

(0.055 - 0.(67)

Oversize

Oversize

'31.4 - 31.6 (1.236 - 1.244)

'4453' - 4507'
J
33.6 - 33.8
j
'-+------ d
(1.323 - 1.331)
Contacting Width (WI: 1.4 . 1.7
(0.055 _ 0.06 7 1

Contacting width (WI: 1.7 - 2.0 (0.0670.079)

:' Machining dala

SEM651D

Standard

Service

In.

35000 - 35.016 (1.3780 - 1.3786)

35.50035516 (1.3976 - 1.3983)

Ex.

31.000 - 31.016 (1.2205 - 1.2211)

31.500 - 31.516 (12402 - 1.2408)

~'ij'

Cylinder head seat recess diameter (0)

In.

0.064 - 0.096 (0.0025 . 0.0038)

Valve seat interference lil

Ex.

0.064 - 0.096 (0.0025 - 00038)

In.

35.080 - 35.096 (1.3811 . 13817)

35580 - 35.596 (1.4008 - 1.4014)

Ex.

31080 - 31.096 (1.2236 - 1.2242)

31.580 - 31.596 (1.24331.2439)

Valve seat outer diameter (d)

In.

6.25 (0.2461)

Depth (H)
Ex.

Height (h)

625 (0.2461)
6.2 - 63 (0.244 - 0.248)

54 - 55 (0.213 - 0.217)

EM-75

Inspection and Adjustment (Cont'd)

Valve shim clearance adjustment
Unit: mm (in)
Valve shim clearance {Cold}
Shim thickness "T'"

Less than 0025 (0.001)

~_---

T,0.025 (0,001)

kG

/ - Rocke'-r
arm-----'
gUide

Available shims
- Valve
Thickness mm (in)

IdenWication mark

2.800 (0. 1102}

28
00

2825 (0.1112)

2.850 (0.1122)

SEM09t>O

28
25

28
50

2.875 (0.1132)

2.900 (0.1142)

2925 (0.1152)

28

75

29

L shim

00

2.950 (0.1161)

2975 (0 1171)

29
75

3000 (0 1181)

30
00

3.025 (0.1191)

30
25

3.050 (0.1201)

30
50

SEM096D

~-~

30

75

3.100 (01220)

31
00

3125 (0.1230)

31
25

3.150 (0.1240)

31
50

3.175 (0.1250)

3200 (0.1260)

mm

29

25
29
50

3.075 (0.1211)

Indicate
T '" 2.800
(0.1102 In)

31

It>

32
00

EM-76

Inspection and Adjustment (Cont'd)

CAMSHAFT AND CAMSHAFT BEARING

Unit mm (in)

Standard

Limit

C;;shatt journal to
nearing clearance

0045 - 0.086
(0.0018 - 0.0034)

0.15 (0,0059)

~ diameter of cam-

28.000 - 28021
(1.1024 - 1.1032)

shalt bearing
C;;;;er diameter of
camshaft journal
Camshaft runout (TIR')

II

27.935 - 27955
(1.0998 - 1.1006)

less than
0.02 (0.0008)

0.1 (0.004)

---------_.
---------Less than

BOC

Camshaft sprocket
runout [TIR"]

025 (0,0098)
-~------0.092 - 0.173
Camshaft end play
(0.0036 - 0.0068)

EM120

Unit: degree

-------------------a

0,20 (0.0079)

240'

EM671

Cam height "A"

Intake

37.920 - 38.t10 (1.4929 - 1.50041

Exhaust

37.920 - 38.110 (1.4929 - 1.5004)

Wear limit of cam

height

0.2 (O.OOB)

Valve lill
Intake

9,2 (0.362)

Exhaust

9.2 (0.362)

'Tolal indicator reading

EM-77

240'

53'

I.~

Inspection and Adjustment (Cont'd)

CYLINDER BLOCK

PISTON, PISTON RING AND PISTON PIN

Unit: mm (in)

Available piston
Unit mm (in)

SEM008D

y
SEM750C

Piston skirt diameter "A"

Standard

SEM686D

Surface flatness
Standard

85.980 - 85.990 (3.3850 - 3.3854)

Grade NO.2

85.990 - 86.000 (3.3854 - 3.3858)

Grade NO.3

86.000 - 86.010 (33858 - 3.3862)

0.20 (0.0079) oversize (Service)

86.180 - 86.210 (3.3929 - 3.3941)

"a" dimension

10.5 (0.413)

Pisfon clearance to cylinder block

0.010 - 0.030 (00004 - 0.0012)

Piston pin hole diameler

21.987 - 21.999 (0.8656 - OB661)

Less than 003 (0.0012)

Limit

0.10 (0.0039)

Cylinder bore
Inner diameter
Standard
Grade No.

86.000 - 86.010 (3.3858 - 3.3862)

Grade No.2

86.010 - 86.020 (3.3862 - 3.3866)

Grade No 3

86020 - 86030 (3.3866 - 3.3870)

Wear limit

0.20 (0.0079)

Oul-ot-round (X - Y)

Less than 0.015 (O.0006)

Taper (A - B and A - C)

Less than 0.010 (00004)

Difference in inner
diameter between cylinders
Limit

Less than 005 (0.0020)

Main journal inner

diameter
Grade No.

Grade NO.1

58.944 - 58.950 (2.3206 - 2.3209)

Grade NO.1

58950 - 58.956 (2.3209 - 23211)

Grade No.2

58956 - 58962 (2.3211 - 2.3213)

Grade NO.3

58962 - 58.968 (2.3213 - 2.3216)

EM-78

Inspection and Adjustment (Cont'd)

CONNECTING ROD

Pis/on ring

Unit: mm (inl

Unit mm (inl

Center distance

Side clearance

13630 {5.3661)

Bend [per 100 (3.94)1

Top
Slandard

0.045 . 0.080
(0.0018 - 0.0031)

limit
Torsion [per 100 (3.94)J

0.1 (0.004)

Limit

limit

2nd

Standard

0030 - 0.065
(0.0012 - 0.0026)
0.1 (0.0041

Limit

015 (00059)

0.3 (0.0012)

Connecting rod small end

inner diameter

24980 . 25000 /09835 - 09843)

Piston pin bushing inner

diameter'

22.000 - 22.012 {08661 - a.8666)

Connecting rod big end

inner diameter

51000 - 51.013 (2.0079 - 2.0084)

~-----------+~---

End gap

Top
Standard

Side clearance

020 - 0.30 10.0079 - 0.0118)

Standard

039 (0.0154)

limit

Limit

1d
Standard

Alter insfalling in conneetillg rod

035 - 0.50 (0.0138 - 0.0197)

0.59 (00232)

Limil

Oil
Standard

020 - 0.60 (0.0079 - 00236)

0.69 (0.0272)

Limit

Piston pin
Unit mm (in)
Piston pin outer diameter
Interference fit of piston pin
to piston

21.989 - 22.001 (0.8657 - 0.8662)

o- 0.004 (0 - 0.0002)

Piston pin to connecting

rod bushing clearance
Standard

0.005 - 0017 (0.0002 - 0.0007)

~-~---~---r---------

_imit

0.023 (0.0009)

. Values measured at ambient temperature of 20'C (68'F)

EM-79

0.20 - 0.35 (0.0079 - 0.0138)

0.5 (0.020)

II
ll:

Inspection and Adjustment (Cont'd)

AVAILABLE MAIN BEARING

CRANKSHAFT
Unit mm (in)

#5

Main journal dia. "Om"

Grade No. 0

54974 - 54980 (2.1643 - 2.1646)

Grade NO.1

54968 - 54.974 (2.1641 - 2.1643}

Grade No.2

54.962 - 54968 (2.1639 - 21641)

Grade NO.3

54956 - 54.962 (2.1636 - 21639)

Oil hole

~
#1

Grade No. 0

47.968 - 47.974 (1.8885 - 1.8887)

47962 - 47968 (1.8883 - 1.8885)

Grade No. :1

47.956 - 47.962 (1.8880 - 1.8883)

Cenler distance" r' '

42.96 - 43.04 (1.6913 - 1.6945)

~~
~~,

~~

r2

Engine

60,

#3

#2

Pin ;ournal dia. "Op"

Grade No.1

#4

front~

~~

\)

~~
SEM685D

Out-at-round (X - Y)
Standard
Main journal

Less than 0.005 (0.0002)

Pin journal

Less than 0.0025 (0.0001)

Main bearing (Standard)

Taper (A - B]

Unit: mm (in)

Standard
Main ;ournal

Less than 0.005 (0.0002)

Pin ;ournal

Less than 0.0025 (0.0001)

Runout [TIRJ

Grade
number

Thickness "T"

1.977 1.980
(0.0778 - 0.0780)

Black (A)

Width "W"

Identification
color (mark)

Standard

Less than 0.025 (0.0010)

Limit

Less than 0.05 (0.0020)

1.9aO - 1.983
(0.0780 - 0.0781)

Brown {Bj

0.10 - 0.26 (0.0039 - 0.0102)

1.983 - 1.986
(0.0781 - 0.0782)

Green (e)

1.986 - 1.989
(0.0782 - 0.0783)

1.989-1.992
(0.0783 - 0.0784)

Blue (E)

1.992 1.995
(0.0784 - 0.0765)

Pink (F)

1.995 - 1.998
(0.0785 - 0,0787)

No color (G)

Free end play

Standard
Limit

0.30 (0.0118)
Om

18.9 - 19.1
(0.744 0.752)

Yellow (0)

Op
SEM954C

OUI-of-round
Taper

Main bearing (Undersize)

Unit: mm (in)

- (f)
-

Undersize

Thickness

"r-

@
0.25 (0.0098)

EM715

EM-80

2.109 - 2.117
(0.0830 - 0.0833}

Main journal
diameter "Om"
Grind so that bearing clearance is the
specified value.

Inspection and Adjustment (Cont'd)

AVAILABLE CONNECTING ROD BEARING

MISCELLANEOUS COMPONENTS

connecting rod bearing

Camshalt sprocket runout limit

standard size

lTIR]
Unit: mm (in)
Flywheel runout limit [TlR]

Grade
number

Thickness

"r

t .500 - t503
(0.0591 - 00592)
1.503 - 1.506
(0.0592 - 0.0593)

Identification
color (mark)

Width "W"

No color (A)
16.9 - 17.1
(0.665 - 0.673)

Black (B)

1.506 - 1.509
(0.0593 - 00594)

Brown (C)

Undersize
Unit: mm (in)

.,
Undersize

Thickness "I"

0.08 {0.0031j

1.541 - 1.549
(0.0607 - 0.0610)

0.12 (0.0047)

1561 - 1.569
(0.0615 - 0.0618)

0.25 (0.0098)

1.626 - 1.634
(0.0640 - 0.0643)

Crank pin journal

diameter "Dp"

Grind so that bearing clearance is the

specified value.

Bearing clearance
Unit: mm (in)
Main bearing clearance
Standard
Limit

0.004 - 0.022 (0.0002 - 0.0009)

0.05 (0.0020)

Connecting rod bearing

clearance
Siandard
LImit

0.020 - 0045 (0.0008 - 0.0018}

065 (0.0256)

EM-81

025 {D.D098)

o 15 (0.0059)

ENGINE LUBRICA-rION &

COOLING SYS-rEMS

SECTION

LC

CONTENTS
PRECAUTION AND PREPARATION
Precaution
Special Service Tools
ENGINE LUBRICATION SYSTEM

2
2
2
4

System Check
Refilling Engine Coolant..
Water Pump
Thermostat

Lubrication Circuit.

Water Outlet

Oil Pressu re Check

Oil Pump

5
8
8
9

Cooling Fan Control System (Motor driven)

Cooling Fan (Crankshaft driven)

Oil Filter

Oil Jet (For piston)

Oil Cooler

Turbocharger Oil Tube

ENGINE COOLING SYSTEM

10

Cooling Circuit

10
11 [;1.
11
12
'.' ",13
14
14 I~'T

Radiator (Aluminum type)

15

Turbocharger Water Tube

SERVICE DATA AND SPECIFICATIONS (5.0.5.)
Engine Lubrication System
Engine Cooling System

19

,-,

20
20
20

""'"
;J'IQi

iFf};,

10

PRECAUTION AND PREPARATION

~:

Precaution
LIQUID GASKET APPLICATION PROCEDURE
a.

Bolt hole

SEM371C

Use a scraper to remove all traces of old liquid gaske: frOITl

mating surfaces and grooves. Also, completely clea ~ any

oil from these areas.
b. Apply a continuous bead of liquid gasket to mating SUr,
faces. (Use Genuine Liquid Gasket or equivalent.)
Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in)
wide (for oil pan).
Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.11 Bin)
wide (in areas except oil pan).
c. Apply liquid gasket to inner surface around hole perimeter area.
(Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before refilling engine oil and
engine coolant.

AEMQ14
---' -

- - - - - - - _ ._ _- - !

Special Service Tools

Tool number
Tool name

Description

ST25051001

Oil pressure gauge

NT050

ST25052000

Adapting oil pressure gauge to cylinder

Hose

NT051

KV10115801

block

/--------

Removing oil filter

/ ~o./ 14 taces
t\-.
..
Inner span 64.3 mm (2.531 in)
'\:t'
(Face to opposite lace)

Oil filter wrench

NT362

EG17650301

Adapting radiator cap tester to radiator

l1adiato( cap tester

filler neck

adapter

NT<l53

LC-2

---

Toot number

PRECAUTION AND PREPARATION

Special Service Tools (Cont'd)
I

Description

Tool name
!~.I!

Pressing the tube of liquid gasket

WS39930000
Tube presser

NT052

Installing radiator upper and lower tanks

KV99f03510

Radiator plate pliers A

NT224

Removing radiator upper and lower tanks

KV99103520
A:--1 i ator plate pliers B

_ _- - - - - - - - I - N - T 2 - 2 _ 5

--

LC-3

--

ENGINE LUBRICATION SYSTEM

Lubrication Circu it
. . Return

Oil tube

::l

Feed
Camshaft

Rocker pivot

Oil filter

Oil cooler

Turbocharger
Oil filter bracket

Oil pump

l--_--'-rr_
. . ....;.-.. -

I.~.~_g_u_I~~~r valve I

--J

I Relief valve
Relief: valve

=:J Oll passage

. . . Oil gallery in cylinder block
~_._._ By-pass passage
_
To oil pan

(Bu1lt into oil filter)

Timing chain

SlC969A

Oil Pressure Check

WARNING:

1.
2.

Be careful not to burn yourself, as the engine and oil may

hot.
Oil pressure check should be done in "Neutral position".
Check oil level.
Remove oil pressure switch.

LC-4

ENGINE LUBRICATION SYSTEM

Oil Pressure Check (Cont'd)

r
5T25051001

3.
4.

5.
I

i!Il

Install pressure gauge.

Start engine and warm it up to normal operating temperature.
Check oil pressure with engine running under no-load.
Approximate discharge pressure: kPa (bar, kg/cm 2 , psi)
Engine speed at idle
More than 78 (0.78, 0.8, 11)
Engine speed at 3,200 rpm

:1

!/
L!

314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 57)

ST25052000
SLC926-A

If difference is extreme, check oil passage and oil pump for oil
leaks.
6. Install oil pressure switch with sealant.

Oil Pump
REMOVAL
1. Remove front cover.
Refer to "TIMING CHAIN" in EM section.
2. Remove oil pump cover.

DISASSEMBlV AND ASSEMBLV

SEC. 135-150

~ Uquid gasket

~3'7'S.O

(O.38 0.51, 2.7 - 3.7)

~---'l

~ 6.4 - 7.5
(0.65 - 0.76, 4.7 - 5.5J

------

~~

"'"

~ 6.4 - 7.5

(O.G5 - 0.76. 4.7 5.5)

Nm (kg-m. fl-Ib)

~ : Apply engine oil

._------~-~

Oil pump cover

Regulator valve

Fran! cover

Spring

Plug
Regulator valve set

(ID

Inner gear

(J)

Washer

@)

Oil strainer

Outer gear

CD

SLC971A

~n

Always replace oil seals and gaskets with new ones.

HQ)l1
When installing oil pump, apply engine oil to inner and
outer gears.

LC-S

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont'd)
INST ALLATION

Before installing front cover assembly, remove all traces

of liquid gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of

cylinder block.

SLC491AI

1.

2.

Apply a continuous bead of liquid gasket to mating surface

of front cover assembly.
Use Genuine Liquid Gasket or equivalent.
Installation is in reverse order of removal.

LC-6

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont'd)

- Straightedge

Feeler gauge

:~,r

SlC495A

@-@=
I

SlC450A
SlC860A

INSPECTION
Using a feeler gauge, check the following clearances:
Unit: mm (in)

Body to outer gear clearance

CD

0.114 - 0.200 (0.0045 - 0,0079)

Below 0 18 (0.0071)

Inner gear to outer gear tip clearance @

Body to inner gear side clearance @

0.05 - 009 (00020 - 0 0035)

Body to outer gear side clearance @

0.05 -

Inner gear to brazed portion of housing

clearance

,\Sher
'\

r,/f.\

a 11

(0.0020 - 0 0043)

0.045 - 0091 (0.001 B - 0 0036)

II the tip clearance () exceeds the limit, replace gear

set.
If body to gear side clearances (CD 1 @, @, ) exceed
the limit, replace front cover assembly.

REGULATOR VALVE INSPECTION

1.
2.

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
freely into the valve hole by its own weight.
If damaged, replace regulator valve set or front cover assembly.

SLC295-A

LC..7

~~,

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont'd)
4.

Check regulator valve to oil pump cover clearance.

Clearance:
: 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump cover.

Oil Filter
The oil filter is a small, full-flow cartridge type and is provided
with a relief valve.
The new and existing oil fil1er designs differ from each
other and are not Interchangeable.

Use Tool KV10115801 for removing oil filter.

SLC972A

Oil Jet (For piston)

INSPECTION

1.
2.

Blow through outlet of oil jet and make sure that air comes
out of inlet.
Push cut-off valve of oi I jet bolt with a clean resin or brass
rod and make sure that cut-off valve moves smoothly with
proper repulsion.

SLC015

When installing oil jet, align oil jet's boss with hole on cylinder block.

LC-8

ENGINE LUBRICATION SYSTEM

w--- ~ ~.; ~.~~~-m.

~

25 - 33 ft-Ib)

<Q:l

a-ring ~

Oil Cooler
REMOVAL AND INSTALLATION
1. Drain engine oil and coolant.
2. Remove oil cooler.
3. Installation is in reverse order of removal.

INSPECTION

;~~~

Oil cooler
1. Check oil cooler for cracks.
2. Check oil cooler for clogging by blowing through coolant
inlet.
If necessary, replace oil cooler assembly.

_ _ Oil cooler

C~

Gask.t~

Oil pressure relief valve

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.

~~

SLC973A

Turbocharger Oil Tube

SEC. 140.144
20

31

~V
~

t'J.J (2.0- - 3.2. 14 - 23)

~/ \
~
~

!'toJ

Turbocharger

.r

QUintet
tube

20 - 31

(2.0 - 3.2, 14 ~ 23)

~: Nm (kg-m. ft-Ib)

SLC983A

~=---------~-----------_.-------------------'

For installation, first hand-tighten bolts connecting tubes. ~!Rl

Then tighten bolts to the specified torques.
Be careful not to deform tubes.
After ins1allation, run engine for a few minutes, and check ~if
for oil leakage.
IRl~

Ii
1
:r{l!k
~l

MJ)JX

LC..9

ENGINE COOLING SYSTEM

Cooling Circuit

o
~eater~

= : Thermostat closed
. . . : Thermostat open

SLC974A

System Check
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 cap and carefully remove the cap
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

Check hoses for improper attachment, leaks, cracks, damage,
loose connoctions, chafing and deterioration.

CHECKING COOLING SYSTEM FOR LEAKS

To check for leakage, apply pressure to the cooling system
with a tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm 2 , 23 psi)

CAUTION:
Higher than the specified pressure may cause radiator damage.

SLCB59AA

LC-10

ENGINE COOLING SYSTEM

System Check (Cont'd)
CHECKING RADIATOR CAP
To check radiator cap. apply pressure to cap with a tester.
Radiator cap relief pressure:
78 - 98 kPa ~0.78 - 0.98 bar. 0.8 .. 1.0 kg/cm 2 , 11 ~ 14

I~r:

psi)

Pull the negative pressure valve to open it. Check that it c l o s e s .

completely when released.

Refilling Engine Coolant

Refer to "Changing Engine coolant" in MA section.

Water Pump

SEC. 210

CAUTION:
igj~:1

When removing water pump assembly, be careful not to

get coolant on drive belt.

Water pump cannot be disassembled and should be ~1'

replaced as a unit.

After installing water pump, connect hose and clamp

securely, then check for leaks using radiator cap tester.
!R\~

SLC975A

REMOVAL
1.
2.

3.
4.

Drain coolant from cylinder block and radiator.

[:{I~\
Remove fan coupling with fan.
Remove power steering pump drive beH, alternator drive
belt and air compressor drive belt.
I~l
Remove water pump.

LC-11

ENGINE COOLING SYSTEM

Water Pump (Cont'd)
INSPECTION
1.

Check for badly rusted or corroded vanes and body assembly.

Check for rough operation due to excessive end play.

2.

SLC976A

INSTALlATION
1.

Use a scraper to remove old liquid gasket from water

pump.
Also remove traces of liquid gasket from mating surface of
cylinder block.

SlC977A I

Apply a continuous bead of liquid gasket to mating surface

of water pump.
Use genuine liquid gasket or equivalent.

2.

2.0

3.0 mm

(0.079 - 0.118 In)

S_LC_9_78_A I

Thermostat
SEC. 210

Liquid gasket application places

0~
~

Thermostat housing

2-3mm
(0.08 0.12 In)
dIs.

C)

Thermostat

...

n--

~-~

'o-u
;)
JJ
~o

~ 3.7 5.0

(0.38 - 0.51, 2.7 - 3.7)

___

Water
outlet

~ Front

______

LC-12

23 mm

(0.08 0.12 In)

dis.

SlC979A

ENGINE COOLING SYSTEM

Thermostat (Cont'd)

---------------------.

INSPECTION
1.

2.

Check valve seating condition at ordinary room temperatures. It should seat tightly.
Check valve opening temperature and maximum valve lift.

Valve opening temperature

I

Maximum valve lift

3.

_____~- SLC"3]

DC rF)
mmJDC (inI"F)

76.5 (170)

':~~r;

Ml~

More than 10190 (0.39/194)

Then check if valve is closed at SoC (9F) below valve ~~~

opening temperature.
Apply a continuous bead of liquid gasket to mating SUrface.
of water inlet. Refer to "Water Pump (LC-11)".
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.

Water Outlet
INSPECTION
Visually inspect for water leaks. If there is leakage, apply liquid gasket.

IS~u

~ rA"
~
I[P ~~ r
~
~

@f

relief plug

INSTAlLATION
1. Use a scraper to remove old liquid gasket from water outlet.

tc'.l6.3 8.3
(0.64 - 0.85,
4.6 - 6.1)

2.

GO'"

Also remove traces of liquid gasket from mating surface of

cylinder head.
!<;r
Apply a continuous bead of liquid gasket to mating surface
of water outlet.
Use Genuine liquid Gasket or equivalent.
iRl~2

I-;:;I~

~ j ~i(j,~~:~O~~8

D liquid gasket
~ : Apply liquid gasket.
~: N.m (kg-m, ft-Ib)

to.J 6.3

~~~

8.3

(~..~_ ~~.~.
SLC980A

._---------------

LC..13

ENGINE COOLING SYSTEM

SEC. 214
~

~ 3.2 - 4.2

~
1\\ D-

Upper

~dlalor

hose

~ Lower radiator hose

~I
.-~ ~
-~
"ill

IJ>
r.

rrJ'l

~3.2

'l ~

I....

4.2 (0.33 - 0.43,2.4 . 3.1)

(0.33 - 0.43.

2.4 - 3.1)

COJ 3.2

-___

----

t~
(OJ

Cooling fan
(Motor driven)

I~

~ III

0,78 - 1.5 (0.08 0.16,0.58 - 1.161

4.2
(0.33 0.43, 2.4 - 3.1)

~
Push and pull
rearward to remove.

~: Nm (kg~m. ft-Ib)

SLC981A

Cooling Fan Control System (Motor driven)

Fans are controlled by ECM. For details, refer to EC section.

Cooling Fan (Crankshaft driven)

SEC. 210

-DISASSEMBLY AND ASSEMBLY

~6.4 7.5
(0.65 0.76,

4.7.5.5

Y/

/.'"

~: Nm (kg-m. ft-Ibl

SLC55BA

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

SLC072

LC-14

ENGINE COOLING SYSTEM

Radiator (Aluminum type)

./',...............

//

"'--...~

~.

. - - . Gil

~-.

~
--~
~ -~ ~'" ~.
~~

::--...
I

Sealing rubber ~

'

cooler securing nut

/-~8 -

12 N.m (0.8 - 1.2 kgm. 5.8

~-.......

~"-....I ~~Washer

'--..

~
-:-....

lower tank

e(~Conical washer ~

8.7 ft-Ib)

~,vo-r;ngo
'I
i
Oil
I

cooler

9
e

AIT model only

L-

SlCB92

P,PJ

Aluminum radiator can be disassembled by using special procedures and special service tools.

PREPARATION
Modification of radiator plate pliers A
For proper maintenance of aluminum radiator, modify the radiator plate pliers A (KV99103510) as
dr "'ribed below. The modified tool will be usable for radiators with either square or circular sealing
rUlIuer.
For radiators with circular sealing rUbber, avoid excessive crimping. The standard crimping height for
this type is larger.

Step 1
1. Draw out pin at @ and disassemble @ from . Then, grind @. (Fig. 1)
2. Grind @. Finish the surface as smoothly as possible. (Fig. 2)
CAUTION:
Be careful not to over-grind the standard size since it might damage washer when caulking.
3. Using a burner on the curved portion. straighten @ until its end is 18 mm (0.71 in) lower as shown
in the figure (Fig. 3) Avoid applying too much force to @.
4. Reassemble the tool in such a way that H' is approx. 9.1 mm (0.358 in) when partion is joined.
(Fig. 1)
5. If dimension H' can not be attained, adjust by grinding portion ar by straightening the curve (R)
further, (Fig. 1, 3)

LC..15

,~j,--;

ENGINE COOLING SYSTEM

Radiator (Aluminum type) (Cont'd)
r-----.-----------------

~LOCkPin

)1

H'
9.1 (0.358)

[Fonner:
10.8 {O.42S)J

7(0.28)

'-.r-l
U

Cut off 7 (0.28)

~1(D.2.1

Fig. 1

Unit: mm (in)

Fig. 3

SlC654C

Step 2
1.

1.5 (O.Q59)

2.

H" = 7.6
(0.299)

3.

4.

Make spacers (steel) with a specification of 1.5 mm (0.059

in) thick x 18 mm (0.71 in) wide x 8.5 mm (0.335 in) long.
Using double sided tape or adhesive, attach the spacer to
the tip of the modified radiator plate pliers A.
Make sure that when radiator plate pliers A are closed
dimension H" is approx.. 7.6 mm (0.299 in).

If dimension H" is out of specification. adjust with the

spacer.

Unit: mm (in)
SLC655C I

DISASSEMBLV
1.

--------

Remove tank with Tool.

-------l

Grip the crimped edge and bend it upwards so that Tool

slips off.
Do not bend excessively.

*
I

L_
LC-16

ENGINE COOLING SYSTEM

Radiator (Aluminum type) (Cont'd)
In areas where Tool cannot be used, use a screwdriver to
bend the edge up.
Be careful not to damage tank.

]1

1:
ii

@f

!
:MJ$\

~:~-91

2.
3.

Make sure the edge stands straight up.

Remove oil cooler from tank. (A/T models only)

iEt
~~

~~
SLC931

1~1

ASSEMBLY
1. Install oil cooler. (A/T models only)
Pay attention to direction of conical washer.
Conical washer ~

/~\lr

~jB)

~,~~

~&

SLC894

2.

Clean contact portion of tank.

~j~

~if

~\~

igjl

SLC932

3. Install sealing rubber.

Push it in with fingers.
Be careful not to twist sealing rubber.

[r1l&
~l

~~~

lC-17

ENGINE COOLING SYSTEM

Radiator (Aluminum type) (Cont'd)
4.

Caulk tank in specified sequence with Tool.

Be careful not to excessively caulk the radiator with circular

shaped rubber. The Tool is not designed for the standard

caulking height (H).

Keep tool perpendicular to

the radiator.

(Grip is Insufticienq

SLC696

Use pliers in the locations where Tool cannot be used.

5.

Make sure that the rim is completely crimped down.

Standard height "HI!:

SlC897
~------------------'

8.0 8.4 mm (0.315 - 0.331 in)

6. Confirm that there is no leakage.
Refer to Inspection.

'~Sealing rubber

SLC554A

INSPECTION
Apply pressure with Tool.
Specified pressure value:
2
157 kPa (1.57 bar, 1.6 kg/cm , 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 as well. (All models only)
SlC933

__

LC-18

-------~t:h~~;-~-------------::====

ENGINE COOLING SYSTEM

Turbocharger Water Tube
--------------------------SEC. 140-144
~
Water
.~
"d~

toJ 20 31
(2.0 -

n~;A

inlet tube

<

~-:;~~~_/
0if-,>
~
b
~~~~r
return ~ ~ ~

,,0.

A 20(2.0- -313.2, 14 - 23) ~ .

LCJ 20 - 31
(2.0 - 3.2. 14 23)

A: Nm (kg-m, ft-Ib)

O~,
"~

./

/ ' Turbocharger

/' .

V~ ~

\.

,; "-'\

~
_~

...

~
fnII
~~~.11120"31

.....!(=2.0=---~_.:;.;,3.2~.. . :.1. .:. . 4_";;;.;23~)

sL_C_9B-----.J4A

When installing water tubes, first hand-tighten bolts connecting tubes, then slightly tighten bracket securing bolts.
Finally, tighten bolts securely.
Be careful not to deform tubes.
After installation, run engine for a few minutes, and check
for water leakage.

LC..19

~~

SERVICE DATA AND SPECIFICATIONS (S.0.5.)

Engine Lubrication System
Oif pump

Oil pressure

Unl!: mm (in)

Engine

Approltimate discharge pressure

rplll

kPa (bar, kg/cm Z , psi)

Idle speed
3,200

Body to outer gear clearance

Inner gear \0 outer gear tip

More than 78 (0.78.0.8, 11)

clearance

314 - ;)92 (3.14 - 3.92, 3.2 - 4.0, 46 . 57)

Regulator valve
Unit: mm (in)

Regulator valve to oil pump

cover clearance

a 05 - 0.09 (0.0020 - 0.0035)

Body to OJter gear side

clearance

0.05 - 0 11 (0.0020 - 0.0043)

Inner gear 10 brazed portion of

0,040 . 0097 (0.0016 - 0.0038)

Engine Cooling System

Cooling system leakage test
Unit: kPa (bar. kg/cm 2 , psi)
157 (157, 1.6,23)

Radiator cap
Unit: kPa (bar. kgJr.m L , psi)
7B - 98

Reliel pressure

(0.78 . 0.98,
O.B - 1.0,11 - 14)

Thermostat
Valve opening temperature

Max. valve

(If!

'crF)

mml"C (InI"F)

Below 0.18 lOD071}

Body to inner gear side

clearance

housing clearance

Testing pressure

0.114 - 0200 (00045 . 00079)

765 (HO)
More than
10/90 (0.39/194)

LC-20

0045 - 0.091 (0.0018 - 0.0036)

i .

ENGINE CONTROL SYS-rEM

@[

SECTION

EC

CONTENTS
PREPARATION AND PRECAUTIONS .. ,
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER"
Engine Fuel & Emission Control System
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM
,
,
,
EGGS Component Parts Location
System Chart..
,
,
System Diagram
,.. ,.. ,
Vacuum Hose Drawing
Circuit Diagram
,
ENGINE AND EMISSION CONTROL PARTS
DESCRIPTION. ""
Engine Control Module (ECM)-ECCS Control
Module
,
'.. ,
,
Camshaft Position Sensor (CMPS)
Mass Air Flow Sensor (MAFS)
Engine Coolant Temperature Sensor (ECTS)
Throttle Position Sensor (TPS) & Soft Closed
ThroWe Position (eTP) Switch
Fuel Injector
,
Fuel Pressure Regulator
"
Fuel Pump
,
,
I-Ieated Oxygen Sensor (H02S)
Power Transistor Unit & Ignition Coil
Fast Idle Cam (FIC) '
Idle Air Control Valve (IACV)-Auxiliary Air
Control (AAC) Valve
Power Steering Oil Pressure Switch
Vehicle Speed Sensor (VSS)
Knock Sensor (KS)
Exhaust Gas Recirculation (EGR) ValvE'! ,

EGR Control (EGRC)-BPT Valve."

EGR and Canister Control Solenoid Valve
ruel Filter
Valve Timing Control (VTC) Solenoid Valve
Carbon Canister.. ..... .....

3
3
4

5
5
8
9
10
11

Wastegate Valve Control Solenoid Valve

Recirculation Valve
Boost Pressure Sensor
ENGINE AND EMISSION CONTROL SYSTEM
DESCRIPTION
Multiport Fuel Injection (MFI) System "
Electronic Ignition (EI) System..
.
Idle Air Control (lAC) System
"
,
Fuel Pump Control
Exhaust Gas Recirculation (EGR) and Canister
Control System
,.. '.. , ,
Air Conditioner Cut Control.........

12
12
12

12
13
13
14

14
14

14

15
15
15
15
16
16
16
16
16
17
1?
.. .. 17

..

'
.

MUlTIPORT FUEL INJECTION SYSTEM

INSPECTION
'
Releasing Fuel Pressure
Fuel Pressure Check ......
Injector Removal and Installation
EVAPORATIVE EMISSION SYSTEM
Description
Inspection ,'
,
CRANKCASE EMISSION CONTROL SYSTEM
Description
Inspection
,
SERVICE DATA AND SPECIFICATIONS (505)
General Specifications.
..
Inspection and Adjustment...
..

tCt

19
19
22

d\1

24

25

~-~

:P,IQ,:

26

26

Valve Timing Control (VTC)

"
Heated Oxygen Sensor (H02S) Heater Control
Cooling Fan ControL.....................
.
Boost Pres sure Control................
..
Fail-safe System
,
Direct Ignition System
.
IDLE SPEEDIIGNITION TIMINGIIDLE MIXTURE
RATIO INSPECTION
"

TROUBLE DIAGNOSES
Contents......

17
17
18

?li\

27
29
29
30
31
33
35
41

~1

.41

208
208

:frr

... 208
. ?09
..210
... 210
,

210

212

212
212
213
213
213

i~,.L

CON-rENTS

(Cont'd.)

When you read wiring diagrams:

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

tzP

PREPARATION AND PRECAUTIONS

Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER Jt
The Supplemental Restraint System "Air Bag" and "Seat Belt Pre-tensioner", used along with a seat
belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The Supplemental Restraint System consists of air bag modules (located in the center of the steering
wheel and on the instrument panel on the passenger side). seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. Information necessary to service the system
safely is included in the RS section of this Service Manual.

tH

WARNING:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed ;L~c.:
by an authorized NISSAN dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system.
All SRS air bag electrical wiring harnesses and connectors are covered with yellow outer insula~
tion. Do not use electrical test equipment on any circuit related to the SRS.
pl~

(;~

~lj'

iI
I

/kll
~~':ij

r~~

~~

igj(g\

@\1
~\~

igW

r~&\

[1

mrn)1

EC-3

i
I

PREPARATION AND PRECAUTIONS

--

Engine Fuel & Emission Control System

ECM

Do not disassemble ECM (ECCS

control module).
Do not turn diagnosis mode selector
forcibly
If a batlery terminal is disconnected,
the memory will return to the ECM
value Th& ECM will now slart to

self-control at its initial value. Engine

operation can vary slightly when the
terminal is disconnected. However. this
is not an indication of a problem. Do
not replace parts because of a slight
variation.

WIRELESS EaUIPMENT
When installing C.B. ham radio or a
mobile phone. be sure to observe the
follOWing as it may adversely sHect
electronic control systems depending
on its installation location.
1) Keep the antenna as far as possible
away from the ECM.
2) Keep the antenna feeder line more than
20 cm (7_9 in) away from the harness
of electronic controls.
Do not Jet them run parallel for a long
distance.
3) Adjust the antenna and feeder line..so
that the standing-wave ratio can be
kept smaller_
4) Be sure to ground the radio to vehicle
body.

12 volt battery as power

FUEL PUMP
Do nol operate fuel pump when Ihere
is no fuel in lines.
TIghten fuel hose clamps 10 the
specified torque.

ECCS PARTS HANDLING

Handle masS air flow sensor carefully to
aVOid damage.
Do not disassemble mass air flow
sensor
Do not clean mass air flow sensor with
any type of detergent,
Do not disassemble IACV-AAC valve.
Even a slight leak in the air intake
system can cause serious problems.
Do not shock or jar the camshaft
position sensor.

WHEN STARTING
Do not depress accelerator pedal when
sfarting
Immediately after starting, do not rev up
engin e unnecessarily.
Do not rev up engine just prior to
shutdown,

ECM HARNESS HANDLING

Securely connect ECM harness
connectors.
A poor connection can cause an
extremely high (surge) voltage to
develop in coil and condenser, thus
reSUlting in damage to ICs.
Keep ECM harness at least 10 cm (3.9
in) away from adjacent harnesses. to
prevent an ECM system malfunction
due to receiving external noIse,
degraded operation of rcs, etc.
Keep ECM parts and harnesses dry.
Before removing parts, turn off ignition
switch and then disconnect battery
ground cable.

SEF181P

EC-4
Ie:

ENGINE AND EMISSION CONTROL OVERALL SYS-rEM

ECCS Component Parts Location

IACV-FICO solenoid valve

Injector
- Ignition co~ and spark plug

Wastegate valve control

solenoid valve
,
Power transistor

EC
,

Boost pressure
sensor
Recirculation valve

Pressure regulator

SFF965P

EC-S

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ECCS Component Parts Location (Cont'd)

SEF966P

SEF967P

SEF968P

SEF969P

.--------------------

SEF971P

EC-6

17_ _- - - - - - - - - - - - - - - - - - - - - - -

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ECCS Component Parts location (Cont'd)
LHD model

B,ake pedal~

~mIL
SEF187PA
------------------------,

RHO model

:s~

ze~
:~n1'
Data link
connector
for CONSULT

~
SEF973PI

Engine rear

i~\11

~IQ)

~,~

[}i,'\1

.[iOl,'-..\

~rRl

~ir

i'

p;;~

il

II
ii

:g):r

i~/~\

~t

r;C)~

EC-7

[I

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

System Chart
Camshaft position sensor

Mass air flow sensor

Engine coolant temperature

sensor

Heated oxygen sensor

Fuel injection & mixture ratio

Injectors

~
Electric ignition system

f-------+

Idle air control system

Ignition switch

Throttle position sensor

Park/Neutral position switch

ECM

control
module)

Air conditioner switch

control

EGR and canister control

Power transistor

solenoid valve

EGR and canister control

solenoid valve

IACV-AAC valve IACV-FICD

Fuel pump relay

Fuel pump control

(ECCS
Diagnostic test mode II
(Heated oxygen sensor moni

Malfunction indicator lamp

(On the instrument panel)

tor & self-diagnosis)

Heated oxygen sensor heater

control

Battery voltage

Cooling fan control

Cooling fan relay

Power steering oil pressure

switch

-------..

Acceleration cut control

Air conditioner relay

Vehicle speed sensor

Wastegate valve control

Boost pressure sensor

Rear window defogger switch

Valve timing control (VTC)

EC-8
,

'"

Knock sensor

Heated oxygen sensor heater

Wastegate valve control solenoid valve

VTC solenoid valve

-Ignition coil

EGA and
canister control
solenoid valve
ECM (ECCS
control mOdule)

Malfunction
indicator
lamp

Power
transistor

()

Boos\ prlSSl,;re
sensor

to

VTC ....
solenOid
valve

Three way catalYSt

Charge air cooler

.,

(J}

""......

U1
"tl

,97
ri

.nfi]
-r-

_'I.

~~

,g)

-1

J9

\0'~';

(~~2)

=--..;1

,q21
-;:~)

2"id

;?>

'pJ
}~

--,,-:>1

,Q)

),y
~'I

=..;:

(':;~\

H'

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

Vacuum Hose Drawing

Pressure regulator
EGR and canister

ReClrculatlojn
valve

Zast,ga,e
/

3-way

IIA'Wastegate connector

valve control
solenoid valve

vallie actuator

Intake mani10ld collector

Recirwlation valve

Throltre body

Air duct (Charge air cooter

to throttle body)
Pressure
regulator

EGR and
canister
control
solenoid valve

Activatl!d
carbon canister
Boost pressure sensor
Orifice

.~

./

E GR valve

EGRC-Bm valve

Air duct (Charge air cooler to tJrottle body)

Orifice

Wastegate valve actuator

Air duct
(Mass air flow

sensor to
turbocharger)

Wastegate valve

control solenoid valve

SEF976P

-------_....-----_......----EC-10

MALFUNCTION
INDICATOR LA\.1P

DATA LINK

CONNECTOR
FOR CONSULT

FUSIBLE LINK

-I

L.r::::::7L

~ E~

'--

CfF ACe ON

ST

:'.Ie

SWI!~

IGNITION

lGNITTON
COIL
RELA Y

1,~

MI

31 47

Eces
IJ RELAY

L..:...J"

r:::l NO.2

I]~:~

L..:::...J"

_~
L...::.:-J . --I---

1-'"

RE~OR
r~vv

CONNECTOR

L....--!

110

....a..

......

25

.-

tj-

g=

.--r-T
L.u.;

IGNITION
COIL

A
Y ~~~~K

g~ A
1
\Jo -2

No.3

3!--- : -

BODST

P~ESSUAE

SENSOR

~
----T

I\,(

~~~in6~ ry===tT

35

---

~1

SENSOR

u_

:
3)

.,.

"

POSITION
SENSO~

rT

t.:<\

KfIoOCK

SENSOR
AIT mede Is

~ :
@.
@ :

__

Manua 1 a ir

E",cept RHO models

AutO

all"

conditioner
coM i t i oner

54

MASS AIR

I
I

44

53

23

JOINT CONNECTOR

lACV-FICO

~~t~~~IO

PO~ITION-F:::::::l

':" SW~ TCH

T V"I
L....--!

'-----

15

for ::urope

NEUT~Al

FFF===;:~~~=~~==]I------;

~
50 60

"'"

14

j.

,--------

ll

13

10
11 AIT

12 CONTROl
34 UNlT

SPEED-

rlru

J-~

::is
~'O'

1~ t::}Jl

35

To tachometer

L--f

VEHICLe
SPEED

~.~-.......,~~~----~.~------

-9E

.- .~

=0?-'

(u,'~

W/iJ
..........1

~@J

2m

2.r..)

,...........~~~

')&:l

..

-inl

DMETEi=l

yr---------,"lL'~

',.Q)

~IC

SWITCH

1::!:!::J - - - - - - - - - - - - - l - - I
~!-

52

STEE~ING

"~~l;:';~~::::~::

'.1-_-1'

c=:::::::'()-Jl_ _--I-----!----J

PCWER

c:::::::::;:'

L-......

FLOW SENSCR

~ELAY

defogger

46

---.,.

OEFOGSEA

sma~t

"'"
To ~ear WlndOW..=r

J:

F
rr1

TO

~~~~~~leunit-r~

42

"'- - - - - - -~

M/T rlIooels

51

--;L__

qEAR WINDO\'j
I

r
-~T
*1

CAMSHAFT

'00

r~

00

SOLENOID r = l

19

ENGINE COOLANT

Nc: .4

107
lOB
. - 116

~~~~5~ATURE

33

~~

..J:=.1

No, 1

102

::r;

CIJ

~ IL.+--+
I~ I~
I~
----t-

4T
-g

1 1---1--- 12

WASTEGAE VALVE CONTROL

SOLENOID VALVE
r=l
SOLENOl D " "
VALVE
r=l

S~~~~OL

UNIT

SENSOR

EGR 6; CANISTER

iii"

5!---~

HEATEDl

~ --= l OXYGEN

- - - - - H - - - - - - l (j

':"

~C

103

--I--b}
~

~--- l

:
115

, - - - - - - - - - - - - - I - - - 1 - - - - - - - l 7 POWER
41--1--- 2
r - - - - - - - - - - + - - I - - - - - - - - 1 9 TRANSISTD~ 21--1--- II

,-----------

('")

f-

112

'\0

PU"lP

If.!

1O~

!AClI-AAC VALVE r-=l

FUEL

-1

113

1 ~" J

18.....

ffi

I"-ECTOR

56

..- 49

r - - - - - - . . t l . . f l~-N
l I....:N....:O:..:.:....:1:...____l____I

RELAY ~

32 I---

' - 105

~~~~ r;-~

2221

r=l ~~O, 4

CHECK

M-::--Q
.+-------

FUSE

I~

V~

SENSOR

~,t:lJ

'1",,_,

,gJ

::0....1

~
M'"

(G'

'-til

:4

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Engine Control Module (ECM)-ECCS Control
Module
The ECM consists of a microcomputer, an inspection lamp, a
diagnostic test mode selector, and connectors for signal input
and output and for power supply. The unit controls the engine.

SEC220B

--------------=-------,
Light emitting
diode

Photo diode
Wave
forming circuit
SEF971E

Camshaft Position Sensor (CMPS)

The camshaft position sensor is a basic component of the
EGCS. It monitors engine speed and piston position, and
sends signals to the ECM to control fuel injection, ignition
timing and other functions.
The camshaft position sensor has a rotor plate and a waveforming circuit. The rotor plate has 360 slits for 1 signal and
u
4 slits for 180 signal. Light Emitting Diodes (LED) and photo
diodes are built in the wave-forming circuit.
When the rotor plate passes between the LED and the photo
diode, the slits in the rotor plate continually cut the light being
transmitted to the photo diode from the LED This generates
rough-shaped pulses which are converted into on-off pulses
by the wave-forming circuit, which are sent to the ECM. For
diagnosis, refer to EC-109, 201.

Mass Air Flow Sensor (MAFS)

Mass air flow

SEF977P

The mass air flow sensor measures the intake air flow rate by
measuring a part of the entire flow. Measurements are made
in such a way that the ECM receives electrical output signals
varied by the amount of heat emitting from the hot film placed
in the stream of the intake air.
When intake air flows into the intake manifold through a route
around the hot film, the heat generated from the hot film is
taken away by tile air. The amount of heat reduction depends
on the air flow. The temperature of the hot film is automatically
controlled to a certain number of degrees.
Therefore, it is necessary to supply the hot film with more
electric current in order to maintain the temperature of the hot
film. The ECM detects the air flow by means of this current
change. For diagnosis, refer to EG-113, 201.

'",

EC-12

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

~-----:--------------.

Engine Coolant Temperature Sensor (ECTS)

The engine coolant temperature sensor, located on the top of
thermostat housing detects engine coolant temperature and
transmits a signal to the ECM.
The temperature sensing unit employs a thermistor which is
sensitive to the change in temperature. Electrical resistance of
the thermistor decreases in response to the temperature rise.
For diagnosis, refer to EC-116, 201.
l

Intake manifold

Throttle Position Sensor (TPS) & Soft Closed

Throttle Position (CTP) Switch
Throttle
position
sensor

An

:W!,g\

SEF97BP

For MIT model

~(

----------

SEFo'oKAI

The throttle position sensor responds to accelerator pedal

movement. This sensor is a kind of potentiometer which transforms the throttle position into output voltage, and emits the
voltage signal to the ECM. In addition, the sensor detects the 1:s:E
opening and closing speed of the throttle valve and feeds the
voltage signal to the ECM.
!(;:t
Closed throttle position of the throttle valve is determined by
the ECM receiving the signal from the throttle position sensor.
This system is called "soft closed throttle position switch". It i*~1
controls engine operation such as fuel cut. For diagnosis, refer
to EC-13S, 204.

models
~
~ , } Wide open/closed
~
throttle pOSItion
~ 2 switch (for AIT
~3
control)
4

E
.

"0

cra

8.0

~---~---'---------'--------I

o.n

Output voltage between

terminal No. 5 and 6

Throttle
position

Supply voltage.
SV (applied between terminal No.4 and 6)

<.0

4.0

~/f':.\

I-------+------r-r---.---'-i

sensor

cQ)
a>

2.0

~-~---7'<t---

~J\

.0

<1l
CI

"II!
"0
>

'5
a.
'5

OLL:---

----.1-

4S

'------

90

________=_

135

~,1

Throttle valve opening angle (degl

~~,

:~1
SEF037Q

~i'/~"

~t

rrQ)jA

EC-13

t:

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Fuel Injector
The fuel injector is a small, elaborate solenoid valve. As thef
ECM sends injection signals to the injector, the coil in the ~.
~.
injector pulls the needle valve back and fuel is released into
the intake manifold through the nozzle. The injected fuel is
controlled by the ECM in terms of injection pulse duration. For ~_,
diagnosis, refer to EC-156, 205.

SEF782K

Fuel Pressure Regulator

The pressure regulator maintains the fuel pressure at 299.1
kPa (2.991 bar, 3.05 kg/cm 2 , 43.4 psi). Since the injected fuel
amount depends on injection pulse duration, it is necessary to
maintain the pressure at the above value. For diagnosis, refer
to EC-208.

SEC091

KI

Fuel Pump
The fuel pump is a turbine type located in the fuel tank. For
diagnosis. refer to EC-159, 202.

S~F476P I

,------------------------~

Heater pad

Zirconia
tube

Isolation
bearing

SEF406H
---J

--------

o '------Rich -

-...1..-_ _

Ideal ratio

.Heated Oxygen Sensor (H02S)

The heated oxygen sensor, which is placed into the exhaust
outlet, monitors the amount of oxygen in the exhaust gas.
The sensor has a closed-end tube made of ceramic zirconia.
The outer surface of the tube is exposed to exhaust gas, and
the inner surface to atmosphere. The zirconia of the tube compares the oxygen density of exhaust gas with that of
atmosphere, and generates electricity. In order to improve
generating power of the zirconia, its tube is coated with plat~
inurn. The voltage is approximately 1V in a richer condition of
the mixture ratio than the ideal air-fuel ratio, while approximately OV in leaner conditions. The radical change from 1V to
OV occurs at around the ideal mixture ratio. In this way, the
heated oxygen sensor detects the amount of oxygen in the
exhaust gas and sends the signal of approximately 1V or OV
to the ECM. A heater is used to activate the sensor. For
diagnosis, refer to EC-152, 203.

--=
- - Lean

Mixture ratio
___

SEF2B80
----J

EC-14

---

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Power Transistor Unit & Ignition Coil
From ECM
Engi"l9 front

(4pinsl -

The ignition signal from the ECM is amplified by the power

transistor, which turns the ignition coil primary circuit on and
'
o ff , .In d
uClng
t he proper high voltage in the secondary circuit.
The ignition coil is a small, molded type located on the spark
plug.
For diagnosis. refer to EC-120, 202.

@~
ilfi);\

,MIl'-.l

To ignition coil
SEF293N

Ignition corl

SEF980P

Fast Idle Cam (Fie)

The FIG is installed on the throttle body to maintain adequate
engine speed while the engine is cold. It is operated by a volumetric change in wax located inside the thermo-element. The
thermo-element is controlled by engine coolant temperature.
For diagnosis, refer to EC-207.

~n

Idle Air Control Valve (IACV)-Auxiliary Air

Control (AAC) Valve

~r%

SEF981P

[~
00

The ECM actuates the IACV-AAC valve by an ON/OFF pulse.

The longer that ON duty is left on, the larger the amount of air
that will flow through the IACV-AAC valve. For diagnosis, refer
to EC-169, 204.

~1

Air

SEF040E

Power Steering Oil Pressure Switch

The power steering oil pressure switch is attached to the
power steering high-pressure tube and detects the power
steering load, sending the load signal to the ECM. The ECM
then sends the idle-up signal to the IACV-AAC valve. For
diagnosis, refer to EC-184, 206.

EC-15

f~,~

,;~:l

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Vehicle Speed Sensor (VSS)

The vehicle speed sensor provides a vehicle speed signal to
the speedometer and the speedometer sends a signal to the
ECM.
The speed sensor consists of a pulse generator which is
installed in the transmission. For diagnosis, refer to EC-145,
202.

/ " Vehicle speed

1'------......,.//

sensor

Knock Sensor (KS)

~Terminal
~~9ht

p;ezo;:.~

The knock sensor is attached to the cylinder block and senses

engine knocking conditions.
A knocking vibration from the cylinder block is applied as
pressure to the piezoelectric element. This vibrational pressure is then converted into a voltage signal which is sent to
the ECM.
For diagnosis, refer to EC-132, 205.

SEF099K

Exhaust Gas Recirculation (EGR) Valve

The EGR valve controls the quantity of exhaust gas to be
diverted to the intake manifold through vertical movement of
a taper valve connected to the diaphragm. Vacuum is applied
to the diaphragm in response to the opening of the throttle
valve. For diagnosis, refer to EC-14B, 203.

SEF6328

To EGR valve

Vacuum signal
source

Air

filter ~iO<iT'=::::;::::=~

EGR Control (EGRC)-BPT Valve

The EGRC-BPT valve monitors exhaust pressure to activate
the diaphragm, controlling throttle body vacuum applied to the
EGR valve. In other words, recirculated exhaust gas is controlled in response to positioning of the EGR valve or to engine
operation. For diagnosis, refer to EC-148, 203.

MEF651D

EGR and Canister Control Solenoid Valve

The EGR and canister control solenoid valve responds to signals from the ECM. When the ECM sends an ON (ground)
signal, the coil in the solenoid valve is energized. A plunger
will then move to cut the vacuum signal (from the throttle body
to the EGR valve and canister purge valve).
When the ECM sends an OFF signal, the vacuum signal passes
through the solenoid valve. The signal then reaches the EGR
valve and carbon canister. For diagnosis. refer to EC-148, 203.
SEF2B7H

EC-16

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

~-----=----------

Fuel Filter
The specially designed fuel filter has a metal case in order to
withstand high fuel pressure.

\.:ji,~,

SEF255A

Valve Timing Control (VTC) Solenoid Valve

V:~

The valve timing control solenoid is installed at the front righl

of the cylinder head, and controls oil pressure which regulates
the position of the intake camshafts. For diagnosis, refer to
EC-166. 205.

SE:F-48ZJ

Carbon Canister
The carbon canister is filled with active charcoal to absorb
evaporative gases produced in the fuel tank. These absorbed
gases are then delivered to the intake manifold by manifold
vacuum for combustion purposes. For diagnosis, refer to
EC-148. 210.

,\ T

PL

Wastegate Valve Control Solenoid Valve

Wastegate
valve control
solenoid valve

The solenoid valve \s actuated by the ON/OFF pulse from the

ECM. The longer that ON duty is left on the larger the amount
of vacuum signals from the suction pipe or compressor outlet
are fed into the wastegate valve actuator. The actuator is hard
to open at this time, When the ECM sends an OFF signal, the
coil pulls the plunger and cuts the route to the suction pipe.
For diagnosis, refer to EC-163, 205.

TI'\I~;

Y1

SEF9a4pl

r----------------

Recirculation Valve
The recirculatiotl valve reduces the noise occurring in the
compressor of the turbocharger during deceleration. This
valve recirculates air compressed downstream of the intercooler to upstream of the compressor using the intake mani- f'l
fold vacuum that occurs when the throttle chamber IS suddenly
closed.
The recirculation valve also must not be disassembled or
adjusted. For diagnosis, refer to EC-206.

SEF985P

EC-17

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Boost Pressure Sensor
Boost pressure
sensor

The boost pressure sensor detects boost pressure at th~

upstream of the throttle body. The pressure signal is transmit_.
ted to the ECM to control the boost pressure precisely. For
diagnosis, refer to EC-128, 206.

SEF986P

EC-18

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Multipart Fuel Injection (MFI) System
INPUT/OUTPUT SIGNAL LINE
ESh.1t

~osition sensor

Engine speed and piston position

-

punl

~ss air Ilow s~ns"or

..

of inl.ke ai,

..--

I Engine coolant te_mpera,we

IEngine coolant temperature sensor

~ Density 01 oxygen in exhaust gas

!Heated oxygen sensor

~~otlle position

Throltle valve opening angle

sensor

-.

ECM

(ECeS

IGe.,

park/Nou~r~r position switch

...

Injector

C1.

control

module)

position

Veh,cle '""ed

Vehicle speed sensor

j Slart
I

--

~gnitiOn SWItch
-

rAir conditioner switch

_J

signal

Air conditioner operation

-

_.-

...

-----

Battery voltage

Batte"ry
I

BASIC MULTIPORT FUEL INJECTION

SYSTEM

VARIOUS FUEL INJECTION

INCREASE/DECREASE COMPENSATION

The amount of fuel injecled from the fuel injector,

or the length of time the valve remains open, is
determined by the ECM. The amount of fuel
injected is a program value mapped in the ECM
memory_ In other words, the program value is
preset by engine operating conditions determined by input signals (for engine speed and air
intake) from both the camshaft position sensor
and the mass air flow sensor.

The amount of fuel injection is compensated for

to improve engine performance. This wi!1 be
made under various operating conditions as
listed below.
< Fuel increase>
1) During warm~up
2) When starting the engine
3} During acceleration
4) Hot-engine operation
< Fuel decrease>
1) During deceleration

EC-19

~~

~l.

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Multipart Fuel Injection (MFI) System (Cont'd)
CLOSED LOOP

SYSTEM

MIXTURE RATIO FEEDBACK CONTROL

ECM

~ECC~

--'\contr~~J,
l
FeedbaC~1
e1n;ectlon pulse

Heated\
oxygen)
sensor

Injector

combustlon~Fuel

IrtJection

The mixture ratio feedback system is used for precise control

of the mixture ratio to the stoichiometric point. so that the three
way catalyst can reduce CO, He and NOx emissions. This
system uses a heated oxygen sensor in the exhaust manifold
to check the air-fuel ratio. The ECM adjusts the injection pulse
width according to the sensor voltage so the mixture ratio will
be within the range of the stoichiometric air-fuel ratio.
This stage refers to the closed loop control condition.

MEF653D I

OPEN LOOP CONTROL

The open loop control condition refers to that under which the
ECM detects any of the following conditions and feedback control stops in order to maintain stabilized fuel combustion.
1) Deceleration
2) High-load, high-speed operation
3) Engine idling
4) Malfunction of heated oxygen sensor or its circuit
5) Insufficient activation of heated oxygen sensor at low
engine coolant temperature
6) Engine starting

MIXTURE RATIO SELF-LEARNING CONTROL

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor.
This feedback signal is then sent to the ECM to control the
amount of fuel injection to provide a 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 "fuel injection duration" to automatically
compensate for the difference between the two ratios.

EC-20

ENGINE AND EMISSION CONrROL SYSTEM DESCRIPTION

Multipart Fuel Injection (MFI) System (Cont'd)
~ InjectIOn pulse
No. 1 cylinder

FUEL INJECTION TIMING

----.J L - -

No.

~ cylinder_------~JL

No.

~ cy,inder

-JnL.....-

n '----

No.4 cylinder-----......l

~ 1 engine ,cycle-----j
Sequential injection
SEFB41 D

No. 1 cvlin~rJ1'-----.Jn'-_ _~
No. 2

cylinde,.Jl"----------'nL....---~

Two types of systems are used - sequential multlport fuel

injection system and simultaneous multipart fuel injection sys- ~[
tern.
1J Sequential mUltiport fuel injection system
Fuel is injected into each cylinder during each engine
cycle according to the firing order. This system is used
when the engine is running.
2) Simultaneous multipart fuel injection system
Fuel is injected simultaneously into all four cylinders twice
each engine cycle. In other words, pulse signals of the
same width are simultaneously transmitted from the ECM. tt
The four 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.

No, 3 cylinderJl...._ _--nL---.....IrL, No.4cylinderJ1

n.. .__....1~

~1 enginecvcle~
Simultaneous Injection

FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.

SEF976E

!~iQ;

~il,

EC-21

Electronic Ignition (EI) System

INPUT/OUTPUT SIGNAL LINE
~ne speed and pIston position

I Camshaft position sensor

~~ou~.t of intake air

I Mass air flow sensor

[

Engine coolant temperature

( Throttle position sensor

~ehiCle

speed sensor

...

~En9ine coolant temperature

senso~

...

Throttle position

..

..

~ Vehicle speed

ECM(ECCS

Start signal

F~nswitch

control
module)

.------~ Power

trans;
'------

I
(

~ngine knocking

Knock sensor

Park/Neutral position switch

:=J-

..

Gear position

Air conditioner operation

[Atr conditioner switch

I
I,

Power steering oil pressure switch

I Battery

..

Power steering load signal

I
I Battery voltage
I

EC-22

..
...

...

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Electronic Ignition (EI) System (Cont'd)
SYSTEM DESCRIPTION

are transmitted to the power transistor.

e.g.
N: 1,800 rpm, Tp: 1.50 msec
A
DBTDC
In addition to this,
1) At starling
2) During warm-up
3) At idle
4) At low battery voltage
the ignition timing is revised by the ECM according to the other data stored in the ECM.

The ignition timing is controlled by the ECM in

order 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 below.
The ECM detects information such as the injection pUlse width and camshaft position sensor
signal which varies every moment. Then
responding to this information, ignition signals
Tp

(msecl

1.75

1.50
Injection

pulse
width

..

1.25

1.00

0.75

600

1,400

1,000

Enginl'l speed (rpm)

The retard system, actuated by the knock sensor

is designed only for emergencies. The basic ignition timing is preprogrammcd within the antiknocking zone, if recommended fuel is used
under dry conditions. Consequently, the retard
system does not operate under normal driving
conditions.

2,200

SEC750A

However, if engine knocking occurs. the knock

sensor monitors the condition and the signal is
transmitted to the ECM (ECCS control module).
After receiving it, the ECM retards the ignition
timing to eliminate the knocking condition.

EC-23
b~~

1,800

~fA
~ffi\

~[R

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Idle Air Control (lAC) System
INPUT/OUTPUT SIGNAL LINE

I Camshaft position sensor

~espeed

~ Amoun\ of intake air

Mass air flow sensor

Engine coolant temperature

rg;ne coolan. tempera'ure

sensor

~tsignal

~ition switch

Throttle position sensor

Throttle position

ECM
(ECCS

~Gear

Park/Neutral position switch

Air conditioner switch

position

~conditioneToperation

Power steering oil pressure

switch

Battery

l_v_e_h_iC_1e__
sp_e_e_d_s_e__
ns_o_r

'I

------..f- IACV-AAC valve

I

Power steering load signal

...

Battery voltage

-------+

-----J~eh icle speed

SYSTEM DESCRIPTION
This system automatically controls engine idle
speed to a specified level. Idle speed is controlled through fine adjustment of the amount of
air which by-passes the throttle valve via the
IACV-AAC valve. The IACV-AAC valve repeats
ON/OFF operation according to the signal sent
from the ECM. The camshaft position sensor
detects the actual engine speed and sends a signal to the ECM.

The ECM then controls the ON/OFF time of the

lACV-AAC valve so that 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 steadily. The optimum
value stored in the ECM is determined by taking
into consideration various engine conditions,
such as noise and vibration transmitted to the
vehicle interior, fuel consumption, and engine
load.

EC-24
Ie:

control
module)

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Fuel Pump Control
INPUT/OUTPUT SIGNAL LINE
[ Camshaft positIon sensor

Ess

air flow sensor

l;9;ne

I Engine speed

...

I Amount of intake air

....
ECM (ECCS
control mod-

coolant temperalure

Engine coolant temperature

...

ule)

Fuel pump relay

sensor

[ Ignition switch

Start signal

Condition

Fuel pump operation

Ignition switch is turned to ON.

Operates for 1 second

:CL

SYSTEM DESCRIPTION
Fuel pump ON-OFF control
The ECM activates the fuel pump for several seconds after the ignition switch is turned on to
improve engine start-up. If the ECM receives a 1
signal from the camshaft position sensor, it
knows that the engine is rotating, and causes the
pump to activate. If the 1 signal is not received
when the ignition switch is on, the engine stalls.
The ECM stops pump operation and prevents the
battery from 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.

Engine running and cranking

Operates

When engine is stopped

Stops in 1 second

Except as shown above

Stops

~W7

r1}~,

EC-25
l--.

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Exhaust Gas Recirculation (EGR) and Canister
Control System
INPUT/OUTPUT SIGNAL LINE
...
l-E-ng-j-ne-sp-e-e-d--------~r--

LCamshaft position sensor

,1

[ Mass air flow sensor

I Amount of intake air

ECM

I Engine coolant tempera1ure

Engine coolant temperature sensor ~ - - - - - - - - - - - - - - . - ,
'.

]
-.JI-T-h-ro-lI-'e-p-O-s-it-io-n--------~

L
Throttle position sensor
1'----~.
L~gnition switch

-~
Start sig. na_'
~

(ECGS
control
module)

EGR and canister

control solenoid
valve

~~_
__

SYSTEM DESCRIPTION
This system cuts and controls vacuum applied to
EGR valve and canister to suit engine operating
conditions. This cut~and-control operation is
accomplished through the ECM and the EGR &
canister control solenoid valve. When the ECM
detects any of the following conditions, current
flows through the solenoid valve. This causes the
port vacuum to be discharged into the atmosphere. The EGR valve and canister remain
closed.

')
2)
3)
4)
5)
6)

Low engine coolant temperature

Engine starting
High-speed engine operation
Engine idling
Excessively high engine coolant temperature
Mass air flow sensor malfunction

Air Conditioner Cut Control

INPUT/OUTPUT SIGNAL LINE
~jr conditioner
~ system
[~

.
I-A_/_C-O-N_-Si-gn-a-I---------+i
ECM

' - - - - - - - - - - - - - - - - - -Y

Th_r~ttle position

Engine coolant temperature sensor

(ECeS
---~

Engine coolant temperature

SYSTEM DESCRIPTION
When the accelerator pedal is fully depressed. or
engine coolant temperature is extremely high,
the air conditioner is turned off for a few seconds,

control

Air conditioner
relay

module)

This system improves acceleration when the air

conditioner is used.

EC..26

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Valve Timing Control (VTC)
INPUT/OUTPUT SIGNAL LINE

~Mass air flow sensor

L

~---.JI

~Engine speed
-----------

Camshaft position sensor

~=

Amou_n_t_of_i_nt_a_ke_a_i_r
r---

Engine coolant temperature

~ coolant temperature sens~
------

Throttle position sensor

_ _ _ _ _ _ _ _-------l

[park/Neutral position switch

Throttle valve opening angle

ECM
(ECCS
control
module)

-----------~

-J

timi~-g

Valve
control
solenoid valve

---.
l,:t

~Neutral position
------

SYSTEM DESCRIPTION
The valve timing control system is utilized to
increase engine performance. Intake valve opening and closing time is controlled, according to
the engine operating conditions, by the ECM.

Engine coolant temperature signals. engine

speed, amount of intake air, throttle position,
vehicle speed and gear position are used to ~rr
determine intake valve timing.
The intake camshaft pUlley position is regulated ;'~Ir
by oil pressure, which is contra/led by the valve
timing control solenoid valve.

EC..27

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Valve Timing Control (VTC) (Confd)
r---------------------------

-'--------------~---------__.

VTC
(Valve timing conirol)
solenoid valve
intake air signal (From mass air flow sensor)
Engine speod signal (From camshaft position sensor)

ECM (ECeS
control

Engine coolant temperature (From engine coolant temperature sensor)

Throttle valve idle position (From throttle position sensor)
Vehicle speed (From vehicle speed sensor)

module)

Oi'

pressure

..

+ Solenoid valve ON ()
Solenoid valve OFF (CD)

Overtap (21')

Drain

Intake
closes

Exhaust opens
BDC

CD
Camshaft sprocket
(IntakA side)
Return spring
Engine speed ---

SEF987P

OPERATION
Engine operating condition

Valve timing control

Intake valve opening

solenoid valve

and closing time

ON

OFF

Valve overlap

Engine torque curve

Advance

Increased

Normal

Normal

CD

Vet1rcle is running.
Engine coolant temperature
is 50C (122F) or more.
Engine speed is between
1,050 rpm and 5,700 rpm.
Engine load is high.
Engine speed is 1,050 rpm
or less

Those other than above

EC..28

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Heated Oxygen Sensor (H02S) Heater Control

INPUT/OUTPUT SIGNAL LINE

[camShaft position sensor

Ft

[ Mass air flow sensor

..

Engine speed

ECM
(ECCS
control

..

01 intake air

Heated oxygen sensor

heater

module)

The ECM performs ON/OFF control of the heated

oxygen sensor heater corresponding to the
engine speed and engine load.

OPERATION
Engine operating condition

Heated oxygen sensor

heater

Engine speed is more than

4,000 rpm.

OFF

------t------------

Heavy load

OFF

Ex.cept above

ON

-----Cooling Fan Control

INPUT/OUTPUT SIGNAL LINE

I Vehicle speed

I Vehicle speed sensor

Engine coolant lemperature

-I

sensor
1

I Air conditioner switch

--------.-..

Cooling fan low speed

ECM

Engine coolant temperature .... (ECCS

control
module)
Air conditioner "ON" signal ..

The ECM controls the cooling fan corresponding

to vehicle speed, engine coolant temperature

Cooling fan high speed

[COOling Ian relay-1

.. I Coolmg Ian relay-2

II

and air conditioner ON signal. The control system

has a 2-step control [HIGH/LOW/OFF].

rg1Ji\

OPERATION
Air conditioner switch is "ON"

Air conditioner switch is "OFF".

C
lU

(5

e
::::l

0-;
Ql

....

c a.
C1l
.C\E
c ~

C (OF)
100 (212)
9S (203)

'~111111""11

c;;;

.!!!

lI.l
o ...

o :l
o-

l)

lI.l

~ '0;.%/:///// /'/'/'./././

...

8g'

.!:

UJ_

UJ ..

Vehicle !>peed km/h (MPH)

c:::=:J:

Cooling fan does not operate

~.

Cooling fan operates at "HIGH" speed,

Vehicle speed km/h (MPH)

1~1
~

Cuoling tan opemtcs at "LOW' ~reed,

The cooling fan operates at HIGH speed if diagnostic test mode II (self-diagnostic reSUlts) for engine
coolant temperature sensor is "NG".

EC..29

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Boost Pressure Control
INPUT/OUTPUT SIGNAL LINE
~ Engine speed and piston position

[CamShaft position sensor

II

Throtlle position sensor

ECk

Throttle valve idle position

ECM

~ne

sensor

(ECCS

knocking

control
module)

I
I

VehIcle speed sensor

I Boost pressure sensor

Wastegate valve control

f----------+ solenoid valve (a duty

type)

, Vehicle speed

, Boost pressure

.....

SYSTEM DESCRIPTION
The output signal maps of the ECM are selected
according to fuel octane rating, gear position
(MIT model) and vehicle speed (A/T model).
The wastegate valve control solenoid valve

changes the source vacuum which activates the

actuator. This results in a proportional boost
pressure to the acceleration.
Knock signs are used to determine fuel octane
rating.

OPERATION
Fuel octane rating

Gear position or vehicle speed

Boost pressure control map

1, 2 and 3 speed gears (MIT model)

Less than 46 km/h (29 MPH) (A/T
model)

A slow response type

Premium
4 and 5 speed gears (MIT model)
More than 46 km/h (29 MPH) (AfT
model)
Lower than the above

Any

Fixed

EC-30
III

A qUick response type

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Fail-safe System
CPU MALFUNCTION
(~l

Input/output signal line

Amount of intake air

Mass air flow sensor

~itiOn

switch

Engine coolant temperature

sensor

II

Throttle position sensor

II

Start signal

..

Engine coolant temperature

...

Throttle valve opening angle

Outline
The fail-safe system makes engine starting possible if there is something malfunctioning in the
ECM's CPU circuit.
In former models, engine starting was difficult
under the previously mentioned conditions. But
with the provisions in this fail-safe system, it is
possible to start the engine.

...

ECM
(ECeS
control
module)

H
H
H
rl
rl

Fuel injector

Power transistor

IACV-AAC valve

The fail-safe mode operates when the computing

function of the ECM is judged to be malfunctioning.
When the fail-safe system activates, i.e. if a malfunction condition is detected in the CPU of the
.ECM, the MALFUNCTION INDICATOR LAMP on
the instrument panel lights to warn the driver.

Fuel pump control unit

Malfunction indicator lamp

Cancellation of fail-safe system when ECM

is malfunctioning
Activation of the fail-safe system is canceled
each time the ignition switch is turned OFF. The
system is reactivated if all of the activating conditions are satisfied after turning the ignition
switch from OFF to ON.

MASS AIR FLOW SENSOR MALFUNCTION

Fail-safe system activating condition when
ECM is malfunctioning

I
I

!~~

;'~il

~Ij'

~:~r

prQ)

It the mass air flow sensor output voltage is

below the specified value, the ECM senses an
F/~\
mass air flow sensor malfunction. In the case of
a malfunction, the throttle position sensor substitutes for the mass air flow sensor.
i~~
Although the mass air flow sensor is
malfunctioning, it is possible to start the engine
and drive the vehicle. But engine speed will not ;~!R1
rise more than 2,400 rpm in order to inform the
driver of fail-safe system operation while driving.

Engine control with fail-safe system,

operates when ECM is malfunctioning

~If

When the tail-safe system is operating, fuel

injection, ignition timing, fuel pump operation,
engine idle speed, and so on are controlled
under certain limitations.

~~

~rr

Operation (Mass air flow sensor malfunction)

r~:,~

Engine condition

Starter switch

Fail-safe system

Stopped

ANY

Does not operate.

Cranking

ON

ferL

Engine will be started by a pre-determined

Operates.

Running

Fail-safe functioning

injection pulse on ECM.

Engine speed will not rise above 2,400 rpm

OFF

EC..31

~ij~

:1I

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Fail-safe System (Cont'd)
KNOCK SENSOR MALFUNCTION

ENGINE COOLANT TEMPERATURE

SENSOR MALFUNCTION
When engine coolant temperature sensor output

voltage is below or above the specified value,

engine coolant temperature is fixed at the preset
value as follows:
Engine condition

Ef1glOe coolanl temperature

preset value "C (OF)

Start

20 (68)

Running

80 (176)

When ECM judged to be malfunctioning, ignition

timing is controlled numerical value for regular
gasoline.

START SIGNAL FOR MALFUNCTION

----

THROTTLE POSITION SENSOR

MALFUNCTION

If the ECM always receives a start signal, the

ECM will judge the start signal "OFF" when
engine speed is above 1,000 rpm to prevent extra
enrichment.
After the engine speed is below 200 rpm. start-up
enrichment will be allowed until the engine
speed reaches 1,000 rpm.

BOOST PRESSURE SENSOR

MALFUNCTION

Description
When the output signal of throttle position sensor
is abnormal the ECM judges it as a malfunctioning of throttle position sensor.
The ECM do not use the throttle position sensor
signal.

When ECM judged to be malfunctioning, the duty

of wastegate valve control solenoid valve is fixed
at 20 %

EC-32

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Direct Ignition System
CHECKING IDLE SPEED AND IGNITION TIMING

Idle speed
1.

Disconnect check connector for voltage type tachometer.

2.

Connect tachometer using a suitable tool.

1/'
.'-"

Ignition timing

1.
2.

3.

Method A (Without SST)

Remove NO.1 ignition coil.
Connect No. 1 ignition coil and NO.1 spark plug with a
suitable high-tension wire as shown, and attach timing
light. For the above procedures, enlarge the end of a suitable high-tension wire with insulating tape as shown.
Check ignition timing.

. :rr

n5:
~$..,-

Cut

Suitable
I)igh-tension Wire-.J

Insulating tape

Electrode~

l)\'~

r,\';;>J

7\

/ Approlt.
12 (0.47)

Approx.

14 (0.55)

~1'1~
APpr6 'll.

Unit: mm (in)
SEF457F

EC-33

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Direct Ignition System (Cont'd)
Method B (Without SST)
Clamp wire as shown_
This wire is provided at the rear end of the engine.

~hl~
pickup

\\

SEF992P

EC-34

IDLE SPEED/IGNITION TfMINGIlDLE MIXTURE RATIO INSPECTION

PREPARATION

2.

1. Make sure that the following parts are in

good order.
3.

Battery

Ignition system
Engine oil and coolant leve's
Fuses
ECM harness connector
Vacuum hoses
Air intake system
(Oil filler cap, oil level gauge, etc.)
Fuel pressure
Engine compression
EGR valve operation
Throttle valve

4.
5.
6.

7.

On air conditioner equipped models, checks

should be carried out while the air condl~
tioner is "OFF".
When checking idle speed, ignition timing t!J:r
and mixture ratio of AIT models, shift lever to
"N" position.
When measuring "CO' percentage, insert ~I~\
probe more than 40 em (15.7 in) into tail pipe.
Turn off head lamps, heater blower, rear
defogger.
I:!~
Keep front wheels pointed straight ahead.
Make the check after the cooling fan has rue
stopped.

Overall inspection sequence

INSPECTION START'

Perform diagnostic test mode 11 (Self-diagnostic results).

NG

Repair or replace

OK

Check & adjust ignition timing.

OK

-.

NG

Check & adjust idle

speed.

OK

NG
~

Check heated oxygen

~~.

~~eCkCO%.

L----_

sensor harness.
OK

Check heated oxygen

NG

sensor function.
~---------,

Check emission control

parts and repair or

replace if necessary

Repair or replace harness.

Replace heated ox.ygen sensor.

OK

NG
~

Check heated oxygen

INSPECTION END

sensor function.

Jf-'IItlIf----------.--~

L-.-------.

EC..35

--

!
i

i
i

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

S_Ti=-RT~
__ ~

C=

Visually check the following:

Air cleaner clogging

Hoses and ducts for leaks
EGA valve operation
Electrical connectors
Gasket
Throttle valve

IISEF81D'S

Start engine and warm it up until engine coolant temper~

ture indicator points to the middle of gauge. Ensure that
engine speed is below 1,000 rpm.

----------.----------Open engine hood and run engine at about 2,000 rpm for
about 2 minutes under no-load.
'---------------------,---------------

[i

Fform diagnostic test mode II (Self-diagnostic results).

SEF247F

~NG

OK

. .e /
\

Repair or replace components as necessary.

I /

~~._-------------~-=-----...,
Run engine at about 2.000 rpm for about 2 minutes under
no-load. Race engine two or three times under no-load,
then run engine for about 1 minute at idle speed.

CHECK-

./

.......

I \

Malfunction indicator
lamp

1) Select "IGNITION TIMING ADJ" In WORK SUPPORT mode.

2) Touch "START",

--------_._------,

I;J

1) Stop engine and disconnect throttle position sensor harness connector.

2) Start engine.

,---

Race engine two or three times to about 2,000 rpm under

no-load. Then run engine al idle speed.

Check ignition timing with a timing

tight.
SEF993PI

15"2 BlOC

ignl~i:~

OK

Adjust
timing by turning clamShaft
position sensor after loosening securing
bolts.

SMA189A~
EC..36

,.

IDLE SPEEDIIGNITION TIMINGIIDLE MIXTURE RATIO INSPECTION

~~-----------

I-

rGN TIMING AOJ

-CONDITION SETTING- -

JGN/T FEEDBACK

HOLD

== =

MONJTOR

CAS.RPM {REF)

IGN TIMING

==

765rpm

15arOC

IDLE POSITION

Check idle speed.

ON

00

Read idle speed in "IGN TIMING ADJ" in "WORK SUPPORT"

mode.

Check idle speed.

OR

800 50 rpm (AIT I" "N" position)

SEFS54K

LNG

OK

..

Ii)

IGN TIMING ADJ.

r=----------

IGNITION TIty1ING FEEDBACK

CONTROL WILL BE HELD BY
TOUCHING START.
AFTER DOING SO. ADJUST
IGNITION TIMING WITH A
TIMING LIGHT BY TURNING
THE CRANK ANGLE SENSOR.

START

1) Select "IGN TIMING ADJ" in "WORK SUPPORT"

mode.
2) Touch "START".
OR
Turn oft engine and disconnect rhrottle position sensor
harness connector. Then start engine.

Race engine two or three times to about 2,000 rpm under

no-load. Then run engine at idle speed.

L-.

SEF816K

@]

Adjust idle speed by turning idle speed adjusting screw.

750 50 rpm (Air In "N" position)

.'~~

00

00
II

Touch "Back".
1) Stop engine and connect throttle position sensor harness connector.
2) Start engine.

Race engine two or Ihree I,mes to about 2.000 rpm under

no-load. Then run engine at idle speed.
-

-r---

-----J

Check idle speed.

Read idle speed in "DATA MONITOR" mode with CONSULT

Check idle speed.

t-------------

OR

--~---------__l

r------------------------------i
800 50 rpm (A/T in "N" posllion)

NG

OK

r Check AAC valve and replace if neces~ry.

'

SEF913J

-]-~- - - - - - - -~
I

Check AAC valve harness and repair it necessary.

____ =r---~~

l~heCk ECM
------------

function' by substituting another known good ECM.

.: ECM may be the cause of a problem, but this is rarely the case.

EC..37

IDLE SPEEDIIGNITION TIMINGIIDLE MIXTURE RATIO INSPECTION

-'1

J
-=-.

II

r---------L..--!-----

CH~,J~N

Run engine at about 2,000 rpm for about 2

minutes under no-load,

PFr-'9"'1
~

Data rink connector for CONSULT

(Connect CHK and IGN terminals
with a suitable harness.)

Set on-board diagnostic system of ECM to Diagnostic Test

Mode 11 (heated oxygen sensor monitor).
SEF265LB

_ _ _ _ _- - - - - - J

NG

Data link connector for CONSULT

(Disconnect the harness.)

SEF273LB

'rMONITOA

'rNO FAIL

CAS- RPM (REF\

2CXX>rorn

M/R FIe MNT

RICH

____1_0_K

_
END

Replace heated oxygen sensor. Connect heated oxygen sensor

harness connector.

RECORD
SEF818K

'~/'
CHECK-

Set on-board diagnostic system of ECM to Diagnostic Test

Mode II (heated oxygen sensor monitor).

........

[;]

/1\
Malfunction indicator

lamp
SEF051PA

~~CYlinder head. cover

~~'-';"\;.

~---

I /

Run engine at about 2.000 rpm for about 2 minutes under

no-load.

[!)

Check heated oxygen sensor signal.

1) See "M/R FIC MNT" in "Data monitor" mode.
2) Maintaining engine at 2,000 rpm under no-load
(engine is warmed up sufficiently.), check that
the monitor fluctuates between "LEAN" and
"RICH" more than 5 times during 10 seconds.
1 cycle: RICH ..---.. LEAN
RICH
2 cycles: RICH ----+ LEAN ----+ RICH ----+ LEAN --4
RICH

-----j.

OR

Make sure that malfunction indicator lamp goes

on and off more th an 5 Ii mes du ri ng 10 seconds
at 2,000 rpm

EC-38

OK
I,

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

LHO models

m m [!1

@[i

,.......--------- - - - - - - - ,

Check heated oxygen sensor harness:

1) Turn off engine and disconnect battery ground cable
2) Disconnect ECM connector from ECM.

:I~~

3) Disconnect heated oxygen sensor harness connector. Then

~;M1

connect harness side terminal for heated oxygen sensor to

ground with a jumper wire.
4) Check for continuity between terminal No. 29 of ECM connec-

It

tor and ground metal on vehicle body.

Continuity exists
Continuity does not exist

OK
NG
NG

OK

~~

II

Repair or replace harness.

(C:lL,

fMil!!
Heated oxygen
sensor harness
connector

~:

Ectt

DISCONNEcT

~ ~

l...lIaI ~

Connect ECM connector to ECM.

L...---_~--.-------~-~

-m~~1

29

I~\:r

~iQ)

?~

Rl/~

MEF661D

~[R\

~If
iRl~

~\j'

r~~

~l

~iQJ~

EC-39

._----------------------i

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

ACTIVE TEST.

ENGINE TEMP

20l)C

:.=:::.=== MONITOr!. =======

CAS.RPM (REF)
INJ PULSE
IGN TIMING

Ofpm

62msec
5BTDC

f---

I~
SEF788K

1) Select "ENGINE TEMP" or "ENG COOLANT TEMP" in

"ACTIVE TEST" mode.
2) Set "ENG COOLANT TEMP" to 20 C (68 F) by touching
"DWN" and "Qd".
OR
1) Disconnect engine coolant lemperature sensor harness
connector.
2) Connect a resistor (2.5 kO) between terminals of
engine coolant temperature sensor harness connector.
G

18

r!1

nlSCONNfCT

Start engine and warm it up until engine coolant temperature

indicator points to the middle of gauge. (Be sure to start engine
after installing a 2.5 kO resistor.)

[:it

00

Ii]

-~
Race engine two or three times under no-load, then run engine
at idle speed.

2.5 kfl reslstor

MEF6630

Check "CO" %.
Idle CO: Less than 1l% (and engine runs smoothly)

Afler checking CO%,

1) Disconnect the resistor from terminals of engine coolant tem-

perature sensor.
2) Connect engine coolant temperature sensor harness connec-

tor to engine coolant temperature sensor

SEF810K

--

Connect heated oxygen sensor harness connector to heated oxy-

~~CYlinder head. cover

~~~";"~ ____
~~'t~~,-,-

~/

gen sensor.

~
Check fuel pressure regulator.

._--~----

Check mass air fluw sensor.

Check injector.

Clean or replace if necessary.

.--

....L--

Check engine coolant h~mperature sensor .

._ ---C~eCk

ECM function' by substituting another known good ECM.

': ECM may be the cause of a problem, but this is rarely the case.

EC..40

'"

TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair
On~board Diagnostic System

_-..

EC- 43
EC- 48 @[

On-board Diagnostic System -

Diagnostic Test Mode I

EC- 50

On-board Diagnostic System -

Diagnostic Test Mode II (Self-diagnostic results)

EC- 50

On-board Diagnostic System -

Diagnostic Test Mode" (Heated oxygen sensor monitor)

EC- 52

Consult

" _. _ EC- 53

Diagnostic Procedure
Basic Inspection

EC- 61

-_ _

EC- 63

[j(.ffi~

=IMI

\C:;I~:

111

How to Execute On-board Diagnostic System in Diagnostic Test Mode II

EC- 66 ~ ,[;

Diagnostic
Diagnostic
Diagnostic
Diagnostic

EC- 70
EC- 71

Procedure
Procedure
Procedure
Procedure

1-

23-

4-

Diagnostic Procedure 5 Diagnostic Procedure 6 Diagnostic

Diagnostic
Diagnostic
Diagnostic
Diagnostic
Diagnostic
Diagnosttc

Procedure
Procedure
Procedure
Procedure
Procedure
Procedure
Procedure

Symptom
Symptom
Symptom
Symptom

Symptom Symptom -

12 13 -

Symptom Symptom Symptom Symptom Symptom Symptom Symptom -

Diagnostic Procedure 14 Diagnostic Procedure 15 -

Symptom Symptom -

7 89-

10 11 -

Diagnostic Procedure 16 -

Symptom -

High Idling after Warm-up

Hunting
Unstable Idle
Hard to Start or ImpoS~ible to
Start when the Engine IS Cold
Hard to Start or Impossible to
Start when the Engine Is Hot
Hard to Start or Impossible to
Start under Normal Conditions
Hesitation when the Engine is Hot
Hesitation when the Engine is Cold
Hesitation under Normal Conditions
Engine Stalls when Turning
Engine Stalls when the Engine is Hot
Engine Stalls when the Engine is Cold
Engine Stalls when Stepping on the
Accelerator Momentarily
Engine Stalls after Decelerating
Engine Stalls when Accelerating or when
Driving at Constant Speed
"
Engine Stalls when the Electrical Load
is Heavy
Lack of Power and Stumble
Knock
Surge
Backfire through the Intake
Backfire through the Exhaust

Diagnostic Procedure 17 - Symptom Diagnostic Procedure 18 - Symptom Diagnostic Procedure 19 - Symptom Diagnostic Procedure 20 - Symptom Diagnostic Procedure 21 - Symptom Diagnostic Procedure 22
MAIN POWER SUPPLY AND GROUND CIRCUIT (Not self-diagnostic item)
Diagnostic Procedure 23
CAMSHAFT POSITION SENSOR (Diagnostic trouble code No. 11)
-

EC-41

IF~

EC- 76
EC- 78

ECECECECECEC-

82
83
84

(ij1l
1~'iJ

85
87
89

r~V)

EC- 91
EC- 93

[f~

EC- 97

~~

EC- 99
EC-l01
EC-102
EC-103
EC-104
EC-104

EC-113

EC-116
EC-120
"

IC:l

EC- 80

EC-109

Diagnostic Procedure 26
IGNITION SIGNAL (Diagnostic trouble code No. 21)
Diagnostic Procedure 27
BOOST PRESSURE SENSOR (Diagnostic trouble code No 26)

EC- 72

EC-105

Diagnostic Procedure 24
MASS AIR FLOW SENSOR (Diagnostic trouble code No 12)
Diagnostic Procedure 25
ENGINE COOLANT TEMPERATURE SENSOR (Diagnostic trouble
code No. 13)
,
__ _

EC-128

l8rRl
~1r
rRl~

TROUBLE DIAGNOSES
Contents (Cont'd)
Diagnostic Procedure 28
KNOCK SENSOR (Diagnostic trouble code No. 34)
Diagnostic Procedure 29
THROTTLE POSITION SENSOR (Diagnostic trouble code No. 43)
Diagnostic Procedure 30
AfT CONTROL (Diagnostic trouble code No. 54)
Diagnostic Procedure 31
START SIGNAL (Not self-diagnostic item)
Diagnostic Procedure 32
VEHICLE SPEED SENSOR (Not self-diagnostic item)
Diagnostic Procedure 33
EGR AND CANISTER CONTROL (Not self-diagnostic item)
Diagnostic Procedure 34
HEATED OXYGEN SENSOR (Not self-diagnostic item)
Diagnostic Procedure 35
INJECTOR CIRCUIT (Not self-diagnostic item)
Diagnostic Procedure 36
FUEL PUMP (Not self-diagnostic item)
Diagnostic Procedure 37
WASTEGATE VALVE CONTROL (Not self-diagnostic item)
Diagnostic Procedure 38
VTC CONTROL (Not self-diagnostic item)
Diagnostic Procedure 39
IACV-AAC VALVE (Not self-diagnostic item)
Diagnostic Procedure 40
IACV-FICD SOLENOID VALVE (Not self-diagnostic item)
Diagnostic Procedure 41
COOLING FAN CONTROL (Not self-diagnostic item)
Diagnostic Procedure 42
POWER STEERING OIL PRESSURE SWITCH (Not self-diagnostic item)
Diagnostic Procedure 43
NEUTRAL POSITION SWITCH & AfT CONTROL UNIT
(PARK/NEUTRAL POSITION SIGNAL) (Not self-diagnostic item)
Diagnostic Procedure 44
REAR WINDOW DEFOGGER SWITCH (Not self-diagnostic item)
Diagnostic Procedure 45
MALFUNCTION INDICATOR LAMP & DATA LINK CONNECTOR FOR CONSULT
(Not self-diagnostic item)
Electrical Components Inspection
Fast Idle Cam (FIC) Inspection and Adjustment

EC-42

EC-132
EC-135
EC-139
EC-142
EC-145
EC-148
EC-152
EC-156
EC-159
EC-163
EC-166
EC-169
EC-172
EC-176
EC-184

EC-187
EC-192

EC-195
EC-196
EC-207

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair

Sensors

INTRODUCTION

SEF233G!

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 kinds of signals are proper and
stable. At the same time, it is important that there are no con- ~\'i~
ventional problems such as vacuum leaks. fouled spark plugs,
or other problems with the engine.
It is much more difficult to diagnose a problem that occurs :lC~
intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or i m p r o p e r .
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,
so a road test with a circuit tester connected to a suspected ~l~
circuit should be performed.
Before checking, talk to customer about drivability complaint.~~L
The customer is a very good supplier of information on such
problems, especially intermittent ones. Through interaction
with the customer, find out what symptoms are present and ~,Iil~
~~J r
under what conditions they occur.
Start your diagnosis by looking for "conventional" problems
first. This is one of the best ways to troubleshoot driveability~rf
problems on an electronically controlled engine vehicle.
1. Verify the complaint.
2. Isolate the cause.
3. Repair
4. Recheck and be sure no new symptoms have been caused.

~'-r);

';l~:",

SEF234GI

t,

EC-43

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
WORK FLOW

c==

CHECK IN

----~---

............................................ _

LISTEN TO CUSTOMER COMPLAINTS

I
I

1-

........ _,

BASIC INSPECTION

STEP I

__

STEP II

(EC-63)

Do self-diagnostic results exisl?" 1

~~

~~

...................................... STEP III

.... No

Yes

ON-BOARD
DIAGNOSTIC

SYMPTOM

FUNCTION

SYSTEM

BASIS

TEST BASIS

Perform diagnostic ~
mode II (Self-diagnostic
results). (Refer to
EC-50.)

Select inspection on the

basis of each symptom.
(Diagnostic Procedure

---r

+:

1- Symptom

~Diagnostic Procedures I ~iagnostic Procedures

31 - 45

EC-l09 - 139

EC-142 - 195

II

(Self-diagnostic item)

1(Not self-diagnostic

-+

INSPECTION OF

23 - 45
EC-109 - 195

EACH MALFUNCTION

CHECK OUT

REPAIR/R_E_P_L_A_C_E

FINAL CHECK
Confirm that the trouble is completely fixed by
performing BASIC INSPECTION and TEST
DRIVE.

ilem &

self_diag~~

IF

IF

NG

Diagnostic Procedures

LNOI

IV

1(Self-diagnostic

item)

L-------_

STEP

t-

23 - 30

1 - 21)

No

--

in FUNCTION TEST with

CONSULT.

EC-70 104

; Do self-diagnostic resulls exist'

~ertorm sequencet~

............................... _

STEP V

*1: If the on-board diagnostic system cannot be performed, check main power supply and ground circuit. (See Dlagnosllc Procedure 22)
*2: If the trouble Is not dupllcaled, see INTERMITTENT PROBLEM SIMULATION (EC-47).

EC-44

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
DESCRIPTION FOR WORK FLOW
STEP

DESCRIPTION

STEP I

Identify the trouble using the "DIAGNOSTIC WORKSHEET"

STEP II

Be sure to carry out the Basic Inspection, or the results of inspections thereafter may be misinterpreted.

STEP III

Check the self-diagnostic results stored in the ECM of the failed vehicle.

~s

shl)wn on Ihe next page

Perform inspection often selecting from the following three tests according to the trouble observed.
1. ON-BOARD DIAGNOSTIC SYSTEM

Follow the self-diagnostic procedure for each item described in "How 10 Execute On-board Diagnostic Syslem in Diagnostic Test Mode II". Non-self-diagnostic procedures described for some items will also provide
results which are equal to the self-diagnostic results.
2. SYMPTOM BASIS
This inspection is of a simplified method. When performing inspection of a part, the corresponding system
must be checked thoroughly by selecting the appropriate check item from Diagnostic Procedures 23 - 45.
3. FUNCTION TEST BASIS (Sequence test)

In this inspection, the CONSULT judges "OK" or "NG" on each system in place of a technician. When per~
STEP IV

forming inspection of a part, the corresponding system must be checked thoroughly by selecting the appropriate check item from Diagnostic Procedures 23 - 45.
4. Diagnostic Procedure
This inspection program is prepared using the data obtained when disconnection of harness or connec-

tors has occurred in the respective Circuit.

Inspection of the "Not self-diagnostic item" does not actually start with the execution of diagnostic test
mode II (self-diagnostic results). However, inspection is started by assuming that the diagnostic test mode
" (self-diagnosUc results) has already been performed.
When a system having the diagnostic test mode " (self~diagnostic results) function contains any circuit

placed outside the range of this diagnostic test mode II (self-diagnostic results) function, it is arranged
that the "Not self-diagnostic item" of such a system will be performed when the self-diagnostic result is
OK.
Example: CAMSHAFT POSITION SENSOR
1. FINAL CHECK item is not described in the "Not self-diagnostic item". However. this FINAL CHECK must be

performed without fail in order to ensure that the trouble has been repaired, and also that the unit disassembled in the course of the repair work has been reassembled correctly.
STEP V

2. If the same trouble phenomenon is observed again in the final check:

Go back to STEP IV. and perform the inspection using a method which is different from the previous method.
3. 1f the cause of the trouble is still unknown even after conducting step 2 above, check the circuit of each sys-

tem for a short by using the lIoliage available at the "ECM INPUT/OUTPUT SIGNAL INSPECTION" terminal.

EC-45

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
DIAGNOSTIC WORKSHEET

KEY POINTS
WHAT .....
WHEN
WHERE
HOW

There are many kinds of operating conditions that lead to

malfunctions on engine components.
A good grasp of such conditions can make trouble-shooting
faster and more accurate.
In general, feelings for a problem depend on each customer.
It is important to fully understand the symptoms or under what
conditions a customer complains.
Make good use of a diagnostic worksheet such as the one
shown below in order to utilize all the complaints for troubleshooting.

Vehicle & engine model

Date, Frequencies
Road conditions
Operating conditions,
Weather conditions,
Symptoms
SEF907L

Worksheet sample
Customer name

Engine

MRIMS

Incident Date

Symptoms

Slartabilily

Model & Year

VIN

Trans.

Mileage

Manuf. Date

In Service Dale

Partial combustion
No combustion
Impossible to start
o Partial combustion affected by throttle position

Possible but hard to start

No fast idle

o
o
o
o
o
o

Others [

o
o

Idling

Driveability

Engine stall

Incident occurrence

o
o

Frequency

o
o

Partial combustion NOT affected by throttle position

Others (

Hot

Cold

Fine

DRaining

Snowing

Others [

o Warm o Cool o Cold o Humid

o DUring warm-up o After warm-up
,

In town

2000
In suburbs

Not affected
At starting

While accelerating

I
4000

Highway

10

Not turned on

EC-46
ft.

8000 rpm

Off road (up/down)

Turned on

6000

~F

While idling
At racing
D While cruising
o While decelerating o While turning (RH/LH)
Vehicle speed
, I
I
I
!
I
I
I
Malfunction indicator lamp

Low idle

Not affected

Engine speed

Driving conditions

o While idling
o While decelerating
Just after stopping o While loading
Just after delivery o Recently
In the morning o At night o In the daytime
All the time o Under certain conditions o Sometimes

o
o

High idle

At the time of start

While accelerating

Temperature

Road conditions

Unstable

Knock o Lack of power

Surge
Intake backfire o Exhaust backfire
]
Others [

Weather

Engine conditions

Stumble

o
o

Weather conditions

20

30

40

50

60 MPH

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
INTERMITTENT PROBLEM SIMULATION
In order to duplicate an intermittent problem, it is effective to

q.... . . . '-.l1tz~~I~~

create similar condItions for component parts, under which the

THIS is the)

problem might occur.

Perform the activity listed under Service procedure and note
the result.

SEF235G

Variable factor

Influential part

Target condition

Service procedure

~ ;---

Mixture ratio

Ignition timing

Made lean

Remove vacuum hose and apply vacuum.

Made rich

Remove vacuum hose and apply pressure.

Pressure regulator
Camshaft position

Advanced

Rotate distributor counter clockwise.

sensor

Retarded

Rotate distributor clockwise.

Heated oxygen sensor

Suspended

Disconnect healed oxygen sensor harness

connector.

ECM

Operation check

Perform diagnostic test mode II (Sel1-diagnostic results) at ?,OOO rpm.

Raised

Turn idle adjusting screw counterclockwise.

Lowered

Turn idle adjusting screw clockwise.

Mixture ratio feedback

control

Idle speed

--

IACV-AAC valve
-

:?,'f

Tap or wiggle.
5

Electrical connection
(Electric continuity)

Harness connectors
and wires

Poor electrical connection or improper

wiring

Race engine rapidly. See if the torque reaction of the engine unit causes electric
breaks.

Temperature

Cooled

Cool with an icing spray or similar device.

Warmed

Heat with a hair drier.

[WARNING: 00 not overheat the unit.]
Wet.
[WARNING: Do not directly pour water on
components. Use a mist
sprayer.]

ECM

Moisture

Electric parts

Damp

Electric loads

Load switches

Loaded

Throttle position sensor condition

ECM

ON-OFF switching

Rotate throttle posillon sensor body.

10

Ignition spark

Timing light

Spark power check

Try to flash timing light for e;::\ch cylinc1m

Turn on headlamps. air conditioner. rear

defogger, etc.

Select the "Variable factor" when the symptom occurs.

Perform the "Service procedure" to try to simulate the intermittent.

EC-47

--

~i'\

, /-\

TROUBLE DIAGNOSES

~~~~
~
~~"'''~
Malfunction
\ Indicator lamp,

On-board Diagnostic System

MALFUNCTION INDICATOR LAMP (MIL)
A malfunction indicator lamp has been adopted on all models.

SEF192P

ON-BOARD DIAGNOSTIC SYSTEM FUNCTION

Diagnostic Test Mode
Condition
Diagnostic Test Mode I

Ignition
switch in
"ON"

Engine
stopped

iD

position

BULB CHECK

Engine

ecea

running

EC-48

ID

MALFUNCTION
WARNING

Diagnostic Test Mode

II
SELF-0 IAGNOSTIC
RESULTS

HEATED OXYGEN
SENSOR
MONITOR

TROUBLE DIAGNOSES
On-board Diagnostic System (Cont'd)
HOW TO SWITCH MODES

I~

l0

Turn ignition

SWilC~

:~Ol start engine.)

Diagnostic Test Mode I (BULB CHECK)

_==r=-

~~

~
I
L..--

-O-_~

CHK IGN

~gnostic Test Mode I ~J

MALFUNCTION WARNING

S_ta_rt engine_._ _ ~

.IJj

Data link connector for CONSULT

(Connect CHK and IGN terminals
~ith a SUi~able harness.\
SEF265LB

~--~
,I

Wait at least 2 seconds.

.------~-

[I;:~~r

Data link connector for CONSULT

(Disconnect the harness.)
SEF273LB

~----

Diagnostic Test Mode II (SELF-OIAGNOSTle RESULTS)

----.----------'

Start engine.

... ~~ostiC Test Mode

I

---------~

1/

(HEATED OXYGEN SENSOR

MONITOR)

------

Data fink conneclor for CONSULT

(Connect CHK and lGN terminals
with a suitable harness.)
SEF265LB

--=r=--

~ at

least 2

second-s.-----~

r-=-==-

,--------------'

i"J"."~GN
I

Switching the modes is nol possible when the engine

is running.
When ignition switch is turned off during diagnosis,
power to ECM will drop after approx. 1 second.
The diagnosis will automatically return to Diagnostic
Test Mode I.

t 1i..Dala link connector for CONSULT

(Disconnect the harness,)
SEF273LB

EC-49

TROUBLE DIAGNOSES
On-board Diagnostic System Mode I
DIAGNOSTIC TEST MODE I -

Diagnostic Test

BULB CHECK

In this mode, the MALFUNCTION INDICATOR LAMP in the

instrument panel stays "ON".
If it remains "OFF", check the bulb in the MALFUNCTION INDICATOR LAMP.

DIAGNOSTIC TEST MODE I -

MALFUNCTION WARNING

MALFUNCTION INDICATOR LAMP

Condition

ON

When the ECM's CPU or camshaft position sensor is malfunctioning.

OFF

OK

f---

On-board Diagnostic System - Diagnostic Test

Mode II (Self-diagnostic results)
DESCRIPTION
In this mode, a diagnostic trouble code is indicated by the number of flashes from the MALFUNCTION
INDICATOR LAMP (MIL) as shown below:
Example: Diagnostic trouble code No_ 12 and Diagnostic trouble code No. 34

0.6

0.3

0.9

0.3

0.6

0.3

2.1

0.6

0.9

2.1

'-----------.,.,---_--.-/

Diagnostic trouble code No. 12

Diagnostic trouble code No. J4

Unit: second

MEF165FI

Long (0.6 second) blinking indicates the number of ten digits and short (0.3 second) blinking indicates
the number of single digits.
For example. the MIL flashes for 0.6 seconds once and then it flashes for 0.3 seconds twice. This indicates the number "12" and refers to a malfunction in the mass air flow sensor. In this way, all the problems are classified by their diagnostic trouble code numbers.
The diagnostic results will remain in the ECM memory_

EC-50
'I!

TROUBLE DIAGNOSES
On-board Diagnostic System - Diagnostic Test
Mode II (Self-diagnostic results) (Cont'd)
Display diagnostic trouble code table
Diagnostic trouble code

Detected items

No.

Camshaft position sensor circuit

11"

12

Mass air flow sensor circuit

13

Engine coolant temperature sensor circuit

21 *

Ignition signal circuit

26

Boost pressure sensor circuit

34

Knock sensor circuit

43

Throttle position sensor circuit

54

Signal circuit from AIT control unit to ECM

55

No malfunction in the above circuits

.. sensor CirCUIt ftrst. If both " CAMSHAFT POSITION SENSOR (No 111
* .. Check Items causing a malfunctIOn of camshaft POSition

'.

and "IGN SIGNAL-PRIMARY (No. 21)" are displayed one after the other.

I~!~

, c

Diagnostic

,I

troUbl~
code No.
11"

Malfunction is detected when ..

Detected ilems

Camshaft position sensor

circuit

Either 1 or 180 signal is not entered for the first

few seconds during engine cranking.
0

Either 1 or 180' signal is not input often enough

while the engine speed is higher than the speci-

Check item (remedy)

Harness and connector
(If harness and connector
are normal. replace camsh aft pas iii on sensor.)

fied rpm.
12

Mass air flow sensor circuit

The mass air flow sensor circuit is open or

shorted.
(An abnormally high or low voltage is entered.)

Harness and connector

(If harness and connector
are normal, replace mass
air flow sensor.)

13

Engine coolant temperature

sensor circuit

The engine coolant temperature sensor circuit is

open or shorted.
(An abnormally high or low output voltage is

Harness and connector

Engine coolant temperalure sensor

entered.)

21 *

Ignition signal circuit

The ignition signal in the primary circuit is nof

entered during engine cranking or running.

Power transistor un it

26

Boost pressure sensor cir

The boost pressure sensor circuit is open or

shorted,

Harness and connector

Boost pressure sensor

cuit

~k
43

Harness and connector

(An abnormally high or low output voltage is

entered.)

sensor circuit

Throttle position sensor cir-

The knock sensor circuit is open or shorted.

(An abnormally high or low voltage is entered.)

cuit

The throttle position sensor circuit is- open or

shorted

Signal circuit from AIT con-

The AIT communication line is open or shorted.

Harness and connector

Knock sensor
Harness and connector
Throttle position sensor

(An abnormally high or low voltage is entered,)

54

Irol unit to ECM (A/T only)

. .

Check Items caUSing a malfunctIon of camshaft POSItion sensor CirCUIt first,

and "tGN SIGNAL-PRIMARY (No. 21)" are displayed one after the other.

EC-51

I'

Harness and connector

both " CAMSHAFT POSITION SENSOR (No. 11)

..

I{$:,

TROUBLE DIAGNOSES
On-board Diagnostic System - Diagnostic Test
Mode II (Self-diagnostic results) (Cont'd)
HOW TO ERASE DIAGNOSTIC TEST MODE II (SELFDIAGNOSTIC RESULTS)
The diagnostic trouble code is erased from the backup memaryan the ECM when the diagnostic test mode is changed
from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer
to "HOW TO SWITCH DIAGNOSTIC TEST MODES".)
When the battery terminal Is disconnected, the diagnostic
trouble code will be lost from the backup memory within
24 hours.

Do not erase the stored memory before beginning diagnostic test mode II (Self-diagnostic results).

On-board Diagnostic System - Diagnostic Test

Mode II (Heated oxygen sensor monitor)
DESCRIPTION
In this mode, the MALFUNCTION INDICATOR LAMP displays
the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor.
MALFUNCTION INDICATOR LAMP

Fuel mixture condition in the exhaust

gas

ON

Lean

OFF

Rich

"Remains ON or OFF

Any condition

Air fuel ratio feedback control condition

Closed loop system

1---

Open loop system

": Maintain conditions just before switching to open loop.

HOW TO CHECK HEATED OXYGEN SENSOR

1.
2.
3.
4.

Set Diagnostic Test Mode II. (Refer to "HOW TO SWITCH

DIAGNOSTIC TEST MODES".)
Start engine and warm it up until engine coolant temperature indicator points to the middle of the gauge.
Run engine at about 2,000 rpm for about 2 minutes under
no-load conditions.
Make sure MALFUNCTION INDICATOR LAMP goes ON and
OFF more than 5 times every 10 seconds; measured at
2,000 rpm under no-load.

EC-52
_lB.

TROUBLE DIAGNOSES
RHO models

~
connector ~\
for CONSULT

Consult

Data link

3~=

CONSULT INSPECTION PROCEDURE

1.
2.

- ':;Q

fuse box cover.)

;:::,-

=
=
IJ

Turn off ignition switch.

Connect "CONSULTil to data link connector for CONSULT.
(Data link connector for CONSULT is located behind the

3.

Turn on ignition switch.

4.

Touch "START".

5.

Touch "ENGINE",

6.

Perform each diagnostic test mode according to the

inspection sheet as follows:

NISSAN

CONSULT

~-~I============

~ART
[

SUB MODE
SEF3921

[l5

SELECT SYSTEM

p=:D]

ENGINE

JIlj~

AfT

:=A=I=RB=A=G~====]

~T=C~s~=====1
LAN

=====~~=========:

SEF347N

I
I

I
I
I

SELECT OIAG MODE

WORK SUPPORT

OJ

SELF DIAG RESULTS

DATA MONITOR

ACTIVE rEST
ECM PARl NUMBER
FUNCTION TEST

For further information, read the CONSULT Operation Manual.

"]

]
SEF424N

EC-53

~~

TROUBLE DIAGNOSES
Consult (Cont'd)
ECCS COMPONENT PARTS APPLICATION
DIAGNOSTIC TeST MODE
ECCS COMPONENT PARTS

WORK suP
PORT

DIAGNOSTIC
RESULTS

MONI~

TOR

ACTIVE TEST

FUNCTION
TEST

Camshaft position sensor

Engine coolant temperature sensor

Heated oxygen sensors

Vehicle speed sensors

Ignition switch (start signal)

Air conditioner switch

Park/Neutral position switch

Power steering oil pressure switch

Battery

Knock sensor

Boost pressure sensor

A/T signal

Injectors
Power transistor (ignition timing)

IACV-AAC valve

X (Ignition
signal)

EGRC-sotenoid valve

Air conditioner relay

X
X

Cooling fan relay

Wastegate valve control solenoid

valve

Valve liming control solenoid valve

OUTPUT

DATA

Mass air flow sensor

Throttle position sensor

INPUT

SElF-

Fuel pump relay

X Applicable

FUNCTION
Diagnostic test mode

Function
This mode enables a technician to

Work support

Self-diagnostic results
Dala monitor

adjust some devices faster and

more accurately by following the
indications on the CONSULT unil
Self-diagnostic results can be read
and erased quickly.
Input/Output data in the ECM can be
read.

--

Diagnostic Test Mode in which CONActive test

SUlT drives some actuators apart

from the ECMs and also shIfts some
parameters in a specified range.

ECM part number

ECM part number can be read.

--

Conducted by CONSULT instead of a

Function test

EC54

",

technician to determine whether

each system is "OK" or "NG".

TROUBLE DIAGNOSES
Consult (Contfd)
WORK SUPPORT MODE
WORK ITEM

CONOITION

USAGE

THnTL POS SEN ADJ

CHECK THE THROTTLE POSITION SENSOR SIGNAL.

When adjusting throttle posi-

(THROITLE SENSOR

ADJUST IT TO THE SPECIFIED VALUE BY ROTATING THE

tion sensor initial position

ADJUSTMENT)

SENSOR BODY UNDER THE FOLLOWING CONDITIONS.

IGN SW "ON"
ENG NOT RUNNING
ACC PEDAL NOT PRESSED

IGNITION TIMING ADJUST

IGNITION TIMING FEEDBACK CONTROL WILL BE HELD

When adjusting initial ignitiDn

BY TOUCHING "START". AFTER DOING SO, ADJUST

IGNITION TIMING WITH A TIMING LIGHT BY TURNING

MENT

timing

THE CAMSHAFT POSITION SENSOR.

lACV-AAC VALVE AOJ
(AAC VALVE ADJUSTMENT)

SET ENGINE RPM AT THE SPECIFIED VALUE UNDER THE

FOLLOWING CONDITIONS.

When adjusting idle speed

ENGINE WARMED UP
-"
FUEL PRESSURE RELEASE

NO-LOAD
FUEL PUMP WILL STOP BY TOUCHING "START" DUR-

When releasing fuel pressure

from fuel line

ING IDLE.

CRANK A FEW TIMES AFTER ENGINE STALLS.

SELF-DIAGNOSTIC RESUL T5 MODE

DIAGNOSTIC ITEM
CAMSHAFT POSI SEW
(CRANK ANGLE SENSOR)

DIAGNOSTIC ITEM IS DETECTED WHEN ...

CHECK ITEM (REMEDY)

Either 1" or 180 signal is not entered for the first few

Harness and connector

(If harness and connector

seconds during engine cranking.

0

are normal, replace cam-

Either 1 or 180 signal is not input often enough while

the engine speed is higher than the specified rpm.
MASS AIR FLOW SEN
(AlA FLOW METER)

shaft position sensor.)

The mass air flow sensor circuit is open or shorted.

{An abnormally high or low voltage is entered.)

Harness and connector

(ll harness and connector
are normal, replace mass
air flow sensor.}

COOLANT TEMP SEN

(ENGINE TEMP SENSOR)

The engine coolant temperature sensor circuit is open or

shorted.
(An abnormally high or low output voltage is entered.)
-

IGN SIGNAL -

PRIMARY

The ignition signal in primary circuit is not entered during engine cranking or running

Harness and connector

Engine coolant temperature

sensor

--

Harness and connector

Power transistor unit

The knock sensor circuit is open or shorted

(An abnormally high or low voltage is entered.)

Harness and connector

(DETONA TION SENSOR)

THROTILE PQSI SEN

The throttle position sensor circuit is open or shorted.

(An abnormally high or low voltage is entered.)

Harness and connector

Throllte position sensor

The AfT communication line is open or shorted.

Harness and connector

KNOCK SENSOR

(THROITLE SENSOR)
AIT COMM LINE

Knock sensor

*: Check items causing a malfunction of camshaft position sensor circuit first, if both "CAMSHAFT POSl SEN (No. 11)" and
"IGN SIGNAL-PRIMARY (No. 21)" are displayed one after the other.
Sensor failures which set a self-diagnosis code are Iisled as due 10 an open or shorl circuit.
A sensor sending a signal which is inaccurate but nol open or shorl will NOT set a self-diagnosis code.
If a driveabilily symptom is present bUI no self-diagnosis code is set, perform further inspections using DATA MONITOR.

EC-55

r~!:~\

TROUBLE DIAGNOSES
Consult (Cont'd)
DATA MONITOR MODE
Remarks: Specification data are reference values_
Specification data are outpullinput values which are detected or supplied by ECM at the connector.
'Specification data may not be directly related 10 their components signalslvalues/operations.
ie. Adjusl ignition timing with a timing light before monItoring IGN TIMING, because the monitor may show the
specification data in spite of the ignition timing being not adjusted to the specification data. This IGN TIMING
monitors the calculated data by ECM according to the input signals from camshaft position sensor and other
ignition timing related sensors,
Jf the real~time diagnosis results are NG and the self-diagnoslic results are OK when diagnosing the mass air
flow sensor, first check to see if the tuel pump control circuit is normal.
MONITOR ITEM

CONDITION

CMPSRPM
Tachometer: Connect
(REF)
Run engine and compare tachometer indication
{CASRPM (REF))
with the CONSULT value.

MAS AIRI FL SE
(AIR FLOW MTR)

Engine: After warming

up, idle the engine
A/C switch "OFF"
Selector lever "N"
position
No-load

Harness and connector

Mass air flow sensor
1.4 - 2.0V

3,000 rpm

More than 70C (158 F)

02 SEN

MIR FIC MNT

o- O.3V
Engine: After warming
up

Maintaining engine
speed at 2,000 rpm

VHCL SPEED SE
(CAR SPEED
SEN)

Turn drive wheels and compare speedometer

indication with the CONSULT value

BATIERY VOLT

Ignition switch: ON (Engine stopped)

THRTL POS SEN

(THROTTLE SEN)

START SIGNAL

CLOSED THIPOS
(IDLE POSITION)

AIR COND SIG

NEUT POSI SW
(NEUTRAL SW)

PW/ST SIGNAL

Ignition switch ON
(Engine stopped)

Engine: After warming

up, idle the engine
Ignition switch: ON

Engine' After warming

up, idle the engine

0.6 - O.9V

LEAN - RICH
Changes more than 5
times during 10 seconds.

Harness and connector

Engine coolant tem~
perature sensor

Harness and connector

Heated oxygen sensor
Intake air leaks
Injectors

Almost the same speed Harness and connector

as the CONSULT value Vehicle speed sensor

Throttle valve fully

closed (Engine: After
warming up)

0.35 - O.65V

Throttle valve fully open

Approx. 4.0V
OFF

Ignition switch: ON ----- START

Ignition switch: ON
(Engine stopped)

11 - 14V

----+

Throttle valve:
Closed throttle position
(Engine:
After warming up)

ON

Throttle valve:
Slightly open

OFF

A/C switch "OFF"

OFF

AIC switch "ON"

ON

Shift lever "P" or "N"

ON

Except above

OFF

Steering wheel in neutral position

(forward direction)

OFF

The steeri ng wheel is

turned

ON

EC-56
(II

Harness and connector

Almost the same speed
Camshaft position senas the CONSULT value.
sor
0.8 - 1.5V

Idle

COOLANT
TEMPIS
Engine: After warming up
(ENG TEMP SEN)
(EXH GAS SEN)

CHECK ITEM WHEN

OUTSIDE SPEC.

SPEC IFI CATION

ON

Battery
ECM power supply
circuit
Harness and connector
Throttle position sensor
Throttle position sensor adjustment
Harness and connector
Starter switch
Harness and connector
Throttle position sen
sor
ThroWe position sensor adjustment
Throttle position
switch
Harness and connector
Air conditioner switch
Harness and connector
Neutral position switch
Harness and connector
Power steering oil
pressure switch

TROUBLE DIAGNOSES
Consult (Cont'd)
MONITOR ITEM

INJ PULSE

CONOITION
Engine: After warming
up
AIC switch "OFF"
Seleclor lever "N"
position
NO-load

Idle

1.7 - 2.5 msec.

2,000 rpm

1_5 - 2-3 msec.

Idle

IGN TIMING

15~

A/F ALPHA

AIR COND RLY

BTDC

ditto
2,000 rpm

IACV-AACIV
(AAC VALVE)

More than 25 BTDe

Idle

ditto

20 - 40%

Maintaining engine
speed at 2,000 rpm

Engine: After warming up, idle the engine

Air conditioner switch OFF ----+ ON

-,

VALVE TIM SOL

Ignition switch is turned to ON (Operates for 1

second)
Engine running and cranking
When engine is stopped (stops in 1 second)

ON

Except as shown above

OFF

Jack up rear wheel

Engine: After warming
up

Idle
Shift selector lever to
any position except
"N" or "P" position
Quickly depress acceleratof pedal, then
quickly release it

When cooling lan is stopped.

COOLING FAN
When cooling fan operates at low speed
(RADIATOR FAN)
When cooling Ian operates at high speed
EGRC SOUV
(EGR CQNT S/V)

WIG CaNT SIV

Engine: After warming

up
A/C switch "OFP'
Shift lever "N"
No-load

Idle

Harness and connector

Camshaft position sensor

--

Harness and connector

Injector
Mass air flow sensor
Heated oxygen sensor
Carbon canister purge
line
Intake air system

ON

FUEL PUMP RLY

Harness and connector

Injector
Mass air flow sensor
Intake air system

75 - 125'Yo

OFF

Harness and connector

IACV-AAC valve

2.000 rpm

Engine: After warming

up

CHECK ITEM WHEN

OUTSIDE SPEC.

SPECIFICA TION

Harness and connector

Air conditioner switch
Air conditioner relay

Harness and connector

Fuel pump relay
--

OFF

OFF ., ON

OFF
LOW
HI
-

-+

OFF

Harness and connector

Valve timing solenoid
valve

Harness and connector

Cooling Ian relay
Cooling fan motor

ON
Harness and connector
EGRC-solenoid valve

2,000 rpm

OFF

Idle

0%

Racing up to 4,000 rpm

20%

ditto

Harness and connector

Wastegale valve control solenoid valve

n,

EC-57

TROUBLE DIAGNOSES
Consult (Cont'd)
ACTIVE TEST MODE
CONDITION

TEST ITEM

FUEL INJECTION

IACV-AACIV OPENING
(AACIV OPENING)

JUDGEMENT

Engine: Return to the original

trouble condition

If trouble symptom d;sappears.

Change the amount of fuel injection with the CONSULT

Engine: After warming up, idle
lhe engine.
Change the IACV-AAC valve
opening percent with the CON~

CHECK ITEM (REMEDY)

Harness and connector

see CHECK ITEM.

Fuel injectors
Heated oxygen sensors

Engine speed changes according

Harness and connector

to the opening percent.

IACV-AAC valve

SULT.
ENG COOLANT
TEMP

Engine: Return to the original

trouble condition

(ENGINE TEMPEAA-

Change the engine coolant ternperature with the CONSULT.

TURE)

Harness and connector

If trouble symptom disappears,

see CHECK ITEM.

Fuel injectors

Engine: Return to the original

trouble condition
IGNITION TIMING

If trouble symptom disappears,

Timing light: Set

Retard the ignition timing with
the CONSULT.

see CHECK ITEM.

Compression

AIC switch "OFF"

Selector lever "N" position

Engine runs rough or dies.

Cut ott each injector signal one

at a time with the CONSULT.
COOLING FAN
(RADIATOR FAN)

Injectors
Power transistor
Spark plugs
Ignition coils

Ignition switch: ON
Turn cooling fan "LOW", "HI"
and "OFF" with CONSULT

Cooling fan moves at low and high

speed, and stops.

Jgnition switch: ON (Engine

stopped)
FUEL PUMP RELAY

Adjust initial ignition timing

Harness and connector

Engine: After warming up, idle

the engine.
POWER BALANCE

Engine coolant temperature sensor

Harness and connector

Cooling fan relay
Cooling fan motor

Fuel pump relay makes the operat- Harness and connector

Turn the fuel pump relay "ON"

and "OFF" with the CONSULT

ing sound.

Fuel pump relay

Each solenoid valve makes an

Harness and connector

operating sound.

Solenoid valve

and listen to operating sound.

EGRC SOLENOID
VALVE

Ignition switch: ON

(EGR CONT SOL

Turn solenoid valve "ON" and

"OFF" with the CONSULT and

VALVE)

listen to operating sound.

VALVE TIM SOL
SE LF-LEARN ING
CONT

In this test, Ihe coefficient of self-learning control mixture ratio returns to the original coefficient by

louching "CLEAR" on the screen.

EC-58
itt

TROUBLE DIAGNOSES
Consult (Cont'd)
FUNCTION TEST MODE
FUNCTION TEST
ITEM
SELF-DIAG
RESULTS

CONDITION

JUDGEMENT

Ignition switch: ON
(Engine stopped)
Displays the self-diagnostic res ults.

Ignition switch: ON
(Engine stopped)
CLOSED THROTTLE
Closed throttle position
POSI
switch circuit is tested
(CLOSED THROTTLE
when throWe Js opened
POSITION SWITCH
and closed fully.
CIRCUIT)
(' 'CLOSED THROTILE
(IDLE POSITION
POS'" is the test item
(IDLE SWITCH CIRname for the vehicles in
CUlT))
which idle is selected by
throttle position sensor.)
Ignition switch: ON
(Engine stopped)
THROTTLE POSI
SEN CKT
Throttle position sensor
(THROTTLE SENSOR
circuit is tested when
CKT)
throttle is opened and
closed luJJy.
NEUTRAL POSI SW
CKT
(NEUTRAL SW CIRCUlT)

Ignition switch: ON
lEngine stopped)
Neutral position switch
circuit is tested when shift
lever is manipulated.

FUEL PUMP
CIRCUIT

Ignition switch: ON
(Engine stopped)
Fuel pump circuit is tested
by checking the pursation
in fuel pressure when fuel
tube is pinched.

CHECK ITEM (REMEDY)

Objective system

Throttle valve: opened

OFF

Throttle valve: closed

ON

Range {Throttle valve fully

opened - Throttle valve
fully closed)

More than
3.0V

OUT OF NIP-POSITION

OFF

IN N-POSITION

ON

Harness and connector

Throttle position sensor
(Closed throttle position
sWitch)
Throttle position sensor
(Closed throltle position
SWitch) adjustment
Throttle linkage
Verify operation In DATA
MONITOR mode.
Harness and conneclor
Throttle position sensor
Throttle position sensor
adjustment
Throttle linkage
Verify operation in DATA
MONITOR mode.
Harness and connector
Neutral position sWltchl
Inhibitor switch
Linkage + InhibItor switch
adjustment

There is pressure pulsation on the fuel

feed hose.

Ignition switch: ON
(Engine stopped)
EGRC SOUV CIRCUlT
EGA conlrol SIV circuit is
(EGR CONT SIV CIRtested by checking soleCUlT)
noid valve operating
noise.

The solenoid valve makes an operating

sound every 3 seconds

Harness and connector

EGRC-solenoid valve

Ignition switch: ON
(Engine stopped)
Valve timing SIV circuit is
tested by checking solenoid valve operaling
noise.

The solenoid valve makes an operating

sound every 3 seconds.

Harness and connector

Valve timing solenoid
valve

Ignition switch: ON
(Engine stopped)
Cooling tan circuit is
tested by checking cooling
fan operation.

The cooting fan rotates and stops

every 3 seconds.

Harness and connector

Cooling fan relay
Cooling fan motor

VALVE TIMING SIV

CKT

COOLING FAN elRCUlT

(RADIATOR FAN
CIRCUIT)

EC-59

Harness and connector

Fuel pump
Fuel pump relay
Fuel filter clogging
Fuel level

lfIJi

TROUBLE DIAGNOSES
Consult (Cont'd)
FUNCTION TEST
ITEM

START SIGNAL
CIRCUIT

PWJST SIGNAL

CIRCUIT

Ignition switch: ON ---+

STAAT
Start signal circuit is
tested when engine is
started by operating the
starter. Battery voltage
and water lemperature
Start signal: OFF
before cranking, and average battery voltage, mass
air flow sensor output voltage and cranking speed
during cranking are displayed.
Ignition switch: ON
(Engine running)
Power steering circuit is
tested when steering
wheel is rotated fully and
then set to a straight line
running position.

CHECK ITEM (REMEDY)

JUDGEMENT

CONDITiON

---+

Harness and connector

Ignition switch

ON

Locked position

ON

Neutral position

OFF

Harness and connector

Power steering oil pressure switch
Power steering oil pump

VEHICLE SPEED
SEN CKT
(CAR SPEED SEN
CIRCUIT)

Vehicle speed sensor cir~

cuit ;s tested when vehicle Vehicle speed sensor input signal is
is running at a speed at 10 greater than 4 km/h (2 MPH)
l<m/h (6 mph) or higher.

Harness and connector

Vehicle speed sensor
Electric speedometer

IGN TIMING ADJ

After warming up. idle the

engine.
Ignition timing adjustment
is checked by reading
ignition timing with a timing light and checking
whether it agrees with
specifications.

Adjust ignition timing (by

moving camshaft position
sensor or distributor)
Camshaft position sensor
drive mechanism

MIXTURE RATIO
TEST

The timing light indicates the same

value On the screen.

Air-fuel ratio feedback circuit (injection system, ignition system, vacuum

system, etc.) is lested by
02 SEN COUNT: More than 5 times
examining the heated oxyduring 10 seconds
gen sensor output at 2.000
rpm under non-loaded
state.

EC-60

INJECTION SYS (Injector,

fuel pressure regulator,
harness or connector)
IGNITION SYS (Spark
plug, power transistor,
ignition coil, harness or
connector)
VACUUM SYS (Inlake air
leaks)
Heated oxygen sensor circuit
Heated oxygen sensor
operation
Fuel pressure high or low
Mass air flow sensor

TROUBLE DIAGNOSES
Consult (Cont'd)
FUNCTION TEST
ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

.-

(~I

Alter warming up, idle the

engine.

POWER BALANCE

rACV~AACIV SYS-

TEM
(AAC VALVE SYSTEM)

Injector operation of each

cylinder is stopped one
after another, and resultDifference in engine speed is greater
ant change in engine rotathan 25 rpm before and after cutting off
tion is examined to evaluthe injector of each cylinder.
ale combustion of each
cylinder. (This is only displayed tor models where a
sequential multi port fuel
injection system is used.)
After warming up, idle the
engine.
IACV-AAC valve system is
tested by detecting change
in engine speed when
IACV-AAC varve opening
is changed to 0%, 20%
and 80%.

Injector circuit (Injector,

harness or connector)
Ignition circuit (Spark
plug, power transistor.
ignition coil, harness or
connector)
Compression
Valve timing

Harness and connector

IACV-AAC valve
Difference in engine speed is greater
Air passage restriction
Ihan 150 rpm between when valve openbetween air inlet and
ing is at 80% (102 steps) and at 20% (25
IACV-AAC valve
steps).
lAS (Idle adjusting screw)
adjustment

Diagnostic Procedure
CAUTION:
1. 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.

SEF28~

----

2. When connecting ECM harness connector, tighten securing bolt until red projection is in line with connector face.

SEF72SH

3.

4.

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 nol any bends or breaks on ECM
pin terminal, when connecting pin connectors.

SEF291H

EC-61

.1.e

TROUBLE DIAGNOSES
Diagnostic Procedure (Cont'd)
Before replacing ECM, perform ECM input/output signal
inspection and make sure whether ECM functions properly
or not. (See page EC-196.)

6.

After performing this "Diagnostic Procedure", perform

diagnostic test mode II (Self-diagnostic results) and driving test.

7.

When measuring ECM signals with a circuit tester, never

bring the two tester probes into contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.

'e/
\

5.

j /

CHECK-

,/

........

I \
SEF051P

NG

""""'"
~O:J )

~K1

Oreuit teste'

SEF348N

EC-62
{II

TROUBLE DIAGNOSES

Basic Inspection

o
~

~
~

SEF1421

BEFORE STARTING
1. Check service records for any recent'
repairs that may indicate a related
problem, or the current need for
scheduled maintenance.
2. Open engine hood and check the following:
Harness connectors for proper connections
Vacuum hoses for splits, kinks. and
proper connections

Wiring for proper connections.

pinches, and cuts

~lL
CONNECT CONSULT TO THE VEHICLE.
Connect "CONSULT" to the data link

RHO models

Data link ~
connector ......\
for CONSULT

1-

connector for CONSULT and select

"ENGINE" from the menu. (Refer to
page EC-53.)

DOES ENGINE START?

Yes

CHECK IGNITION TIMING.

Warm up engine sufficiently and check
ignition timing at idle using timing light.
(Refer to page EC~33.)
Ignition liming: 15" 2" BlDC

NG

Adjust ignition timing:JY"

turning camshaft position
sensor.

~~
ISj~

OK

(Go to

on next page.)

r~n

SEF1441

EC-63

TROUBLE DIAGNOSES
Basic Inspection (Cont'd)

IGN TIMING AOJ

IGNITION TIMING FEEDBACK

CONTROL WIll BE HELD BY

TOUCHING S1 ART
AFTER DOING SO, ADJUST

1. Select "IGN TIMING ADJ" in

~.J

~ ===:=:======:
START

L-

SEF816K

Adjust engine speed by

1------" turning idle adjusting

RPM.

IGNITION TIMING WITH A

TIMING LIGHT BY TURNING
THE CRANK ANGLE SENSOR

NG

CHECK IDLE ADJ. SCREW INITIAL SET

screw.

"WORK SUPPORT" mode.

2 When touching "START", does
engine speed fall to 750 50
rpm (A/T in "N" position)?

1--------OR---------1
~

When disconnecting throttle posi-

~ tion sensor harness connector,

L
m

does engine speed fall 10

750 50 rpm (AfT in "N" posi-

--r
tion~?

_ _ _ _ _------l

CHECK THROTTLE POSITION SENSOR

IDLE POSITION.

THROTTLE SEN AOJ

ADJ MONITOR
THROTTLE SEN

O.4SV

======== MONITOR ========

CAS-RPM (REF)
IDLE POSITION

Orpm
ON

NG
~

i. Perform "THROITLE SEN

ADJ" or "THRTL POS SEN
ADJ" in "WORK SUPPORT"
mode.
2. Check that output voltage of
throttle position sensor is 0.35
to 0.65V. (Throttle valve 1ully
closes.) and "IDLE POSITION"
or "CLOSED TH/POS" stays
"ON".

1. Adjust output voltage

by rotating throttle

position sensor body.

2. Disconnect throttle
position sensor harness
connector for a few
seconds and then
reconnect it.
3. Confirm that "IDLE
POSITION" or

"CLOSED TH/POS"
slays "ON".

r----------OR---------i
MEC157B

Measure output voltage of throt-

~ tie position sensor using

AIT models

voltmeter, and check that it is

0.35 to 0.65V. (Throttle valve tully

closed.)

(Go to

on next page)

SEFOQ30

EC..64

TROUBLE DIAGNOSES
Basic Inspection (Cont'd)
-C1 MONITOR

START SIGNAL
IDLE POSITION
AIR COND SIG
NEUTRAL SW

-C1 NO FAIL

OFF

ON
OJ=J=
ON

NG

CHECK SWITCH INPUT SIGNAL

Select the following switches in

"DATA MONITOR" mode,

Repair or replace the

malfunctioning switch
its circuit.

a) Start signal,

b) Idle position or closed throttle

position,
c) Air conditioner signal,
d) Neutral (Parking) position
switch, and check the switches' ON-OFF operation.

OR

Remove ECM from front dash

side and checK the above switches' ON-OFF operation using lJolt~
meter at each ECM terminal.

Start signal

Voltage

Condition

Switch

(V)

o - Batlery volt-

IGN ON
....... IGN START

age

Accelerator
pedal released
Closed lhrot....... Accelerator
lie position
pedal fully

0.35 - 0.65 ----.

Approx -40

depressed

Ale
AIC signal

Ale

OFF --ON

(Engine

Neutral
(Parking)
posHian
switch

SELF-DJAG RESULTS.
FAILURE DETECTED

running)

Selector leller is
"N" or "P" position
....... Except "N"
and "P" position

Battery voltage
. . . . Approx 0

o ....

4.0 - 5.0

READ SELF-DIAGNOSTIC RESULTS.

rf.S'\

TIME

NO SELF DIAGNOSTIC
FAILURE INDICATED

1. Perform "SELF-DIAG

~~

Go to the relevant inspection procedure.

RESULTS" mode.
2. Read out self-diagnostic

results
3. Is a failure defected?

1 - - - - - - - - OR

tID

-----------,

1. Set Diagnostic Test Mode II.

(Self-diagnostic results) (Refer

to page EC-50.)
2. Count the number of malfunction indicator lamp flashes and

..........

I /

read out the diagnostic trouble

~/"
CHECK-

codes .
3. Are the diagnostic trouble
codes being output?

........

c=

I \

~NO
INSPECTION END

SEF051 P

EC-65

1~lf

TROUBLE DIAGNOSES

How to Execute On..board Diagnostic System in

Diagnostic Test Mode II
Detected items

DIsplay
Diagnostic trouble code No

How to perform diagnostic test mode II (Sell-diagnostic results) judgement

Illustration

Method

MONITOR

CASRPM(REF)
AJRFLOWMTA
ENG TEMP SEN
EXH GAS SEN
MIR FIC MNT
CAR SPEED SEN

Camshaft
position sensor
circuit

NO FAll

BOOrpm
1.55V
81C
O.06V
LEAN

Okm/tl

RECORD

11

SEFOO4Q

PERFORM DIAGNOSTIC TEST MODE II (SELFDIAGNOSTIC RESULTS).

1) Start engine.
2) Select "OATA MONITOR" mode with
CONSULT.

(j)

tr NO FAil

I /

'~

OR
2) Turn igniticn switch "OFF" and then
"ON".
3) Perform diagnostic test mode II (Selfdiagnostic results) with ECM.
Malfunction Indicator lamp displays
dlagnosllc trouble code No. 55.

CHECK.......

1 \
SEF051P

MONITOR

CASeRPM(REF)
AIR FLOWMTR
ENG TEMP SEN
EXH GASSEN
MIA FIe MNT
CAR SPEED SEN

NO FAIL
800rpm
1.55V
81C
O.06V
LEAN

Okmh\

RECORD

Mass air Ilow

sensor circuit

*"

@
@

I /

'~
/ , \

PERFORM DIAGNOSTIC TEST MODE II (SElFDIAGNOSTIC RESULTS).

1) Turn ignition switch "ON" wait for at least 5
seconds and then start engine.
2) Select "DATA MONITOR" mode with
CONSULT.
NO FAil
SEFQG4Q
OR
2) Perform diagnostic test mode II (Selfdiagnostic results) with ECM.
Malfunction Indicator lamp displays
diagnostic trouble code No. 55.

12

CHECK.......

SEF051P

EC..66

TROUBLE DIAGNOSES
How to Execute On-board Diagnostic System in
Diagnostic Test Mode II (Cont'd)
Detected Items

Display
DIagnostic trouble code No.

How to_perform diagnostic test mode II (Self-diagnostic results) judgement

111 ustratio n

*"

MONITOR

'* NO FAIL D

CAS.RPM(REF)
AlA FLOW MTR
ENG TEMP SEN
EXH GASSEN
MIA FIC MNT
CAR SPEED SEN

BOOrpm
1.S5V

BloC
O.06V

PERFORM DIAGNOSTIC TEST MODE II (SELFDIAGNOSTIC RESULTS).

LEAN

Okmlh

00

RECORD

Engine coolant
lemperature
sensor circuit

Method

13

1)..!u rn ignition switch "ON" or start engine

2) Select "DATA MONITOR" mode wIth
CONSULT.
-tl NO FAIL

scrOO4Q

OR

@
\

2) Perform diagnostic lest mode II (Selldiagnostic resu/ls) wIth ECM.

Malfunction Indicator lamp displays

diagnostic trouble code No. 55.

I /

'~

CHECK-

./

........

I \
SEFDS1P

MONITOR

CAS.APM(REF)
AIR FLOWMTR
ENG TEMP SEN
EXH GAS SEN
MIA FIC MNT
CAR SPEED SEN

Ignition signal
circuit

*"

NO FAIL

800rpm
1.55V
81C
O.06V

PERFORM DIAGNOSTIC TEST MODE 11 (SELFDIAGNOSTIC RESULTS).

LEAN

Okm/h

RECORD

21

SEFOOo1Q

I /

'~

1) Start engine.
2) Select "DATA MONITOR" mode with
..
CONSULT.
-Cr NO FAIL
OR
2) Turn ignition switch "OFF' and then
"ON"
3) Perform diagnostic test mode II (SelfdiagPDstic results) with ECM.
Malfunction indicator la.mp displays

diagnostic trouble code No. 55.

CHECK-

./

........

I \
SEF051P

D agnostic test mode

results.

f(

(Sell-diagnostic results)

IS

not performed but this method provides results whIch are equal to the self-diagnostic

:2iL

EC-67

TROUBLE DIAGNOSES
How to Execute On-board Diagnostic System in
Diagnostic Test Mode II (Cont'd)
Detected items

Display
Diagnostic trou-

How to perform diagnostic test mode II (Self-diagnostic results) judgement

'*

MONITOR

*'

CAS-RPM(REF)
AIR FLOW MTR
ENG TEMP SEN
EXH GAS SEN

NO FAll

MIA FIe MNT

RECORD

800rpm

1.55V
81C
O.06V
LEAN
Okm/h

CAR SPEED SEN

Boosl pressure
sensor circuit

Method

Illustration

ble code No.

26

PERFORM DIAGNOSTIC TEST MODE II (SELFDIAGNOSTIC RESULTS).

1) Slart engine.
2) Select "DATA MONITOR" mode with
CONSULT.
'6' NO FAIL
I
OR
SEFOO4Q
1) furn ignition switch "OFF" and then
ON".
2) Pertorm diagnostic test mode II (Selfdiagnostic results) with ECM.
Malfunction indicator lamp displays
diagnostic trouble code No. 55.

I /

'~

CHECK-

./

"-

\
SEFOS1P

MONITOR

CAS.APM(REF)
AIR FLOW MTR
ENG TEMP SEN
EXH GAS SEN
MIA FIe MNT
CAR SPEED SEN

Knock sensor
circuit

*'

NO FAIL

800rpm

1.55V
81C
O.06V
LEAN
Okmlh

RECORD

I /

'~

./

PERFORM DIAGNOSTIC TEST MODE II (SELFDIAGNOSTIC RESULTS).

1) Start engine.
2) Select "DATA MONITOR" mode with
CONSULT.
'6' NO FAIL
OR
SEFOO4Q
2) Turn ignition switch "OFF" and then
"ON".
3) Perform diagnostic test mode \I (Selfdiagnostic reSUlts) with ECM.
Malfunction Indicator lamp displays
diagnostic Irouble code No. 55.

34

00

CHECK-

I \

"-

SEF051P

: Dlagnoshc test mode II (Self-diagnostic results)

results.

IS

not performed but thIs method provides results whIch are equal to the self-dlagnost'c

EC-68

TROUBLE DIAGNOSES

Diagnostic Procedure 1 Idling after Warm-up

Mark (shorl line)

Symptom -

High

Cam follower
lever pin

D
CHECK FAST IDLE CAM.

ACTIVE TEST.

SELF-LEARN
CONTROL

A/F ALPHA

Check fast idle cam

adjustment. (See page
EC-207.)

00

=CAS-RPM
= = MONITOR
=B62rpm
==
(REF)
ENG TEMP SEN
EXH GAS SEN

No

align with the pin center of cam follower

lever?

CHECK INTAKE AIR LEAK .

lCO'h

Does mark (shari line) on fasl idle cam

1. Select "SELF-LEARNING

Yes

,-------.-

Discover air leak

locali~

and repair.

CaNT" in "ACTIVE TEST"

mode.
2. Clear the self-learning control

coefficient by touching
"CLEAR".

89C

O.20V
1OOO,kl

3. Does the engine speed drop?

CLEAR

OR

------ @
l
SEF857K

1. Disconnecl mass air flow sensor harness connectors.

2. After starting and running
engine for at least 30 seconds
at 2,000 rpm, does the engine
speed drop?
No

CHECK THROTTLE LINKAGE.

1. Check that throttle linkage moves

2. Confirm that throttle valve both fully

opens and fully closes.

OK

INSPECTION END

EC-70
!z

Repair throttle linkage or

sticking of throttle valve.
'--.

smoothly.
MEFS86D

~~

'I

Diagnostic Procedure 2 -

OISCONNECT

18

Symptom -

Hunting

\1/

1 fl:J=

/1\

Yes

CHECK HEATEO OXYGEN SENSORS.

Check: healed oxygen

When disconnecting heated oxygen sen- ~ sensor(s). (See

sor harness connectors, is the hunting
EC-152.)

page

fixed?
No

SEF31)7G
~----------~~--------,

PERFORM POWER BALANCE TEST.

1. Perform "POWER BALANCE"
in "ACTIVE TEST" mode.
2. Is there any cylinder which

00

ACTIVE TEST

** *POWER BALANCE ***

;;;"'=':"=~='MONlTOR====-=:=

CAS.RPM {REF}

825rpm

AIR FLOW MTR

153V

Me VALVE.
L.--_~~

L...-_ _

~~tom.

does not produce a momentary

engine speed drop?
OR--

26%

Q=

1I[I]0[~]~ST

DCIDDI

SIART

When disconnecting each injector

harness connector one at a time.
is there any cylinder which does
not produce a momentary engine

SEf=797K
-J

speed drop?

(g

r'

-NG

CHECK SPARK PLUGS.

Remove the spark plugs and check for

Repair or replace ~p;k plug(s).

-----

fouling. etc.

[o~T

'PiO)

OK

Yes

CHECK FOR INTAKE AIR LEAK.

When pinching blow-by hose (lowering
the blow-by air supply), does the engine

Discover air leak location

and repair.

speed rise?
No

(Go to

on next page.)

SEF879J

EC-71

- - - - - - - - - - - - - - - - - =..

=-_._---=------'=,
...,._=----

-=
._
.

.__.._-

.- -

TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)

Symptom -

Hunting

1~

CHECK EGR VALVE.

-------

Check EGR valve for sticking.

L--

----,

Repair or rept:;;;;;-=

OK

L._
o

INSPECTION END
SEC547AI

Diagnostic Procedure 3 -

Symptom

Unstable Idle

D
II

CHECK EGR VALVE.

Check EGR valve for sticking.

;---t

SEC547A

ERFORM POWER

** *

ACTIVE TEST.

POWER BALANCE

** *

=;:S~ ~;~ ~R~~;TOR

~;~;: ~ =

AIR FLOW MTR

rAe VALVE

1 53V
26%

2 -O=~I~-4rL-TE~T
11-0I

DODD

START

BA--L-A-NC-E-T-E-ST-.---------,

m.- - I
_J

Go to

,. Perform "POWER BALANCE"

in "ACTIVE TEST" mode.
2. Is there any cylinder which
does not produce a momentary
engine speed drop?

- - - OR

f1\
~

'L

---------1

When disconnecting each injector

harness connector one at a time,
is there any cylinder which does
not produce a momentary engine

rg---r
speed drop?

____________
S'EF797K I

es

CHECK INJECTOR.
Does each injector make an operaHng

-----r

sound at idle?

(Go to

~---------------

EC-72
fll

es

on next page.)

Check injeclor(s) and

cuit(s).

ci}

TROUBLE DIAGNOSES
Diagnostic Procedure 3 Unstable Idle (Cont'd)

Symptom -

CHECK IGNITION SPARK.

1. Disconnect ignition coil assembly

from rocker cover.

NG

,---._------------,
Check ignition coil, power

2. Connect a known good spark plug to

Spark plug
SEFOOSQ

transistor unit and their

circuits. (See page
EC~ 120,

202.)

the ignition coil assembly.

3. Place end of spark plug against a
suitable ground and crank engine.
4. Check for spark.

.---liJ-C-H-E-C-K-S-P-A-R-K-P-l--U---'lG-:-K-------j NG

Remove the spark plugs and check for

fouling, etc.

SEF1SSf

CHECK FUEL PRESSURE.

.ff.f\

\gv

FUEL PRES RELEASE.

FUEL PUMP WILL STOP BY

TOUCHING START DURING

~,Perform "FUEL PRESSURE

RELEASE" in "WORK
SUPPORT" mode in order to

release fuel pressure to zero.

2. Install fuel pressure gauge and

IDLE.
CRANK A FEW TIMES AFTER

check fuel pressure,

At Idle approx. 245 kPa (2.45

bar, 2.5 kg/cm 2 1 36 psi)
r - - - - - - - - OR ------------j
1. Release fuel pressure to zero.
(Refer to page EC~208.)

ENGINE STALL.

2. Install tuel pressure gauge and

check fuel pressure.

J Repai.
plug(s).

0'

replace

sp.~~
~

Ch,eCk fuel rump and cir-

iFf~

I ;~'11iF

CUlt.

i~\1F

~~

?~f~

~P.!

r\/2.,\

i~~~

(Go to

on next page,)

'\Il
R~@)

~nr

MEF68BD

r~i,~\

l~rL

[:iQ)A(

EC-73

I:
~

TROUBLE DIAGNOSES
Diagnostic Procedure 3 Unstable Idle (Cont'd)
MIXTURE RATIO TEST

ACCELERATE TO 2lXX) RPM

AND HOLD THEN TOUCH

STAAT

CHECK HEATED OXYGEN SENSOR.

II]
1800

2CXX)

1. Start engine and warm it up suffi-

NG
~

Replace healed oxygen

sensor(s).

cienlly.

2200

START

NEXT

Symptom -

2. Perform "MIXTURE RATIO

TEST" in "FUNCTION TEST"
mode.

MEF689D

OR

* MONITOR

*NO FAIL

CAS.RPM (REF)
MIA FIC MNT

00

2<XX>rpm

RICH

2. See "M/R FIG MNT" in "Data

monitor" mode.
3. Maintaining engine at 2,000
rpm under no-load (engine is
warmed up sufficiently.), check
that the monilor fluctuates
between "LEAN" and "RICH"
more than 5 times during 10
seconds.

RECORD

1 cycle: RICH ---. LEAN - RICH

2 cycles: RICH ---. LEAN -

SEF818K

RICH ---. LEAN

. .e/'
\

OR

I /

2. Set "Heated oxygen sensor

monitor" in Diagnostic Test
Mode II. (See page EC-52.)

CHECK-

3. Maintaining engine at 2,000

........

--+

RICH

rpm under no-load, check to

I \

make sure that malfunction

indicator lamp goes ON and
OFF more than 5 times during
SEF051P

10 seconds.
OK

CHECK FOR INTAKE AIR LEAK.

When pinching blow-by hose (lowering
the blow-by air supply), does the engine
speed rise?

to
(Go to

EC-74
ttl

on next page.)

Yes
~

Discover air leak location

and repair.

TROUBLE DIAGNOSES
Diagnostic Procedure 3 Unstable Idle (Cont'd)

.---------_._--- IGN TIMING ADJ. 0

- - CONDITION SETIING --

lGN/T FEEDBACK

HOLD

======z: == MONITOR

CAS.RPM (REF)
fGN liMING
IDLE POSITION

Symptom

==-=.=.::.=::

CHECK IDLE ADJ. SCREW CLOGGING.

762rpm
15BTDC

00

ON

1. Perform "lGN TIMING ADJ" in

"WORK SUPPORT" mode.

No

r------.-

Cvalvj

Check for IACV-AA

clogging or throttle valve
clogging.

2. Can you set engine speed at

:~~

75050 rpm (AfT in "N" pOSISEF786K

\~~

tion) by turning idle adjusting

screw?

j
I

OR

1. Disconnect throttle position

sensor harness connector.

2. Can you set engine speed at

750 50 rpm (AfT in 'ON" posi-

ip~

tion) by turning idle adjusting

screw?

I
,I

J
j

L--

NG

Check compression pressure.

Siandard: kPa (bar, kg/cm 2 , psl)J300

rpm
981 (9.81, 10.0, 142)
Minimum: kPa (bar, kgfcm 2 , psl)/300

COMPRESSION
PRESSURE

rpm
883 (8.83, 9.0, 128)
Difference between each cylinder:
kPa (bar, kg/cm 2 , psl)f300 rpm
98 (0.98, 1.0, 14)
SEf309G

~_-_-__-tK_-----~
Disconnect and reconnect harness connectors in the circuil. Then retest.

~Trouble is not fixed.

Check ECM pin terminals for damage

or the connection of ECM harness con

nector. Reconnect ECM harness connector and retest

EC-75

Check pistons. piston

~.
rings, valves. va I ve seats
and cylinder head gaskets.

Ii
I

TROUBLE DIAGNOSES
Diagnostic Procedure 4 - Symptom - Hard to
Start or Impossible to Start when the Engine is
Cold

o
CHECK BATTERY AND STARTER.

~ Repair

or replace.

Check battery and starter condition.

(Refer to EL section.)
OK

SEF3801

m
0

ACTIVE TEST.
FUEL PUMP RELAY

CHECK FUEL PRESSURE.

0N

=CASRPM
= = MONITOR
=Orpm
==
(REF)
~~
_ _ ION/OFF

1. Turn ignition switch "ON".

No
~

Check fuel pump and

cir~

cuit. (See page EC-159.)

2. Perform "FUEL PUMP RELAY"

in "ACTIVE TEST" mode.
3. Pinch fuel feed hose with fingers.
Is fuel pressure pulsation fell on

the fuel feed hose?

I[OFf]
SEF498L

OR
1. Pinch fuel feed hose with tingers.

2. When cranking the engine, is

there any pressure on the fuel
feed hose?
Yes

i1
CHECK FAST IDLE CAM.
When the engine is cold, does mark

No

Check fast idle cam

adjustment. (See page
EC-207.)

Ves
------.

Check tACV-AAC valve

(long line) on fast idle cam align with

the pin center of cam follower lever?
Yes

II

Ir

CHECK IACV-AAC VALVE.

When pressing accelerator pedal fully,
can you start the engine.

(Go to

SEFO'10,

SEF3821

EC-76

on next page.)

and circuit. (See page

EC-169.)

TROUBLE DIAGNOSES
Diagnostic Procedure 4 - Symptom - Hard to
Start or Impossible to Start when the Engine is
Cold (Cont'd)

CHECK INJECTOR.

Check injector(s) and ci r-

,I

1, Remove camshaft position sensor

from engine (Harness connector

I i~;,:['"

cuH(s).

should remain connected.)

SEF012Q

2. Disconnect power transistor harnes!>

conneclor.
3. Turn ignition switch ON. (Do not start
engine.)

4. When rotating camshaH position sen-

sor shaft. does each injector make an

operating sound?

~ Check ignition coil, power

CHECK IGNITION SPARK.

1. Disconnect ignition coil assembly

SEF008Q

transistor unit and their

from rocker cover.

circuit~_

2. Connect a known good spark plug to

(See page

EC-120, 202 )

the ignition coil assembly.

3. Place end 01 spark plug against a

suitable ground and crank engine.

-r--'

4. Check for spark.

r-----

NG
Repair or replace spark
~ plug(s).

CHECK SPARK PLUGS.

Remove the spark plugs and check for

fouling, etc.
'-

SEF1561

~OK

_..J

CHECK ECM POWER SUPPLY AND

ReJJair or replace.

GROUND CIRCUIT.
Refer to page EC-105.

~OK

--

Disconoecf and reconnect harness connectors in the circuit. Then retest.

~ Trouble is not fixed.

Check ECM pin term;nal, for damage
or the connection of ECM harness connector. Reconnect ECM harnes~ con~

nectar and retest.

frfJ,,0j

EC-77

----------------_0

3 _ _,.

TROUBLE DIAGNOSES

Diagnostic Procedure 5 - Symptom - Hard to

Start or Impossible to Start when the Engine is
Hot

~'---------=-----o

ACTIVE TEST.
FUEL PUMP RELAY

==

== ==

MONITOR
CASAPM (REF)

L-~

. , . [ON/OFF

0N

==Orpm
== ==

D
No

CHECK FUEL PRESSURE.

~ 1. Turn ignition switch "ON".
~ 2 Perform "FUEL PUMP RELAY"
in "ACTIVE TEST" mode
3. Pinch fuel feed hose with fingers.

lOShtijFIJ

SEF498L

Check fuel pump and cir-

f--------. cui! (See page

EC-159.)

Is fuel pressure pulsation felt on

the fuel feed hose?
OR------1. Pinch fuel feed hose with fingers.
2. When cranking the engine, is
there any pressure on the fuel
feed hose?
Yes

CHECK FUEL VAPOR.

1. Disconnect fuet pressure regulator

d"

Check fuel properties.

vacuum hose and plug hose.

2. Can you start engine?

No

CHECK tNJECTOR.
Does each injector make an operating

~ Check injector(s) and circuit(s).

sound at idle?
Ves

I~t

CHECK IGNITION SPARK.

1. Disconnect ignition coil assembly

Click
CtI~.+

from rocker cover.

2. Connect a known good spark plug to
the ignition coil assembly.
3. Place end of spark plug against a
suitable ground and crank engine

II
I

4 Check for spark.

0K

SEF730L

(Go to ~) on next page.)

Spark plug
SEF008Q

EC-78
III

Check ignition coil, power

transistor unit and cir-

cuils.
(See page EC-120. 202.)

I
I

TROUBLE DIAGNOSES
Diagnostic Procedure 5 - Symptom - Hard to
Start or Impossible to Start when the Engine is
Hot (Cont'd)

CHECK ECM POWER SUPPLY AND

GROUND CIRCUIT.
Refer to page EC-105.

NG

Repair or replace.

r-

OK -

Disconnect and reconnect harness connectors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

EC-79
b

=-e
.='c.

TROUBLE DIAGNOSES

Diagnostic Procedure 6 - Symptom - Hard to

Start or Impossible to Start under Normal
Conditions

D
CHECK BATTERY AND STARTER.

EJ

Repair or replace.

Check battery and starter operation.

(Refer to EL section.)

OK

SEF3801

ACTIVE TEST.
FUEL PUMP RELAY

CHECK FUEL PRESSURE.

ON

\J!}

2. Perform "FUEL PUMP RELAY"

Check fuel pump and circuit (See page EC-159.)

3. Pinch tuel feed hose with fingers.

Is fuel pressure pulsation felt on the fuel

~-

_ _ ION/OFF

1. Turn ignition switch "ON".

in "ACTIVE TEST" mode.

=CASRPM
= = MONITOR
=Orpm
= =
(REFj
-~

feed hose?

I[J5FIJ

~------OR--------i

1. Pinch fuel feed hose with fin-

SEF498L

gers.

2. When cranking the engine, is

there any pressure on the fuel
feed hose?
Yes

CHECK INJECTOR FOR LEAKAGE.

When pressing accelerator pedal fully,

I Yes...J

Check injector(s) for leak-I

age.

can you start the engine.

No
Ir

CHECK INJECTOR.
1. Remove camshaft position sensor
from engine. (Harness connector
should remain connected.)
2. Disconnect power transistor harness
connector
3. Turn ignition switch ON. (Do not start
engine.)
4. When rotating camshaft position sen"

SEF3821

sor shatto does each injector make an

operating sound?

~i5@]~

/~ ~~
/ \ C,

Click

(Go to

Turn by hand

SEF012Q

EC-80
(IJ

on next page.)

No

...I

Check injectors and cir-

Icui's.

TROUBLE DIAGNOSES
Diagnostic Procedure 6 - Symptom - Hard to
Start or Impossible to Start under Normal
Conditions (Cont'd)

CHECK rGNITION SPARK.

1. Disconnect ignition coil assembly
from rocker cover.

NG

transistor urllt and

Cir-

cuits
(See page EC-120. 202 )

2. Connect a known good spark plug to

the ignition coil assembly.

SEFOQ8Q I

Check ignition coil, power

3. Place end of spark plug against a

ijL~,

21l~

suitable ground and crank engine.

4. Check for spark.

OK

~
1CHECK SPARK PLUGS.
I Remove the spark plugs and check for
fouling, etc.

NG

Repair or replace sp;rk

I PIUg(S_).

fJ

5 EF156, 1

,------------'-~---------,

CHECK EGR VALVE.

valve for sticking.

NG

I Check EGR

Repair or

rePla==--~

OK
NG

CHECK ECM POWER SUPPLY AND

GROUND CIRCUIT.
Refer to page EC-105.

jO-K

--'-~

' Dis-c-o-n-n-e-ct-a-n-d-reconnect harness conJ

SEC547A

nectors in the circuit. Then retest.

I

~ e is not
'-C-h-e-Ck-E-C-M'-p-i-n-te-r--minaIS for

fixed.

dama~

or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

EC-81

rr~

if

~rl

OK
_ _ _ _ _ _ _ _-

,----------------,
Repair or replace.

TROUBLE DIAGNOSES
Diagnostic Procedure 7 - Symptom
Hesitation when the Engine is Hot

D
CHECK FUEL VAPOR.
1. Disconnect fuel pressure regulator
vacuum hose and plug hose.
2. Perform cruise test.

Check fuel properties.

3. Does the hesitation disappear?

No

fJ
CHECK CANISTER PURGE.
1. Disconnect canister purge line hose
and plug hose.
2. Perform cruise test.
3. Does the hesitation disappear?

Check purge and vacuum

Jmes.

No

m
CHECK FOR INTAKE AIR LEAK
When pinching blow-by hose (lowering
the blow-by air supply), does the engine
speed rise?
No

INSPECTION END

EC-82

'"

Discoverair leak location

and repaIr

TROUBLE DIAGNOSES

Diagnostic Procedure 8 - Symptom Hesitation when the Engine is Cold

D
CHECK SPARK PLUGS.

Remove spark plugs and check for

Repair or repl
plug(s).

fouling, etc.

OK
SEFt561

6
CHECK FOR INTAKE AIR LEAK.
When pinching blow-by hose (lowering

1---.

the blow~by air supply), does the engine

speed rise?
No
Go to DIagnostic Procedure 24 (EC-113_)
Or try a known good mass air flow sensor.
Trouble is not fixed.
CHECK FOR INTAKE VALVE DEPOSITS.

Jf there are deposits on intake \/alves,

remove them.

If

I_N_S_P~E_CT-I_O_N_E_N__D~_~

_____

EC..83

Ves

.1 Discover air Ieak location

~JC

and repair .

TROUBLE DIAGNOSES
Diagnostic Procedure 9 - Symptom
Hesitation under Normal Conditions

o
CHECK SPARK PLUGS.
Remove spark plugs and check for
fouling, etc.

----,-------

Repair or replace spark]

plug(s).
-._--------

OK
SEF1561

CHECK HEATED OXYGEN SENSOR.

1. Start engine and warm it up sufficiently.

MIXTURE RATIO TEST

~)

ACCELERATE TO 2CXXl RPM

AND HOLD THEN TOUCH
START

~
2CXXl
2200

MONITOR" mode.
3. Maintaining engine at 2,000

----=-ST..:....:..A...:...:..R..:.....:.T_

I L-I

rpm under no-load (with

engine warmed up
sufficiently.), check to make

------------------,

MONITOR

CASRPM (REF)
MIA FIe MNT

NO FAIL

2. Perform "MIXTURE RATIO

TEST" in "FUNCTION TEST"
mode.
2. See "M/R FIC MNT" in "DATA

MEF696D

P1

sure that Ihe monitor fluctuates

between "LEAN" and "RICH"
more than 5 limes during 10

2caJrpm
RICH

seconds.
1 cycle: RICH

2 cycles: RICH
RICH
RICH

RECORD

I /

I \

LEAN ----+ RICH

LEAN ----+
----+ LEAN ---+

----+

----+

I--------OR------~

~ 2. Set "Heated oxygen sensor

~j
monitor" in Diagnostic Tesl
Mode II (See page EC-52.)
3. Maintaining engine at 2.000
rpm under no load, check that
malfunction indicator lamp
goes ON and OFF more than 5
times during 10 seconds

SEF818K

sensor(s).

f--------OA--------I

1800
N EXT

I Yes....l Replace heated oxygen

'~/'
CHECK"-

No

r----------~.-------,

SEF051P

CHECK CANISTER PURGE.

1 Disconnect canister purge line hose
and plug hose
2. Perform cruise test.
3. Does the hesitation disappear?

(Go to

EC-84

on next page.)

'Yes

Check purge and vacuum

lines.
L...-

TROUBLE DIAGNOSES
Diagnostic Procedure 9 - Symptom Hesitation under Normal Conditions (Cont'd)
C!)

Yes

!CHECK FOR INTAKE AIR LEAK.

When pinching blow-by hose (lowering
the blow-by air supply), does the engine
speed rise?

Discover air leak location

and repair.

No
INSPECTION ENO
Front

SEF007Q

Diagnostic Procedure 10 Stalls when Turning

Symptom -

o ------1
CHECK FUEL LEVEL

NG

Engine

Fill fuel tank with fuel.

Check to see that there is enough fuel in

tank.
OK
SEF3e61

PERFORM POWER BALANCE TEST.

** *

ACTIVE TEST.

***

AIR FLOW MTR

AAC VALVE

in "ACTIVE TEST" mode.

engine speed drop?

OR

.Q]0[2]~{~
CIDDD STAAT

When disconnecting each Injector

harness connector one at a time,

is there any cylinder which does
not produce a morrlentary engine

SEF797!<

speed drop?

CHECK INJECTOR.

Check injector(s) and cir-

Does each injector make an operating

CUlt(S).

sound at idle?
Yes
(Go to @ on next page.)

At idle

does not produce a momentary

825rpm
153V
26%
~_.-

~W

~ Go to II

2. Is there any cylinder which

POWER BALANCE
:::=-=-====MONITOR ::=-=====

CAS. RPM (REFI

1. Perform "POWER BALANCE"

Clitk

C/.

't'~

SEF730L

EC-85

TROUBLE DIAGNOSES
How to Execute On-board Diagnostic System in
Diagnostic Test Mode II (Cont'd)
Detected items

Display
How to perlorm diagnostiC test mode 11 (Self-diagnostic results) Judgement
Diagnostic trou- 1 - - - - - - - - - - - - ble code No.
Illustration
Mettlod

MONITOR

-(:( NO FAIL

CASRPM(REF)
AIR FLOW MTR
ENG TEMP SEN
EXH GASSEN
MIA FIC MNT
CAR SPEED SEN

800rpm
1.55V

PERFORM DIAGNOSTIC TEST MODE II (SELFDIAGNOSTIC RESULTS).

1) Jack up drive wheels
2) Start engine.

BloC
O.06V
LEAN

Okmlh

3) Shift 10 a suitable gear position (Except "P" or

<ON" position), and run engine at vehicle speed
01 5 km/h (3 MPH) or higher for at least 10 seconds.
4) Select "DATA MONITOR" mode with
CONSULT.
SEFOO4Q ~
<tr NO FAIL

....-_R_EC_O_R_D_ _ I

[,---=
ThroWe position

sensor circuit

43

ff.f\

- - - - - - - - OR - - - - - - - -

4) Turn ignition switch "OFF" and then

'H8/
\

I /

"ON".
5) Perform diagnostic test mode 11 (Selfdiagnostic results) with ECM.

CHECK-

,/

I \

Malfunction Indicator lamp displays

diagnostic trouble code No. 55.

"

SEFOS1P

MONITOR

CASRPM(REF)
AIR FLOWMTR
ENG TEMP SEN
EXHGAS SEN
MIA F/CMNT
CAR SPEED SEN

Signal circuit
from AfT control
unit to ECM

BOOrpm
1.55V

81"C
O.06V

PERFORM DIAGNOSTIC TEST MODE II (SELF

DIAGNOSTIC RESULTS).
1) Turn ignition switch "ON" or start engine.
2) Select "DATA MONITOR" mode with

LEAN
Okmlh

ff.f\

RECORD

----

I
54

'(:( NO fAIL

CONSULT

<tr NO FAll

SEF004Q - - - - - - - - - OR - - - - - - - -

2) Perform diagnostic test mode II (Selfdiag~ostic results) with ECM.

Malfunction 'ndicator lamp displays
diagnostic Irouble code No. 55.

I /

'H8/

,/

CHECK-

I \

"

SEF051P

TROUBLE DIAGNOSES
Diagnostic Procedure 10 - Symptom Stalls when Turning (Confd)

Engine

~-------'-----,

~ Check ignition coil. power

CHECK IGNITION SPARK.

1 Disconnect ignition coil assembly
from rocker cover

transistor unit and cir-

2. Connect a known good spark plug to

Spark plug

cuits.
'"
I
(See page EC-120. 20~

the ignition coil assembly.

3, Place end of spark plug against a

SEF0080[

suitable ground and crank engine.

4. Check for spark.

FUEL PRES RELEASE.

OK

FUEL PUMP WILL STOP BY

TOUCHING START DURING
IDLE.
CRANK A FEW TIMES AFTER
ENGINE STALL.

Ir

CHECK FUEL PRESSURE.

~

1. Perform "FUEL PRESSURE

RELEASE" in "WORK

ING ..J Check fuel pressure regu-

lator diaphragm.

SUPPORT" mode in order to

:===========~=========::::::;

L,__S_T_A_RT

release fuel pressure to zero.

2. Install fuel pressure gauge and

check fuel pressure

At Idle approx. 245 kPa (2.45
bar, 2.5 kg/cm 2 , 36 psi)
The moment throttle valve Is

fully open:
approx. 294 kPa (2.94 bar, 3.0
kg/cm 2 , 43 psi)
~------OR---------.I

1. Release fuel pressure to zero.

(Refer to page EC-208.)
2. Install fuel pressure gauge and

check fuel pressure,

OK
CHECK ECM POWER SUPPLY AND

GROUND CIRCUIT.
Refer to page EC-105
OK
Disconnect and reconnect harness connectors in the circuit. Then retest
Trouble is no! fixed.
r

Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect EeM harness connectar and retest.

"-----------~

EC-86
'77

Repair or replace.

TROUBLE DIAGNOSES
Diagnostic Procedure 11 - Symptom Stalls when the Engine is Hot

Engine
':}f

D
CHECK FUEL VAPOR.
1. Disconnect fuel pressure regulator
vacuum hose and plug hose.

2. Perform cruise test.

3. Does the engine stall disappear?
_ _S_E_FOd

***

ACTIVE TEST

Im\

.--o~

POWER BALANCE

PERFORM POWER BALANCE TEST.

1, Perform "POWER BALANCE"

***

:O~S:;;~~R~~;TOR ~;5~;;=:O
AIR FLOW MTA

t 53V

II Q] mQJ
CICIDD,

Go to

fit .

in "ACTIVE TEST"' mode.

2. Is there any cylinder which

I
~~

260J~_

AAC VALVE

to

fJ

does not produce a morpentary

engine speed drop?

TES~

f--------OR---------1
When disconnecting each injector

START
SEF797K I

harness connector one at a time,

is there any cylinder which does
not produce a momentary engine
speed drop?

CHECK INJECTOR.
Does each injector make an operating
sound at idle?

--_.

11

((f8

/~t

Click

At Idle

Ct'('.+

CHECK IGNITION SPARK.

1. Discon nect ignition coli assemb Iy
from rocker cove r.
2. Connect a known good spark plug to

No

NG

....I Check injector(s) an~

cuit(s),

Check ignition coil, power

transistor unit and their
circuits. (See page

EC-120, 202.)

the ignition coil assembly.

3. Place end of spark plug agains1 a
suitable ground and crank engine.
4, Check for spark.

1/
,-I

~----~

(Go to

on next page.)

m
0:'1

c'

Spark plug

SEF006Qj

EC-87

~--.

TROUBLE DIAGNOSES
Diagnostic Procedure 11 - Symptom Stalls when the Engine is Hot (Cont'd)

FUEL PRES RELEASE

FUEL PUMP WILL STOP BY

TOUCHING START DURING
IDLE
CRANK A FEW TIMES AFTER

1 __

(g

----~

NG _I Check fuel pressure regu

CHECK FUEL PRESSURE.

ENGINE STALL

~---sT~~

Engine

\~

1. Perform "FUEL PRESSURE

RELEASE" in "WORK
SUPPORT" mode in order to

release fuel pressure to zero.

=:J

2. Install fuel pressure gauge and

check fuel pressure .

At idle approx. 245 kPa (2.45

bar, 2.5 kg/cm 2 , 36 psi)
The moment Ihrottle valve is

fully open:
approx. 294 kPa (2.94 bar. 3.0
kg/em', 43 psi)
f - - - - - - - - - OR - - - - - - - 1

tm
~

MEFS99D
-----------------'

l
I

1, Release fuel pressure to zero,

(Refer to page EC-208.)
2. Install fuel pressure gauge and
check fuel pressure
OK

~p'ir or repI._c_e_,

CHECK ECM POWER SUPPLY AND

GROUND CIRCUIT.

I Refer to page EC-105_,

---.-J

----~~isconnect
harne;s~

and reconnect

nectars in the cirCUit Then retest.

---=troUb,e

Check ECM pin

IS

not fixed

termin~-f-or-d-a-m-a-ge-l

or the connection of ECM harness connector Reconnect ECM harness connector and retest
-----'

EC-88

lator diaphragm.

TROUBLE DIAGNOSES

Diagnostic Procedure 12 - Symptom Stalls when the Engine is Cold

Engine

H-E-C-K-FA-S-T-ID-L-E-C-A-M-'-------T10C heck

When the engine is cold, does fast idle

cam keep cam follower lever in posi-

~n_?

fasl idle cam

adjustment. (See page

EC-207 )

Marl< (long Iinel

IYes

SEFQ11Q

--------------'

6
1

~iD

I=;:s~i;ii~~:;~~~i~l~
AIR FLOW MTR
AAC VALVE

1 53V

26%

IIQ][2]Q] TES~

DCICID STA~J

2. Is there any cylinder which

does not produce a momentary

engine speed drop?

00

OR
When disconnecting each injector
harness connector one at a time.
there any cylinder whJch does
not produce a momentary engine

IS

speed drop?

(I

I-C-H-E-C-K-I"N-J-E-C-T-O-R-.-----'-------------~ NG

Does each Injector make an operating

I

(Go to

/~\t
Click

C/_
'r.+

SEF730L

EC-89

ts

sound at idle?

0K

AI Idle

OK

SEF797K

~G~6.

PERFORM POWER BALANCE TEST.

1. Perform "POWER BALANCE"
in "ACTIVE TEST" mode.

SEF",,!

------------

(e81 ~
{) ~

and circuils. (See page

EC-169.)

No

!J

Check IACV-AAC valve

pedal fully?

~---=~-

L-

I the engine when pressing accelerator

~<0

Yes

CHECK IACV-AAC VALVE.

When the engine is cold, can you start

on next page)

Check injeclor(s) and elrcuit(s).

TROUBLE DIAGNOSES
Diagnostic Procedure 12 - Symptom
Stalls when the Engine is Cold (Confd)

Engine

-------------------

~ Spark plug
SEF006Q

CHECK SPARK PLUGS.

Remove the spark plugs and check for
fouling, etc.

CHECK FUEL PRESSURE.

1. Perform "FUEL PRESSURE
RELEASE" in "WORK
SUPPORT" mode in order to
release fuel pressure to zero.
2. Install fuel pressure gauge and
check fuel pressure.
At idle approx. 245 kPa (2.45

~
~

SEF1561

FUEL PRES RELEASE.

FUEL PUMP WILL STOP BY

TOUCHING START DURING
tOLE
CRANK A FEW TIMES AFTER
ENGINE STALL

Repair or replace spark

Check fuel pressure re 9 u-1

~ I plug(s).

~ Ilator diaphragm.

bar, 2.5 kg/cm 2 , 36 psi)

The moment throltle valve Is
fully open:
approx. 294 kPa (2.94 bar, 3.0
kg/cm 2 , 43 psi)
OR - - - - - - - - - - 1
~. 1. Release fuel pressure to zero.
~
(Refer to page EC~20B.)
2. Insta II fuel pres5u re gauge and
check fuel pressure .

~======S=T~==RT========~

~OK
CHECK ECM POWER SUPPLY AND
~ROUND CIRCUIT.
~fer to page EC-105.

,I

~OK
Oi scen neet and reco nnee t harness connectors in the circuit. Then retest.

~ Trouble is not fixed.

MEF70m

Check ECM pin terminals for damage

or the connection of ECM harness connector Reconnect ECM harness connector and retest.

EC-90
t"

Check ignition coil, power I

transistor unit and circuits.
(See page EC-120, 202 )

CHECK IGNITION SPARK.

1. Disconnect ignition coil assembly
from rocker cover.
2. Connect a known good spark plug to
the ignition coil assembly.
3. Place end of spark plug against a
suitable ground and crank engine.
4 Check for spark.

Repair or replace.
I

TROUBLE DIAGNOSES

Diagnostic Procedure 13 - Symptom - Engine

Stalls when Stepping on the Accelerator
Momentarily

AAC VALVr SYSTEM.

LE:.' ENGINE tOLE.

THE'"

:.r

TOUCH STAAT
(A/C SW.L1GHT SW OFF)

".

No

CHECK IACV-AAC VALVE.

ACTIVE

AACN OPENING

SYSTEM" in "FUNCTION

TEST.

TEST' mode
OR

34%

00

== == ==

MONITOR::::. =. =
CASRPM (REF)
875rpm
AlA FLOW MTA
1 OOV

ENG TEMP SEN

--

1. Select "AACIV OPENING" or

"IACV-AACIV OPENING" in

"ACTIVE TEST" mode

- ec

2. When touching "Qu" and

83C

sufficiently.

Check IACV-AAC valve

and circUit. (See page
EC-169 )

2. Perform "AAC/V SYSTEM" or

"IACV-AACIV

SEF19Sl

1. Start engine and warm it up

"Qd", does the engine speed

change according to the per-

~[Dp~1 OWN l~
SEF319l

'I::l,

cent of IACV-AAC valve opening?

I
\.:1'.(

OR

When disconnecting IACV-AAC

valve harness connector, does

:~\<r

the engine speed drop?

'---.

~T"

f1

PERFORM POWER BALANCE TEST.

~

~
SEf1461

does not produce a momentary

J}"

~r,~ LO,'

When disconnecting each injector

***

harness connector one at a time,

is there any cylinder which does
not produce il momentary ~ngine

:4<
+: POWER BALANCF
===:= = :==MONITOR ::;:: = =::;= =
CA~RPM (REF)
8?Srpn~

A\R FLOW MTR

AAC VALVE

~ i~\

engine speed drop?

\ - - - - - - - - - - OR - - . - . - - - - - - - i

f\CTIVE 1FST

~Gotom

1, Perform "POWER BALANCE"

in "ACTIVE TEST" mode
2. Is there any cylinder which

1 53V

?f\%

:~~2Cf

speed drop?

IIQ][]QJ

~DDD~
SEF791K

CHECK INJECTOR.
Does each injector make an operating
sound at iLlle?
Yes

(Go to (~ on next page.)

MEC1258

EC-91

Check inieclor{s)
their clrcJit(s)

~nd

:OJ"'"

If

Ii

h~

(~

/~t

At idle

TROUBLE DIAGNOSES
Diagnostic Procedure 13 - Symptom
Engine
Stalls when Stepping on the Accelerator
Momentarily (Cont'd)
~)

Click
C/,

;~!r

CHECK IGNITION SPARK.

1. Disconnect ignition coil assembly
from rocker cover.
2 Connect a known good spark plug to
the ignition coil assembly.
3 Place end of spark plug against an
earth point with engine cranking.
4 Check for spark.

/ I

SEF7JOL

CHECK FUEL PRESSURE.

~ 1. Perform "FUEL PRESSURE
~
RELEASE" in "WORK
SUPPORT" mode in order to
release fuel pressure to zero
2. Install fuel pressure gauge and
check fuel pressure.
At idle approx. 245 kPa (2.45
bar, 2.5 kg/cm 2 , 36 psi)
The moment Ihrotlle valve Is
fully open:
approx. 294 kPa (2.94 bar, 3.0
kg/cm 2 , 43 psi)

Spark plug
SEF008Q

FUEL PRES RELEASE.

FUEL PUMP WILL STOP BY

TOUCHING START DURING

transistor unit and their

circuits. (See page
EC-120.202)

Check fuel pressure regu-

~ 11ator diaphragm.

~------OR-------i

~
~

IDLE.
CRANK A FEW TIMES AFTER
ENGINE STALL

~==RT=========:::;

:========S=T

1. Release fuel pressure to zero.

(Refer to page EC-20B.)
2. Install fuel pressure gauge and
check fuel pressure.

~OK
!CHECK ECM POWER SUPPLY AND
GROUND CIRCUIT.
Refer to page EC-105.

~OK
Disconnect and reconnect harness connectors in 1he circuit. Then retest.

~ Trouble is not fixed.

MEF699D

Check ECM pin terminals for damage

or the connection of ECM harness connector Reconnect ECM harness connector and retest

EC-92
fir

~ Check ignition corl, power

Repair or replace.

TROUBLE DIAGNOSES

Diagnostic Procedure 14 Stalls after Decelerating

AAC VAl VF SYSTEM.

LET ENGINE IDLE

TH!:r-.:
TOUCH START

Symptom -

Engine

ICHECK IACV-AAcvALVZ------

(A/C SWL\GHT SW OFF)

ff.f\

L
~~
Li:G:T_luTART ~

SEF196L

No

1. Start engine and warm it up

sufficiently.

Check lACV-AAC valve

and circuit. (See page

EC-169.)

? Perform "AACIV SYSTEM" or

"IACV-AACIV SYSTEM" in
"FUNCTION TEST" modp

r - - - - - - - - - - - - - - - - - - - - - - , ' r - - - - - - - OR - - - - - - - - - l
(~\ 1. Select "AACIV OPENING" or
ACTIVE
~
"IACV-AAC/V OPENING" in

TEST. 0

AAC.rv OPENING

34%

"ACTIVE TEST" mode.

::::. == = MONITOR:::: == =

? When touching "Qu" and

CAS.RPM (REF)

B75rpm

"Od", does the engine speed

AlA FLOW MTR

ENG TEMP SEN

160V
83C

change according to the per-

~LQLII DWNJ~

;"2

cent of IACV-AAC valve opening?

;',1

When disconnecting IAGV-AAC

SEF3BL

va Ive harness con nector, does

the engine speed drop?

l~~~f

CHECK IDLE ADJ. SCREW CLOGGING.

~\

f1

1. Perform "IGN TIMING ADJ" in

2. Can you set engine speed at
75050 rpm (AlT in "N" position) by fuming idle adjusting

SEF:461

IGN TfMrNG ADJ.

sensor harness connector

2. Can you set engine speed at
750 50 rpm (AfT in 'ON" posi-

- - CONDITION SETIING - IGN/T FEEDBACK:

-------------1

1. Disconnect throttle position

HOLD

tion) by turning idle adjusting

screw?

= MONITOR ===-:=-==
CAS RPM {RE rj
762rpm
rGN TIMING
15BTDC
IOU:: POSITION
ON

~=====

(Go to

SEF786K

Front

EC-93

IYes
+
on next page)

No
Check lor IACV-AAC valve
,--------.
.
h
cloggIng or t rottle body

"WORK SUPPORT" mode

screw?
f - - - - - - - - OR

j\

Ii
';1

'Z:,I

~':" !....,

f - - - - - - - - - - - OR - - - - - - - - - ,

FQ:

clogging.
-'-----

-;{x

Ac:rIVF TFST

POWl: r~ 8A.LANCE
MONITOR
==::
CASRPM (REF)
B25rpm
AlA FLOW MTR
1 53V
AAC VALVE
26%

=-=-= =

PERFORM POWER BALANCE TEST.

~ 1. Perform "POWER BALANCE"

r-~
'-----------:u.J

110Q]~1

DCIDD

Engine

***

***
:== '" ==

::c

TROUBLE DIAGNOSES
Diagnostic Procedure 14 - Symptom Stalls after Decelerating (Cont'd)

JEST

No

Go to
'--------------

in "ACTIVE TEST" mode

2. Is there any cylinder which

START

does not produce a momentary

engine speed drop?
r-------OR---------1
When disconnecting each injector
harness connector one at a time,

is there any cylinder which does

not produce a momentary engine
speed drop?

No

CHECK INJECTOR.
1. Does each injector make an operating

/-----.

Check injector(s) and

cuit(s).

c~

sound at idle?

OOw

Yes

~
CHECK IGNITION SPARK.
i. Disconnect ignition coil assembly

At Idle

from rocker cover.

the ignition coil assembly.

3. Place end of spark plug against a

suitable ground and crank engine
SEF730L

4. Check for spark.

Ignition cotl

(Go 10

-{:{

'"~
\

~-/
'r

"\
\

Spark plug
SEF0080

EC-94
(P,

Check ignition coif, power

transistor unit and circuits.

2. Connect a known good spark plug to

NG

en next page.)

(See page EC-120, 202.)

TROUBLE DIAGNOSES
Diagnostic Procedure 14 - Symptom ------------------,
Stalls after Decelerating (Cont'd)
FUEL PRES RELEASE.

FUEL PUMP W(L~ STOP 8'(

TOUCHING START OUR/,\/G

!OL~

Engine

pr-essu-~(]U~]

CqANK A FEW TIMES AFTER

Check fuel

E'\JGINE STALL

latar diaphragm.

. . ~I

----'--

"-:-:,"',

MEF58BO

MIXTURE RATIO TES!

CHECK HEATED OXYGEN SENSOR.

1. Start engine and warm it up sufficiently,
'~ 2 Perform "MIXTURE HATIO
~
TEST" in "FUNCTION TEST"
mode.
---OR-----

ACCELEHATE TO 2000 RPM

AND HOLD THEN TOLICH

START

2.000

[' NEXT-I

2200

2. See "M/R FIe MNT" in "DATA

START
MEF6S9D

~ MONITOR

trNO FAIL

CAS RPM (REF)

M/R F/C MNT

Replace heated oxyqen

sensor(s).

III]
1&D

NG

200)rpm

RICH

MONITOR" mode
3. Maintaining engine at 2,000
rpm under no-load (with
engine warmed up
sutficienlly.), check to make
sure that the monitor II ucluates
between "LEAN" and "l=lICH"
more than 5 limes during 10

seconds.
1 cycle: RICH

LEAN -. RICH
'. LEAN -.
RICH ,LEAN -.
RICH
- - - - OR - - - - - - - - - - - 1
f~\ 2. Set "Heated oxygen sensor
~
monitor" in Diagnoslic Test
-+

2 cycles; RICH

RECORD
SEFB16K

:",.-,

~'.

Mode II (See page Ee-52.)

3. Maintaining engine at 2,000

"

rpm under no-10ad. cheCK that

malfum.:lion indic~tor lamp

I /

~e/
CHECK,/

goes ON and OFF more than 5

times during 10 seconds,

-......

I \
(Go to

SEF051P

EC-95

on next page.)

j-,

TROUBLE DIAGNOSES
Diagnostic Procedure 14 - Symptom Stalls after Decelerating (Cont'd)

CHECK ECM POWER SUPPLV AND

GROUND CIRCUIT.
Refer to page EC-105.

lOK
Disconnect and reconnect harness connectors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

EC-96
In

Engine

Repair or replace

TROUBLE DIAGNOSES

Diagnostic Procedure 15 - Symptom - Engine

Stalls when Accelerating or when Driving at
Constant Speed

0
* * *POWEI-! BALJ\NCE * * *
====-====MCNITOR =====:::=

ACT,V\: IfC;T

CAS RPM (REF)

S25'lm'

AIR FLOW MTH

AAC VALVE

5,)V
26%

~Gotom

':,1"':'
c ~"~

L_

....

'"j

2. Is there any cylinder which

does not produce a momentary

engine speed drop?

f---------OR----------J

When disconnecting each injector

harness connector one at a time,
is there any cylinder which does
not produce

momentary engine

speed drop?

res

",.:l,

--------------------,

.-------------Check injector(s) and cir-

CHECK INJECTOR.

cuH(s).

Does each injector make an operating

/~~

~,m
~,~-

sound at idle?
---~

~Yes

Click

At Idle

_
'co,,"

CHECK fGNfTlON SPARK.

1. Disconnect ignition coil assembly

from rocker cover,

2 Connecl a known good spark plug to

/1

NG

f------+

Check ignition coif, power

transistor unit and circuits.
(See page EC-120, 202 )

- r

the ignition coil assembly.

3. Place end of spark plug against a
SEF7:jOL

------------------

suitable ground and crank engine.

l:' -

I '

}~~

4. Check for spark.

Ignition cod \

'Y

(Go to r'l;) on next page.)

~>I:
f

'--

Spark plug
SF FOOflO

I'
( l,,"

11:',::',

EC-97

TROUBLE DIAGNOSES
Diagnostic Procedure 15 - Symptom - Engine
Stalls when Accelerating or when Driving at
Constant Speed (Cont'd)

FUEL PRES RELEASE.

FUEL PUMP WILL STOP BY

TOUCHING START DURING
IDLE
CRANK A FEW TIMES AFTER
ENGINE STALL

NG

CHECK FUEL PRESSURE.

==========5==-T~==RT==========

f-----..

1. Perform "FUEL PRESSURE

RELEASE" in "WORK

Check fuel pump. circuit

and fuel pressure regufator_

SUPPORT" mode in order to

release fuel pressure to zero .

2. Install fuel pressure gauge and
check fuel pressure
At Idle approx. 245 kPa (2.45

bar, 2.S kg/cm 2 , 36 psi)

The moment throttle valve Is
fully open:
approx. 294 kPa (2.94 bar, 3.0
kg/cm 2 , 43 psi)

OR

MEF70ml

I(j)

1. Release fuel pressure to zero.

(Refer to page EC-208,)
2 Install fuel pressure gauge and

check fuel pressure.

(;J

l4

CHECK FOR tNTAKE AIR LEAK.

When pinching blow-by hose (towering
the blow-by air supply), does the engine

Discover air leak

and repair.

locali~

speed rise?

No

Front

SEFOQ7Q

~ECK ECM

~air or

POWER SUPPLY AND

GROUND CIRCUIT.
Refer to page EC-10S_

=r=

replace.
I

[ Disc-o-nn-e--c-t-a-n-d reconnect harness con-

nectars in the circuit. Then retest.

~-=:Uble is not fixed

i-C-h-eC-k-E-C-M--pj-n-t-e-rm ina Is fa r

r the connection of ECM

nector. Reconnect

nector and retest.

EC~.

dama~e

harness con-

harness conI

EC-98
7

TROUBLE DIAGNOSES

Diagnostic Procedure 16 - Symptom - Engine

Stalls when the Electrical Load is Heavy

--1

CHECK BATTERV AND ALTERNATOR-.

Check battery and alternator condition

(Refer to EL section)

SEF3891

e--------------

\~)

**

825rpm

AIR FLOW MHl

AA( VAl VE

1 53V

1,

I Repair or replace.

Go to ~ .

Perform "POWER BALANCE"

in "ACTIVE TEST" mode.

2 Is there any cylinder wh ich

POWER BALANCE
MONITOR :.",,= "'- -==-

CAS.RPM (REF)

NG

I ,PERFORM POWER -----.:.S-A-LA-N-C--E-r-ES-T-.----------. No

~

ACTIVF TEC\T

** *===
=
:.:::.-=

does nol produce a mornerllary

engine speed drop?

26,e

f--------OR------l<ff\ When disconnecting each injector

~ harness connector one at a time.
;s there any cylinder whIch does
not produce

momentary engine

speed drop?

'------------

__J:_

CHECK INJECTOR.

No

Check injector(s) and Clr-

cUIl(s)

Does each injector make an operafing

sound at idle?

CHECK IGNITION SPARK.

1. Disconnect Ignition coil assembly
from rocker cover

/~t
Click

C/o

'C'~

~ SUitable

2. Connect a known good spark plug to

the ignition coil assembly
3. Place end 01 spat k plug against a

suitable ground and crank engine.

4 Check for spark.

OK
(001

(Go lo~) on next page)

SEF730L

-------

Spark plug
SEf008Q

EC-99

NG

Check ignition coil. power

transistor unit and cir-

CUI!S
(See page EC-120 202.)

FUEL PRES RELEASE.

FUEL PUMP WILL STOP BY

TOUCHING START DURING
IDLE
CRANK A FEW TIMES AFTER
ENGINE STALL

TROUBLE DIAGNOSES
Diagnostic Procedure 16 - Symptom - Engine
Stalls when the Electrical Load is Heavy
(Cont'd)

NG
Check fuel pressure re 9 u-1
~
lator diaphragm.

CHECK FUEL PRESSURE.

1. Perform "FUEL PRESSURE

RELEASE" in "WORK
SUPPORT" mode in order to
release fuel pressure to zero.
2. Install fuel pressure gauge and

check fuel pressure.

At idle approx. 245 kPa (2.45

bar, 2.5 kg/cm

36 psi)

The moment throttle valve is

fully open:
approx. 294 kPa (2.94 bar, 3.0
kg/em:>', 43 psi)

OR

MEF699D

1. Release fuel pressure to zero.

(Refer to page EC-20B.)

' Install fuel pressure gauge and

check fuel pressure.

I

J,OK
~

! CHECK ECM POWER SUPPL V AND

l;_ _-------'
GROUND CIRCUIT.

Repair or replace.

Refer to page EC-105.

0K

,-----------

Disconnect and reconnect harness connectors in the circuit. Then retest.

_ _ _ _ _ ~Trouble is not fixed.

heCk

ECM pin terminals for damage

or the connection of ECM harness con-

nector. Reconnect ECM harness con-

neelor and _r_et_e_s_t.

EC-100

TROUBLE DIAGNOSES

Diagnostic Procedure 17 of Power and Stumble

FUEL PRES RELEASE.

Symptom -

Lack

FUEL PUMP WILL STOP BY

TOUCHING START DURiNG

;':J. r

NG

CHECK FUEL PRESSURE.

IDLE
CRANK A FEW TIMES AFTER
ENGINE STALL

00

1. Perform "FUEL PRESSURE

Check luel pressure regulator diaphragm.

RELEASE" in "WORK

SUPPORT" mode in order 10

release fuel pressure to zero

2. Install fuel pressure gauge and

check fuel pressure.

At Idle applox. 245 kPa (2.45
bar, 2.5 kg/cm 2, 36 psi)
The moment throttle valve Is

fully open:

approx. 294 kPa (2.94 bar, 3.0

kg/cm 2 , 43 psi)
OR

MEF708D

1. Release fuel pressure to zro.

(Refer to page EC-20B)
2. Install fucl pressure gauge and
check fuel pressure.

----------

CHECK FOR INTAKE AIR LEAK.

Discover air leak location

When pinching blow-by hose (lowering

the blow-by air supply), does the engine

and repair.

speed rise?

No

SEFDD7Q

'NSPECTION_E_N_D

EC-101

~_

TROUBLE DIAGNOSES

TROj
Q

(~

Diagnostic Procedun

me

--

CH
n4
Ra

CHECK FOR INTAKE AIR lEAK.

When pinching blow-by hose (iowl

I ~_e blow-by air supplYl. does the

in

~eed

rise?
~~-

SEf1561

II

SEF0070

CHECK EGR OPERATION.

f1

oj

2CXXl

2200

START

L-_NE_XT----Jil

2. Check to see that the engine fur

rough or dies.

C
1J

\em

I~
1

~---

~ Yes

CAS-RPM (REF)
MIR Fie MNT

V---~

____________

~_------_SE_F_B2_0_FA_.J1

CIRCUIT" In "FUNCTION
TEST" mode.

('Ii)

DOES THE 501 FNOID

200Jrpm
RICH

1. Turn ignition switch 'ON"

2 PerfOrm "EGR CONT SIV

CIRCUIT" or "EGRC SIV

EGR CONf S'V CIRCUIT!

-tlNO FAIL

CHECK EORC-SOlENOID VALVE .

.r=-

MEn11D

tr MONITOR

1. Apply vacuum directly to the EG

valve using a handy vacuum PUi

MIXTURE RATIO TEST

ACCELERATE TO 2(XJ() RPM
AND HOLD THEN TOUCH
STA.RT

to

Front

---OR----1. Turn ignition switch 'ON"

~~ 2 Select "EGR CONT SOLIV

VALVE MAKE

'EGRC SOL VALVE" in ,

AN OPERATING SOUNDJ

EVERY 3 SECCNDSJ

L.~_

C~EXT

-IUJo !!YE5l
MEf569B

'8]

- - - - .. _--_.~

3.

.........

ACTIVE TEST.

I /

EGR CONT SOLlY

~/
CHECK-

3 Turn EGRC-solenoid valve

and OrF.
4 Check operating sound
--~----- OR - - - - IU\ 1. Disconnect EGRC-solenoid
~
valve harness conneclor.
2 Supply EGRC-solenoid val\
terminals with batlery cum
and check operating sound

OFF

= = MONITOR =Or;:Jm
==
CASRPM (REF)

......

,,/

"ACTIVE TEST" mode

10K

- - - - -~- _ _ - ...

CHECK VACUUM HOSES.

/1'\

Check the following vacuum hoses fe

clogg ing, cracks and poor connectiol

a) Vacuum hose between EGR valve

and EGRC-solenoid valve.

b) Vacuum hose between EGRC-sole

nOld valve and throttle body port

c) Vacuum hose between EGRC-sole

noid valve and air duct.

BAITERY

(Go 10 @ on next page.)

SEF930M

EC-102

TROUBLE DIAGNOSES
Diagnostic Procedure 22
MAIN POWER SUPPLY AND GROUND CIRCUIT (Not self-diagnostic item)

EC-MAIN-01
Refer to
EL-POWER.

SR

*1

LHO mode 1s
RHO mOdels
For Europe

Except

*1 ... (1) R
*2<D BIR'
*3"'@ B/R:

1~1~640;

.----,.
III ]1

SR

SA

<IT>:

l$J~l:o;

__~-O

<I>:

:
:

RIG
SR
BR

I....

JOINT
CONNECTOR
@ID

~
SiR

ECCS

~ RELAY

<t

$J<HQ)

~,.-O

*3

*2

~ em

RIB

B/W

RIB

B/W

;-~

491

45
1GN

VB

SW

GNO
-C

GNO

150 I

60
8

-c

GNO
-1
~

GNO
-I
I~ I

GND
-E
11~7 I

ECM
(ECCS
CONTROL
MODULE)
(IT)

-L . e-e-.-.-I
I

. r

.-.

-!-

<Eg)

-!-

liD
Refer to last page
(Fa ldaut page) .

@Q>,OO
~ CB)

r:

[:i.

<ED
L
SEF824P

EC-105

--

TROUBLE DIAGNOSES
Diagnostic Procedure 22 (Confd)
Harness layout
----I~I~-

mI

CONNECT

JA

L.m)~~
ECM

4?f

INSPECTION_S~T_A_R_T

r.i.1

F ' - - - - - - - - - ' - - - - - - - - - - - - , OK

CONNECTOR]

CHECK POWER SUPPLY

1) Turn ignition switch "ON"
2) Check voltage between ECM terminals '[il) , @ and ground.
Voltilge: Ballery vollage

4959

,~

MEC137B

(;)

II

EcH

CONNECTOR~ ~ iv'

CHECK GROUND CIRCUIT

1) Turn ignition switch
"OFF"
2) Disconnect ECM harness connector.
3} Check harness continuity between ECM
terminals @J~,
GE),QID,@and
engine ground.
Continuity should
exist.
If NG, repai r harness or
connectors .

_~--

Check ECM pin terminal'l

for damage or the connection of ECM harness
connector.
~

MEF415D

EC-106

TROUBLE DIAGNOSES
Diagnostic Procedure 22 (Cont'd)
@

..

~.

NG

CHECK HARNESS CONTINUITY

ho"'"
f---- R'poi,
nectars

BETWEEN ECCS RELAY AND ECM

0'

'O~

1) Turn ignition switch "OFF".

2) Disconnect ECM harness connector

3) Disconnect ECCS relay.

4) Check harness continuity between

ECM terminals @ , @ and lerminal

MEC138B

,
I'

Continuity should exist.

Ii]

--

OK

Ii]
CHECK VOLTAGE BETWEEN ECGS
RELAY AND GROUND.

NG

'-----"

1) Check voltage between lerminals

CD, @)

(@D,@
Harness connectors

@D,@)
Harness continuity
between EGGS relay

MECI39B

and battery
If NG, repair harness or

connectors.

CONNECTOR

ECM

131

,58;109,

CHECK VOLTAGE BETWEEN EGM AND

GROUND

NG

---+

1) Check vollage between EGM termi-

nals ,~~.

Gill

and ground.

Voltage: Sallery voltage

MEC140B

OK
ECM

75A fuse
Harness connectors

and ground

Vollage: Battery \/oltage

OK

~io~
g
I]

Check the following

:l
50

CONNECT:]

60

~ "E8' IiCHECK GROUND CIRCUIT

'--v-'

1) Check harness continuity between

Check the following.

Harness continuity
between EGM and harness connector ill)
If NG, repai r harness or
connectors
L -_ _..

NG

-------+-

-Repair harness or connectars.

ECM terminals @ . !@ and engine

ground
Continuity should exisl.

MEF418D
r=c-----~---------

II

~i8~~i5
~
A
LltiP
EGM

CHECK OUTPUT SIGNAL CIRCUIT

1) Check harness continuity between
ECM terminal @ and terminal @.
Continuity should exist.

~OK

CONNECTOR]

~)

16

tvlEC141B

EC-107

Repair harness or can- .

nectars
--

-1

J
--

Diagnostic Procedure 22 (Cont'd)

III

CHECK INPUT SIGNAL CIRCUIT

1} Turn ignition switch "ON".
2) Check voltage between ECM terminal
and ground.
Voltage: Battery voltage

NG

OK

MEF420D

Check the following.

Harness connectors

@D,GD

Joint connector @
(Models for Europe)
Harness continuity
between ECM and ignition switch
If NG, repair harness or
connectors
~-

CHECK COMPONENT
(ECCS relay).
Refer 10 "Electrical Components
Inspection". (See page EC-206.)

~OK
Disconnect and reconnect harness connectors in the circuit. Then retest.

~ Trouble is not fixed.

Check ECM pin 1erminals for damage
or the connection 01 ECM harness connector. Reconnect ECM harness connector and retest.

EC-108

~~

Replace ECCS relay.

Diagnostic Procedure 23
CAMSHAFT POSITION SENSOR (Diagnostic trouble code No. 11)

LHD MODELS

EC-CMPS-01
@: A/T models

: M/T models
*11,3
*2cm QID

to EL-PDWER.

*3"'~'~
,

CAMSHAFT

Fl

POSITION~

SENSOR

1r$J :1:~

Fl

1*1 &4;
R

~
1

ECCS

~ RELAY

S/W

Ii,-

R/B

B/W

rn
7 j

lbjJ3
R/8

4J
8

....

,.

-=-:'"

...

(,

.... 1

JOINT
CONNECTOR

I
I

I
I
I
I
I

s/w@

~j

I
I
I
1,-

B/W@

...

....

rT
w

8/w

IfT6iJ I 4-91 I 5~ I
SSOFF 118

~@)
W/S

"

W/B@

Fl

W/8 ~

W4Til~
REF

liB

REF

POS

POS

ECM

(ECCS
CONTROL
MODULE)

em

-~-@

Refer to last page

(Fa ldout page) .

~GY

SEF825P

EC109

c.; .~

Diagnostic Procedure 23 (Cont'd)

EC-CMPS-02

RHO MODELS
CAMSHAFT

POSITION~

BATTER:.,,] Refer to EL-POWER.

~J

Jr'i

8/W ~

R/G

B/W

rOO1

CE1)

1$1 :l~o;

1~lr::;

n ECCS

U RELAY

RIB

I
I
I
I

B/W

I
I

E~

r _I~=;

rrT6il 1:9 I
SSOFF VB

I
I

I
I
I

I
I
I
I

I
I

~,..

'"

T,

B/W

I
I

I
I

EU

R/8

t
I
I
I
I
I

")

I
I

1'1/8

11211
""'iF

,..

"
II~I

~ <EQ)

R/G

SENSOR

: For Europe
: Except for Europe
*1 <TIl> W/B, B/W

rT
w

B/W

-----.

1'1

4d

59

REF

VB

ECM

(ECCS
B
CONTROL

MODULE) . ,
(IT)
!- =

@~

~~
~GY

Refer to last page

(Foldout page) .

(ill
L
SEF853P

EC-110

Diagnostic Procedure 23 (Cont'd)

"Engine ground

-7//-l~

r=--~~C-~=~
INSPECTION START

,r

-m

CHECK rOWER SUPPLY.

1) Disconnect camshafl position sensor
harness connector.
2) Turn ignition switch "ON"
3) Check voltage between terminal iE;>
and ground.
Voltage: Ballery voltage

NG

Check the following.

Harness connectors

'I

QD,@)
(LHD AIT models)
Harness connectors

@,@ID
(LHO MIT models)
Harness connr"c\ors

@,QD

OK

-. t.,

(RHO models)

Joint connector @
(Models lor Europe)
Harness continuity
belween camshaft posilion sensor and ECCS
relay
if NG, repair harness or

l_ con necto_r_s_.- - -_ _--.J

MEF720B

r-=--lNG~
CrlECK. GROUND CIRC.. U.1 1 . _
t) Turn ignition switch "OFF"
2) Loosen and retighten ground screwS
3) Check harness contmuity between
terminal and engme ground.
Conlinuily should e xlsl.

.--l

1OK~---

MEF721B

EC-111

epalr . arness or cannectars h

.

i;~

1"1

Diagnostic Procedure 23 (Cont'd)

-:. MONITOR
CASRPM (REF)

NO FAIL

(Po)

BOOrpm

CHECK INPUT SIGNAL CIRCUIT

(j-' 1) Reconnect camshaft position
sensor harness connector.
2) Start engine
3) Read "CAS RPM' or
"CMPSRPM signal in
"DATA MONITOR' mode with
CONSULT
800 50 rpm (AIT: in "N"
position)
OR
1) Disconnect ECM harness connector
2) Check harness conllnui1y
between terminal and
ECM terminals if2) , ~.~ (1'
signal), terminal @ and ECM
terminals ifD, @ (180 signal)
Conlinuily should exist.

~)

RECORD
MEC142B

F~

'--'

Repair harness or
nectars

con~

(j)

~OK

-~

NG

CHECK COMPONENT
(CamshaH position sensor)
Refer to "Electrical Components
Inspection'. (See page EC-201 )

f--

Replace camshaft position sensor.

--_.

~OK
Disconnect and reconnect harness connectars in the circuit. Then retest.

I!

Trouble is not fixed

Check ECM pin terminals for damage

or the connection of ECM harness connector Reconnect ECM harness connector and retest.

Perform FINAL CHECK by Ihe following procedure after repair

is completed.
FINAL CHECK

-l

:_-_-_-_-_~~~_-_-~_-_-_-_-_-_L-~~~~~_~~~_---.J
___,
1) Erase the diagnostic test mode II
(Self-diagnostic results) memory.

NG

f--.

(Refer to EC-52.}
3) Perform diagnostic test mode II
(Self-diagnostic results) again
(Refer to EC-50)

EC-112

nals for damage or the

connection of ECM harness connector

2) Perform test drive.

INSPECTION END

Recheck ECM pin termi-

Diagnostic Procedure 24
MASS AIR FLOW SENSOR (Diagnostic trouble code No. 12)

EC-MAFS-01
<C>:

Refer to EL-PDWER.

:
*1"

LHD
RHO

models
models

<D

lf1

A
R/G

I
*1

ll$J ~1:~;
R

u$Jj ~~

B/W

"
R

MASS

AIR

FLOW

SENSOR

3J

")

~
~

-1
I
I
I
I

ECCS
RELAY

I
I

2J~

R/B

-,----..
I
I

B/W

It,-

A/B

8/W

1s1 14~1

SSOFF VB

"

8/W

59
VB

27
QA+

1:61
QA-

ECM

(EceS
CONTROL
MODULE)

CED

Refer to last page

(Fa ldout page) .

@Q).<flQD
(8Q), < E ) n

i;:;;;::;:;:;:;:;;;;::;::;::::::;:::::;:;:;:;;:;;:r::::;~;::;:;:;~~:r;:r.::;l
L
SEF626P

EC-113

TROUBLE DIAGNOSES
Diagnostic Procedure 24 (Cont'd)
Harness layout

INSPECTION START

CHECK POWER SUPPLY.

1) Disconnect mass air flow sensor harness connector.
2) Turn ignition switch "ON".
3) Check voltage between terminal
and ground.
Voltage: Battery voltage

~io

~io

1r=[=E=C=M~'~ ~
26

&a

I I
'------------~

.OK

EC-114

Check the following.

Harness continuity
between mass air flow
sensor and ECCS relay
If NG, repair harness or
connectors

CHECK GROUND CIRCUIT.

1) Turn ignition switch "OFF"
2) Disconnect ECM harness connector.
3) Loosen and retighten ground screws
4) Check harness continuity between
terminal and ECM terminal @
Continuity should exist.

-NG

NG
-----I>-

Repair harness or
nectars.

TROUBLE DIAGNOSES
Diagnostic Procedure 24 (Cont'd)

MONITOR

~NO

AIR FLOW MTR

FAIL

1 48V

;'1

, - - - - - - - - .. _ - - - - -

RECORD]
SEF824K

CHECl< INPUT SIGNAL CIRCUIT.

(~ 1) Reconnect mass air flow sen~
sor harness connector and
ECM harness connector.
2) Start engine and warm it up
s u Hie ien t1y
3) Read' AIR FLOW MTR" or
"MAS AIR/FL SE" signal in
"DATA MONITOR" mode with
CONSULT.
Voltage: 0.8 - 1.5V
(At idle)
1 - - - - - - - - - OR - - - - - - - - l
1) Check harness continuity
'@
between terminal @ and
ECM terminal @ .
Continuity should exlsI.

Repair harness or connectors.

I.":

rm

_----~-

MEC144B

I
I

CHECK COMPONENT
;
(Mass air flow sensor)
Reier to "Electrical Components
Inspection". (See page EC-201.)

yG

J_O_K

Replace mass air flow

sensor.

.------J

~.

,':t

~i:rf

--.

Disconnect and reconnect harness connectors in the circuit. Then retest.

~ Trouble is not fixed.

heck ECM pin terminafs for damage

or the connection of ECM harness connector Reconnect ECM harness conI nectar and retest

~
L

:-'-,1

"_

Perform FINAL CHECK by the follOWing procedure af1er repair

is completed.
FINAL CHECK

,---------_ J_

NG

1) Erase the diagnostic test mode II

(Self-d iagnostlc results) memory

connection of ECM har-

(Refer to EC-52 )

ness connector

2) Perform test drive

3) Perform diagnostic test mode II

.. - - - -

._--~

(Self-diagnostic results) agai n

(Refer to EC-50.)

0K

L~~~~~~~IN~S_-_P~E~C~T_IO_N_E_N_O

EC-115

rz

termi~!

Recheck ECM p.in

nals tor damage or the

-_

TROUBLE DIAGNOSES
Diagnostic Procedure 25
ENGINE COOLANT TEMPERATURE SENSOR (Diagnostic trouble code No. 13)

EC-ECTS-01

L.....-.;<r~;---............",..-.+-,r:--'

ENGINE COOLANT
TEMPERATURE
SENSOR
(ffiID

LIOR UID

<D:

LHD models

: RHO models
CD: AIT models
~H(D

SR

1~~----4J1

L/OR

1-

O--eD--

t
L/OR

281

11;01

TW

GNO
-A

35

SENS
GNO

ECM
(ECCS
CONTROL
MODULE)

AIT
CONTROL
UNIT
~:CD

em

~m

tmztj

GY

em
L
SEF627P

EC-116

Diagnostic Procedure 25 (Cont'd)

Harness layout
LHD models

Driver' $ dash lower

EC-117

TROUBLE DIAGNOSES
Diagnostic Procedure 25 (Confd)
"<:1 MONiTOR

tf NO

ENG TEMP SEN

FAIL

I
L

INSPECTION START

95"C

CHECK POWER SUPPLY

@
1) Start engine and warm it up
~
sufficiently.
2) Seleci "ENG TEMP SEN" or
"COOLAN TEMPtS" signal in
"DATA MONITOR" mode with
CONSULT.
3) Stop engine.
4) When restarting engine make
sure that CONSULT indicates
"ENG TEMP SEN" or "COOLAN TEMPtS" is 50'C (122"F)
or more.

RECORD
SEFB25K

~io ~fZJ
~

'-ill1ili7

~'-~~--~~~~~---.

Check the following.

Harness continuity
between ECM and harness control @
Jf NG, repair harness
or connectors.

MEC145B

OK

r------.---~-----------,

CHECK GROUND CIRCUIT.

1) Turn ignition switch "OFF".
2) Check harness continuity between
terminal if) and engine ground.
Contlnuity should exist.

NG

r------------

Check the following.

Harness connectors

(E),@)
(AtT models)
Harness continuity
between ECM and harness connector (ill)

OK

Harness continuity
between AIT control
unit and harness connector@
If NG, repair harness or
connectors.

MEC146B

CHECK COMPONENT
(Engine coolant temperature sensor).
Refer to "Electrical Components
Inspection" (See page EC-201.)

OK
Disconnect and reconnect harness connectors in the circuit Then retest
Trouble is not fi xed.
Check ECM pin terminals for damage
or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

EC-118

NG

f---

Replace engine coolan~

temperature sensor. ~~

TROUBLE DIAGNOSES
Diagnostic Procedure 25 (Cont'd)
Perform FINAL CHECK by the following procedure after repair
is completed.
FINAL CHECK

~l

.----------~l~-1) Erase the diagnostic test mode II

(Sell-diagnostic results) memory

(Refer to EC-52.)
2) Perform test drive
3) Perform diagnostic test mode"
(Self-diagnostic results) again.
(ReIer to EC-50.)

INSPECTION END

NG

f-------

~!

Recheck ECM pin termInals for damage or the

connection of ECM har-

lK

..

IJl

EC-119

ii
i

ness connector.

.:
.~

TROUBLE DIAGNOSES
Diagnostic Procedure 26
IGNITION SIGNAL (Diagnostic trouble code No. 21)

LHO MODELS

EC-IGN/SG-01
Refer to EL-POWER.

C10
A

m
<MIQ)

OFF

ST

'~

R ~

ACC

~Jcrn

'i
~
R

2 j

8/R~

I~j
B/R<E1ID
I

ECCS
RELA Y

B/R <8ID

1$1

em

B/R (ffi

B/W

I------~I

B/W

B/R

~rn~ COIL AELAY

ell
RIB

~1
SS
OFF

~
BIR

A/B

IGNITION

SWITCH
(QJ)

BIW

IGNITION

B/W

ECM

(ECCS

CONTROL
MODULE)

em

L.

@
~([W
~

~ B/Y

-e>

Next page

t-,

rn

~
Refer to last page
(Foldout page) .

em
L

SEF828P

EC-120
"1

TROUBLE DIAGNOSES
Diagnostic Procedure 26 (Cont'd)

EC-IGN/SG-02
ECM
(ECCS
CONTROL
MODULE)

IGN

(IT)

#1
1 J

11 J

R/W (ffi R/Y

12

RIG

R/L

RIG

RIL

RIG

RIL

21

11

I$~ !6~ i$t ---{~~ --- $

R/W

R/Y

R/W

R/Y

....

I
rn

.-I

R/L

R/L

-...
R/L

rnl

~~ ~t~

--- ---~t11

TRANSISTOR

~
7

POWER

R/W

lbjdJ

RIG

lc!Jt ---&~$ --i$~ ---------i$~ ---------i$1

RESISTOR

RIL

I~l

00

RIG
rA"

BR

R/W

UNIT
~

3 J

1J..J..

$- - - (F-4) - - ~---- - ---- ~ -- --- ----~ @Ll

l$~ --- q:~1? - - $ ---------$

AIL
~ R/W
R
No . 1
~I
No .2

I CHECK
i1J CONNECTOR
(E20)

<Fi06)

00

II 3 I

(E43)

---------iciJl
No .3
~

RIG

,
No .4
,JJ....:;!.3.l!..-------.<tW

IGNITION
COIL &
SPARK
PLUG

lhiJ

~. BI/Y t

~~~~eding<&

ll4Jl

1t

1 J

t IJ

t I~

l4J
Wt I~

~J

-- ---1--'-1---1---:
8

SlY _ .

-!

.______

~~
w

~ ([@) ~ <fl@ (flQ)

~ GY GY GY GY
~~

'.!J w

Refer to last page

(Foldout page) .

C::tW

r-----------------~

i~
,

I
I~

GY

&rnJ:
I

GY

JI

h=;::::;::::::;:::;::::;::::;:::::;::::::;=;:::::;:;:::::::;;::::;:::::;:::=:;:::~;::;;:;:::;:;::::;;;;;lCED
L
SEF829P

EC-121

TROUBLE DIAGNOSES
Diagnostic Procedure 26 (Cont'd)

EC-IGN/SG-03

RHO MODELS

Refer to EL-POWER.

RIG

AIGOO

~
R (fITQ)

1 1
5T

' ....

R ~

ACe

I~I

~R@

ON

IWI
' T "

SiR

B/R~

,...,

db
II 1 If

I~J
I

I]
"""""'!:-r.---o,-,!3!:-r;-Jj

R/L~

ECCS
RELAY

AIL @Q)

I$j

B/W

B/R

I------~I

~w

RIB

B/W

B/W

16
55

1:91

1;9\

VB

VB

IB~

~5UI~ COIL RELAY

-II
OFF

IGNITION

SWITCH

IGNITION

ECM

(EGGS
CONTROL

L.

t,

~~~~LE)

~ <E!Ql)
L

(D-

B/Y

-@> Next

page

~~
Refer to last page
(Foldout page} .

(ill
L
SEP830P

EC-122

TROUBLE DIAGNOSES
Diagnostic Procedure 26 (Cont'd)

EC-IGN/SG-04
ECM
(ECCS

IGN

IGN

4=Jl
R/W

IbI=iJ

CONTROL
MODULE)

Cl)

*2

Ii

RIG

R/Y

I I I

r nl

R/W
__
...................

~~:m

......
R

.-

RESISTOR

wJ

RIL

R/Y

RIG

:rtJl

:1" t

m ]
R/L

POWER
TRANSISTOR
UNIT

llf tTrn
l

SR

R/W

RIG

~---m--Q1---------$---------

2
R

R/L

I CHECK
c1J
CONNECTOR

R/L

(FiB)

R/W

Gl

....
= .....
.L

rn

RIG

ffi

~..I!....-~

IGNITION

COIL 0:

SPARK

PLUG

21

1]

lLjJJ

2J

2]

J
~~~~eding~~ :rt i..J--fl-i---fl-l-J--i.!.lL,

!-

!XL@)

[[[gJ

~~

\!J

~ 0=103),

a:::r:gTI)

GY

"@, (J]@, ([106)

GY

GY

GY

r~----------~-----~

:adtw .U):
I

:L

GY

GY

~~
~W

~~~~;;;;::;:;::;:;:;:;:;~~~~~~cm
L
SEF831P

EC-123

TROUBLE DIAGNOSES
Diagnostic Procedure 26 (ContJd)
Harness layout

' " MECI17B

EC-124

TROUBLE DIAGNOSES
Diagnostic Procedure 26 (Cont'd)

INSPECTION START

m
CHECK POWER SUPPLY-I.
1) Disconnect ignition coil harness connectars.
2) Turn ignition switch "ON".
3) Check voltage between terminal @
and ground.
Voltage; Battery voltage
MEF215F

10K

f-+

Go to "CHECK GROUND
CIRCUlT-W' on nexl
page.

NG

Ii)

CHECK POWER SUPPLY-II.

1) Turn ignition switch "OFF".
2) Disconnect ignition coil relay.
3) Check harness continuity between
terminal and terminal @.
Continuity should exist.

NG

f-+

--

Check the following

Harness connectors

@),@

Harness continuity
between ignition coil
and ignition coil relay
If NG, repair harness or
connectors

OK

[!J
NG

r-------

CHECK POWER SUPPLY-III.

1) Turn ignition switch "ON".
2) Check voltage belween terminals
CD, and ground
Voltage: Battery voltage

MEC147B

Check the following.

Harness connectors

@D,@)

Harness connectors

@I),aD

Harness continuity
between ignition coil
relay and ignition
switch
Harness continuity
between ignition coil
relay and ECCS relay
If NG. repair harness or
connectors.

OK

(!]
MEC148B

CHECK GROUND CIRCUIT-I.

1) Turn ignition switch "OFF".
2) Check harness continuity between
terminal @ and engine ground.
Conllnulty should exIst.
OK
CHECK COMPONENT
(Ignition coil relay).
Refer to "Electrical Components
Inspection". (See page EC-206.)

lJ1

Disconnect and reconnect harness connectors in the ci rcui!. Then retest

Trouble is not fixed.
Check ECM pin terminals for damage
or the connection of ECM harness conneelor. Reconnect ECM harness connector and retest.

EC-125

--

~NG

~OK
MEC1498

Repair harness or connectars.

Replace ignili:::==J
relay.

TROUBLE DIAGNOSES
Diagnostic Procedure 26 (Cont'd)
,-------------~~~--_.------.

CHECK GROUND CIRCUIT-II

1) Turn ignition switch 'OFFII 2} Check harness continUity
between terminal and
engine ground.
Continuity should exist.
3) Dlsconnecl power transistor unit harness connector.
4) Check harness continuity
between terminal CD and
I
engine ground
"~
I
Continuity should eXist~

NG

Repair harn-~s=:Jor
connectors
.

~ . _ -

Ii

MEF219F

F
CHECK OUTPUT SIGNAL CIRCUIT
~ 1) Check harness continuity
between terminals CD. CD. ,
CD and terminal @.
Continuity should exiSt.
2) Disconnect ECM harness connector
3) Check harness continuity
between following terminals

-NG

(LHD models)
Harness connectors

@D,@)
(LHD models)
Harness connectors

@-
@-@

@,<lliD

Continuity should exisl.

MEC150B

(tHD models}
Harness continuity
between ignition coil
and power transistor
unit
Harness continuity
between ECM and
power transistor unit
If NG, repair harness or
connectors.

OK

~i5 @3 ~i5
~

crrIT

[ill
CD

NO.1 cylinder

G) No.2 cylinder

---.~

No3 cylinder
No4 cylinder

CHECK COMPONENTS
(Ignition coil and power transistor unit)
Refer to "Electrical Components
Inspeclion" (See pages EC-202.)

CD

MEC 1518

'---

~~ ~NONECl

L.a],.;

~TORI]

ECM
2

11

~io
Cd re:fTI: l~)

Disconnect and reconnect harness conneclors in the circuit Then retest

Trouble

[Q]
[ill

I'.

not fixed.

Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnecl ECM harness conLector and retest

[ill

fS

[ill
MEC1528

EC-126

NG

l-----

---~---

OK

12

@,@
Harness connectors

@.@

III

G)-@
@-@

Check the following.

Harness conneclors

. -

Replace malfunctioning
component{s).

TROUBLE DIAGNOSES
Diagnostic Procedure 26 (Cont'd)
Perform FINAL CHECK by the following procedure after repair
is completed.

FINAL CHECK

--

~---~~-_. ~--- NG

1) Erase the diagnostic test mode II

(Self-diagnostic results) memory.
(Refer to EC-52)
2) PerforlT' test drive.
3) Perform diagnoslic test mode 11
(Sell-diagnostic results) again.
(Refer [0 EC-50)
L-__..

0K

INSPECTION END

__~

\',

'~

Recheck ECM pin terminals tor damage or the

connection of ECM harness connector

L-

.
I

~
~. c'

'[-

II

EC-127

:c

TROUBLE DIAGNOSES
Diagnostic Procedure 27
BOOST PRESSURE SENSOR (Diagnostic trouble code No. 26)

EC-BOOST-01
BOOST
PRESSURE
SENSOR
@
~

LG/R

ill:
<D:
<ED:

rl!~
I~.]

I
I rlw]
! I
I
t

LG/A

00>

*1 ..

~-----.--~--$

--I

LG/R~

(b) G7 , A2

*2, .. <D A11.

*3 .. <D 811,
*4 (b) 812,
*5
B ,
*6 <D BR

LG/A t8:@

A/T models
LHO models
RHO models

82
C2
81
8/R
B

I$t-----i$~-J38 --i$1

LG/R Cf1)

"

! !
I

!~...

B-~----I

351

30
GND

TPRES

ECM

(ECCS

CONTROL
MODULE)

(IT)

EtttfIf1iEj em
W

cm::lli

SENS

, . . . ._.
~

35J

-A

<m~

O~---_. *6 ~ B

i-

A/T

GND

CONTROL
UNIT

___
-

~:@

(QZ)

Refer to last page

GY

(Foldout page) .

(ill
L
SEF839P

EC-128

b.

TROUBLE DIAGNOSES
Diagnostic Procedure 27 (Cont'd)
Harness layout
LHD models

(t

Drive(s dash lower

\~!---

'J

DD~;RH' ~

MEC10BB

EC-129

,
I

TROUBLE DIAGNOSES
Diagnostic Procedure 27 (Cont'd)
INSPECTION START

~
NG

CHECK POWER SUPPLY

1) Disconnect boost pressure sensor
harness connector
2) Turn ignition switch "ON'.
3) Check voltage between terminal @
and ground.
Voltage: Approximately 5V
OK

MEC1538 I

.@D
Harness connectors

@:D.@@
Harness conllnuity
between ECM and
boost pressure sensor
It NG. repair harness or
connectors.

Ii]
CHECK GROUND CIRCUIT.
1) Turn ignition switch "OFF".
2) Loosen and retighten ground screws.
3) Check harness continuity between
terminal @ and engine ground.
Continuity should exist.

-NG

ECM

IJ'CONNECTORI!

35

QD,@

(AfT models)
Harness continuity
between ECM and
boost pressure sensor
Harness continuity
between AfT control
unit and boost pressure
sensor
If NG, repair harness or
connectors.

[!]
CHECK INPUT SIGNAL CIRCLIIT.
1) Disconnect ECM harness connector.
2) Check harness continuity between
ECM terminal @ and terminal @.
Conl!nulty should exist.

NG

f----+

@,@)

@,

'-------

~OK

Disconnect and reconnect harness c : j

nectars in the circuit. Then retesl
Trouble is fixed.
Check ECM pin terminals for damage
or the connection of ECM harness connector Reconnect ECM harness connector and retest.

EC-130

Cill.D

Harness continuity
between ECM and
boost pressure sensor
II NG, repair harness or
connectors.

OK

CHECK COMPONENT
(Boost pressure sensor].
Refer to "Electrical Components
Inspection" (See page EC-206.)

Check the tollowing.

Harness connectors
Harness connectors

MEC1558

r::

@,@D

Harness connectors

@,<illD

MEC1548

[L

Check the following

Harness connectors

Harness connectors

OK

~io'~ ~io

Check the following.

Harness connectors

Replace boost pressure

sensor

Diagnostic Procedure 27 (Cont'd)

Perform FINAL CHECK by the following procedure after repair

is completed.
FINAL CHECK

T
1) Erase the diagnostic test mode II
(Self-diagnostic results) memory
(Refer to EC-52 )

NG

Recheck ECM pin lermi"

nafs for damage or the
connection of ECM harness connector

2) Perform test drive

3) Perform diagnostic lest mode II
(Self~diagnostic results) again.

(Refer 10 EC-5D.)

___JO-K-----.----,
L_-_-_I~N_S_PE_C_T_I_~_N_E_N_D

_ _ -----..J

EC-131

_ _ _ _ _ _ _ _ _ _~ = = = = ~ ~

__l

TROUBLE DIAGNOSES

Diagnostic Procedure 28
KNOCK SENSOR (Diagnostic trouble code No. 34)

EC-KS-01

EGM
(EGGS

CONTROL
MODULE)

CEJ)

KNK
23]
W

f .
- - - - - -..
I

I
I

I
I
I
I

I
I
I
I
I,:" . _. . .

~
lr'2l-'-j-' <till)

f .1 -...

I
I
I
I
I

I
I
I

'.::

KNOCK
SENSOR
<E@

ELl~
@GY

em
L
SEF636P

EC 132
w

TROUBLE DIAGNOSES
Diagnostic Procedure 28 (Cont'd)
Harness layout

Hj1

~gine

~-~

ground

--7'/;C1~

'@. @) ~~
I

f1

'i-

MEC1118

I~I

EC-133

TROUBLE DIAGNOSES
Diagnostic Procedure 28 (Cont'd)

~io~~i5

D ~ CONNECTOR II

INSPECTION START

~-

CHECK INPUT SIGNAL CIRCUIT

1) Disconnect ECM harness connec1or
and harness conneclors @, @)

23

"
NG
-----.j.. Repair harness or connectors

2) Check harness continUily belween

terminal @ and ECM 1ermlnal @
Continuity should exist.
MEC1568

!OK
Loosen and retighten ground screws.
!

CHECK COMPONENT

Replace knock sensor.

(Knock sensor).
Refer to "Electrical Components
Inspection" (See page EC-205)
!OK
Disconnect and reconnect harness connectors in the circuil. Then retest.
! Trouble is fl~ed
Check ECM pin terminals for damage
or the connection of ECM harness connector. Reconnect ECM harness connector and retesl.

Perform FINAL CHECK by the following procedure after repair

is completed.
FINAL CHECK

---~

1) Erase the diagnostic test mode II

(Self-diagnostic results) memory.

(Refer to EC-52.)
2) Perform lest drive
3) Perform diagnostic lest mode II
(Self-diagnostic results) again
(Refer to EC-50.)

--

0K

INSPECTION END

EC-134

NG

Recheck ECM pin terminals for damage or the

connection 01 ECM harness connector

TROUBLE DIAGNOSES
Diagnostic Procedure 29
THROTTLE POSITION SENSOR (Diagnostic trouble code No. 43)

EC-TPS-01
THROTTLE

POSITION
SENSOR

@:

L.,,--\--r.-~h---,,--,!:-r.-J ~
W

<D:

*1-(D BR ,

f :;

I
I

tI
I
I
I

AlT models
LHO models
RHO models

I
I

l~

I
I
I

O-:X:-----

I
I
I
I
I
I
I
I

I
I
I

I
I
I
I
I

f
I
I
I
I
I

~ wr-I-~----I
B

i,1

13~1

SENS
GND

ECM
(ECCS
CONTROL
MODULE)
(ill

AlT

CONTROL
UNIT
~:

~_m

@TI) BR

t.l.

ern
L
SEF835 P

EC-135

"rROUBLE DIAGNOSES
Diagnostic Procedure 29 (Coot'd)
Harness layout
LHD models
Driver's dash lower

~/DO"Rj~

MEC108B

~ Throttle

/~~
sensor~~,

position
h~rne.s,s connector

~glne

~ ~ ~,XECi26B

"

Throttle position sensor

harness connector

\~~\\

~-~

ground

-7'/,-C1r"'\

~. f1 ~~
-;:..
@

MEC111B

EC-136
!II

TROUBLE DIAGNOSES
Diagnostic Procedure 29 (Cont'd)

~~~~J_N_S_P_[~TSTART

~I

,-------- - - - - - NG
~ Repair h. arness
CHECK POWER SUPPLY
1) Disconnect throttle position sensor
nectars
harness connector.
2) Turn ignition switch' ON".
3) Check voltage between terminal @
and ground.
Vollage: Approximately 5V

0..

con-~I

MEF513E

OK

I;]

._-----~------

!CHECK GROUND CIRCUIT

1) Turn ignition switch "OFF".
2) Loosen and retighten ground screws
3) Check harness continuity between
terminal @ and engine ground.
Continuity snould exis!.

OK

MEF514E

c-----------------

THROnLE SENSOR CKT

Check the folJowing

Harness connectors

@,@
(A/T models)
Harness continuity
between ECM and
throttle position sensor
Harness continuity
between AIT control
unit and throttle position sensor
II NG. repair harness or
connectors

'------

DEPRESS
CHECK INPUT SIGNAL CIRCUIT
1) Reconnect throttle position
~
sensor harness connector.
2) Turn ignition switch "ON".
3) Perform "THROTTLE SENSOR
CKT" or "THROTTLE POSI
SEN CKT" In TUNCTION
TEST" mode with CONSULT.

THROTILE FULLY
THEN
TOUCH START

NFXT
L-~~

I@]

---,S::...;T---,A-,,--R,-,-T_

,--I

MEF634l
_

~_~~

THROTTLE SEN ADJ

*. * ADJ

MONITOR

THROTTLE SEN

IDLE POSITION

L-

O.45V

===::==== MONITOR ::=::==::==

CASRPM (REF)

~--~---OR

Approx.4.0V

~l
MEC157S!

"THRTL POS SEN" signal in

'WORK SUPPORT" mode with
CONSULT.
Throllle valve fully closed:
0.35 - O.65V
ThroUle valve lully open:

f------~--OR

Orpm
ON

3) Read "THROTTLE SEN' or

---------1

1) Disconnect ECM harness con-

nectar.
2) Check harness conlinuity
between ECM terminal @
and terminal @.
Continuity should exist.

r ..'

,1' ,

'~'L

MEC158B

EC-137

TROUBLE DIAGNOSES
Diagnostic Procedure 29 (Cont'd)

CHECK COMPONENT
(Throttle position sensor)
Refer 10 "Electrical Components
lnspection". (See page EC-204.)

Replace throttle posItion

..
sensor.

~OK
Disconnect and reconnect harness connectors in the circuit Then retest

~ Trouble is not fixed

Check ECM pin terminals for damage
or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

Perform FINAL CHECK by the following procedure after repair

Is completed.
FINAL CHECK

r----------

L ___

1) Erase the diagnostic test mode II

(Refer to EC-52)
2) Perform lest drive.

nals tor damage or the

ness connector.

(Self-diagnostic results) again.

(Refer to EC-50.)

EC-138

Recheck ECM pin termiconnection of ECM har-

3) Perform diagnostic fesf mode II

INSPECTION END

NG

f---+

[Self-diagnostic results) memory

TROUBLE DIAGNOSES
Diagnostic Procedure 30
AIT CONTROL (Diagnostic trouble code No. 54)

EC-AT/C-01

ECM
(ECCS

CONTROL
MODULE)

Oli

DT2

DT3

l!:iJl

~J

L/G

L/W

em

.-

L/R

I
L/G

CEZ)

L/W

L/R

L/G

L/W

L/R

$ -------$ -------QJI

@:

A/T models

L/G

L/W

10
DTt

11
DT2

LlR

rf2ll
DT3

A/T
CONTROL

UNIT

@:

-r
;

T-"',

r- i,

em
L
SEF839P

EC-139

TROUBLE DIAGNOSES
Diagnostic Procedure 30 (Cont'd)
Harness layout

,
'f

lHD models
Driver's dash lower

EC-140

TROUBLE DIAGNOSES
Diagnostic Procedure 30 {Cont'd}

------ ----------~

INSPECTION START

-~

CHECK INPUT SIGNAL CIRCUIT

1) Disconnect ECM harness connector
and AfT control unit harness connec-

NG

f---

0, @ill
Harness continuity
between ECM and AfT
control unit
II NG, repair harnes S or

tor,
2) Check harnesS continuity between

ECM terminal and terminal @J,

EeM terminal (4) and terminal !1}),

MEF2<llF

Check the following

Harness connecto rs

connectors

ECM terminal @ and terminal @

III

Continuity should exist.

~OK
Disconnect and reconnect harness con-

nectors in the circuit Then retest

. ~ble is -;'ot fixed,
Check ECM pin lerminals for damage
or the connection of ECM harneSS connector. Reconnect ECM harness connector and reteSt.

L---

--"

Perform FINAL CHECK by the folloWing procedure after repair

is com leled.

1) Erase the diagnostic test mode II

NG

(Self-diagnostic results) memory

(Refer to EC-52,l
2) Perform test drive
3) Perform diagnostic test mode II

(Self-diagnostic resultsl again

(Refer to EC-50)
OK

-I-N-S-P-E-C-T-'O-N-EN-D-------lJ

EC-141

Recheck ECM pin terminals for damage or tlie

connection of ECM halness connector

TROUBLE DIAGNOSES
Diagnostic Procedure 31
START SIGNAL (Nol self-diagnostic item)

EC-S/SIG-01

Refer to EL-POWER.

OR/L

OAIL Q1@

OAIL (ill

ORIL

43
5T

5W

ECM
(ECCS

CONTROL

MODULE)

em

Refer to last page

(Foldout page) .

em
L
SEF844P

EC-142
(II

Diagnostic Procedure 31 (Cont'd)

Harness layout

"-,,

INSPECTION START
START SIGNAL CKTI

1 CLOSE THROTILE. SHIFT

TO P OR N RANG~

2 TOUCH START AND

START ENGINE
IMMEDIATELY

CHECK OVERALL FUNCTION

1) Turn ignition switch "ON".

00

A:....:.:RT~

L-....:NE:..-XT-----.JI 1L----,,5:-.:...:T

MEF4B1B

00

r---------.---",MONITOR

",NO FAIL

START SIGNAL
IDLE POSITION
AIR eOND SIG
NEUTRf\.L

~-

INSPECTION END

2) Perform "START SIGNAL

CKT" in "FUNCTION TEST"
mode with CONSULT.
OR
2) Check "STft.RT SIGNAL" in
"DATA MONITOR" mode with
CONSULT.

OFF
ON
OFF
ON

sw

IGN "ON'"
IGN "STAAT"'

OFF
ON

OR

@
[

II

ECM

RECORD

C.ONNECTOR I]

"START".

2) Check voltage between ECM

terminal @ and ground.
SEF3B4J

1) Turn ignition switch to

is

43

Voltage:
Ignilion switch "START"
Ballery voltage
Except above
Approximately OV

NG
'-~--K+

_.)1....--.....

[Zheck if 7.5A fuse is

OK~._~Place

~OK
(!>

MEF473D

EC-143

7.5A fuse.

'

TROUBLE DIAGNOSES
Diagnostic Procedure 31 (CooI'd)
(A)

~i~)

=EC=M~]O[CONNECTORI]

ic"11

L_

~i5
7,SA

[Z)

43

----

CHECK INPUT SIGNAL. CIRCUIT

1) Turn ignition switch "OFF".

Harness connectors

2) Disconnect ECM harness connector

and 7.5A fuse

Harness continuity

Check the 10110wing.

3) Check harness continuity between

MEC1S9B

ECM terminal @ and fuse block

Continuity should exist.

em,@
between ECM and fuse
block
If NG, repair harness or
connectors

0K

Disconnect and reconnect harness connectors in the circuit. Then retest

Trouble is not fixed .

..

_-

Check ECM pin terminals for damage

or the connection 01 ECM harness connector. Reconnect ECM harness connector and retest.

EC-144

TROUBLE DIAGNOSES

Diagnostic Procedure 32
VEHICLE SPEED SENSOR (Not self-diagnostic item)

I!

EC-VSS-01
Refer to EL-PDWER.

I
COMBINATION
METER
(SPEEDOMETER)
~

VSP

ECM
(EGGS
CONTROL
MODULE)
(ill

[ ,~f

I', [

r---------------------------,

i~~l
~i
2B

:
I

IL

2122

29

35

~oo
tttij GY

o~~

Refer to last page

(Foldout page} .

GY

em

~~~~~;;;:;:~~~~~~

L
SEFB37P

EC-145

Ii

TROUBLE DIAGNOSES
Diagnostic Procedure 32 (Cont'd)
Harness layout

lJ~--;J

~n/combination
~

meter
harness connector
MEC1228

EC-146
fsr

Diagnostic Procedure 32 (Cont'd)

INSPECTION START
r.AR SPEED SE'J CIRCUIT.

AFTER TOUCH START,

DRIVE VEHICLE
AT 10 kmih (6 mph) OR
MORE WITHIN 15 sec

CHECK OVERALL FUNCTION.

1) Jack up drive wheels

M
\J.!I)

NEXT

II

STA~
SEF631L

'" MONITOR

NO FAIL

CAR SPEED SEN

INSPECTION END_J

~---~-----

2) Perform "CAR SPEED SEN

CIRCUIT" or "VEHICLE
SPEED SEN CKT" in "FUNCTION TEST'" mode with CONSULT.
f-------OR---------j
2) Read "CAR SPEED SEN' or
"VHCL SPEED SE" signal in
"DATA MONITOR" mode with

Om ph

CONSULT,
CONSULT value should be the
same as the speedometer
Indication.
I-------OR---------j

RECORD.=:=J

2) Disconnect ECM harness con-

nector.
SEF587\

~iotea{ZJ

=E=CM~HCONNECTOR II

3) Turn ignition switch "ON".

Ml

4) Rotate drive wheel by hand.

5) Check voltage between ECM

terminal @ and body ground.

Voltage should vary belween

r;=!1

approx. 0 to 5V.

53

~NG
Check vehicle speed sensor and circuit.
(ReIer to EL section.)

CHECK SPEEDOMETER FUNCTION

Make sure that speedometer functions
properly,
MEC160B

~io@3~i5

'.

\I~"\

=EC=M==::':E CONNECTOR I]

1-;=1

53

CHECK INPUT SIGNAL CIRCUIT.

1) Turn ignition switch "OFF'.
2) Disconnect ECM harness connector
and combination meter harness connector.
3) Check harness continUity between
ECM terminal @ and terminal @.
Continuity should exist.

NG

---..

Check the following

Harness connectors

,@
Harness continuity
between ECM and combination meter
If NG, repair harness or
connectors.

-MEC161B

Disconnect and reconnecl harness connectors in the circuit. Then retest.

~ Trouble is not fixed.

Check ECM pin terminals lor damage
or the connection of ECM harness connector Reconnect ECM harness connector and retest.

EC-147

TROUBLE DIAGNOSES

Diagnostic Procedure 33
EGR AND CANISTER CONTROL (Not self-diagnostic item)

EC-EGRC/V-01
Refer to
EL-POWER.

SR

i:t1
1

EGA CANISTER
CONTROL
SOLENOID
VALVE
~

L/R~

l<@
L/R

~<EW

~(ffiQ)
l/R

I
~O~

: LHO models
: RHO mode Is

<A>:

AlT models
MIT models

1 ... (b) E2,

*2, .. <0 G1.

*3

.. <D BIR ,

I
~O~

L/R ~
L/R ~
L/R ~ ~
J
L/R CE)
L/A eEl)
I
kH>-o~
L/R

H7
H4

BR

~O~
I

L/R
102

EGR

ECM
(ECCS
CONTROL
MODULE)

em

Chi

I CEID
w

Refer to last page

(Foldout page) .

SEFB32P

EC-148

Diagnostic Procedure 33 (Cont'd)

Harness layout

EGA & canister control

solenoid valve
harness connector

'"

"

/'\

INSPECTION 8TART

1
CHECK OVERALL FUNCTION.
1) Start engine and warm it up sufficiently.
2) Perlorm diagnostic test mode If (Selfdiagnostic results).
Make sure that diagnostic trouble
code No. 12 is not displayed.
3) Make sure that EGR valve spring
moves up and down (Use your finger) under the following conditions.
At idle:
Spring does not move.
Racing engine from Idle to 3,000
rpm:
Spring moves up and down.

C~H

-MEF637B

OOCf~H

~tD

CHECK VACUUM SOURCE TO EGR

VALVE.
1) Disconnect vacuum hoses to EGR
valve and activated carbon canister.
2) Make sure thai vacuum exists under
the following conditions.
AI Idle:
Vacuum should nol exist.
Racing engine from Idle to 3,000
rpm:
Vacuum should exist

tNG

EC-149

INSPECTION END

1?1l]

'--------------"

OK

f-----

CHECK COMPONENTS
(EGR valve. EGRC-BPT
valve and activated carbon canister}.
Refer to "Electrical Componen1s Inspeclion".
(See pages EC-203. 210.)

1
Replace malfunctioning
component(s).

TROUBLE DIAGNOSES
Diagnostic Procedure 33 (Cont'd)

CHECK CONTROL FUNCTION

1) Check voltage between ECM termInal

OK

I----

@and ground under the following

conditions
Voltage:

CHECK VACUUM HOSE.

1) Check vacuum hose
lor clogging, cracks
and proper connection

Al Idle
Approximately OV
EngIne speed Is 2,000 rpm
Battery voltage

[!]

II

ECM~

CONNECTORI]

~~

"EJ

102

NG

iii
CHECK POWER SUPPLY.
1) Stop engine.
2) Disconnect EGA & canister control
sotenoid valve harness connector.

NG

f--"-

@D,@
Harness connectors

@D,(ill!)

3) Turn ignition switch "ON".

4) Check voltage between terminal (ii)

.10Aluse

and ground

MEF4350

Harness continuity
between EGR & canister control solenoid
valve and fuse
If NG, repair harness or

Voltage: Battery voltage

~.
C".,
Clogging

OK

__

Ii~\

~_

Improper connection
SEF816F

Check the following.

Harness connectors

connectors.

Ii
CHECK OUTPUT SIGNAL CIRCUIT
1) Turn ignition switch "OFF".
2) Disconnect ECM harness connector.
3) Check harness continuity belween
ECM terminal @D and terminal .
Conllnully should exist.
OK

NG

Check the followi ng.

Harness connectors

@,@)
Harness connectors

@D,@
Harness connectors

@),QD
(RHO models)
Harness connectors

@,@
(LHD AIT models)
Harness connectors

@,QD
(LHD MIT models)
Harness continuity
between ECM and EGR
& canister control solenoid valve

MEC1638

" NG,

~io~~i5

;;===E=C=M=='~

102

EC-150
(fl

"'3;' h"o"" no

connectors

TROUBLE DIAGNOSES
Diagnostic Procedure 33 (Cont'd)
EGR CONT SiV

C1RC~IT

l.

DOES THE SOLENOID

VALVE MAKE

AN OPERATING SOUND
EVERY 3 SECONDS)

~::.:,-c==~:::==~==~

[N?YJ[iillJi

YES

MEF5698

ACTIVE TEST.

EGR CONT SOL/V

==

MONITOR
CAS RPM (REF)

0
OFF

===

----

l~'G

CHECK COMPONENT
(EGR & canister control solenoid valve).
(~) 1) Reconnect EGR & canister
~
control solenoid valve harness connector and ECM harness connector.
2) Turn ignition switch "ON".
3) Perform "EGR CONT SIV
CIRCUIT'" or "EGRC SOLIV
CIRCUIT" in "FUNCTION
TEST" mode with CONSULT.
} - - - - - - - - OR ----------1
~ 3) Turn EGR & canister control
~
solenoid valve "ON" and
"OFF" in "ACTIVE TEST"
mode with CONSULT and
check operating sound.

1---------0R----------1

tV\

Orpm

Refer to "Electrical Components

Inspection". (See page EC-203)
OK

SEf222N

Disconnect and reconnect harness connectors in the circui' Then retest.

Trouble is not fixed.
Check ECM pin terminals for damage
or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

EC-151

-.----

"-~-l

Replace EGR & canister

control solenoid valve

TROUBLE DIAGNOSES
Diagnostic Procedure 34
HEATED OXYGEN SENSOR (Not self-diagnostic item)

EC-H02S-01

Refer to EL-POWER.

SR

SR <S2ID

$8R@

8R

1
HEATED
OXYGEN
SENSOR

2J
w

(F25)

I T1
I !l t

I j1S1

29

02H

02S

ECM
(ECCS
CONTROL
MODULE)

em

I
8

t,

<QZ)

Refer to last page

(Foldout page) .

rr.;;;~~;.:::;;;;:;:;;rr:;:r;:;:;.:;;::::;::;::;:;;;~~~~:;;:;~~~;;;:;:::rn:;:;~~;::;;:~~;-,
L
SEF83JP

EC-152
[II

TROUBLE DIAGNOSES
Diagnostic Procedure 34 (Cont'd)
Harness layout

II

I'

f~

ret
!i!il'J
.~

irf

J:'I2l

ji

I:

I:I'
~Ik

fj
j

' r'!,iA\
~rf)~

I!} n1.

'~r(

~~,

tL

EC-153

Diagnostic Procedure 34 (Cont'd)

~-----------------,

MIXTURE RATIO TEST.

ACCELERATE TO 2!XXl
RPM AND HOLD THEN
TOUCH START

2iXXJ

J
SEF815L

'ClMONITOR

200Jrpm

RICH

RECORD

]
SEF61BK

CHECK POWER SUPPLY

1) Stop engine.
2) Disconnect heated oxygen sensor
harness connector.
3) Turn ignition switch "ON".
4} Check voltage between terminal @
and ground.
Voltage: Battery voltage

Malfunction indicator
lamp
MEC219B

CHECK OUTPUT SIGNAL CIRCUIT.

1} Turn ignition switch "OFF".
2) Disconnect ECM harness connector.
3) Check harness continuity between
terminal and ECM terminal (ill).
Continuity should exist.

"-----1(,+

~D
___

SENSOR~KK~

INSPECTION END

]
~_

\!V

'ClNO FAIL

CAS RPM (REF)

M/R FIC MNT

r-

1) Start engine and warm it up sufficiently.

~ 2) Perform "MIXTURE RATIO
~
TEST" in "FUNCTION TEST"
mode with CONSULT.
f-------OR--------!
@
2) Make sure that "M/R FIC
MNT" in "DATA MONITOR"
mode indicates "RICH" and
"LEAN" periodically more
than 5 times during 10 sec
onds af 2,000 rpm.
f - - - - - - - OR - - - - - - - - 1
i~ 2) Run engine at about 2.000
~
rpm lor about 2 minutes under
no-load.
3) Set ECM Diagnostic Test
Mode II.
4) Keep engine speed al 2,000
rpm and make sure thaI the
malfunction indicator lamp on
the instrument panel goes on
and off more than 5 times during 10 seconds.

2200

START

IIIL

NEXT

INSPECTION START

CHECK HEATED OXYGEN

CIRCUIT

IJ

10CX)

~ Check the following.

Harness connectors

.OOD
lOA fuse
Harness confinuity
between heated oxygen
sensor and fuse
If NG. repair harness or
connectors.

NG

r------------Repair harness or connectors.

.OK
SEF327J

I Q ..'l,,"-_...J
- -

MEC165B

----'

EC-154

TROUBLE DIAGNOSES
Diagnostic Procedure 34 (Cont'd)

NG
Repair harness or conCHECK INPUT SIGNAL CIRCUIT
~
nectars
\) Loosen and retighten ground screws.
-2) Check harness continuity between
ECM terminal @ and terminal @.
ContInuity should exist.

0K

MEF4470

Disconnect and reconnect harneSs

nectars in (he circuit Then relest

COI1-

. ~ Trouble is not lixed.

Check ECM pin terminals for damage
or the connection of ECM harness connector. Reconnect ECM harness connector and retest
Trouble is not fixed.
Replace heated oxygen sensor.

EC-155

---

TROUBLE DIAGNOSES

Diagnostic Procedure 35
INJECTOR CIRCUIT (No' self-diagnostic item)

EC-INJECT-01

Refer to EL-POWER.

:
:

LHO models
RHO models

*1 .(b) BIR ,

ST

<B>

RIL

IGNITION
SWITCH

lEW

ON

3J
BIR

l[illJl lillD
~Q3JQ)
~H

1$l lMW
W)
*1
~o:gz)

l[JJllflW
R

.I - - - .I
R

~ NO.3
INJECTOR

rn

rn

1 j

W/B

INJECTOR
NO.1
(ffiID
~

~I No.2

INJECTOR

Y/B

GIB

LIB

V/B

GIB

LIB

10
INJ

103

INJ

11~ I

INJECTOR
NO.4
~

~--&n--i~~-------i~~-------i~
W/B
10

~I

INJ
#1

#2

#3

INJ
#4

ECM

(ECCS

CONTROL
MOOULE)

em
r-------I

~ ~ ~ ~

: f1i3fl ~ : <0 F3FITl run :

mJ W
CIIJ W
I

,
I

:
I
I

([ill) ([ill) ~ (ffi)

(!@B'B'S'B

to last page
(Fa ldaut page) .

Refe~

~------------------------~

~m

~GY

CfI)
L
SEF834P

EC-156

TROUBLE DIAGNOSES
Diagnostic Procedure 35 (Cont'd)
Harness layout

PI

.ACTIVE TEST.

POWER BALANCE ....

=MONITOR
BOOr pm
CAS.RPM IREF)
098V
AIR FLOW MTR
41%
AAC VALVE

==

= =

- _ . INSPECTION START

CHECK OVERALL FUNCTiON.

CONSULT
3) Make sure that each circuit

produces a momentary engine

MEF587BA
r,~

/~~

r'
r--L

10K

1) Start engine.
(~) 2) Perform "POWER BALANCE'

in .. ACTIVE TEST'" mode with

.[2J0[4:r~~l
DOOD

eli, k

r"

"r/r

',-

I~

speed drop.
OR - - - - - - - - - 1
2) listen to each inlector operating sound
Clicking noise could be heard.

~NG

..-

II
SEF730L

EC-157

.,

1
INSPECTION END

1,
---------.J

TROUBLE DIAGNOSES
Diagnostic Procedure 35 (Cont'd)
@

III

NG

CHECK POWER SUPPLY

1) Stop engine
2) Disconnect harness connectors

@,@D

@),

CillD

Harness connectors

@,(]ill

3) Turn ignition switch "ON'

4) Check voltage between terminal

Ie

Harness Connectors

@,@D
Harness continuity
between ignition switch

OK

~18ecea ~16
ECM

and ground.
Vollage: Batlery voltage

MEC166B

Check the following

Harness connectors

and harness connector

@)
If NG, repair harness or

B CONNECTOR I]

connectors.

110101112103

[!]
NG
~

CHECK OUTPUT SIGNAL CIRCUIT

1) Turn ignition switch "OFF".

@,(@)

2) Disconnect ECM harness connector

3) Check harness continuity between
ECM terminal @and terminal @,
ECM terminal @and terminal

EeM terminal @and terminal

EeM terminal @and terminal

Check the following.

Harness connectors
Harness continuity
between ECM and harness connector

If NG, repair harness or

connectors.

Continuity should exist.

OK

@DNo.1 cylinder @:No.3cylinder

@ NO.2 cylinder @}No.4 cylinder

CHECK COMPONENT
(Injector).

Replace injeclor.

Refer to "Electrical Components

Inspection". (See page EC-205.)

MEC167B

OK
Disconnect and reconnect harness connectors in the circuit. Then retest
Trouble is not fixed
Check ECM pin terminals for damage
or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

EC~158

Diagnostic Procedure 36
FUEL PUMP (Not self-diagnostic item)

EC-F/PU~P-01

Refer to EL-POWEA.

:
:
(b):

*2

"
II :~Fua

*4
*5" .

n PUMP

IJ RELAY

1*.21

*3

B/Y

CHID
@l)~

e/y

@@

e/y

B/Y--.

*.5

<I> 1,

<C> B/P ,

e/y
3
SlY

elY

l
a/v

Pia

1I 6 II
'T'

PIS

1..

o..g;.

<D 2.

*3 @

B/W B/W

rn

'.

i ~'. "
~.

LHD mode 1s
RHO models

:
*101, (8)2

B/W

For Europe
Except for Europe

JOINT
CONNECTOR

elY

~
B

,---~O

FUEL
PUMP

(fiO)

rfsn
FPR

ECM

(ECCS

CONTROL

MODULE)

em

~Q]])
~ w

Refer to last page

(Foldout page) .

~~:;:;::;::;:;:;;::;;::;:;::;:;:;;::;:::;::::::;::::;:;::::~:;::;;::;;:;~;l

em
L
SEF845P

EC-159

'..

,,

*5 ~

$*5

TROUBLE DIAGNOSES
Diagnostic Procedure 36 (Cont'd)
Harness layout

MEC127B

'"

TROUBLE DIAGNOSES
Diagnostic Procedure 36 (Cont;d)

L __

I_NSPECTION

a.

~HECK

~~ART

'J

~SPECTION END . ~
~

OVERALL FU-N-C-T-IO-N-

OK

1) Turn ignition switch "ON'

2) Listen to fuel pump operating sound

Fuel pump should operate for 1 second alter ignition switch is turned
"ON".

ING

SEF9801

CHECK POWER SUPPLY.

Check the following

1) Turn ignition switch "OFF".

15A fuse
Harness conti nuity

2) Disconnect fuel pump relay.

3) Turn ignition switch "ON".

between fuel pump

4) Check voltage between terminals

relay and 1use

(i), @ (LHD models],

(~,

@ (RHO

if NG, repai r harness or

models) and ground

CD0

connectors.

Voltage; Battery vollage

LHD models

@G) RHO models

OK

MEC168B

WDI'SCOO~

..

~HECK GROUND CIRCUIT.

l..a1v~

NG

I----

1) Turn Ignition switch "OFF"

GID

@}D,ill)

2) Disconnect fuel pump harness can-

Harness connect ors

nectar.

13J

@,GD

Check harness continuity between

terminal

Harness conti nu; ty

between tuel pu mp and

and body ground, fermi-

nal and terminal @.

Continuity should exist.

Check the followin 9

Harness connect ors

fuel pump relay

Harness continul ty
between fuel pu mp and

OK
MEC1698I

body ground

!1

r:

~io ~~io
ECM

R'WNNECTOR]
18

LitmJ

It NG, repair harne ss or

connectors.

l!1
NG

CHECK OUTPUT SIGNAL CIRCUIT

1) Disconnect ECM harness connector

2) Check harness continuity between

(LHD models),

CD

RHO models

0)

(RHO models)

Continuity should exis!.

--

MEC1708

OK

----

Check the followin 9

Harness connect ors

(ill, @)
Joint connector @
(Models for Euro pel

ECM terminal @ and terminal I])

@ LHD models

.~

Harness conti nUl ty

between ECM an d fuel
pump relay
If NG, repair harne ss or
connectors

' - - - - - - - - - - _..

,"

EL

EC-161

-rROUBLE DIAGNOSES
Diagnostic Procedure 36 (Confd)

FUEL PUMP CIRCUIT.

PINCH FUEL FEED HOSE
WITH FINGERS. IS THERE
ANY PRESSURE
PULSATION ON THE FVEL

CHECK COMPONENT
(Fuel pump relay)
1) Reconnect fuel pump relay,

FEED HOSE?

OR
DOES THE FUEL PUMP
RELAY MAKE AN
OPERATING SOUND
_~VERY 3 SECONDS?

NEXT

If

NO

~)

11ill]
SEF194L
I

ACTIVE TEST.
FUEL PUMP RELAY

ON

= = =

MONITOR
CASRPM (REFJ

-~
_ION/OFF

Replace fuel pump relay.

Replace fuel pump.

fuel pump harness connector

and ECM harness connector.
2) Turn ignition switch "ON".
3) Perform "FUEL PUMP
CIRCUIT" in "FUNCTION
TEST" mode with CONSULT.
OR
3) Turn fuel pump relay "ON"
and "OFF" in "ACTIVE TEST"
mode with CONSULT and
check operating sound.

==
Orpm

![QF]

OR
Refer to "Electrical Components
Inspection". (See page EC-206.)

~OK

SEF49Bl

CHECK COMPONENT
(Fuel pump).
Refer to "Electrical Components
Inspection". (See page EC-202.)

~OK
Disconnect and reconnect harness connectars in the circuit. Then retest.

~ Trouble is not fixed.

Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness connector and retest.
'--------

EC-162

TROUBLE DIAGNOSES

Diagnostic Procedure 37
WASTEGATE VALVE CONTROL (Not self-diagnostic item)

EC-WG/V-01
Refer to EL-POWER.

SR

ti
SR

[~JI ~

'=r' ~
SA

SR

/~j lMQQ)

LHO mode Is
RHO models

'"T" @
SR

=-2
,= c:.

*~
I

SR

I~
2

DRIB

WASTEGATESOLENOID
VALVE
CONTROL
VALVE
<D:@
: flL)

O~

J>
L

~@

<lli?) (fill)
OAIB
DRIB

<p

~ DRIB ~O

OR/B
251

WGC
I

ECM
(ECCS
CONTROL

MODULE)

em

[il2
W
B

(jJ: ~ @: lITZ)

~~
~W

Refer to last page

(Foldout pagel.

@,

(ill
L
SFB41P

EC-163
b

1;'

TROUBLE DIAGNOSES
Diagnostic Procedure 37 (Conl'd)
Harness layout

INSPECTION START

fa

-n-----\ I

. AIr passage hose connected to

wastegate valve control solenoid valve

MEC1718

OK
CHECK OVERALL FUNCTION.
~
1) Start engine and warm it up sufficiently.
2) Perform diagnostic test mode II (Selfdiagnostic results). Make sure that
diagnostic trouble code No. 55 is displayed
3) Stop engine .
4) Disconnect air passage hose to
wastegate valve control solenoid
valve and restarl engine.
5) Make sure that boost pressure exists
under the following conditions
At idle:
Boost pressure should nol exist
Engine is racing quickly
(Up to aboul 5,000 rpm).
Boost pressure should exist

CHECK COMPONENT
(Wastegate valve actuator).
Refer to "TURBOCHARGER" in EM section.
If NG, replace wastegate
valve actuator
OK

INSPECTION END

tNG

EC-164
(e,

TROUBLE DIAGNOSES
Diagnostic Procedure 37 (Cont'd)

.-------------~.--------------- OK
~

....

Check air passage hose

for clogging, cracks and
proper connection

MEC172B

~.
Crack

NG

CHECK POWER SUPPLY.

1) Stop engine.
2) Disconnect wastegate valve control
solenoid valve harness connector.
3) Turn ignition switch "ON".
4) Check voltage between terminal
and ground.
Voltage; Battery voltage

Clogging

D
.

'"
"'"

Improper connection
SEF816F

Check the following

Harness connectors

@D,@)
(LHD models)
Harness connectors
~,QD
(RHD models)
10A fuse
Harness continuity
between waste gate
valve conlrol solenoid
valve and fuse
If NG, repair harness or
connectors.

OK

Ii1

r---~~~-_--L-_~~~---

NG

CHECK OUTPUT SIGNAL CIRCUIT

1) Turn ignition switch "OFF".
2) Disconnect ECM harness connector
3) Check harness continuity between
ECM terminal @l and terminal
Continuity should exist.

I---

@ID,@D

(LHD models)
Harness connectors

~,QD

(LHD models)
Harness continuity
between EeM and
wastegate valve conlrol
solenoid valve
If NG, repair harness or
connectors.

OK

~i5~~i5

U::C=C=====E==C==M~~ONNECTORJI

Check the following

Harness connectors

25
r-------~-------~NG

MEC174B

CHECK COMPONENT
(Wastegate valve control solenoid
valve)
Refer to "Electrical Components
Inspection". (See page EC-205)

-----..-

Replace wastegate valvel

control solenoid valve.
I

OK

Disconnect and reconnect harness conneclors in Ihe circuit Then relest.

Trouble is nol fixed.
Check ECM pin terminals for damage
or the connection of EeM harness connector. Reconnect ECM harness connector and retest.

EC-165

Dr

Fl.

TROUBLE DIAGNOSES
Diagnostic Procedure 38
VALVE TIMING CONTROL (Not self-diagnostic item)

EC-VTC-01

Refer to EL-POWER.

SR

SR Q3Q)

tOJ <ru
SA

SR

~
I

VTC

SOLENOID
VALVE

l4=Jl (F31)
y

113
VTC

Refer to last page

(Foldout page) .

....-'T'::::L~

4..1J.gp

ECM
(ECCS
CONTROL
MODULE)
(IT)

ern
L
SEF642P

EC-166
If)

Diagnostic Procedure 38 (Cont'd)

Harness layout

,
I.--~~-/

!~
/

Door RH)::::::=:::'::::
MEC108B

r-~._--,--.---~----!
INSPECTION START

MEF495D

~i5

=E=CM~SCONNECTOR II

\"f=(

113

00

CHECK CONTROL FUNCTION

1) Jack up drive whe~ls.
2) Start engine.
3) Shift gear to any position except the
neutral position (MIT modell.
Shift selector lever to any position
except' 'N" or "P" position (A/T
model).
4) Check voltage between ECM terminal
(ill) and ground under the !ollowing
conditions.
Voltage:
Quickly depress accelerator
pedal, then quickly release it.
Approximately OV
Al Idle
Battery vollage
<.-.---~----- ------_.---~

lNG

MEF496D

EC-167

CHECK VTC SOLENOID

VALVE OPERATION.
1) Stop engine.
2) Connect a suitable
jumper wire between
ECM terminal @
and body ground
3) Start engine and make
sure that improper idle
condition occurs
If it does nol occur, go to
CHECK COMPONENT
(VTC solenoid valve)

loccurs.

INSPECTION END

TROUBLE DIAGNOSES
Diagnostic Procedure 38 (Cont'd)

1
CHECK POWER SUPPLY
1) Stop engine

Check the following.

Harness connectors

@ill.

2} Disconnect VTC solenoid valve harness connector.

3) Turn ignition switch "ON"
4) Check voltage between terminal

10A fuse
Harness continuity
between VTC solenoid

and ground.
MEC1758

valve and fuse

If NG, repair harness or

Voltage: Battery vollage.

connectors.

~i8~~i5
r===E=C=M==:::':n CONNECTOR

I]@

CHECK INPUT SIGNAL CIRCUIT

1) Turn ignition switch "OFF"

NG
~

Repair harness or connectors.

2] Disconnect ECM harness connector.

113

3J Check harness continu ity between

'erminal and ECM terminal @
Continuity should exist.

MEC1768

NG

r----

VALVE riMING S/V CKT.

DOES THE SOLENOID
VALVE MAKE
AN OPERATING SOUND
EVERY 3 SECONDSl

NEXT

II

I\JO

II

YES

I
SEF711L

ACTIVE TEST.
VALVE TIMING SOL

OFF

========

MONITOR ========
CAS-RPM (POS)
Orpm
16%
AACVALVE

I ON

lioN/OFF

1m.

MEC2118

~OK
Disconnect and reconnect harness connectors in the circuit. Then retest

~ Trouble is not fixed

Check ECM pin terminals for damage
or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

EC-168

'"

Replace VTC solenoid

valve.

TROUBLE DIAGNOSES

Diagnostic Procedure 39
IACV-AAC VALVE (Not self-diag nostie item)

EC-AAC/V-01

Refer to EL-POWER.
S/Y

(b): LHD mode 1s

BIY~

RHO mOde Is

*1- .. (b)

$B/Y <MIQ)

B7,

AU

B/Y@Q)

$
B/y(B)

',fr

S/Y

lACV-Me
VALVE
(F30)

sB

58

4
IsC

~,

c'

ECM
(ECCs

CONTROL

MODULE)

em

Ci
I

Refer to last page

(Foldout page) .

~;:=;:~~~~:;:::;:::;:;:;~;:;:;:;~~~~Cill
L
SEF840P

EC-169

1_'

Diagnostic Procedure 39 (Conl'd)

Harness layout

IGN TIMING ADJ.

- - CONDITION SETIING - -

IGNrr FEEDBACK

IGN TIMING

...L.-

~'~

HOLD

=
= = MONITOR =8(XJrpm
==
CAS RPM (REF)
iOLE POSITION

INSPECTION START

15BTDC
ON
SEFl86KA

CHECK OVERALL FUNCTION.

1) Start engine and warm it up sufficienlly
2) Check idle speed.
800 50 rpm (A/T: in uN" position)
If NG, adjusl idle speed

Drops.,

-,

INSPECTION END

~L---

3) Perform "IGN TIMING ADJ"

in "WORK SUPPORT" mode

with CONSULT.

Disconnect throttle position

sensor harness connector.
4) Make sure that idle speed drops.

Does not drop.

EC~170

Diagnostic Procedure 39 (Cont'd)

Gru

at "15'

NG

CHECK POWER SUPPLY

1) Stop engine.
2) Disconnect IACV-AAC valve harness
connector
3) Check vol1age between terminal (!)
and ground.

[\l]

f----+

(iliD,

@,QD
7.5A fuse
Harness continuity
between IACV-AAC
valve and fuse
If NG, repair harness or
connectors.

MEF991A

OK
AAC VALVE SYSTEM.
LET ENGINE IDLE
THEN
TOUCH START
lAIC SWL1GHT SW OFF)

NEXT

AACN OPENING

00

00

34%

Repair harness or connectars.

21 Perform "AAC VALVE OPENING TEST" or "IACV-AACIV

OPENING" in "ACTIVE TEST"

l00V
83C

mode with CONSULT.

OR
1) Disconnect ECM harness connector.
2) Check harness continuity
between ECM terminal @
and terminal .
Continuity should exisl.

'-C-H-E-C-K-C~-O-M-P-O-N-E-NT

CONNECTOR!'

LE

OR

~DEVT

11

SYSTEM" in "FUNCTION
TEST" mode with CONSULT

SEF319L

fCN

iij
~
[Qgj1:::;;:!:===Up:::::::::::;rll==0W=====:=N::;r::llM

NG

CHECK OUTPUT SIGNAL CIRCUIT

1) Reconnect IACVAAC valve
harness conneclor.
2) Perform "AAC VAL VE
SYSTEM" or "IACV-AACIV

=
= = MONITOR =875rpm
==
CASRPM jREF)
AIR FLOW MTR
ENG TEMP SEN

~
IC5fART
ACTIVE TEST.

;: (,.'J

SEF196L

Harness connectors

Voltage: Battery voltage

(!]

Check the following

Harness connectors

- - -,

~RePlace

(IACV-AAC valve).
ReIer to "Electrical Components
Inspection" (See page EC-204)

MEF491D

=TOK

-D-is-co-n-n-e-c~t -and recon-n-eC~!-h-a-r-ne~s-.s-c-o-n--

<:

nectors in lhe circuit. Then retest

,.--

~-~xed.

Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness connector and retest

EC-171

IACV-AAC valve.

TROUBLE DIAGNOSES
Diagnostic Procedure 40
IACV-FICD SOLENOID VALVE (Not self-diagnostic item)

EC-FICO-01

LHD MODELS
Refer to EL-POWER.

GIS

L/OR

,---------~I

L/OR <HIQ)

LlOR

I~J

L/OR~

G/B

THERMO
CONTROL

Im I

[~

531

AIR
CONDITIONER THERMISTOR
RELAY
..."...,!,:-r:------rr-;!,-2...- (@

L/R

G/Y

To compressor

(~~~:/C:~
and
HA-A/C. A.)

L/R.

L/R

G/Y

L/R

::

G/Y

$ ---- ~:o ---il$l

AMPLIFIER

I
R

2J
Y/S

Y/S

To auto Ale
unit or push
control unit
(Refer to
HA-A/C.M and
-A/C, A ,J

'~r----li---~-------------------i~1
L/R
@
G/Y
R

1 IACV-

rn

FICO
SOLENOID

II 2 II VALVE

~ ~

OFF--~

ON

TRIPLEPRESSURE

SWITCH

lbjd1

SIR

B/W

AC

AIR
CON

461

RLY

1-,-=-

ECM
(ECeS
CONTROL
MODULE)

em

""="

~@

1Zl~

PU

I:Ql@

Refer to last page

(Foldout page) .

ITI:m w

~;:;;;~~~~:;:;:::;r.;:;;::;;:;r.;;r.;;;:;;~~CED
L

SEF846P

EC-172
(f'

TROUBLE DIAGNOSES
Diagnostic Procedure 40 (Cont'd)

RHO MODELS

EC-FICD-02
Refer to EL-POWER.

.----------

L/OR

GIS

L/OR<EITID

1$1

L/OR~

GIS

THERMO
CONTROL
AMPLIFIER

~~1 ICONDITIONER
AIR
THERMISTOR

[~

RELAY

G/W

1[Qg]1
<illD
9F<HIQ)
LlR

1~1(8Q)
'F4'

rn
2

~....:.L..,;~~

\.:!..I

L/R

To compressor
(Refer to
HA-A/C. M and
HA-A/c. A. i

ON

OFF -

To auto AIC
unit or push
control unit
(Refer to
HA-A/C. M and
-A/C, A.)

c.

I~I

G/Y (ffiQ)

IACVFICO
SOLENOID
VALVE
@

II~
'1=4'
GIY

RLY

~
AIR
CON

AG

t,

B/W

\,.:!./

ECM
(EGGS

CONTROL
MODULE)

em

i2SJ@

G.ID

PU

J::Ql@
~

Refer to last page

(Fo Idout page) .

~~r.::;::r.;~~n=;:;:~~~;;:;;:;~~s~~;;:;:;:~~~::;:r:::;;;;::;;::;~~~~(IT)
L
SE~847P

EC-173

Y/S

TRIPLER
PRESSURE
~
SWITCH
I~l
~
tp\
~
R ~

G/Y
~QD

q:m

.'~'.

Y/S

L/R
1

1 j

L___

L/R

~I*"";..---,-----,,-.,!,-2r.'J C[)

L/R

I .. .

Diagnostic Procedure 40 (Cont'd)

Harness layoul

MONITOR

CAS-RPM (REFl

NO FAIL

INSPECTION STAAT

800rpm
CHECK OVERALL FUNCTION.
1) Start engine and warm it up sufficiently
2) Check idle speed.
Read idle speed in "DATA
~
MONITOR" mode with CONSULT.
~ Check idle speed.
~
800 50 rpm (A/T: In "N" posilion)
If NG, adjust idle speed.
3) Turn air conditioner switch and
blower fan switch "ON".
4) Recheck idle speed.
800 rpm or more

RECORD
MEC1428

0K

1
_I
I
I

INSPECTION END

'--------------'

~NG

r - - - - - - - - - - ' - - - - - - - - - - - - , NG
Check if air conditioner compressor
functions normally.

Refer to HA section.

~OK

MEF634E

EC-174

Diagnostic Procedure 40 (Cont'd)

'---K+

Il:::::>!----....

wr
R,p'''' 'ACV-F1CO ",.-

CHECK COMPONENT

I (IACV-FICD solenoid valve).

I ~efer'o "Electrical Components

noid valve.

~spection". (See page EC2051

OK

Disconnect and reconnect harness connectors in the circuit Then retest.

Trouble is not fixed
Check ECM pin terminals for damage
or the connection of ECM harness connector. Reconnect ECM harness connector and retest.
L-._

EC-175

TROUBLE DIAGNOSES
Diagnostic Procedure 41
COOLING FAN CONTROL (Not self-diagnostic item)

EC-COOL/F-01
Refer to

EL-POWER.

B/W

L/OR

!~:------I

iffi9! lllill
~ L/OR -~~I----1IIIIl

LlOR

LIOR

B/W

1 I

B/W
COOLING

n FAN

1 COOLING

.-"'-'i'-"-_--"'-'i5r--"-1

n FAN

IJ RELAY-l

...."....,!<-r.-----or-::!:-r:-'J

ORIL

BR/W

U RELAY-2

L,,-J""""""--oT""':3!:-r,-Jj

en):

W/R

L/G

1......1-

...--_..

L/G

~} Next

-OR/L~

page

COOLING

FAN

MOTOR

:ru>

:~

@: RHO models for Europe

: Except RHO models for Europe

t,

(ffi)@L)
Refer to last page
(Foldout page) .

~<ffi>

\l1Y

SEF850P

EC-176
(n,

Diagnostic Procedure 41 (Cont'd)

EC-COOL/F-02

~~~~eding

<9- LlG
{

~OR/L

-0-

LlG ~ L/G ~ L/G

(illD:~ <8Q):

OAIL ~ OAIL ~ ORIL-O

L

0-:::0--------..
I

OR/L
3

.-------.!I~~-.,

TRl PLEPRESSURE
SWITCH

(b):~

L..--_~-4-.----l

<D:

:
:

LHD models
RHO models
Except RHO models

for' EUr'ope

*1,,(0 10
*2"'CD Ai2

'
I

I
:-,

ER
ORIL

26
Ai

L/G

.---..!L1f1!..:i"g~1_..!J.;1 3=.,,-3!J.!.J----. ECM

RF
RL

RF
RH

(ECCS
CONTROL

MODULE)

(D: ~ (D: (Ql)

em

:~:~

~<D:

Refer to last page

(Fo Idout page) .

<U) @: ~
I

~~~~~:;;;::;::;::;::;;:;:;::;::;::;;:;:;r.:;r.;;r.~

em
L
SEF851P

EC-177

TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Confd)
Harness layout

(\

'Intake

~
~ ~UJ\\~,
manifold
collector

MEC113B

INSPECTION STAAT

m
r;==r:::::::===~ Cooling fan

CHECK OVERALL FUNCTION-I

1) Turn ignition switch "ON".
2) Make sure that engine coolant temperature is low.
3) Start eng i ne
4) Make sure thal cooling fan is not
operating

(I)
~

~NG

ID C~H
MEC 1788

EC-178

OK

f----

Go to "CHECK OVERALL
FUNCTION-I!"' .

TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Cont'd)

~---~------

NG

CHECK HARNESS CONTINUITY

BETWEEN COOLING FAN RELAY-1 AND
GROUND
1) Slop engine,
2) Disconnect cooling fan relay-1,
3} Disconnect triple-pressure SWitch
harness connector_
4) Check harness continuity between
terminal @ and terminal (C), termiI ~~I liD and body ground,
~onllnultY should exlsl.

Check the following

Harnoss connectors

@D.@

(LHD models)
Harness connectors

@D.@)

(LHD models)
Harness continuity
between cooling fan
relay-1 and triple-pressure switch
Harness continuity
between triple-pressure
swifch and body
ground.
If NG, repair harness or
connectors

- --~[

CHECK COMPONENT
(Triple-pressure switch),
Refer to "HA section',
OK

SI~I

Go to "CHECK OUTPUT
CIRCUIT" in ~EDQ.R~

[!]

With air conditioner

CHECK OVERALL FUNCTION-II.

]
NG

CHECK COOLING FAN LOW SPEED

a PERA T:.:Io=-cN""'---n-,r--__
[WITh'air conditioner I

Without air conditioner

Cooling fan

~
ID

1} Start engine,
21 Set temperature lever at fu II cold
position,
3) Turn air condilioner switch "ON"
4) Turn blower lan switch "ON"
5) Run engme at idle for a few minutes
with air conditioner operating.
6) Make sure that cooling fan operates
at low speed

f--

IO~W

Check cooling fan

speed control cirCUlI

00'

C,,',"r

,,[

tr

RHO models for

Europe
Excepl RHD models
lor Europe

OK
MEC180B

EC-179

~TI

rGO to

@:

CY~~H

-l

INSP~~O

J r~

,L

TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Cont'd)
(B)

1
CHECK COOLING FAN HIGH SPEED
OPERATION.

Check cooling fan high

,.---+ speed control circuit.

1) Turn both air condilioner switch and

(Go to

blower fan switch "OFF".

2) Stop engine.

~OCED~BJ )

3) Connect 400 f! resistor between terMEC181 B

~-_._ ..

NG

minals and (J) on harness connector

(Refer to 'Diagnostic
Procedure 25")

4) Restart engine and make sure thai

cooling fan operates at high speed

INSPECTION END

EC-180

L-

TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Cont'd)

PROCEDURE A

INSPECTION START

I'---~~~~-

._~~-~

~_~I
__

MEC1828

RHO models for Europe

~i5~ ~~6
~

@)

CHECK POWER SUPPLY

1) Stop engine.
2) Disconnect cooling fan relay-1.
3) Turn ignition switch "ON"
4) Check voltage between terminals
CD, @ and ground.
Voltage: Baltery voltage

Lr~ ~I

~ Check the following.

Harness connectors

@,CillD
7.5A fuse
30A fusible link
Harness continuity
between cooling fan
relay-1 and fuse

OK

Harness continuity
between cooling tan
relay-1 and fusible link
If NG, repair harness or

[ill

connectors.

Except RHO models for Europe

~io~ ~i5

LeJl

~'I

Ii
CHECK GROUND CIRCUIT.
1) Turn ignilion switch "OFF'.
2) Disconnect cooling tan motor har-

NG

r---

Repair

harne~~
~

nectors.

ness connector.
3) Check harness continuity between
terminal @ and terminal , terminal @ and body ground.

[ill

Continuity should exlsl.

OK

MEC183B

CHECK OUTPUT SIGNAL CIRCUIT

1) Disconnect ECM harness connector.
2) Check harness continuity between
ECM terminal and terminal @.
ContinuUy should exlsl.

NG

f---+-

Harness connectors

@),@
Harness continuity
between ECM and cooling fan ;elay-1
If NG, repair harness or

OK
1

...

fOIlOW~

@ill,@

L-------- ----------

Check the

Harness connectors

'---+L"~t - - - '

connectors.

MEC184B

CHECK COMPONENT
(Cooling fan relay-1).
Refer to "Electrical Components
Inspection". (See page EC-206)

EC-181

NG

Replace cooling fan

relay

n,

TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Cont'd)

RADIATOR FAN CIRCUIT.

DOES

III

RADIATOR FAN
ROTATE AND STOP
EVERY 3 SECONDS)

CHECK COMPONENT
(Cooling tan motor)
1) Reconnect cooling fan relay-1,
cooling fan molor harness
connector and ECM harness
connector
2) Turn ignition switch "ON".
3) Perform "RADIATOR FAN
CIRCUIT" or "COOLING FAN
CIRCUIT in "FUNCTION
TEST" mode with CONSULT.
OR
3) Perform "RADIATOR FAN
TEST" or "COOLING FAN" in
"ACTIVE TEST" mode with
CONSULT.
OR
Refer to "Electrical Components
Inspection" (See page EC-206)

NG

f------+

Replace cool ing tan

motor

@
!

NEXT

II

NO

II

YES

I
MEF534E

ACTIVE TEST
RADIATOR FAN

=-====

OFF

MONITOR

ENG TEMP SEN

===-=-==
88C

~OK

HI
SEF828K

Disconnect and reconnect harness connectors in the circuil Then retest.

~Trouble is not fixed.

Check ECM pin terminals for damage

or the connection at ECM harness connector Reconnect ECM harness connector and retest.

PROCEDURE B

INSPECTION START

II
CHECK POWER SUPPLY
1) Stop engine.
MEC1858

2) Disconnect cooling tan relay-2.

between cooling fan

3} Turn ignition switch "ON".

relay-2 and harness

connector @ED

4} Check \loltage between terminals

@, and ground.
Vollage: Battery voltage
OK

EC-182
,e,

NG
Check the following
~
Harness continuity

Harness continuity
between cooling tan
relay-2 and fusible link
If NG. repair harness or
connectors.

r------~-----

I'J

~i5 UZJ ~i8

_I

IB

~~

M_E_C1_B_6B_

~io~~i5
A

"]1=E=C=M==:g CONNECTOR I]

Diagnostic Procedure 41 (Cont'd)

11

CHI:CK GROUND CIRCUIT.

1) Turn ign ition switch "OFF"
2) Disconnect cooling lan motor har~
ness connector.
3) Check harness continuity between
terminal @ and terminal @, terminal @ and body ground.
Continuity should exist.

CHECK OUTPUT SIGNAL CIRCUIT

1) Disconnect ECM harness connector.
2) Check harness continuity between
ECM terminal @ and terminal (1).
Conllnully should exist.

II

II

NEXT

NO

I!

CHECK COMPONENT
(Cooling fan relay-2).
Refer to "Electrical Components
Inspection". (See page EC-206 )

MEF534E

II

ACTIVE TEST.

RADIATOR FAN

OFF

======== MONITOR ========

ENG TEMP SEN

83C

CHECK COMPONENT
(Cooling fan motor).
(~ 1) Reconnect cooling fan relay2,

cooling fan motor harness

connector and ECM harness
connector.
2) Disconnect 400 n resistor
from harness connector @.
3) Turn ignition switch' 'ON'
4) Perform "RADIATOR FAN
CIRCUIT" or "COOLING FAN
CIRCUIT" in "FUNCTION
TEST" mode with CONSULT .
OR
4) Perform "RADIATOR FAN
TEST" or "COOLING FAN" in
"ACTIVE TEST" mode with
CONSULT
OR
ReIer to "Electrical Components
Inspection", (See page EC-206)

,,---

"=-~

CHIJI

OK

~-

LOW l~

""-"'EC1BBB

(illD,@

@Q),@

NG

f--

=c
-,C

Replace cooling fan

relay.

OK

II

YES!

Chp.ck the following.

Harness connectors
Harness connectors

OK

RADIATOR FAN CIRCUIT.

DOES
RADIATOR FA/'.;
ROTATE AND STOP
EVERY J SECONDS ~

NG

r-----

Harness continuity
between ECM and cooling fan relay-2
If NG, repair harness or
connectors,

,---

MECI8~B

Repair harness or connectors.

OK

13

9IriJ

33

NG

f----

Disconnect and reconnect harness connectors in the circuil. Then retesl

Trouble is not ti xed.
Check ECM pin terminals lor damage
or the connection of ECM harness connector Reconnect ECM harness connector and retest.

EC-183

NG

r-----

Replace cool ing fan

motor.

TROUBLE DIAGNOSES
Diagnostic Procedure 42
POWER STEERING OIL PRESSURE SWITCH (Not self-diagnostic item)

EC-PST/SW-01
ECM
(ECCS

CONTROL
MODULE)

em

PWST
34

PU/W

{>
PU/W

$(8)
21 ~

PU/W

~<fITID

~~

PU/w

t
0

PU/W

IFDJ
ON

POWER STEERING
OIL PRESSURE
SWITCH

<D: lE1ID

OFF- - -

;~

IB
I

.I-

<D:ffi
@: (Q7)

(0:

<D:@

(0: lHO models

@: RHO models

:~

Refer to last page

(Foldout pagel.

UID,: ~

SEF849P

EC-184

TROUBLE DIAGNOSES
Diagnostic Procedure 42 (Cont'd)
Harness layout

Lt

r Fm

TROUBLE DIAGNOSES
Diagnostic Procedure 42 (Cont'd)
INSPECTION START

HOLD STEERING WHEI::cL

IN A FULL

POSITION
THEN
TOUCH START

NEXT -=11-------'s:::....:T...:..-A.:..ccR;...;...T_

FAIL

OFF

RECORD

NG

SEF831K

CHECK GROUND CIRCUIT

1) Stop engine.
2) Disconnect power steering oil pressure switch harness connector.
3) Check harness continuity between
terminal and body ground
Conllnulty should exist.

m II~coNNEcroRI1 ~ i5
34

CHECK INPUT SIGNAL CIRCUIT

1) Disconnect ECM harness connector.
2) Check harness continuity between
ECM terminal @ and terminal @.
Continuity Should exist.

MEF47SD

NG
~ Repair harness or connectors.

OK

[!]

NG
~ Check the following.
Harness connectors

.~

(LHD models)
Harness connectors

@,@1)

(LHD models)
Harness continuity
between ECM and
power steering oil
pressure switch
If NG, repair harness or
connectors

OK

CHECK COMPONENT
(Power steering oil pressure switch)
Refer to "Electrical Components
Inspection". (See page EC-206)
SEF217K

r-~

~Qi8'

'--~

r
I

~~K

___

NG
~

st~

Replace power
oil pressure switch.

I,

Disconnect and reconnect harness

nectors in the circuit Then retesl.

CF{j[CONNECTORI]

Trouble is not fixed.

34

lP~1- '
_____

INSPECTION END

SEF200L

PW/ST SIGNAL

CHECK CONTROL FUNCTION

1) Start engine and warm it up sufficiently.
2) Perform "PW/ST SIGNAL

CIRCUIT" in "FUNCTION
TEST" mode with CONSULT.
OR
2) Check "PW/ST SIGNAL" in
"DATA MONITOR" mode with
CONSULT.
Steering Is neutral position: OFF
Steering Is turned: ON
OR
2) Check voltage between ECM
terminal @ and ground.
Voltage:
When steering wheel Is
turned quickly
Approximately OV
Except above
4 - 5V

LOCKED

t:r MONITOR t:r NO

.~-[-----~

PWfST SIGNAL CIRCUIT.

Check ECM pin terminals 'or damage

or the connection of ECM harness connector. Reconnect ECM harness connector and retest.

~_MEF476DII
EC-186

TROUBLE DIAGNOSES
Diagnostic Procedure 43
NEUTRAL POSITION SWITCH & A/T CONTROL UNIT (PARK/NEUTRAL POSITION SIGNAL)
(Not self-diagnostic item)

EC-PNP/SW-01

ECM
(ECCS

CONTROL
MODULE)

@:
@:

NEUT

Cill

44
*1

~ ~-:]A=-""'------"

<I>~

GIOA
~cm
l~1 <MQ)
GIOA

RIG

GIOR

$RIG ~

~~
1~lltW

IlfJJ~

'=r @D

GIOA

GIOA

~~I~~~I---~
OTHER - -

CD

_~",_

c.::

RIG

rrf3ll

NEUTAAL
POSITION
SWITCH
(fW): aD

AIT
PARK I NEUTRAL CONTROL

POSITION
SIGNAL

UNIT

@:

: AIT

<ID:

models

MIT models
*1- _. @
RIG

G/OA

Refer to last page

(Foldout page) - J

@Q).OO)
I.MID, ~

~:::;:::::;:::::;::::::::;:::::;::::::;=;:::;::::;::;:::;::::::;:::::::;:::::;::::;;:::;::;;~;;;l

CD
L
SEF843P

EC-187

~l

TROUBLE DIAGNOSES
Diagnostic Procedure 43 (Cont'd)
Harness layout

(,

LHO models
Drivers dash lowe"

/ o~)f~

MEC1D8B

,---~------~--~~.---.

EC-188
j

TROUBLE DIAGNOSES
Diagnostic Procedure 43 (Cont'd)

~eutral' position

NEUTRA.L SW CIRCUIT.

L _~PEcnON STA~ J

SHIFT
OUT OF

switch

__

NIP

RANGE

THEN

CHECK OVERALL FUNCTION.

TOUCH START

L~[

SEF206L

"MONITOR

"NO FAIL

START SIGNAL
IDLE POSITION
AIR COND SIG
NEUTRAL SW

1) Turn ignition switch "ON"

\.:~," I

~I!j 2} Per10rm "NEUTRAL SW

START ]

CIRCUIT" or "NEUTRAL POSI

SW CKT" in 'FUNCTION
TEST" mode with CONSULT
I-----_~

,T

- _ OR - - - - -

2) Check "NEUTRAL SW" or

~I
"NEUT POSI SW" signal in

OFF
ON
OFF
ON

"OATA MONITOR" mode with

::,,~.

'co

CONSULT.
Neulral position: ON
Excepl above: OFF

f----~---- OR ----.---~

RECORD]
-----SEl=3B4J

m
\~

B>~ONNECTORII ~

ECI1

4.

DISCONNEt T

E:D

1) Set shill lever to the neutral

position
2) Disconnect FCM harness connector
3) Check harness continuity
between ECM terminal @
and body ground

Conlinulty should exist.

NG
Turn ignition switch "OFF".

00
L -_ _

~--------~~-

MEF47901

CHECK GROUND CIRCUIT

1) Disconnect neutral position switch

NG

~----

harness connector.
2) Check harness continuity between
terminal (Ii) and body ground
Conlinuity should ell:ist.

L ~--~r~--'~

Check the following

<illD.@
Harness continuity
between neutral position switch and body
ground
If NG, repClir harnesS or
conner.lors

i--~1

MEC1B9B .

--------1

Disconned ECM harness connector

T-----

EC-189

Harness connectors

;',':

Diagnostic Procedure 43 (Cont'd)

~i8~~181~

[CE~NECTORII

NG

CHECK INPUT SIGNAL CIRCUIT

1) Check harness continuity between

44

ECM terminal @ and terminal

r---

Ca;

Check the followi ng

Harness connectors

Cill,@)

Continuity should exisl.

Harness connectors

@,@ill

OK

Harness conneclors

@D,@!)

MEC190B

Harness continuity
between ECM and neutral position switch
It NG. repair harness or

connectors.
NG

CHECK COMPONENT

,---

(Neutral position switch)

Refer to "ON-VEHICLE SERVICE" in MT
seclion.
OK

II

Disconnecl and reconnect harness connectors in the circuit. Then retest

r-

~ e IS

not fixed.

Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness cOnnector and retest.

Replace neutral position

switch

Diagnostic Procedure 43 (Cont'd)

l!J I

IAlT CONTROL UNIT (PARK/NEUTRAL

NEUTRAL SW CIRCUIT.

SHIFT

I\J/P-RA.NG~

OUT OF

POSITION SIGNAL) CIRCUIT

INSPECTION START

THEN

0
CHECK OVERALL FUNCTION.
f--1) Turn ignition swilch "ON".
2) Perform "NEUTRAL SW
CIRCUIT" or "NEUTRAL POSI
SW CKT" in "FUNCTION TEST"
mode with CONSULT
OR
2) Check "NEUTRAL SW" or
"NEUT POS/ SW" signal in
"DATA MONITOR" mode with
CONSULT.
uN" or Upll:
ON

TOUCH START

C~I

STARt=]
SEF206L

<.z MONITOR

<.z NO FAIL

START SIGNAL

OFF

IDLE POSITION

ON

AIR eOND SIG

NEUTRAL sw

OFF
ON

SEF384J

lX.MECT

OFF

Except above:

RECORD

:R

l. ,~,

@
ECM

~SPECTIONEND

OR
2) Check voltage between ECM
terminal and ground under
the lo/Iowing conditions.

C'..

Voltage:
"N IJ or UP,1

Approximately OV
CONNECTOR

II

Except above
Approximately 5V

44

_~_NG

II

__

,='----~

~'~ ~J

MEC191B

_ _--,

CHECK INPUT SIGNAL CIRCUIT

1) Turn ignition switch "OFF"
2) Disconnect ECM harness connector.
3) Disconnect AfT control unit harness
connector.
4) Check harness continuity between
ECM terminal @ and terminal @.

NG
_

Check the fol/owing.

Harness connectors

@,@)
Harness continuity
between ECM and AIT
control unit
If NG, repair harness or
connectors.

Continutly should exist.

OK
CHECK INHIBITOR SWITCH FUNCTION.
Make sure that inhibitor switch functions properly. (Refer 10 AT section).

Il

.---

~_O_K

Disconnect and reconnect harness

nectors in the circuit. Then retest.

.--------------1
Check inhibitor SWit~h
and circuit
(Refer to AT section,]

c~
_~

Trouble is not lixed.

MEF242F

NG

:I

Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness connector and retest

Fl

EC-191

re

TROUBLE DIAGNOSES
Diagnostic Procedure 44
REAR WINDOW DEFOGGER SWITCH (Not self-diagnostic item)

EC-DEF/S-01

I BATiRY I

IGNITION SWITCH
ON or START

~A~15A

7.5A

Refer to EL-POWER.

LiJ []]] LtJ [ill

1261
G

BIR

slY

B/R

B/Y

~ ~~~)GGER

L/R

L/A

~~----~~~----~~"IREAR WINDOW

1
l!lLiJj

RELAY

1---i-X--I

L/Y

1--1

LlR

<EID

L/R

L/R

(ill)

L/R

~--~:--~$I

!'

L!Y

To EL-DEF

LlR <MQ)

1$1

L/R CH)

II

L/R

To EL-DEF

CD:

:
:

L/R

AIT mode 1s
LHD models
RHO models

*1 .. (1) P2,

5Jf

LOAD

M12

ECM
(ECCS
CONTROL
MODULE)

(IT)

W
2

5 7

3 6

Refer to last page

(Fa Idout page) .

CHID
SR

6~~~~:r;::r:;~~;:;:;;::;~~~~~;;;;~~;;;:;::;:~~;:;;:;~~;;;;-]<ID
L
SEF849P

EC-192

TROUBLE DIAGNOSES
Diagnostic Procedure 44 (Cont'd)
Harness layout

}'J:o)

?~\

I,
k.

I,
~

!(
ii

~~}~:

EC-193

:1

TROUBLE DIAGNOSES
Diagnostic Procedure 44 (Cont'd)

-(( MONITOR

NO FAlL

LOAD SIGNAL

-I

INSPECTION START

'----------------.---~

OFF

CHECK OVERALL FUNCTION

INSPECTION END

1) Turn ignition switch "ON".

rF.f\

RECORD

\.J!J

2) Check "LOAD SIGNAL"

In

"DATA MONITOR" mode with

CONSULT.

Rear window defogger switch

MEC212B

"ON": ON
Rear window defogger switch

"OFF": OFF
r---~---

OR - - - - - - - - 1

2) Check voltage between ECM

terminal i@ and ground
under the following conditions.

Voltage:
Rear window defogger
swilch "ON"
MEC1928

Battery voltage
Rear window defogger
swilch "OFF"
Approllimalely OV
NG
,-

--L..

Check if rear window defogger funclions normally.

~ Check rear window

defogger circuit. (Refer to
EL section)

OK

MEC193B

~~~CK

1) Turn ignition switch "OFF".

2) Disconnect ECM harness connector.
3) Disconnect rear window defogger
relay.

Check the following

Harness connectors

(]ill,

Harness continuity
between ECM and rear

4) Check harness continuity between

ECM terminal

and terminal

Continuity should exist.

OK
Disconnect and reconnect harness connectors in the circui1. Then retest
Trouble is not fixed.
Check ECM pin terminals for damage
or the connection of ECM harness connector Reconnect ECM harness connector and retest.

EC-194
[I'

-NG

INPUT SIGNAL CIRCUIT

window defogger relay

!f NG, repair harness or

connectors

TROUBLE DIAGNOSES

Diagnostic Procedure 45
MALFUNCTION INDICATOR LAMP & DATA LINK CONNECTOR FOR CONSULT (Not
self-diagnostic item)

EC-MIL-01

~~7.5A

Refer to EL-POWER.

LtJ'~ ~1261
G

(0: LHD models

@: RHO models

I l...---,

l'

COMBINATION
METER
(MALFUNCTION
INDICATOR
LAMP)
@
"

OR
3

G/R

G/W

12-2114-71

LED-R

SCI

RX

(In)

311
SCI CHECK SCI

TX

elK

(Out)

ECM
(ECCS
CONTROL
MODULE)
(IT)

,---------------------------1
I

II
I

WREJ
21

fhTTl;rTrf1
~ @) :I
I

~CBID
~GY

Refer to last page

(Foldout page) .

JI

rr.::;:;;:;:;;:;;;:;:;;;:;.~r:;:;::;:~;:::;:;;:;:;;;:~~;rr=;s;;:;;;;:;;~;;;:~~~;::;:;:;~~~

em
L
SEF852P

EC-195

TROUBLE DIAGNOSES

Electrical Components Inspection

ECM INPUT/OUTPUT SIGNAL INSPECTION
1.

ECM is located at passenger's dash side. For this

inspection, remove the passenger's dash side cover.

2.

Remove ECM harness protector.

3.

Perform all voltage measurements with the connectors

connected.
Extend tester probe as shown to perform tests easily.

MEF50SD

L~=1
Thin wire

Tester probeJ

SEF3671

ECM HARNESS CONNECTOR TERMINAL lAYOUT

MEC196B

EC-196
tv

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
'Data are reference values.
TER~

ITEM

MINAL
NO.
.~~-

'DATA

CONDITION

. - - ----- - - " ...

.~~-

IEngine is ru~
19

Cooling fan
(Low speed)

~gine is running

23

Knock sensor

Approximately OV

20 - 30V

Engine is running. I

L
Wastegate valve conlrol solenoid
valve

---'-~'.

BATTERY VOLTAGE
(11 ~ 14Vl

Cooling fan is operating

!Engin is running.
I

25

Cooling Ian is not operating

-~

BATTERY VOL TAGE

(11 - 14Vj

Idle speed

!Engine is running. I

L Engine is racing up to 5,000

Approximafely 5V

rpm.
IEngine is running.] (Warm-up condl~
tion)

L
l

081.5V

Idle speed

27

Mass air flow sensor

IEngine is running.j (Warm-lip condition)

14 - 2.0V

Engine speed is 3,000 rpm

28

Engine coolant temperature sensor

~ngine is running.!

0- 50V
Output voltage varies with engine
coolant temperature

IEngine is running. I
29

Heated oxygen sensor

Aller warming up sufficiently

and engine speed is 2,000 rpm.

[Engine is running.

33

o~

0.3V ..... 06 - 0 9V

Cooling fan is not operatirg.

Cooling fan is operating at low

BATTERY VOL TAGE

(11 - 14Vj

speed.

Cool ing fan (High speed)

!Engine is run~ingJ

Cool ing Ian is operating al high

speed.

Approximately OV
--

[Engine is running.1
34

Power steering

011

pressure switch

L Steering. wheel stays straight

Li:'ngine is running.

Boos! pressure sensor

Approximately OV

Steering wheel is turned

~ine is running.\

L
35

4.0 - S.OV

Approximately 2V

Idle speed

!Engine is running.\

Engine is racing up to 4,000

rpm

Approximately 2.2V

EC-198

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
Data aro roforerlce values
TERMINAL

ITEM

CONDITION

'DATA

}i

NO.

38

Throttle position sensor

41

Camshaft position sensor

51

(Reference signal)

42

Camshalt position sensor

(Position signal)

L
L

03 - 06V

Do not run engine at high speed

under no-load.
is running.

Start signal
!'gnition switch "START"

!Ignition switch "ON"

44

sis)

(A/T models)

Ignition switch

4.0 - 50V
Except the above conditions

!Ignition switch

L
Air conditioner swilch

OV

yNj

IEngine is running. I

46

BATTERY VOLTAGE
(11 - 14Vj

AfT control unit (AfT models)

L
45

Ge" p,,;tioo ;, "Ne"'ea'

pgnition switch "ON"

Output voltage slightly varies with

engine speed.
OV

posilion" (MIT models).

Gear position is "N" or "P"

Neutral positio'1 switch (MIT mod-

Output voltage slightly varies with

engine speed.
2.0 - 3.0V

Do not run engine at high speed

under no-load.

~nition switch "ON"

43

Output voltage varies with throttle

valve opening angle.

l!':ngine is ru~

I Engine

52

0.35 - 4.0V

!Ignition SWitch "ON" I

BATTERY VOLTAGE
(11 . 14V)
BATTERY VOLTAGE

Air conditioner switch is "OFF".

(11 . 14V)

~ne is running. I

Both air conditioner switch and

Approximately OV

blower fan switch are "ON".

48

49
59

Power source for sensors

~n switch "ON"I

Power source for EeM

:llgnition switch

"ON"]

Ilgnition switch "ON"

Approximately 5.DV
BATTERY VOLTAGF
(11 - 14V)

I
BATTERY VOLTAGE

Rear window defogger switch is

(11 - 14Vj

"ON"

54

Load signal

~gnition SWItch "ON"

Rear window defogger switch is

ApproXimately OV

"OFF".
BATTERY VOLTAGE

58

Power supply (Back-up)

pgnilion switch "OFF"I

EC-199

(11 - 14Vj

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
'Dala are reference values
TERMINAL

'DATA

CONDITION

ITEM

NO.
101
103
110
112

Injeclors

BATTERY VOL rAGE

[Er19ine is running. I

(11 - 14V)

IEngine is running. (Warm-up cond i-

102

EGR & canister conlrol solenoid

valve

tion)

L
L

Approximately OV

Idle speed

[Engine is running. I (Warm-up condiBATTERY VOLTAGE

(11 - 14V)

lion)

Engioe speed is 2,000 rpm

IEngine is running I (Jack-up condiBATTERY VOLTAGE

lioo)

(11 14V)

Idle speed

113

VTC solenoid valve

IEngine is running

I (Jack-up

condi

lion)

Approximately OV

Engine is racing up to 2,000

rpm.
IEngine is runninQ.]

L
115

Engine speed is belween idle

and 4,000 rpm.

Approximately OV

Healed oxygen sensor heater

[fngine is running. I

8ATTERY VOLTAGE
Engine speed is above 4,000
rpm.

(11 - 14V)

EC-200

'"

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
CAMSHAFT POSITION SENSOR
1.

2.
3.

SEF015Q

Remove camshaft position sensor from engine. (Camshaft

position sensor harness connector should remain connected.)
Turn ignition switch "ON".
Rotate camshaft position sensor shaft slowly by hand and
check voltage between terminals CD, and ground.

_ _ ~~er_rn_in_~a,,--I_ _ -.+
(1) (180" s.ignal)
@ (1' signal)

Volta~

Voltage flucluates between 5V and O. W

If NG, replace camshaft position sensor_

After this inspection, diagnostic trouble code No. 11 might be
displayed though the camshaft position sensor Is functioning
properly. In this case erase the slored memory.

MASS AIR FLOW SENSOR

1. Fold back mass air flow sensor harness connector rubber
as shown in the figure if the harness connector is con2.
3.
4.

Conditions

Voltage V

Idle speed

OB - 1.5

3,000 rpm

1.4 - 2_0

5.

nected.
Turn ignition switch "ON".
Start engine and warm it up sufficiently.
Check voltage between terminal CD and ground.

If NG, remove mass air flow sensor from air duct. Check
hot film for damage or dust.

ENGINE COOLANT TEMPERATURE SENSOR

1.
2.

Disconnect engine coolant temperature sensor harness r~i~\,

connector.
Check resistance as shown in the figure.
Temperature

'c ('F)

20 (68)

50 (122)
80 (176)

Resistance kO
2.1-2.9

0.68 - 1.00
030 - 0.33

If NG, replace engine coolant temperature sensor.

L-

__

_SEF536
_____.J

EC-201

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
IGNITION COIL
1.
2.

Disconnect ignition coil harness connector.

Check resistance between terminals CD and
Resistance: Approximately 1 Q
If NG, replace ignition coil.

SEF016a

POWER TRANSISTOR
1.
2.

Disconnect power transistor harness connector.

Check power transistor continuity between terminals with
analog tester as shown in the figure.

Terminal combina-

Tester

tion

polarity

e
1

e
a

e
b

e
3

e
4

G)

EB
8

G)

Continuity

No

Tester
polarity

Continuity

e
EB

Yes

Yes

8
EB

Yes

Yes

8
EB

No

If NG, replace power transistor.

FUEL PUMP

In lhe trunk room

1.
2.

Disconnect fuel pump harness connector.

Check resistance between terminals and @.
Resistance: Approximately 0.2 5.00
If NG, replace fuel pump.

SEF017Q

VEHICLE SPEED SENSOR

1.
2.
3.

Jack up rear wheels. Use stands to support vehicle.

Disconnect vehicle speed sensor harness connector.
Check continuity between terminals and @ while rotating rear wheel by hand.
Continuity should come and go.
If NG replace vehicle speed sensor.

~
E8

OISCONIIfCT

l 00

SEF754H

EC-202

Electrical Components Inspection (Cont'd)

EGR AND CANISTER CONTROL SOLENOID VALVE
Check air passage continuity.
",=1

Condition

Air passage
continuity
between

i!l

and

Air passage

.-l"

continuity

between

and @

12V direct current supply between terminals

<IJ and
- - _..
SEF931M

Yes

No

No

Yes

No supply

EGA VALVE
Apply vacuum to EGR vacuum port with a hand vacuum pump.
EGR valve spring should lift.
If NG, replace EGR valve.

III
I

=C'
r

-------

MEF716D

EGRCBPT VALVE
Plug one of two ports of EGRC-BPT valve.
Apply a pressure above 0,490 kPa (4.90 mbar, 50 mmH 2 0, 1.97
inH 2 0) to check for leakage. If a leak is noted, replace valve.
To:
h.
I

EC381A

HEATED OXYGEN SENSOR HEATER

Check resistance between terminals @ and @.
Resistance: 3 " 1,0000
If NG, replace heated oxygen sensor.

SEF6251

THROTTLE POSITION SWITCH (A/T model only)

Refer to "TROUBLE DIAGNOSES" in AT section.

EC-203

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
THROTTLE POSITION SENSOR
1.
2.

Disconnect th rottle position sensor harness connector.

Make sure that resistance between terminals and @
changes when opening throttle valve manually.
Accelerator pedal condition

Completely released

Resistance

Approximately 0.7
07 5

Partially released
Completely depressed

kn

Approximately 5

SEF019Q

If NG. replace throttle position sensor.

Adjustment of throttle posilion sensor (idle position)

If throttle position sensor is replaced or removed, it is necessary to install it in the proper position, by following the procedure as shown below:
1. Install throttle position sensor body in throttle body. Do not
tighten bolts. Leave bolts loose.
2. Connect throttle position sensor harness connector.
3. Start engine and warm it up sufficiently.

*.

THROTILE SEN ADJ

AOJ MONITOR

THROTILE SEN

Perform "THROTTLE SEN ADJ" or ''THRTL POS SEN

ADJ" in "WORK SUPPORT" mode
Measure output voltage of throttle position sensor
using voltmeter.

O.45V

======== MONITOR ========

CASRPM (REF)
IDLE POSITION

Orpm
ON

MEC157B

5.

AIT models

6.
7.

r:J__
~ront/

---.L

Adjust by rotating throttle position sensor body so that

output voltage is 0.35 to 0.65V.
Tighten mounting bolts.
Disconnect th rottle position sensor harness connector for
a few seconds and then reconnect it.

~
+SEF0030

IACVAAC VALVE

Check IACV-AAC valve resistance.

Resistance:
Approximately 10n
Check plunger for seizing or sticking.
Check for broken spring.

SEFJ521

Electrical Components Inspection (Cont'd)

~

OIstO'"H'

~. Intake m~ilo'd ~ IV
I collector ~ ~
~-~-~._- ~

~I': I

ill

.">

TI

-~

-~

l.---=:I..

-=--r:::=::----.

....

C<ill?)

~~a~
"--- rn'

IACVFICD
T
\.'"
valve J \j
harness connector:::----.

J . solenoId

IACV-FICD SOLENOID VALVE

Disconnect IACV-FICO solenoid valve harness connector.
Check for clicking sound when applying 12V direct current
to terminals.
Check plunger for seizing or sticking.
Check for broken spring

~I

---,-~

J:<'

SEF0202Q

KNOCK SENSOR
Disconnect knock sensor sub-harness connector.
~
Check continuity between terminal and ground.
Continuity should exist.
It is necessary 10 use an ohmmeter which can measure
more than 10 MO.
1.
2.

CAUTION:
Discard any knock sensor which has been dropped or has
undergone shocks; use a new one.

INJECTOR
1. Disconnect inj ector harness connector.
2.

Check resistance between terminals as shown in the fig-'I

ure.
Resistance: 10 - 1M2
If NG, replace injector.

SEF855J

VALVE TIMING CONTROL (VTC) SOLENOID VALVE

Check valve timing control solenoid valve for normal operation by supplying it with battery voltage between terminals
and @.
If NG, replace solenoid valve

SEF0210

WASTEGATE VALVE CONTROL SOLENOID VALVE

Check air passage continuity.
Air passage continuity
ConditIon

12V direct current supply between terminals

and (Ii)
No supply

SEF022Q

If NG, replace solenoid valve

EC-205

between

Yes
No

and

ft

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
BOOST PRESSURE SENSOR
Check resistance between terminals.
Resistance:
and Approximately 1.1 kQ
and Approximately 0.5 kf.!:
and @ Approximately 0.3 kQ
ab
Measure
b-c )
between: (

a-c

SEF0230

POWER STEERING OIL PRESSURE SWITCH

1.
2.

Disconnect power steering oil pressure switch harness

connector.
Check continuity between terminals.
Continuity

Conditions

SEF0240

Steering wheel is being turned

Yes

Steering wheel is not being lurned

No

I
COOLING FAN MOTOR

l}

~
a
c d

~io

1.
2.

Disconnect cooling fan motor harness connector.

Supply cooling fan motor terminals with battery voltage
and check operation.

Cooling fan motor

harness connector
Fan speed

SEF422N

Terminal
(jj

Low

High

Ia),@

@
@,@

Cooling fan motor should operate.

If NG, replace cooling fan motor.

ECCS RELAY, FUEL PUMP RELAY, IGNITION COIL

RELAY AND COOLING FAN RELAY 1-2
Check continuity between terminals @ and @.
Continuity

Conditions

12V direct current supply between

Yes

terminals G) and @

No

No current supply

RECIRCULATION VALVE
Check air passage continuity between
Condition

A vacuum of above -27.3 to -34.0 kPa (-273 to

-340 mbar, -205 to -255 mmHg, -B07 to -1004

and

.
Continuity
Yes

inHg) is applied to vacuum port

No vacuum applied

No

If NG, replace recirculation valve

Do not disassemble and adjust recirculation valve.

EC-206

TROUBLE DIAGNOSES
~~--------'--'------'~~-~------'

CCJ 20

I "',r

- 2.9 N.m

, . . . 2.14

1/

(0.204 - 0.296 kg-m,

Fast Idle Cam (FIC) Inspection and Adjustment

REMOVAL AND INSTALLATION

"

"-~~;/~/

CJl~

a-ring

lr~I;~

Thermoelemenl

Do not extract thermo-element by pulling center rod.

Always replace C-ring with a new one.
Lubricate C-ring with a smear 01 engine oil.
After installation, check for water leakage.

SEF025Q

l'

I , )~-:'

c:)

front

INSPECTION

1.

Start engine. Warm the engine coolant up to 80C (176F)

and keep it there for 10 minutes.
2. Check that mark A (short line) on FI cam aligns with roller
a.

center.
If NG, measure thermo-element stroke (L) and engine coolant temperature.
If stroke L is in the specification shown in the figure, adjust
FI cam with adjusting screw.
If stroke (L) is out of the specification, replace thermo-element with a new one.

~
,=~

~~'lf

ADJUSTMENT
1.

Start engine. Warm the engine coolant up to 8GoC (176F)

and keep it there for 10 minutes.
Loosen adjusting screw and align mark A (short line) on FI
cam with roller center.
Tighten lock nut to the specification.
Cool down the engine coolant to 25C (7rF) and keep it

4.

there for 5 minutes

Check that mark B (long line) on FI cam aligns with roller

2.

Adjusting
scre'SEf026Q

\::r --jr--------

11

center

10.8 (0.425)

',1::::1

~~-th

,
I
I

6.1 (0.240)
(0.236) - - - - - - - - - - - - -

,I

'"

I
I

~ 6

"0

2 (O.197)

c4

I
I

11 (0.157)

*3

~ 10.118)

t 2

\.=:

~0.079)

(OO~)

I
I

I
I
I
I

(OJ

-30
(-22)

0
(32)

25
(n)

Engme coolanl temperature

_ _ ~,

80
(176)
QC (OF)
SEF0270

._~~_~--J

EC-207

~1))

F!~\

MULTIPORT FUEL INJECTION SYSTEM INSPECTION

Releasing Fuel Pressure

FUEL PRES RElEASE.

Before disconnecting fuel line, release fuel pressure from fuel

line to eliminate danger.
rI~\ Perform "FUEL PRESSURE RELEASE" in "WORK
\I/ SUPPORT" mode with CONSULT.

FUEL PUMP WILL STOP BY

TOUCHING START DURING
IDLE
CRANK A FEW TIMES
AFTER ENGINE STALL

L__~s~TA---=..:R-...:..-.:T~_-----,
MEF720D

@ ~:

Remove fuse for fuel pump.

Start engine.
3. After engine stalls, crank it two or three times to
release all fuel pressure.
4. Turn ignition switch off and reconnect fuse for fuel
pump.

Fuel Pressure Check

a.

Make sure that clamp screw does not contact adjacent

parts.
b. Use a torque driver to tighten clamps.
c. Use Pressure Gauge to check fuel pressure.
d. Do not perform fuel pressure check while fuel pressure
regulator control system is operating; otherwise, fuel pressure gauge might indicate incorrect readings.
1. Release fuel pressure to zero.
2. Disconnect fuel hose between fuel filter and fuel tube
(engine side).
3. Install pressure gauge between fuel filter and fuel tube.
4. Start engine and check for fuel leakage.

5.

Read the indication of fuel pressure gauge.

At idling:
When fuel pressure regulator valve vacuum hose
connected.
Approximately 245 kPa (2.45 bar, 2.5 kg/cm 2 ,
psi)
When fuel pressure regulator valve vacuum hose
disconnected.
Approximately 294.1 kPa (2.94 bar, 3.0 kg/cm 2 ,
psi)

EC-208
fit

is
36
is
43

MULTIPORT FUEL INJECTION SYSTEM INSPECTION

Fuel Pressure Check (Cont'd)
6.
7.

8.

Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold.
Plug intake manifold with a rubber cap.
Connect variable vacuum source to fuel pressure regula- iQf

tor.

Start engine and read indication of fuel pressure gauge as tiE;

vacuum is changed.
Fuel pressure should decrease as vacuum increases. I f .
results are unsatisfactory, replace fuel pressure regulator.

9.
Vacuum

Fuel pressure

lO~SO

~
tl

nL-...J'ti""-~L

&D

To pre5sure regulator

-Insulator

Ld
111--

O-ring~

_.

----l.-

----

1.

Local~

pI.ate
on thIs side.

'

~/

....-Insulator

c::=;::::::::r"
I

'Ml"f

Injector Removal and Installation

Fuel\Ube~
assembly

(t,(l

SEF71aB

I"

~~

SEF6 1 6NI

Remove injectors with fuel tube assembly.

&li (
Refer to "INTAKE MANIFOLD" in EM section.
2. Push out any malfunctioning injector from fuel tube assembly.
~~ij

Do not extract injector by pinching connector.

Always replace O-rings and insulators with new ones.

;!A

Lubricate O-ring with a smear of silicone oil.

3. Installation is in the reverse order of removal.
CAUTION:
After properly connecting injectors to fuel tube assembly, Ritk
check connections for fuel leakage.

EC-209

'I

EVAPORATIVE EMISSION SYSTEM

Description
To air cleaner

Fuel check valve

with vacuum
relief valve

Fuel tank

Air

. . Fuel vapor

L_

_________________
MEF609D I

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 carbon canister.
The fuel vapor from sealed fuel tank is led into the canister
when the engine is off. The fuel vapor is then stored in the
canister. The canister retains the fuel vapor until the canister
is purged by air.
When the engine is running, the air is drawn through the bottom of the canister. The fuel vapor will then be led to the intake
manifold.
When the engine runs at idle, the purge control valve is
closed. Only a small amount of vapor flows into the intake
manifold through the constant purge orifice.
As the engine speed increases and the throttle vacuum rises,
the purge control valve opens. The vapor is sucked through
both main purge and constant purge orifices.

,-----------------

(~~'lo
@lQ

Inspection
ACTIVATED CARBON CANISTER
Check carbon canister as follows:
1. Blow air in port and ensure that there is no leakage.

2.

Apply vacuum to port .

Cover port @ with hand.
Blow air in port and ensure free flow out of port

SEF312N

EC-210

EVAPORATIVE EMISSION SYSTEM

Inspection (Cont'd)
FUEL TANK VACUUM RELIEF VALVE
1.
2.

Wipe clean valve housing.

Suck aIr through the cap. A slight resistance accompanied
by valve clicks indicates that valve is in good mechanical \H
condition. Note also that, by further sucking air, the resistance should disappear with valve clicks.
3. If valve is clogged or if no resistance is felt, replace cap
as an assembly.

SEC308A

FUEL CHECK
r.=::::::=:::::::;====1 ~

1.

'r==--~==;::::I ."

VALVE~Je;

Air

. . fuel vapor

Blow air through connector on fuel tank side.

.A considerable resistance should be felt and a portion of
air flow should be directed toward the canister.
2. Blow air through connector on canister side.
Air flow should be smoothly directed toward fuel tank.
[:;~
3. If fuel check valve is suspected of not properly functioning
in steps 1 and 2 above, replace it.

SEC309A

EC-211

CRANKCASE EMISSION CONTROL SYSTEM

Description
This system returns blow-by gas to the intake
collector.
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 air inlet

tubes into crankcase through a hose. The hose
connects the air inlet tubes and the rocker cover
Under full-throttle condition, the manifold vacuum
is insufficient to draw the blow-by flow through
the valve. Flow then goes through the hose connection in the reverse direction.
Under any condition, some of the flow goes
through the hose connection to the air inlet tubes.
This will occur on vehicles with an excessively
high blow-by.

Engine not running

or backfiring

Cruising
. '

Fresh air

...

Blow-by gas

~:

Blow-by gas during

high-load operation

~lE:J5R ~~
=--

Baffle plate

Idling or
decelerating

Acceleration or
high load

- ~~ .m:;,~~

. --~~

SEF030Q

Inspection
PCV (Positive Crankcase Ventilation) VALVE
With engine running at idle, remove 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.

SEC137A

VENTILATION HOSE
1.
2.

Check hoses and hose connections for leaks.

Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.

ET277

EC-212

SERVICE DATA AND SPECIFICATIONS (SOS)

General Specifications
PRESSURE REGULA TOR

Fuel pressure at idling

kPa (bar. kg/em', psi)
Vacuum hose is connected

Approximately
245 (2 45, 2 5. 361

Vacuum hose is
disconnected

Approximately
294 (2.94, 3.0, 43)

Inspection and Adjustment

Idle speed'1

FUEL PUMP

rpm

No-load'2

Resistance

MIT & A/T (in "N" position)

--.-+--------Air conditioner: ON
MiT & A/T (in "N" position)

u[

02-50

BOO50

-H-E-A-TE-O-O-X-Y-G-e-N-s-e-N-.l-S-O-R-H-E-A-T-E-R--- f'"

BOO50

15 2 BTOC

Ignition timing

Resistance

Throttle position sensor idle

position

3 - 1,000

'1: Feedback controlled and needs no adjustments

'2: Under the following conditions:
Air conditioner swi\ch: OFF
Steering wheel: Kept straight
Electric toad OFF (Lights, heater, Ian & rear defogger)
Cooling fan: OFF

IACV-AAC VALVe
Resistance

Approximately 10

INJECTOR

IGNITION COIL
Primary voltage

Primary resistance
[at 20'C (68'F)]

12

Resistance

10 - 14

Approximately 1

THROTTLE POSITION SENSOR

ENGINE COOLANT TEMPERATURE

SENSOR

Accelerator pedal conditions

PArtially released
Temperature 'C ('F)

Resistance kfl

20 (68)

2.1 - 29

50 (122)

0.68 - 1.00

80 (176)

030 - 033

Resistance kll.

Completely released

Completely depressed

07 - 5
Approximately 5

EC-213

Engine Control

System utilizing llmers wilh enhanced real-lime processin

functions, highpreClsion A-D converter,
af'ld hlgh'spee
DroceSSl("'g.

M6M12561J
,-----,
r------,

I ROM
I
L~~~I,!":

r - ---1

,RAM
l
l~~~~(! J

,..---'\r -----".,.

: Pon ::TimeI,:Ot<;OOer '~

L.-l-r...JL-flJI..--J--_..1

Ie
,---------------,

I,",

,s

Hybrid

!
(

IOpetal1on :

amoll!]..-I :
M5223
M52Z4
nd

!iO

Analog

on

Input
t

~---I

!'Yb"d Ie

Dighal

Comoa.

InpUI
I J

t310(

NQise

rilte
I

'-----'

Diagnosis displav.

-.

',e

M5233
M52H I I
a,.,d so on 1

.1

10-b/l

x8

ACCELERATOR CONTROL, FUEL &

EXHAUST SYSTEMS
,~r

SECTION

FE

CONTENTS
PREPARATION/ACCELERATOR CONTROL
SYSTEM
Special Service Tool..............
Accelerator Control System
Adjusting Accelerator Wire

2
.. 2

FUEL SySTEM
Fuel Tank
Fuel Pump and Gauge
EXHAUST SYSTEM

3
3 t;Q.,
.. .. 5
-.. 7

:M11

111

PREPARATION/ACCELERATOR CONTROL SYSTEM

Special Service Tool
Tool number
Tool name

Description
Removing and installing fuel tank lock ring

KV999GOO10

Fuel tank lock ring socket

NT057

Accelerator Control System

CAUTION:

When removing accelerator wire, make a mark to indicate lock nut's initial position.
Check that throttle valve opens fUlly when accelerator pedal is fully depressed. Also check that It
returns to idle position when pedal Is released.
Check accelerator control parts for improper contact wUh any adjacent parts.
When connecting accelerator wire, be careful not to twist or scratch wire.
Refer lo "AUTOMATIC SPEED CONTROL DEVICE" in EL section for ASeD wire adjustment.
Refer to "ONVEHICLE SERVICE" in AT section for Kickdown switch adjustment.
SEC. 180

~~.j~ :,~

'. ':'.,,

~~ 8 12 to.8 1.2, 5.8 8.7)

Ep!

Klckdown swltch

." ,~:::-,
'-.

(AIT models only)

'-...

~~3-4
c
(0.3 0.4,

2.2 2.9)

Return springm

~~
Accelerator ~
pedal

COJ: Nm (kg-m, ft-Ibl

SFE363A

Adjusting Accelerator Wire

Loc\( nut

~8 11 N'm
(0.8 1.1 kg-m,
5.8 8.0 Itlbl

1.

2.

>t:==--'~HA'r--,

Loosen lock nut, and tighten adjusting nut until throttle

drum starts to move.
From that position turn back adjusting nut 1.5 to 2 turns,
and secure lock nut.

Acceleralor wire

SFE249AA

FE-2

---------------

FUEL SVSrEM

WARNING:
Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
Be sure to lurnish workshop with a CO 2 fire extingUisher.

CAUTION:
Before removing fuel line parts carry out the following procedures:

@[

a.
b.
c.

~,~

Put drained fuel in an explosion-proof container and put the lid on securely.
Release fuel pressure from fuel line. Refer to "Changing Fuel Filter" In MA section.
Disconnect battery ground cable.
When installing fuel check valve, be careful of its designated direction. (Refer to EC section.)
Always replace O-ring and clamps with new ones.
Do not kink or twist tubes when they are being installed.
Do not tighten hose clamps excessively to avoid damaging hoses.
After installing tubes, run engine and check for fuel leaks at connections.

SEC. 172

~CD~30-35

~~_$1
(2.7 3.7,

20 - 27)

(3.1 3.6, 22 26)

./1

/'

/'"" ~I>
~~"_,,
j

(4.4 - 5.8, 32 421

~./ t2
Front

CD

@l
@

Lock ring
Upper plate
Seal packing
Fuel pump
Fuel gauge

(J)
@

@J

Mounting band
Fuel tank
Fuel tank protector
Fuel check valve
Filler collar

COJ:

Nm (kg'm, ftlbj

Filler hose

Filler tube
Grommet
Filler cap

@
@

SFE364A

Fuel Tank
REMOVAL
CAUTION:
00 not disconnect any fuel line unless absolutely necessary.
Plug hose and pipe openings'o preven1 entry of dust or oil.

FE-3

~iMI

Lt

FUEL SYSTEM
Fuel Tank (Cont'd)
======~.-~

1.

2.
3.

Release fuel pressure from fuel line.

Refer to "Changing Fuel Filter" in MA section.
Remove inspection hole cover located behind the rear
seat.
Disconnect harness can nectars under inspection hole
cover.

SFE365A

4.

Disconnect fuel tubes located on the lower right-hand side

of fuel tank.
Put mating marks on tubes for correct installation.

srE366A

5.

6.

7.
8.
9.

Remove exhaust center tube, propeller shaft, differential

carrier, rear suspension member and drive shafts (Refer
to RA section).
Disconnect filler hose at fuel tank side and vent hose at
filler tube side.

Remove fuel lank protector.

Remove fuel tank band mounting bolts while supporting
fuel tank.
Remove fuel tank.

INSTALLATION
Installation procedure is the reverse order of removal.

When installing filler collar, place the protrusion of the

collar flange upward.

SFE368A

FE-4

-----------------

FUEL SYSTEM
Fuel Tank (Cont'd)

Grommet

When installing the grommet of the filler tube, align the

protrusion on the grommet with the notch on the filler tube.

When installing the inspection hole, put the arrow mark iL,1f,
forward.

SFE369A

L~1~~
Mark
SFE370A

.--------------~

Fuel Pump and Gauge

REMOVAL
1. Release fuel pressure from fuel line.
Refer to "Changing Fuel Filter" in MA section.
2. Remove inspection hole cover located behind the rear 1PllQ1
seat.
3. Disconnect harness connectors and fuel tubes on upper
pi ate.
'f!lA
Pul maling marks on tubes for correcl installation .
4. Remove lock ring (Use Tool).
5. While lifting upper plate, disconnect fuel tube and harness
connectors.

sFE376Al

FUEL SYSTEM

Fuel Pump and Gauge (Cont'd)

6,
Fuel pump
bracket

Front

7.
a.

Remove fuel pump pulling the top end of the fuel pump
bracket upward.
Remove fuel gauge unit.
Pull fuel gauge unit horizontally to the Ieft.

SFE372A

b. Remove harness connector.

Carefully place the removed connector in the fuel tank so
that it can be purled out for the installation.

SfE373A

INSTALLATION
Installation procedure is the reverse order of removal.
CAUTION:
When Installing upper plate, align the' mark on it with the
center of marks on fuel tank.

FE-6

EXHAUST SYSTEM

CAUTION:

Always replace exhaust gaskets with new ones when reassembling.

!~f
With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
After installation, check to ensure that mounting brackets ~~
and mounting Insulator are 'ree from undue stress. If not
installed properly, excessive noise or vibration may be
~uI1Il
transmitted to the vehicle body.

----

~ 13 - 16

SEC. 200

(1.3 _ 1.6, 9 _ 12)

'/)5l, ~5.1
~
(0.52 6.5
_ 0.66,

'r ~:

~S.l

- 6.5 (0.52 0.66,3.8 -

'='"'

~"

J .~
~
._

AfT mode's

"""

<z . ~
~
I

(1.3

- 16

- 16 (1.3 1.6, 9 - 12)

--'f'

.~~

'~~,,-

.~

(cl

(~13-"

:':#nj

~ ~L

3.8 - 4.8)
I'nI
~-"j 51 - 65 (5.2 6.6, 38 48)

~ 30 - 39 (3.1 - 4.0, 22 - 29)

~ ~O~5;~~.66, 3.8 - 4.8)

.' -'" '\~~

A~43-55

~ 5.1 _ 6.5

~~

'fi,flJ.

(4.4 5.6, 32 41)

(0.52 0.66, 3.B - 4.8)

~5.1 6.5 (0.52 - 0.66, 3.8 - 4.8)

i~j

~iW

.>.~

~
I

1.6~

I'!'l"l 13
p-~

~13'
16 (1.3 -1.6, 9 -12) ~~~13 .16
I
~13.'6'
(1.3-1.6,9-12)

(OJ 13

'l~

models only

l ~~-y ~:'v

(0.52 0.66,

......... ~.

. ~~~",;"
,

",,0;,

~AfT

~I
~
I,.L

n;til A
4.8)~ ~ I !

"
/09
~~ ,'b
,.)

~ : N.m (kg-m, fHb)

.~--------- ------~-------~-----------~-----

~'J;1

~'T

~~
~ii'

~~

iEt
~~m

FE-7

I
,

SFE37M

CLUTCH
,;11

SECTION

C L ~,t

CONTENTS
PRECAUTIONS AND PREPARATION
Precautions.................

Special Service Tools

Commercial Service Tools

CLUTCH SySTEM
INSPECTION AND ADJUSTMENT
AdjlJsting Clutch Pedal
Bleeding Procedure

HVDRAULIC CLUTCH CONTROL

2
2
2
2

4
4
,

6 ~
7

Clutch Master Cylinder

Operating Cylinder

CLUTCH RELEASE MECHANiSM

CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel
Clutch Disc
.
SERVICE DATA AND SPECIFICATIONS (5D5)

General Speciftcations

Inspection and Adjustment..

8
10
10
11

12
12
12

~~n

irr
-',,",

Pi;

,oo:~

g/j.:'"
f)P~

~~oI

K',:2
~~l'

li/;'\
~l
11

[,[PJA

[I

~!
I;

PRECAUTIONS AND PREPARATION

Precautions

Recommended fluid is brake fluid "DOT 3".

Never reuse drained brake fluid.

Be careful no1 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.
Never use mineral oils such as gasoline or kerosene. It
will ruin the rubber paris of the hydraulic system.
WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do
not use compressed air.

Special Service Tools

Tool number
Tool name

Description
Removing and installing each clutch piping

GG94310000
Flare nut torque wrench

.~

~~
~

NT406

---------+-

a: 10 mm (0.39 In)

---------

ST20600000

Clutch aligning bar

NT405

ST20050240

Diaphragm spring
adjusting wrench

Installing clutch cover and clutch disc

a: 15.9 mm (0.626 In) di8.

b: 22.8 mm (0.898 In) dla.

c: 55 mm (2.11 In)
Adjusting unevenness of diaphragm spring
of clutch cover
a: 150 mm (5.91 in)

b: 25 mm (0.98 In)

NT404

Commercial Service Tools

Tool name

Description

Bearing puller

Removing release bearing

NT07i

Bearing drift

Installing

relea~e

bearing

a: 50 mm (1.97 in) dia.

NT063

CL-2

CLUTCH SYSTEM

...

~-

tDJ8-1~

(O.8-1.1~

>

5.8 - 8.0)~

,~ 16 22 (1.6 - 2.2, 12 - 16)

'.....----~

~~~~ 13 -16 (1.3 - 1.6, 9 -12)

o

1/~~~

~~~

16 - 22 (1.6 - 2.2. 12 16)

..

I~!~

~ I
f/~

~~,

!gjiXl

COJ:

m :

j1

Nm (kg-m, ttlb)
A.pply lithium-based grease

including molybdenum disulphide,

%~
SCl604

tJ) Clevis pin

@ Clutch disc

@ Fulcrum pin
@ Pedal bracket
@ Return spring

Snap pin
Clutch pedal

@Dust Gover

Lock

@ Release bearing
@ Clutch cover

CD Clutch

master cylinder

nut

@Locl< nut

~'J

Operating cylinder

@Withdrawal lever

~'f~,

@Bleeder screw
67) Clutch connector
,~-l

r:~;z

CL..3

INSPECTION AND ADJUSTMENT

Adjusting Clutch Pedal

1.

lHD 192 - 202 mm (7.56 - 7.95 in)

Push rod

Lock nut

toJ8 . 12
(0.8 ~ 1.2.
5.8 - 8.7)
Pad

Dash lower
panel

Adjust pedal height with pedal stopper.

Pedal height IIH":

RHD 188 - 198 mm (7.40 - 7.80 in)

2. Adjust pedal free play with master cylinder push rod. Then
tighten lock nut.
Pedal free play uA":
9 - 16 mm (0.35 - 0.63 in)
Pedal free play means the following total measured at position
of pedal pad:
Play due to clevis pin and clevis pin hole In clutch pedal.
3. Make sure that clevis pin can be rotated smoothly. If not,
readjust pedal free play with master cylinder push rod.

Melt sheet

CL-4

INSPECTION AND ADJUSTMENT

////

///
//0
Air bleeder

/ Clutch piping

/ connector
()

_
Bleeding Procedure
Bleed air from clutch master cylinder (RHD model only)
according to the following procedure.
I'k.i
Carefully monitor fluid level at master cylinder during bleeding operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. FUlly depress clutch pedal several times.
d. With clutch pedal depressed, open bleeder valve to ~/A
release air.
e. Close bleeder valve.
f. Repeat steps c through e above until brake fluid flows from 'Rl&\
air bleeder valve without air bubbles.
2. Bleed air from clutch operating cylinder according to the
~\iPl
above same procedure.
3. Bleed air from clutch piping connector according to the
above same procedure.
~1
4. Repeat the above bleeding procedures 1 through 3 several
times.
1.

Clutch

tUbe!

)=
/%
~ Y
SCL594

Remarks
When replacing clutch tube, install new one parallel to body
floor panel. If not, air bleeding might be difficult.

Cl..5

HYDRAULIC CLUTCH CONTROL

Clutch Master Cylinder

SEC. 305
lHD model

m CD

Apply rubber lubrIcant

I!'fi! @ : Apply

silicone grease

Apply rubber grease.

~: Nm (kg-m, tt-Ib)

Cylinder body

m(f)Rubbing
surface
to piston
assembly
Packing

Apply brake fluid when assembling.

Valve stopper

~ 1.52.9

(0.15 - 0.30,1.1 - 2.2)

Remove this stopper, when

removing piston and return spring.
SCL608

SEC. 305

C~P1ring~

RHO model

<~Stopp.rj
,r/

Push rod

E2l! Contact

PIston
assembly/

Cylinder body"""'\

m(i)Rubbing

~U'" s~;ng / //
~.

- surface
to piston
assembly

~-

mCD: Apply rubber lubricant

!i3!l(l:

Apply silicone grease.

m ; Apply rubber grease.

/~

,
~

surface to piston assembly

~
Lock nut

tql8 - 12 (0.8 -1.2. 5.8 - 8.7)

Dust CO\ler

m Rubbing surface to
push rod

~l Nm (kgm, fHb)

SCUi05

DISASSEMBLY AND ASSEMBLY

Push piston into cylinder body with screwdriver when

removing and installing valve stopper.

Cl6

HYDRAULIC CLUTCH CONTROL

Clutch Master Cylinder (Cont'd)

Align groove of piston assembly and valve stopper when

installing valve stopper.
Check direction of piston cups.

Groove

SCL214

INSPECTION

cracks, deformation

or

Operating Cylinder
SEC. 306

E:i! CD

: Apply rubber lubncant

SCl590

INSPECTION

Check rubbing surface of cylinder for wear, rust or damage. Replace if necessary.
Check piston with piston cup for wear or damage. Replace
if necessary.
Check piston spring for wear or damage. Replace jf necessary.
Check dust cover for cracks, deformation or damage.
Replace if necessary.

CL..7

--

CLUTCH RELEASE MECHANISM

SEC. 321
Oust cover

~
j

/Ret~-

Withdrawal rever

fm~sPring
~

HOI~pring

B~~---

~'~,

m~m
~

Rele.se sleeve
Release bearing

!Ii! :

Apply lithIum-based grease including molybdenum disurphide.

SCL617

REMOVAL AND INSTALLATION

Install retainer spring and holder spring.

SCL217

_=_==-----==1I04:'

Remove release bearing.

Install release bearing with suitable drift.

C_l_ 1-----J45

Press.

L __.. .

SCL222I

CL-8

CLUTCH RELEASE MECHANISM

INSPECTION

Check release bearing to see that it rolls freely and is free

from noise, cracks, pitting or wear. Replace if necessary_
Check release sleeve and withdrawal lever rubbing sur- @[
face for wear, rust or damage. Replace if necessary.
I~!l!~"

l,:e

LUBRICATION
Apply recommended grease to contact surface and rubbing surface.
Too much lubricant might damage clutch disc facing.

~':~

:-r~

Pack this recess.

m : Apply lithium-based grease including

molybdenum disulphide.
SCL223

*TI
/~',1

i~,TI)

~I~,<

~i~\

~~(

;)~f

'~~
I

'~{r

l
1

[{/}\

II

It

:1

I'T)J/{

1
i
1

CL-9

_ _ _I

CLUTCH DISC AND CLUTCH COVER

SEC. 300

Flywheel

Clutch cover
Apply lithium-based grease Including
molybdenum disulphide.

SCl354-B

--------------------- ------------------------,---------------,

Clutch Cover and Flywheel

INSPECTION AND ADJUSTMENT

Check clutch cover installed on vehicle for unevenness of

diaphragm spring loe height.
Uneven limit:
0.5 mm (0.020 in)
If out of limit, adjust the height with Tool.

SCL606

~--Flywheel

FLVWHEEL INSPECTION

Dial gauge

Check contact surface of flywheel for slight burns or discoloration. Repair flywheel with emery paper.
Check flywheel runout.
Maximum allowable runout:
Refer to EM section ("Inspection", "CYLINDER
BLOCK").

SCL349I

INSTALLATION

Insert Tool into clutch disc hub when installing clutch cover
and disc.
Tighten bolts in numerical order.
Be careful not to allow grease to contaminate clutch facIng.

CL-10

CLUTCH DISC AND CLUTCH COVER

~-----------,-------

Wear limit

Clutch Disc
INSPECTION

Check clutch disc tor wear of facing.

Wear limit ot facing surface to rivet head:
0.3 mm (0.012 in)
Check for backlash of spline and runout of facing.
Maximum backlash of spline (at outer edge of disc):
1.0 mm (0.039 In)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
115 mm (4.53 in)
Check clutch disc for burns, discoloration or oil or grease
leakage. Replace jf necessary.

INSTAllATION

Backlash of
spline

Apply recommended grease to contact surface of spring

portion.
Too much lubricant might damage clulch disc facing.

SCL490
'----------_.------'

CL-11
L

~~

SERVICE DATA AND SPECIFICATIONS (505)

__

General Specifications
CLUTCH DISC

CLUTCH CONTROL SYSTEM

Unit: mrn (in)

Hydraulic

Type 01 clutch control

Facing size
(Outer dia. x inner dia.
l( thickness)

CLUTCH MASTER CYLINDER

Inner diameter

mm (in)

240 x 160 x 3,5

(9.45 x 6.30 K 0.138)

Thickness of disc assembly

15.87 (SIB)

mm (in)

With load

CLUTCH OPERATING CYLINDER

Inner diameter

240

Model

1.9 - 6.3 (0.311 - 0.327)

with 4,903 N

(500 kg, 1,103 Ib)

CLUTCH COVER

19.05 (3/4)

240

Model
Full load

N (kg, IbJ

5.688 (580, 1,279)

Inspection and Adjustment

CLUTCH PEDAL

CLUTCH COVER
Unit: mm (in)

Unit: mm (in)

Model
Pedal height "H'''

LHD

RHD

192 - 202

188 - 198

(756- 7.95)

(7.40 - 7.80)

Pedal free play "A"

(At pedal pad)

Model
Uneven limit of diaphragm
sprIng toe height

9 - 16 (0.35 . 0.63)

": Measured from surface of mell sheet to pedal pad

CLUTCH DISC
Unit: mm (in)
Model

240

Wear limit of lacing surface 10

rivet head

0.3 (0.012)

Aunout limit of facing

1.0 (0.039)

Distance of runout check

point (Irom the hub center)

115 (4.53)

----

Maximum backlash of spline

(at outer edge of disc)

1.0 (0.039)

CL-12

240
0.5 (O.020)

MANUAL -rRANSMISSION

SECTION

MT

CONTENTS
PREPARATION
,
Special Service Tools

2
4
5

Commercial Service Tool

ON-VEHICLE SERViCE....... __
Replacing Rear Oil Seal
Check of Position Switches
REMOVAL AND INSTALLATION
Removal
Installation
,
MAJOR OVERHAUL.
Case Components
Gear Components .,
Shift Control Components
DiSASSEMBLy

5
5
6
6
7
8
8
9
10
11

Case Components
Shi'ft C antro I C ompanents
Gear Components
INSPECTION
Shift Control Components
Gear Components
ASSEMBLY
__
Gear Components
Shift Control Components
Case Components

,
,

11
12
,

SERVICE DATA AND SPECIFICATIONS (5DS)

General Specifications.,
Inspection and Adjustment

~I:;L

12

15
15

15
17 i~~,1
17
23
___ 24

~rru

I~:p)

27

27
28

~I~\

;g:1

Special Service Tools

Tool number
Tool name

DescrIption

ST2381 0001
Adapter setting plate

Fixing adapter plate with gear assembly

8: 166 mm (6.54 In)

b: 270 mm (10.63 In)

~T407

KV3110Q401

Pressing counter gear and mainshaft

Transmission press stand

NT06&

Tightening mainshaft locK nut

ST22520000

Wrench

a; 100 mm (3.94 In)

b: 41 mm (1.61 In)

NT409

Remo\llng and installing fork rod retaining pin

ST23540000

Pin punch

Ill: 2.3

mm (O.D91 In) dis.

b: 4 mm (0.18 In) d18_

NT442

ST300310QO

Puller

~emoving and installing 1st gear bushing

Removing main drive gear bearing
Measuring wear of baulk rings

a: 90 mm (3.54 In) dla.

b: 50 mm (1.97 in) dla.

NT411

ST23860000

Installing counter drive gear

Drilt

e: 38 mm (1.50 In) dla.

b: 33 mm (1 .30 In) dllll.

NT065

ST22360002

Installing counter gear front and rear end

Drift

bearings

8: 29 mm (1.14 In) dla.

b: 23 mm (0.91 In) dla.

NTOO5

MT..2

Special Service Tools (Cont'd)

Tool number

Tool name

Description

5T22350000

Installing OD gear bushing

Drift

a: 34 mm (1.34 In) dIe.

b: 28 mm (1.10 In) dis.

"'TOSS

--------------.,1----------------ST23800000

Installing front cover oil seal

Drift

.~
N1065

1T33400001

8: 44

mm

(1.73 In) die.

b: 31 mm (1.22 1n) die.

Installing rear oil seal

jrifl

8: 6D mrn (2.36 In) dis.

b: 47 mm (l.BS 1n) die.

NT086

Removing rear oil seal

ST33290001

Puller

a: 250 mm (9.84 In)

b: 160 mm (6.30 In)

NH14

,J

'!

Installing mainshaft ball bearing

ST30720000
Drift

a: 77 mm (3.03 in) dis.

h: 55.5 mm (2.185 In) dis.

NT115

Installing main drive gear bearing

5T30613000
Drift

8: 71.5 mm

(2.815 in) dla.

b: 41.5 mm (1.870 In) dis.

NTD7J

InstallJng counter rear bearing

Installing 3rd & 4th synchronizer assem-

8133200000
Drift

bly

It:

0 mm (2.M In) die.

b: 44.5 mm (1.752 In) dis.

NT09'

MT-3

,~L

PREPARATION

Special Service Tools (Cont'd)

Toot number
Tool name

Description

Removing overdrive mainshaft bearing

KV32101330

Puller

8: 447 mm (17.60 In)

b: 100 mm (3.94 in)

NT408

Commercial Service Tool

Tool name

Description

Puller

Removing counter bearings. counter

drive and 00 gears

NT077

MT-4
'0

ON..VEHICLE SERVICE

-----------------,

Replacing Rear 011 Seal

REMOVAL

INSTALLATION

SMH77AA

Check of Position Switches

Switch

Gear position

Continuity

Reverse

Yes

Other than reverse

No

Neutral

Yes

other than neutral

No

!k,l

Reverse lamp switch

Neutral position switch

/--~\

;p~

.~~

fdA\

'I

~-

!~,IR\

P""""~VJ?'>::l )~

~:r

f.l~

'~ Neutral position switch

~If

SMT451 SA

t'
If~

!.
I>

~L

r[Q)!{

MT-5

REMOVAL AND INSTALLATION

Removal

Exhaust tube
mounting bracket
SMT675C

1.
2.
3.
4.

Remove battery negative terminal.

Remove snift lever with control housing from transmission.
Remove clutch operating cylinder from transmission.
Disconnect speed sensor, reverse lamp switch and neutral
position switch harness connectors.
5. Remove starter motor from transmission.
6. Remove propeller shaft. - Refer to section PD.

Insert plug into rear 011 seal after removing propeller shaft.
Be careful not to damage spline, sleeve yoke and rear oil
seal when removing propeller shaft.
7. Remove exhaust tube mounting bracket from transmission.
8. Support manual transmission with a jack.
9. Remove rear mounting bracket.
10. Lower manual transmission as much as possible.

11. Remove transmission fixing bolts.

12. Remove transmission from engine.
Support manual transmission while removing it.

MT..6

REMOVAL AND INSTALLATION

Installation

@ MIT to engine
~

MIT 10 oil pan

Tighten transmission fixing bolts.

3
Bolt No.

SMT676C

Tightening torque
Nm (kg-m. ft-Ib)

\~[

"f" mm (in)

CD

70 - 79 (7.1 - 8.1, 51 - 59)

68 (2.68)

7079 (7.1 - 8.1,51 - 59)

63 (2.48)

70 - 79 (7.1 - 8.1,51 59)

78 (3.07)

29 - 39 (3.0 - 4.0, 22 - 29)

60 (2.36)

29 - 39 (3.0 - 4.0. 22 - 29)

30 (1.18)

Install any part removed.

MT-7

SEC. 320-321

Neutral position switch

~ 20 29 (2.0 - 3.0, 14 . 22)

~ Bolt thread

~19 -

_~~s
25 (1.9 - 2.5, 1 4 - <

s:

-I
I

co

16 - 21 (1.6

~ Bolt thread

2.1, 12 - 15)

Transmission case

(I)

!:
~

?)

~: Nm (kgm, fHb)
~: Apply recommended
(Nissan genuine part:

MAJOR OVERHAUL

Gear Components
Baulk ring

SEC. 322

3rd & 4th coupling sleeve ~

Needle bea
ring

Pilot bearing

M .

Snap ring

am drive
gear b aII bearing
.
,
Washer

Snap

'ing":~~J

Mainshaft

Snap ring ~
~

~
L
~$~ M

OD malnshaft bearing

ai@
j&~l1II<);~J

2nd
outer
baulk ring
2nd inner
baulk
ring
Synchronizer cone

2nd maing(ear

~.

N
~

OD (5th) reverse
~

=
.

~
or'.!

( ~

~
..~: g "",,,,,,,:;f.fL.... ring.~ ~
~nShaft
~~~
.-~137 ~
Th

Snap

Rolle'
OD

"-Sp,
A

Washe,"

d
ea

sleeve

W~~o~

(1

17.0. 101 - 123)

t Tool

(10.0 - 13.0 72

- 94)
OD coun'e,

"

Coun R

eanng

r gea'
gearspace,

:_~~~
=~ rse mai~~~~\
snapR,~::r~~i:::i~1tsnap
~
~~
ge~.,~~1n
e e bea,ing

everse coun'e

) C

Shim.

lock nu'
- 167

beanng

c~up"ng
~~
spnng~"

aulk nng ((:17- Shifting ins

Ne dl

Bush

,ust washer

D 15th) mein gear

0
gear bushing
Reverse count

#?

synchmnizer hub

"-J

hub" ronlzer

~snap ring~

Needle bearing

1st & 2nd

spnng
synch Insed
.

Needle be.,ing

E\) . ~

L:peedomete, ddve ge.,

ountershaft
S

7t:4

nap 'ing.
front bearing

ounle'

,~@J \

'ing

Counle'
drive gear"
Sub-gear

--L

"
R

Reverse idl: thrust washe'

Reverse idle' gear b

.
F' Reverse idler Ihr
eanng
ncllon dampe,
ust washe'

:~l,

averse idler shaft

Apply geer all to
Sub-gear
spring ~
sub-gear
bracket

a.d
gears.
sh.ft. y nohm.'.....
~ ., bearl.'
Selec,gWit,;:"e.
eembllng.
p
proper
thick
'"'. ay attention to"t
. ness .
-.111: N.m (kg-m, ft-lb)1 s direction,
SMT678C

MT-9

<

SEC. 328

Return spring plug

~ Thread of bolts

~ 20 - 29 (2.0 - 3.0. 14 ~ 22)

Bushing
Mating surface to control lever

Return spring

Select check plunger

Striking rod

<V

Stnklng lev",

M 9 - 12 (0.9 - 1.2, 6.5 - ,8.7)

s:-t

Retaining pIn ~

@@

Check ball

CheCk sp,ing

~V/ 4 II
Check ball

/~

Check ball Plu

g

D Thread of bOItS

""19
._
.. (1.9-

_25 ., 14 _818)10 _ 13)

25

14 _ 18.

\ )

(1 4 - 1.
Contra' housing
', \
g - S p r i ng

.....
I

c::>

6
Gasket

3rd &. 4th shift 'ork

tD.J : Nm
(f)

-t

(kg-m. ft-Ib)

~ : Apply recommended sealant (Nissan

genume part: KP610-Q(250) or

equivalent.

00 &; reverse shift fork

v/

DISASSEMBLY

Case Components
1.
a.

L._~-

Remove rear extension.

Remove control housing, check ball, return spring plug,
select check plunger and return springs.

b.
c.

Drive out striking arm retaining pin.

Remove striking arm from striking rod.

d.

Remove rear extension by lightly tapping it.

2.

Remove front cover, gasket, shim of countershaft front

bearing, and snap ring of main drive gear ball bearing.

3.

Remove transmission case by tapping lightly.

Soft hemmer

SMT320B

'----

-".ATO"

--TM753

MT-11

@[

DISASSEMBLY
Case Components (Confd)
4.

Remove front cover oil seal.

Shift Control Components

1.
2.
3.

Set up Toolan adapter plate.

Remove striking rod from adapter plate.
Remove check ball plugs, check springs, and check balls.

4.

Drive out retaining pins. Then drive out fork rods and
remove interlock balls.

5.

Draw out 3rd-4th and DO-reverse fork rods.

TM754-A

~I

Gear Components

EndPlav

"Ge<lr

Mainshaft
bushing

1.

or~

Before removing gears and shafts, measure each gear end

play.
Gear end play: Refer to SDS, MT-28.
If not within specification, disassemble and check contact
surface of gear to hub, washer, bushing, needle bearing
and shaft.

SMT025

MT..12

DISASSEMBLV
Gear Components (Cont'd)
2.
3.

Mesh 2nd and reverse gear, then draw out counter front
bearing with suitable puller.
Remove snap ring and then remove sub-gear bracket, subgear spring and sub-gear.
@,[

SMT174A

4.

Draw out counter drive gear with main drive gear assembly with suitable puller.
When drawing out main drive gear assemblYt be careful
not to drop pilot bearing and baulk ring.

L(~

I~~

5. Remove rear side components on mainshaft and counter.

a.

~:~;~se staking on countershaft nut and mainshaft nut and /~lf

loosen these nuts.
Mainshaft nut: Left-hand thread

b.
c.
d.

e.

Pull out OD counter gear with bearing with suitable puller.

Draw out reverse counter gear and spacer.
Remove snap rings from reverse idler shaft and draw out
reverse idler gear, thrust washers and reverse idler gear
bearing.
Remove speedometer drive gear and steel ball.

[83:J

SMT164A

'-------------------

Remove snap ring and pull out 00 mainshaft bearing, then

remove snap ring.
g. Remove mainshaft nut.
h. Remove steel roller and washer.
i. Remove roller bearing and washer.
j. Remove 00 main gear, needle bearing and baulk ring
(00).
k. Remove 00 coupling sleeve and shifting inserts.

f.

SMT456C

MT..13

N~

~:l

r:':qJ~

DISASSEMBLY

Gear Components (Cont'd)

I.

Press out mainshaft and counter gear alternately.

Press down mainshaft and counter gear alternately and
carefully. Do not allow gears attached to mainshaft and

counter gear underneath adapter plate to hit each other.

SMT75tA

6.
a.
b.

Remove front side components on mainshaft.

Remove 1st gear washer and steel ball.
Remove 1st main gear and 1st gear needle bearing.

c.

Press out 2nd main gear together with 1st gear bushing
and 1st & 2nd synchronizer assembly.
Remove mainshaft front snap ring.

SMT363A

d.

5T30031 000

SMT451CA

e.

Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing.

7.

Remove main drive gear bearing.

Remove main drive gear snap ring and spacer.
Press out main drive gear bearing.

SMT385A
~-----------------------'

a.
b.

L-

SMT420AA!

MT-14

INSPECTION

Shift Control Components

SMT137

Check contact surface and sliding surface for wear,

scratches, projections or other damage.

Gear Components

Malnshaff and gear

GEAR AND SHAFT

Check shafts for cracks, wear or bending.

Check gears for excessive wear, chips or cracks.

SMT386Aj

Counter gear

SMT550AI

SYNCHRONIZERS

Shifting insert

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 spread spring for deformation.

SMT387AI

MT-15

~.X\

~1

INSPECTION
Gear Components (Cont'd)

Measure clearance between baulk ring and gear.

Clearance between baulk ring and gear
(1 st, main drive, 00 and reverse baulk ring):

8aulk ring to
gear clearance

Dimension

1st

Main drive
SMT140

Standard

12-16

(0.047 - 0.063)

1.2 - 1.6

(0.047 - 0.063)

aD

1.2 - 1.6
(0.047 - 0.063)

Reverse

1.10 - 1.55
(0.0433 - 0.0610)

Unit: mm (in)
Wear limit

0.8 (0.031)

07 (0.028)

If the clearance is smaller than the wear limit, replace baulk

ring.

a.
b.

Inner baulk ring

~~k'ing

i~h~niler cone

c.
d.

ST~31=~
0;a1

ST30031000

indicato,

SMT041~

,---------------------------,

e.

SM~T04'BA

____

Measure wear of 2nd and 3rd baulk rings.

Place inner baulk ring in position on synchronizer cone.
Hold baulk ring evenly against synchronizer cone and
measure distance "A".
Place outer baulk ring in position on synchronizer cone.
Hold baulk ring evenly against synchronizer cone and
measure distance "B".
Standard:
Inner-A 0.6 - 1.1 mm (0.024 .. 0.043 In)
Outer-B 0.7 - 0.9 mm (0.028 .. 0.035 in)
Wear Limit:
0.2 mm (0.008 in)
If distance "A" or "8" is smaller than the wear limit.
replace baulk ring.

BEARINGS

Make sure bearings roll freely and are free from noise,
crack, pitting or wear.

MT-16

ASSEMBLY

Gear Components

Malnsha" bel! bearing In adapter plate

1.

Install bearings into case components.

@[:

Counter rear bearing In edapter plate

SMT429BAI

2.

Assemble adapter plate parts.

Install oil gutter on adapter plate and expand on rear side.

a.

Install bearing retainer.

Insert reverse shaft, then install bearing retainer.

SMT153A

SMT673CI

b. Tighten each screw, then stake each at two points.

MT..17

ASSEMBLY
Gear Components (Cont'd)

3.
a.
b.

Install main drive gear bearing.

Press main drive gear bearing.
Install main drive gear spacer.

c.

Select proper main drive gear snap ring to minimize clearance of groove and install it.
Allowable clearance of groove:

SMT425AAI

o - 0.13 mm (0 - 0.0051 In)

Main drive gear snap ring:
Refer to SDS, MT-28.

SMT426A

1.t & 2nd. 3rd 4th

~---~

Hub end coupling sleeve

4.

Assemble synchronizers.
1st & 2nd, 3rd & 4th synchronizers

Check coupling sleeve and synchronizer hub orientation.

1st & 2nd

Coupling slee....e

Synchronizer hub

Synchronizer hub
SMT681CI

MT-18

ASSEMBLY
Gear Components (Cont'd)

SMT047B

OD & reverse synchronizer

5.
a.

Install front side components on main shaft.

Assemble 2nd main gear, needle bearing and 1st & 2nd
synchronizer assembly. Then press 1st gear bushing on
mainshaft.
b. Install 1st main gear.

1st gear
thrust washer
SMT752A

c.

Install steel ball and 1st gear washer.

Apply mUlti-purpose grease to steel ball and 1st gear
washer before installing.

SMT403A

MT..19

rf,Ii;
nln\

ASSEMBLY
Gear Components (Cont'd)
6.

a-

Install mainshaft and counter gear on adapter plate and

main drive gear on mainshaft.
Press mainshaft assembly to adapter plate with Tool.

b.
c.

Press counter gear into adapter plate with Tool.

Install 3rd main gear and then press 3rd & 4th synchronizer assembly.

Pay attention to direction of 3rd & 4th synchronizer.

d.

Install thrust washer on mainshaft and secure it with mainshaft front snap ring.
Select proper snap ring to minimize clearance of groove
in mainshaft.
Allowable clearance of groove:
o - 0.18 mm (0 - 0.0071 in)
Mainshaft front snap ring:
Refer to 50S, MT-28.
Apply gear oil to mainshaft pilot bearing and install It on
mainshaft.

SMT7SOA

Insert spring

SMT679C

e.
TM<1dl

---------------,

f.

Press counter drive gear with main drive gear with Tool.

ST23860000

MT-20

ASSEMBLY
Gear Components (Cont'd)

Front

Pay attention to direction of counter drive gear.

SMT62DA

g. Install sub-gear components.

(1) Install sub-gear and sub-gear bracket on counter drive
gear. Then select proper snap ring to minimize clearance
of groove in counter gear.
Allowable clearance of groove:
o . 0.13 mm (0 - 0.0051 in)
Counter drive gear snap ring: Refer to SOS, MT28.
(2) Remove snap ring, sub-gear bracket and sub-gear from
counter gear.
(3) Reinstall sub-gear. sub-gear spring and sub-gear bracket.

LSUb~ear
Sub-gear spring

Sub-gear bracket

~(C

SM T52B A

h.

Install selected counter drive gear snap ring.

i.

Press counter gear front bearing onto counter gear.

7.

Install rear side components on mainshaft and counter

gear.
ril&i
Install reverse idler gear to reverse idler shaft with
spacers, snap rings and needle bearing.

TM.1fi6

KV311Q0401

TM443-A
~--------_.-----~

a.
Front

SMT680C

MT-21
b

ASSEMBLY
Gear Components (Cont'd)
00 (Sth) & reverse

b.

Sh,It,ng ,nso"1 syncn'Q

~lccu~ngspring
~[ead

''---J'F......-:;\

Install insert retainer and 00 & reverse synchronizer to

mainshaft.
Pay attention to direction of hub.

sleeve

SMT672C

C. Install 00 gear bushing with Tool.

d. Install 00 main gear and needle bearing_
e. Install spacer, reverse counter gear and OD counter gear.

OD main gear and OD counter gear should be handled as

a matched set.
f. Install washer, roller bearing, steel roller and thrust
washer.
g. Tighten mainshaft lock nut temporarily.

Always use new lock nut.

/

SMT531-A

h.

Install countershaft rear end bearing with Tool.

8.

Mesh 2nd and reverse gears, then tighten mainshaft lock

nut with Tool.

SMT003AA

MT..22

--

ASSEMBLY
Gear Components (Cont'd)

c
Torque wre"ch

9.

Use the left chart when deciding the reading torque.

(Length of torque wrench vs. setting or reading torque)
Tighten countershaft lock nut.
Always use new lock nut.

-Lmlft)
0,10m
(0.33 hI Nm
(kg.m)
(ftlbl
157
(16)

(1101

147
(15)

4>
;)

C7

137
(14)

;;, 11001
!::
'0
....

a:
u

(90)

(BOI

108

on 0.4

0.5

0,8

0.6

(1.51

(2.0)

12.51 (ftl

L: Length of torque wrench

SMTOO4A

10. Stake mainshaft lock nut and cQuntershaft lock nut with a
punch.
11. Measure gear end play. For the description, refer to DIS ~If
ASSEMBLY for Gear Components, MT-12.

Mainshaft

'~/k

Shift Control Components

Fork rod
(1st & 2nd)

1.

Install shift rods, interlock plunger, interlock balls and

check balls.

:,81;gt,

Fork rod
(3rd & 4th)
Interlock plunger
vrl==~u-...lnterlock

Check

ball....s:q~o----I+-Q5-.,...,f::j

ball

Eli
a.

1st-2nd shift fork

MT..23

ASSEMBLY
Shift Control Components (Cont'd)
b.

3rd-4th shift fork

c.

OD-reverse shift fork or reverse shift fork

SMT991

ST23800000

Case Components

~r+1,ess.

1.

Install front cover oil seal.

Apply multi-purpose grease to seal lip of oil seal before
installing.

2.

Apply sealant to mating surface of transmission case.

3.

Install gear assembly onto transmission case.

SMT036-A

- -

-----.-J

SMT013

MT-24

ASSEMBLY
Case Components (Cont'd)

4.

Install snap ring of main drive bearing.

5.

Set 1st & 2nd, 3rd & 4th and 5th & reverse shift forks in J'!C
neutral position.
Install striking rod onto adapter plate while aligning striking lever with shift brackets.
'~tE

Slriking rod

6.
Shift bracket
Striking lever

L._ _

SMT801BI

7.
8.

Apply sealant to mating surface of adapter plate.

Install rear extension while inserting striking arm into
striking rod.

&,1
~fQ)

~~

l_

"--seal;Jat
..

_--

iR\fJ,..

SMT062C

9.

Install striking arm retaining pin.

Q\;Q\

.Q"r,(,

~;r

Wl
~n

SMTB008

A: Distance from bearing

surface to transmission
case

10. Select counter front bearing shim.

Counter front bearing shim: Refer to 50S, MT-29.

11. Install gasket and front cover.

~=f /~\

e1.

CD

WfJ)~
Transmission case
Counter gear front bearing
Counter gear
TMJ71

MT-25

ASSEMBLY
Case Components (Cont'd)
12. Install return spring plugs, check ball, return springs and
select check plunger.
13. Install control housing and gasket.

- - - - - - - - -

SMT9B2

----J

MT..26
r"

SERVICE DATA AND SPECIFICATIONS (SDSL

--

General Specifications
Transmission model

FS5W71C

Number of speeds

l-tJII

Shift pattern

Warner

Synchromesh type
Gear ratio

1st

3.321

2nd

'.902

3rd

1.308

4th

1.000

00

0.838

Reverse

3.382

Number of teeth
Mainshatt

Counlershalt

Drive

22

1st

33

2nd

27

3rd

26

00

22

Reverse

36

Drive

31

1st

14

2nd

20

3rd

28

00

37

Reverse

1S
21

Reverse idler gear

[(Imp pt)

Oil capacity
Remarks

2.5 (4-3/B)

Sub-gear

0.

Reverse synchronizer

Double baulk ring type

synch ron izer

2nd and 3rd synchronizer

MT-27

---

SERVICE DATA AND SPECIFICATIONS (50S)

Inspection and Adjustment

GEAR END PLAY

AVAILABLE SNAP RINGS

Gear

Main drive gear bearing

End play mm (in)

151 ge;:lr

031 - 041 (0.0122 - 0.0161)

2nd gear

0.1' - 0.21 (0.0043 - 0.0083)

3rd gear

o 11

00 gear

0.24 - 0.41 (0.0094 - 0.0161)

Allowable clearance

- {l21 (O.OQ43 - 0.0083)

CLEARANCE BETWEEN BAUlK RING AND

GEAR

1st. main drive, 00 and reverse baulk ring

Unit mm (in)

1st

1.2 - 1.6
(0.047 - 0.063)

Main drive

1 2 - 1.6
(0.047 - 0.063)

0.8 (0.031)

1.10-1.55
(0.0433 - 0.0610)

0.7 (0.026)

2nd and 3rd baulk ring

Unit: mm (in)

Synchronizer cOl'e

Standard

32204-78001

1.94 (0.0764)

32204-78002

2 01 (0.0791)

32204-78003

2.08 (0.OB19)

32204-78004

o - 0.18

mm (0 0.0071 in)

Thickness mm (in)

Part number

24(0.094)

32263-V5200

2.5 (0.098)

32263-V5201

26 (0.102)

32263-V5202

00 mainshaft bearing

SMT044B

0- 0.14 mm (0 - 0.0055 in)

Thicknoss mm (in)

Pari number

1.1 (0.043)

32228-20100

1 2 (0.047)

32228-2010 I

1.3 (0,051)

32228-20102

1.-1 (0.055)

32228-20103

Allowable clearance

Wear limit

06- 1.1

0- 0.13 mm (0 - 0.0051 in)

Thickness mm (in)

Pari number

1.4 (0.055)

32215-E9000

1.5 (0.059)

3221 o-E900 1

1.6 (0.063)

3221S-E9002

(0.024 - 0.043)

r>?
B

32204-78000

1.87 (0.0736)

Counter drive gear

Inner baulk ring

1.80 (O.0709)

Allowable clearance

Outer baulk ring

Dimension

32204-78005

Allowable clearance

1.2 - 1.6

1.73 (0.0681)

Mainshaft front

(0.047 - 0.O63)

Reverse

Pari number

Wear limit

Standard

00

0- 0.13 mm (0 - 0.0051 in)

Thickness mm (In)

(DOOa)

0.7 - 0.9
(0.028 - 0.035)

MT..28

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Cont'd)
AVAILABLE SHIMS

Counter front bearing

Unit. mm (In)

A: Distance from bearing

surface to transmission
case

CD
<V

Counter gear front bearing

Counter gear

Allowable clearance

"A"
4,52 - 4.71 (0.1780 - 0.1854)

Transmission case

TM371

0- 0.16 (0 - 0.0063)
Thickness
of shim

Part number

Not necessary

4.42 - 4.51 (0.1740 - 0.1776)

0.1 (0.004)

3221B-V5000

4.32 - 4.41 (0.1701 - 0.1736)

0,2 (0.008)

32218-V5001

4.22 - 4.31 (0.1661 - 0.1697)

0.3 (0.012)

32218-V5002

4.12 - 4.21 (0.1622 - 0.1657)

0.4 (0.016)

32218-V5003

4.02 - 4.11 (0.1583 - 0.1618)

0.5 (0.020)

32218-V5004

3.92 - 4.01 (0,1543 - 0.1579)

0.6 (0.024)

32218NSOOS

MT-29
b

PROPELLER SHAFT &

DIFFERENTIAL CARRIER

SECTION

POI
I

---------~-----~

................ 2
2

PREPARATION
Special Service Tools

Commercial Service Tool

PROPELLR SHAFT

,---C-_'"

------'

PROPELLER SHAFT

5
6
.6
..... 6

On-vehicle Service.
Removal.

Installation

Inspection

. .8

Disassembly ..

.. 8

Assembly
_~

FINAL DRIVE

ON-VEHICLE SERVICEIREMOVAL AND

.
.
; INSTALLATION.
Front Oil Seal Replacement.
Side Oil Seal Replacement.
Removal.

."
.
.

Installation

FINAL DRIVE

-.=J

L..... __.

.
.

9
9
9
10
11

.12

DISASSEMBLY ..

13

.... 13

Differential Carrier
.

... 16
.... 16

Ring Gear and Drive Pinion

Bearing

..16

ADJUSTMENT.

. 17

Drive Pinion Height

..... 17

Side Bearing Preload

19
23
24

Tooth Contact.

ASSEMBLY.

Differential Case

24
25

Differential Carrier.

DIFFERENTIAL OIL COOLER SYSTEM . ..

.. 29

Description.

..... 29

Removal and Installation.

..... 29

.30

Wiring Diagram
.

".... .

""

Trouble Diagnoses

.32

" ..

... 32

SERVICE DATA AND SPECIFICATIONS (50S)

Propeller Shaft
Final Drive

"',:'1 I

..... 16

Differential Case Assembly.

Inspection .

.1

.. 15

DiflerentJal Case.
INSPECTION........

C==---J

13

Pre-inspection .

.
.

When you read wiring diagrams:

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

35
35
35

.'
.

PREPARATION
Special Service Tools
Tool r',\Jmh+;>r

Description

Tool name
KV38100BOO

Mounting final drrve

Differential attachment

(To use, make

new hole)

a: 152 mm (5.98 in)

NT119

------------j-------------------------- ------ST3090S000

Removing and installing drive pi nion rear

Drive pinion rear Inner

cone

race puller set

(1) ST30031 000

Puller

'-?) ST3090 1000

Basp.
a: 79 mm (3,11 in) dia.

b: 45 mm (1.77 in) dia.

c: 35 mm (1.38 in) die.

NT527

----------

ST33Q6S0Ql

Removing and installing differential side

Differential side bearing

hearing inner cone

puller set

CD

ST3305S001

Body

(?) ST33061000

(2-'1

~-E

Adapter

a: 28.5 mm (1.122 in) dia.

b; 38 mm (1.50 In) diil.

NT072

ST30611000

Install ing pinion rear bearing outer

ra~e

Drift

NT090

-----------+---------------STJ061380a

'nsta II i ng pi nion fro nt beari n9 oute r race

Drift

a; 72 mm (2.83 in) dia.

NT07J

-------------+-------------------sn0621000

b: 48 mrn (1.89 in) dia.

Installing pinion rear bearing outer race

Drill

8:

79

mm (3,11 In) dia.

b: 59 mm (2.32 in) dia.

NTQ73

PD-2

PREPARATION
Special Service Tools (Cont'd)
Tool number

Description

Tool name

Installing side oil seal

KV3810020D

Gear carrier side oil seal

drift

a: 65 mm (2.56 In) dia.

b: 49 mm (1.93 in) dia.

NT115

----------------+---------------------KV38100500

Installing front oi I seal

Gear carrier front oil seal

drift

a: 85 mm (3.35 in) dia.

b: 60 mm (2.36 in) dia.

NT115

Installing side bearing inner cone

KV38100300

Differenllal side bearing

inner cone

- 1
_,l,

8: 54 mm (2.13 in) dia.

b: 46 mm (1.81 in) dia.

c: 32 mm (1.26 in) dia.

NT085

Installing side bearing spacer

KV38100600

Side bearing spacer drift

a:

e rnm

b: R42.5

NPi28

(0.31 in)

mm (1.673 in)

ST3127S000

Measuring pinion bearing preload and

Preload gauge

total preload

(1) GG91030000

eD-----O==~~

Torque wrench
(~; HT62940000

Socket adapter

, l

'I'

----f;)

(~) HT62900000

(~

Socket adapter

--t

124

HT72400000

Slide hammer

Removing differential case assembly

~~~

_ _- - N T 1 2 5 - - - - - - - - ~

i ~_. ,:',-

PD-3

PREPARATION
Special Service Tools (Cont'd)
Tool n unlber
Description

Tool name

KIJ381039S0

Selecllng pinion height

Drive pinion height

adj ustmg washer

setting gauge

(1' KV38103910
Dummy shaft
'2

KV38100120
Height gauge

t'J:

KV38100140
Stopper

KV3810790-0------T'

NT226

Installing final drive side flange

Side oil seal protector

NT129

Commercial Service Tool

Tool name

Description

Drive pinion llange

Removi ng and insla Iling propeller shaft

wrench

lock nut. and drive pi nion lock. nut.

_ _ _ _~

I_N_r_35_5

f1_:8_1_"2_S_rn_m_<_3_"1_9_88_in_l

PD-4

PROPELLER SHAFT

SEC. 370
3S71A

MIT model

@I--------Apply a coat of multi-purpose lithium

grease containing molybdenum disulfide
to the end face of the center bearing and
bott1 sides of the washer.

I
~ ~~ ~55'65(56'66,41'48IJ

CY

AIT model

~I
@~~

L!J /

<1l"'"

i ~
~ 1l-~

~i'(~
~

I"'~)

\~
~/

~~

~ 43 55 14.4 5.6,32

41,

245294 (25 - 30,181 - 2171)

~ 34 44 (3.5 - 4.5, 25 33)

..

Nm (kg-m. tt-Ih)

Final drive companion flange

Center bearing

Companion flange

Propeller shaft 2nd tube

Center bearing cushion

Center bearing upper mounting

(j)

Center bearing lower mounting

bracket

Lock nut
Propeller shall lsi tube

Washer

bracket

Clip

l.

(l

(4',

~,IJ
~~~\
~

. I,
. i

PD-5

ED

PROPELLER SHAFT

On-vehicle Service
PROPELLER SHAFT VIBRATION
\t vibration is present at high speed, inspect propeller shaft
run out first.
1. Raise rear wheels.
2, Measure propeller shaft runout at indicated points by rotating final drive companion flange with hands.
Runout limit: 0.6 mm (0.024 in)

Propeller shaft runout measuring points:

Distance:

Joum7

Center bearing

"An 155 mm (6.10 in)

-_._~~

"B" 165 mm (6.50 in)

185 mm (7.28 in)
If runout exceeds specifications, disconnect propeller shaft
at final drive companion flange. Then rotate companion
flange 90, 180 or 270 degrees and reconnect propeller
shaft.
Runout limit: 0.6 mm (0.024 in)
Check runout again. If runout still exceeds specifications,
replace propeller shaft assemblyPerform road test.

"e"

!-I
C :
I

4.
5.

APPEARANCE CHECKING

Removal

Transmission

/-~.:.

II

..

,
I

L___ _

.<---

,l~/:::-, I
j;'

'.'
f-'-

',I.

Inspect propeller shaft tUbe surface for dents or cracks.

If damaged, replace propeller shaft assembly.
If center bearing is noisy or damaged, replace it.

Draw out propeller shaft from transmission and plug up

rear end of transmission rear extension housing,

~
,

\c-:L.....-

' /

L __ Plug
SPD3S9

Installation

[ALIGNMENT MARK ARRANGEMENT

Companion flange

ri

/'

If companion flange has been removed, put new alignment

marks 8 and C on it. Then reassemble using the following
procedure. Perform step 4 when final drive and propeller shaft
are separated from each other. Also perform step 4 when
either of these parts is replaced with a new one.

~---

.- C

SPDOSJA

PD-6

PROPELLER SHAFT
Installation (Cont'd)
1.
2.

Erase original marks Band C from companion flange with

suitable solvent.
Mark (B)
A. Measure companion flange vertical runout.
B. Determine the position where maximum runout is read
on dial gauge. Put mark (shown by B in figure at left)
on flange perimeter corresponding to maximum r LI nout
position.

'.1

Companion flange
SPD062A

3.

Mark (C)
A. Measure companion flange surface runout.
B. Determine the position where maximum runout is read
on dial gauge. Put mark (shown by C in figure at left)
on flange perimeter corresponding to maximum runout
position,

Companion fl8nge
SPD063A

4.

5.

6.

Position companion flange and propeller shaft using alignment marks A and B. Set the marks A and B as close to
each other as possible. Temporarily attach bolts and nuts.
Press down propeller shaft with alignment mark C facing
upward. Then tighten the lower nut to specified torque.
Tighten remaining nuts to specified torque.

Alignment mark C
SPD061 A

Inspection

Inspect propeller shaft runout. If runout exceeds

specifications, replace propeller shaft assembly.
Runout limit: 0.6 mm (0.024 in)

Inspect journal axial play.

If the play exceeds specifications, replace propeller shaft
assembly.
Journal axial play:
o mm (0 in)

SPD106

SPOS,'"

PD-7

PROPELLER SHAFT

Disassembly
CENTER BEARING
1.
2.

Put matchmarks on flanges. and separate 2nd tube from

1 st tube
Put matchmarks on the flange and shaft.

3.
4.

Remove locking nut with suitable tool.

Remove companion flange with puller.

5.

Remove center bearing with Tool and press.

Tool number: ST30031000

Assembly
CENTER BEARING

L_

When installing center bearing, position the "F" mark on

center bearing toward rear of vehicle.
Apply a coal of grease to the end face of center bearing
and both sides of washer.
Use multi-purpose lithium grease that contains molybdenum disulfide.

SPDI14

Stake the nut. Always use new one.

Align match marks when assembling tubes.

PD-8

ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION

Side Oil Seal Replacement (Cont'd)

3.

Remove oil seal.

4,

Apply multi-purpose grease to sealing lips of oil seal.

Press-fit oil seal into carrier with Tool.
Tool number: KVJ8100200

5.

Install tinal drive side flange,

Use Tool to prevent side oil seal from being damaged by
spline portion of side flange.
Tool number: KV38107900
Install drive shaft,

6.

""\

''-,

Removal
CAUTION:
Before removing the final drive assembly, disconnect the ABS
sensor from the assembly. Then move it away from the final
drive assembly. Failure to do so may result in damage to the
sensor wires and the sensor becoming inoperative.

Remove propeller shaft.

Plug up rear end of transmission rear extension housing.

SPO)15A

Remove drive shafts.

Refer to "Drive Shaft" of "REAR AXLE" in RA section.
Remove nuts securing final drive rear cove to susren.c;ion
member.
Support weight of final drive using jack.
Remove final rlrive mounting member from front of final
drive.
Move final drive 10rward together with jack. Remove rear
cover stud bolts from suspension member.
Lower final drive using jack. Remove jack from rear 01
vehicle.

PD-10

ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION

Removal (Cont'd)
CAUTION:

Be careful not to damage spline, sleeve yoke and tront oil

seal, when removing propeller shaft.

After removal, support suspension member on a stand to

prevent its insulators from being twisted or damaged.
, d

'I

Installation

Fill final drive with recommended gear oil.

Models equipped with oil cooler system -

Check oil level and for oil leakage from hoses after oil
cool er has been operated,

',1

PD-11

ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION

Front Oil Seal Replacement

1.
2.

Remove propeller shaft.

Loosen drive pinion nut with suitable tool.

3.

Remove companion flange.

4.

Remove front oil seal.

" I

5.
6.
7.

Apply
Press
Install
Install

multi-purpose grease to sealing lips of oil seal.

front oil seal into carrier.
companion flange and drive pinion nut.
propeller shaft.

Side Oil Seal Replacement

1.
2.

Disconnect final drive side flange and drive shaft flange

and suspend drive shaft flange with wire.
Remove final drive side flange.

PD-9

R200V

I~EC. 380
20 - 29
\,,3~\ F'l
~ (OJ (2.0
_ 30,
\

14 - 22)

rn1

,~~
U

(k -m ft-Ibl

:. AdJustme
Nm 9 nt'iS required

n'
r
~
App y
i:.) :: Apply

po'] ,
~\:-

sealant.
sealant
loc k'ng
I

2
~ 186._-- 294 (19 - 30 , 137 217)
Sf'032.1A

Gear carrier
'3\

, 4,'

5'
C,'

(ji,

SIde bearmg a d;usting

J
washer
Side bearing

Companion flange
Front oil seal
,
Pinion Iron I bearing
_ ting
Pi'1lon bearing adlUS

. \ case
DifferentIa
, . R sf-ter
Side gear thrust wa
SIde gear (RH)

washerbearing
,
adiusling
spacer
Pinion
,

re~r

beanng
Pinion
d'usling washer
Pinion relght a J
Dnve pinion
Bearing cap
S 'de oil seal
,
.
Side
bear Ing
s pacer

....2',

,~~J)

'~4'

~
Pinion
ma te shaft_
ale geal
Pmion
m ale th ru st washer
.
Pinion m
"th viscous
Side gear (lH) WI
couplng
Ring gear
HYPol"d gear set A
U llferential case

PD-12

Gasket
Rear cover
Filler plug
Drain plug
Breather
ABS sensor
Bracket
Oil tilter

Oil outrel,
'lch
Warning lamp SWI 'I h
Oil tempera \ u re SWI C

DISASSEMBLY

fS1.-""~'

Pre-inspection
Before disassembling final drive, perform the following
inspection.

Total preload
1) Turn drive pinion in both directions several tlmes to set
bearing rollers.
2) Check total preload with Tool.
Tool number: 5T31275000
Total preload:
1.4 - 3.1 N'm (14 - 32 kg-em, 12 . 28 in-Ib)

L'

SPOOS6A

Ring gear to drive pinion backlash

Check ring gear-to-drive pinion backlash with a dial indicator at several points.
Ring gear-to-drive pinion backlash:
0.10 0.15 mm (0.0039 - 0.0059 in)

,'.!.,

SPDS13

':,'11

Runout limit: 0.05 mm (0.0020 In)

Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit: 0.05 mm (0.0020 in)
Tooth contact
Check tooth contact. Refer to Adjustment (PD-23).

SPDB86

Differential Carrier
1.

l~

Using two 45 mm (1,77 in) spacers, mount carrier on Tool,

Too! number: KV38100800

2.

For proper reinstallation, paint or punch matchmarks on

one side of the side bearing cap.
Bearing caps are line-board during manufacture. Replace
them in their proper positions.

r .'

, !

PD-13

DJSASSEMBl Y
Differential Carrier (Cont'd)
3.

4.

Remove side bearing caps.

Lift differential case assembly out with Tool.

Tool number: HT72400000

Keep the side bearing outer races together with inner cone _
do not mix them up.
Also, keep side bearing spacer and adjusting shims together
with bearings.

5.

6.

7.
8.
9.

L...--

l Dosen drive pinion nut and pull 011 companion flange.

Take out drive pInion (together with rear bearing inner

race, bearing spacer and adjusting washer).
Remove oil seal.
Remove front bearing inner race.
R?move side oIl seal.

._ _

PD-14

DISASSEMBLY
Differential Carrier (Cont'd)

~]

10. Remove pinion bearing outer races with a brass drift.

; 01,

-';,,'1

11. Remove plnlon rear beari ng inner race and drive pi nion
height adjusting washer with suitable too!.
L~ I

-,

-r)
Suitable tool

--~

.L.

Differential Case
,. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:

Groove

5T33055001

aD 5T33061000

'I

-.

Be careful not to confuse left and right-hand parts. Keep bear~

ing and bearing race for each side together.

=-----------_._-------,

2. Loosen ring gear bolts in a criss-cross fashion.

3. Tap ring gear off the differential case with a soft hammer
Tap evenly all around to keep ring gear from binding.

SP0024

4.
5.

Loosen screws on differential cases A and B.

Separate differential cases A and B.

Malchmarks
I

______- -

SP06621
PD-15

INSPECTION

Ring Gear and Dr;ve Pinion

Check gear teeth for scoring. cracking or chipping. If any part
is damaged, replace ring gear and drive pinion as a set
(hypoid gear set).

Bearing
1
2.
sr0715

Thoroughly clean bearing.

Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation
damaged, replace outer race and inner cone as a set.

If

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion mate gears. pinion mate shaft and thrust washers.
Check viscous coupling for oil leakage. If necessary.
replace it with new one.
---------- --------

_ _ _ _ _ _'00319AAI

'1.,

Differential case 8

'----4'

PIn;on male thrust washer

(2-'

Side gear thrust washer

~S'

Pinion mate shaft

.6 '

Pinion mate gear

3'

Side gear (RH)

PD-16
ttl

l!J

Side gear (LH) with VISCOUS

coupling

cID

Differential case A

ADJUSTMENT
To avoid confusion while calculating bearing shims, it is absolutely necessary to stay with the metric system. If you measure
anything in inches, the results must be converted to the metric system.

Drive Pinion Height

~~
~)

,3:

cJ\
~);;
-

SP0024A

First prepare Tools for pinion height adjustment

(1) Dummy shaft (KV38103910)

2.

"\

I
L
-

1.

Height gauge (KV3B100120)

Stopper (KV38100140)
To simplify the job, make a chart. like the one below, to
organize your calculations.

~~_~TT:~_
N: Measuring clearance

HUNDREDTHS OF

M~LIMET~R

--_

'i

3.

Write the following numbers down the chart

H: Head number

4.

Set Tool (Dummy shaft) as shown below and tighten drive

pinion nut carefully to correct preload of 1.0 to 1.3 Nm (10
to 13 kg-em, 87 to 113 in-lb).
Tool number: KV381 0391 0

Head number (H)

SPD542

---------------------,

PD-17

'i

t~

ADJUSTMENT
Drive Pinion Height (Cont'd)
5.
KV3Bl00120 --,

e---....
/
:-'~'---\/
~ El~/

6.

Attach Tool (Height gauge) to gear carrier, and measure

the clearance between the height gauge and the dummy
shaft face.
Substitute these values into the equation to calculate the
thickness of the washer.

If value signifying H is not given, regard it as zero and

late.
T (Thickness of washer) =-- N - (H )( 0 01) + 3.00
Example:

calcu~

N = 0.23

SP0598

H = 1
T = N-(H xO.01) + 3.00
= 0.23 - (1 x 0.01) + 3.00
(1)

+1

(2)

+1

x 0.01

+ 0.01
(3)

............. ,

0.23

- (+0.01)
0.22

0.22

(4)

+3,00
3.22
:. T = 3.22
7.

Select the proper pinion height washer.

Drive pinion height adjusting washer:

Refer to 50S (PO-36).
If you cannot find the desired thickness of washer, use washer
with thickness closest to the calculated value.
Example:
Calculated value ... r = 3.22 mm
Used washer ... T = 3.21 mm

PD-18
(II

ADJUSTMENT

Drive Pinion Height (Confd)

-

Washer selection when replacing hVpoid gear set -

Drive pinions may be different in height due to the manufacturing process. Use a washer of proper thickness to adjust the
height of new drive pinion. Select the washer as follows:
T = (t, - \2) X 0.01 + To
where T: thickness of the washer to select
To: thickness Df the washer used
t 1 : old drive pinion head number
t;;>: new drive pinion head number
Example:

,/ Head number

To = 3.21, t , = +2, t 2
T
{2 - (-1)} x 0.01
3 x 0.01 + 3.21

SP0542-A
L

--~

_ _-

__

( , '!

-1

+ 3.21

0.03 + 3.21
3,24
T
3.24 mm
Drive pinion height adjusting washer:
Refer to 50S (PD-36).
,.i,

Side Bearing Preload

1,

To simplify the job, make a chart like the one below to

organize your calculations.
VAl.UE

LETTERS

left hOUSing

B:

Right housing

c:

Differential case

D-

Dilferentlal case

H:

(+) or (-), rirg gear

E:

Left Side bearing

.-

(=
F:

--_.-

--

--

-------

--

21 - Measured height)

Right side bearing

(= 21 - Measured height)
G'

--_._-'

Side bearing spacer

(= 8 1 - Measured thickness)
X

-1 97

------_.-

.--_.----

---

---- - - - -

----

2.

- ----

.. -

--- -

--

------

207

Write the following numbers down in the chart.

If numbers for A, B, C, IJ and H are not given, regard them

as zero.
A & B: Figures marked on gear carrier

i I.

PD-19

ADJUSTMENT
Side Bearing Preload (Cont'd)
C & D: Figures marked on diHerential case

H: Figure marked on ring gear

Do not confuse negative and positive values .

.-------------------~

3.

E & F ~ 21 mm (0.83 in) - Measured bearing height

Bearing height can be measured as follows:
a. Measure height of bearing race which will be used as
a base for the opposite side of a side bearing assembly.

Micrometer

Jl [ ~E]

Calculate "E" and "F" as follows.

'

""'0',-rr,///,rn;;r;;"""'//,""'~~

pposite side of
bearll"lg race

wm///'cw$//,.rW//,,10
Base plate

SPD025A

b. Set bearing assembly to be measured on the base race

and measure the total height.
Lubricate bearing assembly and turn it several times to
settle it on the base for accurate measurement.
c. Subtract base race height from total height.

Micrometer

Bearing
assembly being

----,-----r--.......-----.---.---- "mea 5 ured

Opposite sIde of
bearing race
Base plate
SPDO?6A.

'------------------------~

4.

Calculate "G".
G: This is the difference in thickness of side spacer from
standard width [8.10 mm (0.3189 in)].
G = 8.10 mm (0,3189 in) - Measured thickness

SPDS44

PD-20

ADJUSTMENT
Side Bearing Preload (Cont'd)
VALUE

LETTERS
A'

Left housing

B:

Right housing

c:

Differential case

0:

Differential case

H:

(+) or ( - ): ring gear

E:

Left side bearing

-----+--_.-- -

,'i
_._--

_._..._ - _

..

(= 21 - Measured height)

F'

Right side bearing

(= 21 - Measured height)
G:

Side bearing spacer

(= 8 1 - measured thickness)

X:

1,97

Y:

207

Ca Icul at ions:
Side bearing spacer is used on the right
Left side washer thickness
T 1 = (A - C + 0 - H) x 0.01 + E + Y
Right side washer thickness
T 2 = (8 - 0 + H) x 0.01 + F +- G + X
Side bearing spacer is used on the left
Left side washer thickness
T 1 = (A - C + D - H) x 0.01 + E + G + X
Right side washer thickness
T 2 = (B - D + H) x 0.01 + F + Y

'f!

'I

PD-21

ADJUSTMENT
Side Bearing Preload (Cont'd)

ExalTl~pl;-f-or R200V -Which~~ side

5
Co _. 6

G
X
Y

H = -2

=
=-0

0.15

0.08
1_97
2.07

Left side washer thickness (without spacer)

T 1 = (A - C + 0 - H} x 0.01 + E + Y

,-----------------'
4
A

-1

+ 6
---------.
= 5
- (-?)

= 7
x 0.01
,--------

0.18

--,

0,25

x 0.01
---- -----

+ 207
=

11

'

-_.~-------

3
-6

+ E

+- (-2)
._------

+
-- -

= -5

-c----

+ 0.15
---o 10

+ y

0.08

0.18
1.97

--

H
- - - I----- - - - - - -

x 0.01

x 0.01
= -005

+ F
-

---- ---- - - - - _ . -

+ G
+ X

2.15

232

2.32 mm

B
D

= -3

+0
-H

= 0,07

.-

Right side washer thickness (with spacer)

T 2 = (8 - D + H) x 0.01 + F + G + X
,-----_._------

-c

-5

--

---------------

E :: 0 18

bearing spac-;r on the riyllt

1 2 = 2.15 mm

5. Select the proper shims Refer to 80S (PD-36).

If you cannot find the desired thickness of shims, use shims
with the total thickness closest to the calculated value.

PD-22

ADJUSTMENT
Tooth Contact
Checking gear tooth contact pattern is necessary to verify
correct relationship between ring gear and drive pinion.
Hypoid gears which are not positioned in proper arrangement
may be noisy and/or have a short life Check gear tooth contact pattern to obtain the best contact for low noise and long
life.

Thoroughly clean ring gear and drive pinion teeth

Lightly apply a mixture of powdered titanium oxide and oil
or the equivalent. Apply it to 3 or 4 teeth of ring gear drive
side.

1.
2.

"c

SPD357
;',~' :

3.

Hold companion flange steady by hand and rotate the ring

gear in both directions.

SPD308

Usually the pattern will be correct If shims are correctly calculated and the backlash is correct.
However, in rare cases, trial and error processes may be employed to obtain a correct pattern.
The tooth pattern is the best Indication of how well a differential has been set up.
Heel contact

Face contact

Toe conlacl

'

To correct, Increase thickness of pinion

height adJusting washer to bring drive

p,n,oo

......

Flank contact

To correct. reduce thickness of pinion

height adjusting washer to position drive
pinion away from ring gear

~;~:,

/~I~

Correct tooth contact

, I

After adjustment, be sure to wipe oH the ferric

oxide and 011 or their equivalent.

SPDOQ,' ,\

PD-23

ASSEMBLY
Differential Case
Whenever side gears or pinion mate gears are replaced,
selection Of thrust washers should be carried out
Before selecting thrust washers, make sure all parts are clean
and well Iuol icated with hypoid gear oil.

THRUST WASHER SELECTION

1,

Install the previously removed thrust washer on right side

gear. On left side gear, install a suitable thrust washer.
Temporarily tighten differential cases using two screws.

2.

fPi1

Feeler gauge

','1 1 0.03 (0.0012)

,~~, 0.10 (O.0039)l

, .j

~~'

r' Feeler gauge

,(1) 0.03 (0.0012)

'-~tIl

~~~-

d\Lt

0.10 (0.0039)

Side gear (RH)

~,;>~~

'-:.:::~-~~/

Unit mm (in)
SPQB63-A

-----------

Position differential assembly so that right side gear is on

the upper side. Place two feeler gauges of 0.03 mm (0.0012
in) thickness between right side gear and thrust washer as
shown.
Do not insert feeler gauge in oil groove portion of differential
case.
3. Rotate right side gear with a suitable tool attached to
splines.
If hard to rotate, replace thrust washer on left side gear
with a thinner one.
4. Replace both 0.03 mm (0.0012 in) feeler gauges with 0.10
mm (0.0039 in) gauges. At this point, make sure riqht side
gear does not rotate. If it rotates, replace thrust washer on
left side gear with a thicker one to prevent rotation

ASSEMBLY
1.

Matchmarks....

'.

Install differential case A and 8.

tiJ~

~-

l}

l ~

SPD862

--------~

2. Place differential case on ring gear.

3. Apply locking sealant to ring gear bolts, and Install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

SPD5~.1

PD-24
IF'

ASSEMBLY
Differential Case (Cont'd)
4

--Tool

Press-fit side bearing inner cones on differential case with

Tool.
Tool number:
(A) KV38100300
(ID 5T33061000

C@
SPD353

Differential Carrier
1.

2.

Press-fit front and rear bearing outer races with Tools

Tool number:
(A) 5T30611000
C~) 5T30621 000
(~ 5T30613000
Select pinion bearing adjusting washer and drive pinion
bearing spacer. Refer to ADJUSTMENT (PD-17),

SPD679

3.

Install selected drive pinion height adjusting washer in

drive pinion. Using press and Tool, press-fit pinion r'ear
bearing inner cone into it.
Tool number: 5T30901000

4.

Place pinion front bearing inner cone in final drive housing.

Press -----//

SP0581
' - - - - - - - - - - . - - - - - - - - - - - - _ . -.. __ .. _ . -

PD-25

ASSEMBLY
Differential Carrier (Cont'd)
Set drive pinion assembly (as shown in figure at left) in
differential carrier and install drive pinion. with press and
suitable tool.
Stop when drive pinion touches bearing_
Apply multi~purpose grease to pinion rear bearing inner race.
pinion front bearing inner race.
5.

S?D896

6.

Apply mUlti-purpose grease to cavity at sealing lips of oil

seal. Jnstall front oil seal with Tool.
Tool number: KV38100500

SPD5571

7.

Install companion flange, and tighten pinion nut to specified torque with suitable tool.
Make sure that threaded portion of drive pinion and pinion nut
are free from oil or grease.

PD416

8.

Turn drive pinIon in both directions several times. and

measure pinion bearing preload.
Pinion bearing preload:
1.1 .. 1.4 N-m (11 .. 14 kg-em, 9.5 - 12.2 in-Ib)
When pinion bearing preload is outside specifications,
replacement is required for pinion bearing adjusting washer
and spacer. Replace with those of different thickness.

SPD056A

PD-26

ASSEMBLY
Differential Carrier (Cont'd)
9.

Select side bearing adjusting washer. Refer to ADJUSTMENT (PD-19).

10. Install differential case assembly with side bearing outer
races into gear carrier.

11. Insert left and right side bearing adjusting washers in

place between side bearings and carrier.

I
'_,)1

Side bearing spacer

tt

12. Drive in side bearing spacer with Tool.

Tool number: KV38100600
Spacer location: Right side

SPD559

13, Align mark on bearing cap with that on gear carrier and
install bearing cap on gear carrier.

14. Check runout of ring gear with a dial indicator.

Runout limit: 0.05 mm (0.0020 in)

-------_

SPDS2~

..

_._- .. _ - -

PD-27

"",fr

ASSEMBLY

Ditferential Carrier (Conrd)

"--------------------------'

15. 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)

If backlash is too small, adjustment of shim thickness is

required. Decrease thickness of left shim and increase
thickness 01 right shim by the same amount.
If backlash is too great. reverse the above procedure.
Never change the total amount of shims as it will change the
bearing preload.

16. Check total preload with Tool.

When checking preload, turn drive pinion in both directions
several times to seat bearing rollers correctly.
Total preload:
1.4 ~ 3.1 N'm (14 - 32 kg-em. 12 - 28 in-Ib)

If preload is too great. remove the same amount of shim

from each side.

1f 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. Difference in number of shims will change ring gear to
drive pinion backlash.
17 Recheck ring gear to drive pinion backlash. Incre3se or
decrease in thickness of shims will cause change to ring
gear to pinion backlash.

Check whether the backlash varies excessively in different

places. Foreign matter may be caught between the ring
gear and the differential case causing the trouble.

The backlash can vary greatly even when the ring gear
runout is within a specified range. In that case, replace the
hypoid gear set or differential case.
18. Check tooth contact.
Refer to ADJUSTMENT (PO-23).
19. Apply multi-purpose grease to cavity at sealing lips of oil
seal. Install side oil seal.
Tool number: KV38100200
20. Install rear cover and gasket.

PD-28
II'

DIFFERENTIAL OIL COOLER SYSTEM

--

Description

The differential oil pumps automatically repeat ON-OFF operation according to the differential gear
oil temperature.
OFF - ON
130"C (266~F)
ON - OFF
120C (248~F)
However, the pumps will not operate when the vehicle speed is less than 120 km/h (75 MPH).
When the oil temperature becomes excessively high, the warning lamp in the combination meter will
illuminate.
Differential gear oil:
OFF - ON
180"C (356F)
ON - OFF
150C (302F)

Removal and Installation

- - - - - .. - -_.------_." ....

"

\.'11

Oil pump mountlnQ bracket

(5)

Oil cooler prolector

(9

Oil temperature switch

(~)

Oil pump assembly

',6:\

Oil

,'frI,

Connector bracket

'-.3)

Oil pump bracket

,'J}

Inlet connector

'11'

Final drive

Oil cooler assembly

(8;

Warning lamp SWitch

'1)

(~)

COO,l er

tube assembly

PD-29

DIFFERENTIAL OIL COOLER SYSTEM

Wiring Diagram

PD-DIFF-01
<b): LHO models

<B>:

Aefer to EL-POWER.

RHO models

Mi",

<D

<ID

Q5

M2

*3 .. <I)

R7
3
6
R4

<ID

Q8

<D
<])

rrill1
1

,----__----jf

IL........-.----~---,----JI

$OIFF OIL

L/A

R/Y

1(ffiJ)

I[jl- - - - -

$L/R <D : CID, <ID : eN)

R/Y~

rm
OFF

Y/G
.~

4J1

lCP----QdJ
R/Y

Y/G

em

rn

Y/G

~Next

poge

VEHICLE
SPEED

DIFFERENTIAL
OIL

SENSOR

WARNING LAMP

------" @ID

SWITCH
~

llow

~
Y/G

~
-.- (]D

R!Y
L~

_L (fill)

-mJ1

LJR

temp)

I (WI

<I>; ~.<ID: ~

ON

QITQ)

$L/R)

(High

TJ ~ lTJ t
I
I

COMBINATION
METER

L_

SPEEDOMETER

temp)

1-,

CBD

r----------------------------------l

: rtn-T;1l3fJl
: ~~J
IL-----

lvd1 ftl14IJTi1 tG2O'

~ ~~J ~ l

rl J

'W

(11)

~ GY

J\

@@

~ (E20i)

~ GY

Refer to last page

(Fa Idaut page) _

cHIQ)

@1)

(TI)

&1(lli)

(08

SPD326A

PD-30
",

DIFFERENTIAL OIL COOLER SYSTEM

Wiring Diagram (Cont'd)

PD-DIFF-02
<D : LHD models
<ID : RHO models

Refer to EL-POWER.

*4"'~ 29

---~
1~1
L

caD

~CID

<C>
<ID

L/W

ffi IF1l1
L

SPEED CONTROlJ
AMPLIFIER

~~~_..:.L....=:.....-L'----_-----,

IGN

.'- - - -

DIFFERENTIAL
RELAY-2
OIL
COOLER

II 3 II (ITg)

II 1 II
=r=-'

~
Y

IT"f?\s'
~

GID

--. I

W
DIFFERENTIAL

OIL

temp) TEMPERATURE

L!

OIL PUMP

II 2 II

(Hq~h

GND

L/W

II~II DIFFERENTIAL
B

~bf~A

GND

,
tv1

SIGNAL

It )LI

Y/G

~~crB

DIFFERENTIAL
"1] OIL
COOLER
1 RELAY-1

e------I

SP

*6 .,

':I:' 'JIJ'

Preceding.---At. Y/G
page
~

<D

-e-------,.,
L

(R) 28
M1
(ID 07

~f5' ..

OFF'--

SWITCH

(Lo~

temp)

"

....

-=_ _-....

8
~

r!l (ill)
l0 8

~Q@

til

<ffg)

'ill)
8

+
2

Refer to last page

(ffi)

(Fa 1dout page) _

aID
GY
! I,
SP0317A

PD-31

DIFFERENTIAL OIL COOLER SYSTEM

Inspection
Thoroughly clean all parts in cleaning solvent and blow dry
with compressed air. if ~vAilable_

OIL PUMP ASSEMBl V

Replace oil pump assembly when motor does not rotate
because of motor sei7ure or other damage.

OIL COOLER ASSEMBL V, OIL TUBE ASSEMBLY, OIL

HOSE
If oil leakage is detected during removal, replace oil cooler
assembly or oIl tube.

-------------------

'-----------------------'

Trouble Diagnoses
SYMPTOM:
Oil pump does not rotate.
CHECK OIL PUMP OPERATION
1. Disconnect speed control amplifier harness connector.
2. Disconnect oil pump temperature switch harness connector.
3. Turn iQnition switch' ON"
4. Connect jump wire between oil temperature switch harness connector term inal .j) and ground.
Oil pump rotates:
Refer to Procedure A.
Oil pump does not rotate:
Refer to Procedure B.

PD-32

DIFFERENTIAL Oil COOLER SYSTEM

r--

Trouble Diagnoses (Cont'd)

Procedure A

l -- - - ---]

nePla~e-~em;ralu~~l

[ CHECK OIL TEMPERA rURE SWITCHJNG

1) Remove oil temper alure switch
2) Check proper operation
Operating temperature:
OFF -, ON 130'C (266-F)
~--

----l-OK - -- --------

SP0330A
- - -- - -

----- - - - -

-.

NG

CHECK SPEED CONTROL AMPLIFIER

POWER SUPPLY
1) Disconnect speed control amplifier

--

harness connector
2) Turn ignition SWitch ON"
3) Check voltage between :'2). (Ii) and
ground_
Baltery voltage should exist.

OK

:\'

l~~.nl\~ ~ ~
I
1
(Blue)-"
Oil cooler

~T

(OJ
-

r~\ay-2

(Black)

. Speed control
,amp_ harness
. connector

--:SPD332A

CHECK SPEED CONTROL AMPLIFIER

GROUND CIRCUIT_
1) Turn ignition switch "OFF"

2) Disconnect speed control ampllfier

harness connector
3) Check harness continuity between
G), @) and ground.
Continuity should exist.

:---=r

NG

Check and repc-lIr the to,llowing parts Harness continuity

between speed control
ampldJer harness connector terminal (2',
and fuse
Harness contilluily
between speed control
amplifier harness COIlnector terminal ..4' and
oil cooler relay-2 harness connector term inal 111
Harness continUity
etween 011 cooler
relay-2 hal' ness connector terminal 2: and
fuse
Oil cooler relay2

. .. -- ----I
Repair or replace harI

~-

ness-

----.J

ffiJ"
V~

---

~I
OISCO~

switch

CHECK SPEED SIGNAL INPUT CIRCUIT

1) Discon necl speed control ampllf IeI'

harness connector and combination

meter harness connector.
2) Check harness continuity between
speed contro I am p Iit i er h ar ness connector terminal '-J' and combination
meter harness connector terminal
,~)

Continuity should exist.

SPD333A

PD-33

l_

N_G----....' Repair or replace helrness

DIFFERENTIAL Oil COOLER SYSTEM

Trouble Diagnoses (Cont'd)
Procedure B

.----------------_._------,
NG

CHECK POWER SUPPLY

I) Disconnec t oi I Ie mpe rature S'AI itch

I-------+--

harness connector and speed control

ampl ifier harness con nectar

relay-t harne::;s con-

3) Check voltage between oil temperature sWitch hal ness connector termi-

nal

G)

and ground

OK

.,,------'------------,
1) Disconnect oil pump harr"tess son-

@ and

oil cooler relay-2 harnal @)

2) Turn ignition swilch ., ON"

3) Check voltage between oil pump

harness connecto r term ina I

(D

and

ground.
Battery voltage should exist
\1 NG, check and repaIr the following
parts:

Harness continuity between oil

cooler re[ay-l harness connector
Fuse

Harness continuity between cd

cooler relay-1 harness connector

and oil pump harness

connector terminal

CD

Oil coolp.r relay-1

_._------y
J

= _

CHECK GROUND CIRCUIT.

1) Turn ignition switch "OFF"

2) Disconnect oi I pump harness connector.
3) Check harness continuity between

oil pump harness connector terminal

/~ and ground,

Continuity should exist.

If NG, repair or replace harness

a-c-e-o-i1-p-u-m-~

L-R-e-p-I

PD-34

Oir cooler relay,

Oil cooler relay-2

Harness continui\y
between oil cooler
relay-2 harness conner-tor terminal @ and
oil temperature switch
hnrness conneclor lerminal (11

terminal @ and fuse

,-S

np-c\or \erminal

ness connector term i-

nectar,

terminal

CD

relay-l harness con-

E8~

nector terminal

and tuse
Fuse
Harness continuity
between oil cooler

Batlery voltage should exist.

O'SCD~NECI ~

lowing parts'

Harness continuity

between oil cooler

2) Turn ignition switch 'ON'

'------------------------'

Check and repair jhe fol-

..

_----J

SERVICE DATA AND SPECIFICATIONS (SDS)

Propeller Shaft
GENERAL SPECIFICATIONS

SPECIFICATIONS AND ADJUSTMENT

Unit mm (in)

M/T

Applied model

Unit: mm (in)

A/T

Propeller shaft model

3S71A

-_.-

Propeller shaft model

3S71A

Number 01 jOints

Propeller shaft runoul limll

Journal axial play

----

Coupling method wdh

06(00/4)
0(0)

Sleeve type

t ransmlSS I on

Type 01 Journal beMlngs

Shell type (Non-disassembly type)

Distance between yokes

--_.-

630 (2.480)

,---_.

---

Shalt length
(Spider to spider)
421,0 (16.57)

1st

441

a (17

36)

2nd
Without ABS

6500 (2559)

With ASS

636.0 (25.04)

Shaft outer diameter

1st

75.0 (2.953)

2nd

50,8 (2.000)

75.0 (2,953)

Final Drive
Available side gear thrust washers

GENERAL SPECIFICATIONS
Applied model
----

_~.

M/T

--_.- -

---~~

Final drive model

R200V

Ring gear pitch diameter

205 (8,07)

mm (In)
Gear ratio

3.692

Number of teeth

3.916

48/13

(Ring gear/drive pinion)

Oil capacity

Thickness

All

~-----

( (Imp pi)

_.

-,-

Number of pinion gears

Side gear bearing spacer

Right

location

INSPECTION AND ADJUSTMENT

Ring gear runout
Ring gear runout limit

005 (000201

mm (111)

Side gear adjustment

Clearance between Side gear
and differential case

(0

003 009
0012 - 00035)

PD-35

Part number
38424-40F60

0.83 (00327)

38424-40F61

0.86 (0,0339)

38424-40F62

0.89 (0 0350)

38424-40F63

092 (00362)

38424-40F64

0.95 (0 0374)

38424-40F65

0.98 (0.0386)

38424-40F66

1.01 (00398)

38424-40F67

1.04 (0 0409)

38424-40F68

1,07 (0,0421)

38424-40F69

1.1 0 (0 0433)

38424-40F70

47112

12- 1 4 (2-1/8 - 2-1J2)

__ .....

mm (in)

080 (0.0315)

1.13 (0 0445)

38424-40F71

1.16 (00457)

38424-40F72

1,19 (0,0469)

38424-40F73

1.22 (0 0480)

38424-40F74

1.25 (0 0492)

38424-40F75

1.28 (0 0504)

38424-40F76

1.31 (0,0516)

38424-40F 77

1 34 (0,0528)

38424-40F78

I 37 (0.0539)

38424-40F79

140(00551)

384?4-40F80

1 43 (00563)

38424-40F81

1 46 (00575)

38424-40F8?

1 49 (00587)

38424-40r83

SERVICE DATA AND SPECIFICATIONS (50S)

Final Drive (Cont'd)
Drive pinion height adjustment

Available drive pinion bearing preload adjusting spacers

Available pinion height adjusling washers

Thickness

mn (in)

---

PM! number

30g(012171

381 S,1-P60 17

3 12 (e 12281

38 154-P60 18

(C 1240:

38154P6019
38154P60?O

321 (01264)

38154-P6021

1~

3 2,1 (0 1276)

28154-P6022

J 27 (01287)

3815~-P6023

.)30 (0 1299)

36154;-5024

333(01311)

:\R 1:';.1- P6025

336 \0 1323)

33154 -P6026

3 3<:1 (0 UJ5)

3i3 1~4-fJ6027

342 (0 1346)

38154-P6028

345 (f) 1358)

38154-P6029

3.48 (0 1370)

3815J\P6030

38165-84004
38165-61001

Total preload adjustment

Dr've pl"lion to ring gear'
backlash
mm (in)

o 10

. 0.15

(00039 - 00059)

'.4 . 3.1

TOld' preload

N'm (kg-ern. m-Ib)

------

114 - 32.12 - 28)

--~-----------

Side bearing adjusting method

Adjusl,ng washer

Available side bearing adjusling washers

357 (0 1406)

38154-P6033

360 (0 1417)

38 154-P6034

2 05 (0.OB07)

384S~-N~10 1

363 (0 1479)

381 54 - P6035

2,10 ,:0,0827)

384 53-N31 02

366 (0 1441)

38154-P6036

011 seal

N m (kg-em, in ,b)

200 (00787)

Available drive pinion bearing preload adjusting washers

eo - 382

(0 \496 -

Part number
1504)

38125-61[}O~

3 A/' - J 84 (0 1504 - 0 1512)

38126-61'JO 1

38 11 - 386 :0,1512 - 0 IS/O)

3812701001

386 - J 88 iO.1520 - 0 1528)

3812861001

388 - J !=lO

in

1528

0 1535)

.3 90

392101535 - 0 ~543)

:I ~~

:>

')~

to

381~SI-61001

38130-61001

\~";4J - 0 '~~l)

38131-61001

'394 - 396 (0 1551 - 0 1559)

38132-61001

~ti

(0 1 ~ 59 - 0 15671

38133-61001

398 - 4 00 (0156701575)

1R 134-61001

4 O? (a 1575 - 01583)

"- 02 - 4 04

(f)

1S83 - 0 1S9 1)

06 i') 159 - 01598)

408(01598

38135-61C01
3[J13[)61001
3813]-61001

OIGOG\

38 13B-610C}1

408 - 4 10 (0 1606 - 0 1514)

38139-6WJ1

mm (in)

Thickness

Pinion bearing adjusting

'.1 - 1.4
.11 - 14. 9.5 - 1<? 2)

-:j

55 7Q (2 1929)

56,Oa (22047)

38154-P6031

D'ive pinion preload Willi !ront

401

38165-B~003

38 154 -P6032

washer arid spacer

,jop,

38'65-B4002

354 (0 1394)

method

4 DO

3B:6~-1::34001

351 (0 1382)

Dr tve lJlnlOn bearmg adjusting

3 gti . J

38165-84000

5480 (2 1575)

J5AO (2 t!31

Drive pinion preload adjustment

.3

Pac! number

54.50 (2 1457)

55,'0 (2 1693)

318 (0.1252)

mm (In)

Length

PD-36

Part number
38453-N3100

2 1510.0846)

384S3-N31 :)3

220 {O 0866\

3B453-N3104

225 (008861

384:J3-NJ 105

2 30 (0.0906)

38453-N3106

2.35 (0 U92tl)

38453-N3107

240 (::10945)

38453-N31 08

? 4S (a,0965)

38453 -N31 09

250 (0098.1)

1R45'J-N3110

2 55 (O 1004)

38453-N3111

fiO (0 1024)

38453-N3112

265 (0 1043)

38453-N3113

FRONT AXLE &

FRONT SUSPENSION

FA
CONTENTS
2

PRECAUTIONS AND PREPARATION .,.

Precautions. _

..... "

Special Service Tools

.
Commercial Service Tools .. ,_

,.. "

,.,

FRONT SUSPENSION SYSTEM ..

ON-VEHICLE SERVICE ."., .-."

Front Axle and Front Suspension Parts
Front Wheel Bearing"._-

.. "

Front Wheel Alignment ",

FRONT AXLE"..

.,

".2
... 3
_., .. ,.. _.4
_.. _.5
.. 5
,5

.
"

-."" ."

".

,..

8
10

Wheel Hub and Knuckle .. , " .. ,-.-ABS Sensor Rotor .... _

Baffle Plate

,.-,

-- .

10

FRONT SUSPENSION.,
Coil Spring and Strut Assembly.--

__ 11

Tension Rod and Stabilizer Bar ..

Transverse Link and Lower Ball Joint

SERVICE DATA AND SPECIFICATIONS (SOS) -

,,12
13
14

",,15

General Specifications" . ,

_15

.. ,8

Inspection and Adjustment

,,-

15

i'

PRECAUTIONS AND PREPARATION

Commercial Service Tools
Tool name

Description

Equivalent to GG94310000

CD

Removing and installing each brake piping

Flare nut crows foot

@ Torque wrench

,'I'

a: 10 mm (0,39 in)

NT360

Baffle plate drift

Installing baffle plate

a: 88 mm (3.46 in) dia.

b: S8 mm (2.68 in) dia.

NT06S

Tension rod bushing drift

Removing and installing tension rod bushing

a:
b:
c:
d:

NT155

7S
66
62
2S

mm (2.95 in) dia.

mm (2.60 in) dia.
mm (2.44 in) dia.
- 5S mm (0.98 2.17 in) dia.

-----------1------------------------------------Attachment

Measure wheel alignment

Wheel alignment

a: Screw M22 )( 1.5

b: 35 (1.38) dia.
c: 65 (2.56) dia.

I,,':

d: 56 (2.20)

e: 12 (0.47)
Unit mm (in)

NT148

I:
I

FA-3

PRECAUTIONS AND PREPARATION

Precautions

\. GG94310000

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.
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Use flare nut wrench when removing or installing brake
tubes.

Always torque brake lines when installing.

SBr-B20B

Special Service Tools

Tool number
Tool name

Description

HT72520000

Removing tie-rod outer end and lower ball

Ball JOint remover

jo'nt

NT\46

HT71780000
Spring compressor

NT144

ST35652000

~4
!--------------]
----

Strut attachment

NT1'15

GG94310000

Removing and installing cOil spring

Fixing strut assembly

Removing and installing brake piping

;::Iare nu~ torque wrench

a: 10 mm (0.39 In)

NT406

FA-2

FRONT SUSPENSION SYSTEM

------------- -

---

SEC. 401
When instelllng rubber parts. 'lnal tightening must be
carried out under unladen condllion- with
tires on ground.
* Fuel, radiator coolant end engine 011 full.

Spare tire. jack. hand tools and mats in daslgnated

positions.

~ ~30 - 54

(4.0 - 5.5, 29

-7

II
---)

.-

Front

~~ 88 - 108 (9.0 - 11.0, 65 - 80)

~, N.m (kg-m. ft-Ib)
SFA615B

1
'2,1

:(,
:4,1

Strut mounting Insulator

(5)

Front suspension member

,~:

Air guide

Spring upper seal

Front stabilizer

IJij]

Transverse link with ball joint

Coil spring

r)
(7)

TenSion rod bracket

:fD

Brake rotor

Strut assembly

'8:1

TenSion rod

FA-4

ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts
Check front axle and front suspension parts for looseness.
cracks, wear or other damage

Shake each front wheel to check for excessive play

Retighten all axle and suspensions nuts and bolts to the

specified torque
Tightening torque:
Refer to FRONT SUSPENSION (FA-11).

Make sure that cotter pins are inserted

,I

SMA525A

Check strut (shock absorber) for oil leakage or other damage.

Check suspension ball joint for grease leakage and ball
joint dust cover for cracks or other damage.
If ball joint dust cover is cracked or damaged, replace
transverse link.

SHul

Ball joint
SFA3928

Check suspension ball joint end play.

(1) Jack up front of vehicle and set the stands.
(2) Clamp dial indicator onto transverse Iink and pi ace indicator tip on lower edge of brake caliper
(3) Make sure front wheels are straight and brake pedal is
depressed.
(4) Place a pry bar between transverse link and inner rim of
road wheel.
(5) While raising and releasing pry bar. observe maximum
dial indicator value.
Vertical end play:
o mm (0 in)
(6) If ball joint movement is beyond specifications, remove
and recheck it

Front Wheel Bearing

Check that wheel bearings operate smoothly

Check axial end play.
Axial end play:
0.05 mm (0.0020 in) or less
If out of specification or wheel bearing does not turn
smoothly, replace wheel bearing assembly.
Refer to FRONT AXLE -- Wheel Hub and Knuckle (FA-8)

I~

SFA325B

Front Wheel Alignment

Radial

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.

runout

-! -

SFA515B

_ _ _ _ _ _ _ _ --.J

FA-5

ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
PRELIMINARY INSPECTION
1.
2.

3.
4.
5.
6.
7.
~--------------c~--------,

_____
SFA948A

Check tires for wear and improper inflation.

Check wheel runout.
Wheel runout
Refer to 50S (FA-15).
Check front wheel bearings for looseness.
Check front suspension for looseness.
Check steering linkage for looseness.
Check that front shock absorbers work properly.
Check vehicle posture (Unladen).

CAMBER, CASTER AND KINGPIN INCLINATION

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 50S (FA-15).
2. If camber, caster or kingpin inclination is not within
specification, inspect front suspension parts. Replace
damaged or worn out parts.

TOEIN
Front

Hub center
height

Measure toe-in using following procedure. If out of

specification, inspect and replace any damaged or worn front
suspension parts.

WARNING:

Base line

SFA6148

---------------------'

Perform following procedure always on a flat surface.

Make sure that no person is in front of the vehicle before
pushing it.
1. Move rear of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (196.9 in),
3. Put a mark on base line of the tread (rear side) at the same
height of hub center to be a measuring point.
4. Measure distance "A" (rear side).
5. Push the vehicle slowly ahead to turn the wheels around
180 degrees.
If the wheels have passed 180 degrees, try the above procedure again from the beginning. Never push vehicle backward.
6. Measure distance "B" (front sIde).
Toein (A - B):
Refer to 50S (FA15).

7.
a.
b.

Adjust toe-in by varying length of steering tie-rods.

Loosen lock nuts.
Adjust toe-in by turning forward and reverse tie-rod,

FA-6

ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)

c.

Make sure both tie-rods are the same length

Standard length "Lit:
Refer to 50S in ST section.
Tighten lock nuts to specified torque,
Lock nut tightening torque:
Refer to ST section.

"

SFA545A

FRONT WHEEL TURNING ANGLE

\.~-__I__-f:.__/

< ;---/

[l]i

LTf
.

,~:,I1ti
.
-A" Inside
"
Front

B" OutSide

':

SFA439B

-----.J

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 lett: measure
turning angle,
Do not hold the steering wheelan full lock for more than 15
seconds.
Wheel turning angle (Full turn):
Refer to SOS (FA-15).

FA-7

,.1

<,'I'I

FRONT AXLE

Wheel Hub and Knuckle

rqJ

Nm (kg-m. ft-Ib)

C!)

Knuckle spindle

' ID

Wheel bearing lock nut

Baf/le plate

(6)

Wheel hub bearing

Whee! nut

(8)

(j.~,

(~)

Hub cap

:3'

A8S ring

.J)

Lock washer

@.J

ASS sensor

G:

Hub bolt

REMOVAL
CAUTION:
Wheel hub bearing usually does not require maintenance. If
any of the following symptoms are noted, replace wheel hub
bearing assembly.

L__

Growling noise is emitted from wheel hub bearing during

operation.

Wheel hub bearing drags or turns roughly. This occurs

when turning hub by hand after bearing lock nut is tightened to specified torque.

If the wheel hub bearing assernbly is removed, it must be

renewed. The old assembly must not be re-used.
Remove brake caliper assembly and rotor.
Before removing the front axle assemblYI disconnect the ASS
wheel sensor from the assembly. Then move it away from the
front axle assembly area.
Failure to do so may result in sensor wires being damaged
and the sensor becoming inoperative.
Suspend caliper assembly with wire so as not to stretch brake
hose.
Be careful not to depress brake pedal, or piston will pop out.

FA-8

FRONT AXLE
Wheel Hub and Knuckle (Cont'd)

Remove wheel bearing lock nut Remove wheel hub from

spindle.

Remove tie~rod ball joint and lower ball joint.

Disconnect knuckle from strut.

SFA571AA

---------

.r

SFA825A

INSTALLATION

..

Install wheel hub.

Tighten wheel bearing lock nut.
~;
206 284 N-m
(21 - 29 kg-m, 152 - 210 ft-Ib)

Clinch two places of Jock nut.

SFA60BB

~1.-

Spi'dl.

~Clinc"
-

~LOCk

nut

Sl'A599B

-------

FA-9

FRONT AXLE
Wheel Hub and Knuckle (Cont'd)

SF'A325R

Check wtleel bearing axial end play.

Axial end play: 0.05 mm (0.0020 in) or less

I
ABS Sensor Rotor
REMOVAL
Remove ABS sensor rotor (models equipped with ASS) or
labyrinth plate (models without ASS) with suitable tool.

SFA595B

INSTAlLAliON
Press-fit ASS sensor rotor or labyrinth plate.

r
SF J\59B

Baffle Plate
REMOVAL

Matchmarks

Mark matchmarks on baffle plate before removing.

If baffle plate replacement requires removal of knuckle
spindle, separate it equally using a screwdriver.
Be careful not to scratch knuckle spindle.

SFA.548A

INSTALLATION
With rnatchmarks aligned, install baffle plate bY' tapping it with
a copper hammer and a suitable tool.

FA-10

FRONT SUSPENSION

SEC. 401

~~ 59 - 78 (6.0 - 8.0, 43 - S8)~

~

Wilen Installing rubber parts, final tightening

~~ ~ 39 54 (4.0 5.5, 29 _

40)

~--------C@

must be carned out under unladen condition

with tires on ground.
Fuel, radiator coolant and engine all full.
Spare tire, Jack. hand tools and mat, In

---__ ~.q.i
~
~

designated positions.

~~108.127
(11.0 - 13.0,
80 - 94)

///~."!.
8

(~~'II
-

~ , I

I'

I\~,

fl
L

17
~ 96 - 120

\,,'n

(9.8 12.2,
71 - 88)

r
Front

2m

~~~12

-14
(1.2 - 1.4, 8.7 - 10.1)

(OJ 12

~ : Nm (kg-m, ft-Ib)

- 14
(1.2 - 1.4, 8.7 - 10.1)

'------------_._----------

\1)

Cap

S1I ul assembly

Q~J

C~

Gasket

QID

Plastic clip

1t,

Knuckle spindle

@
@
@

Strut mounting insulalor

Front suspension member

Tt'

Transverse link wllh ba',1 jOlnl

Lock washer

~?J

Stabi lizer

tfg')

Tension rod

Upper seat

Bushing

~_~

Air guide

~)

(Polyurethane tube)

Clamp

Coil spring

@
@

TenSion rod bLishing

(J)
CID

@
r
@)

\Iv

Stabilizer connecting rod

Bound bumper

FA-11

Cotler pin

Tension rod bracket

~I

FRONT SUSPENSION

Coil Spring and Strut Assembly

REMOVAL
Remove strut assembly fixing bolts and nuts (to hoodledge).
Do not remove piston rod lock nul on vehicle.

DISASSEMBLY
1.

Set strut assembly on

rod lock nut.
Do not remove piston rod
2. Compres5 spring with
lator can be turned by

vise with Tool, then loosen piston

lock nut.
a Tool so that strut mounting insu-

hand.

\
SFA4~5BA

3.

Remove piston rod lock nut.

Sf'A022A

INSPECTION
Strut assembly

Check for smooth operation through a full stroke, both

compression and extension.
Check for oil leakage on welded or gland packing portion.
Check piston rod for cracks, deformation or other damage.
Replace if necessary.

Strut mounting insulator

Check cemented rubber~to-metal port'lon lor' separation or

cracks. Check rubber parts for deterioration.

Lock washer
Check for cra~ks, deformation or other darnage. Replace if
necessary.

Coil spring
Check for cracks, deformation or other damage. Replace if
necessary.

FA-12

FRONT SUSPENSION
Coil Spring and Strut Assembly (Confd)
ASSEMBLY

Top

~
.-~-,-,
\

----

---'-:::-"

~
l --/-'

When installing coil spring, be careful not to rever'se top

and bottom direction. (Top end is flat.)
When installing coil spring on strut, it must be positioned
as shown in figure at left.

~
Bottom

',-- Lower end

SFA397B

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _---.J
-----------------~

Left

Front

Install upper spring seat with its cutout facing the inner
side of vehicle.

~ight

Cutout
(I nner side of veh icle)
Upper seat

SFA576A

<,'I:

Tension Rod and Stabilizer Bar

REMOVAL AND INSTALLATION

Drift

Remove tension rod and stabilizer bar.

Place one drift on lower side of tension rod bushing and
another on upper side, as shown. Remove tension rod
bushing by pressing it out.
Place arrow mark on bushing facing tension rod before
installing bushing.

SFA lD5B

Install stabilizer rear side bushings, then install front side

bushings.
When installing stabilizer bar clamp, make sure direction
is correct (as shown at left).
When removing and installing stabilizer bar, fix portion A.

Install stabilizer bar with ball joint socket properly placed.

View from B

OK

NG

SFA449BA
---------------

FA-13

.!

FRONT SUSPENSION
Transverse Link and Lower Ball Joint

--

REMOVAL AND fNSTAllATION

Remove stabilizer, tension rod, ball joint and transverse

link assemblyDuring installation, tinal tightening must be carried out at
curb weight with tires on ground.
After installation, check wheel alignment.
Refer to "Front Wheel Alignment" of ON-VEHICLE SERVICE (FA-5).

SFA552A

INSPECTION
Transverse link

Check transverse link for damage, cracks or deformation.

Replace it if necessary_
Check rubber bushing tor damage, cracks and deformation.
Replace transverse link if necessary.

lower ball joint

Ball joint

SFA85BAA

Check ball joint for play Replace transverse link assembly in any of the following cases: Ball stud is worn, play in
aXial direction is excessive or joint is hard to swing.
Before checking, turn ball joint at least 10 revolutions so
that ball joint is properly broken in.
Swinging force "A": Refer to 50S (FA-15).
(measuring point: cotter pin hole of ball stud)
Turning torque "B": Refer to 50S (FA-15).
Vertical end play "e": Refer to 50S (FA-15).
Check dust cover for damage. Replace it if necessary.

FA-14

SERVICE DATA AND SPECIFICATIONS (50S)

General Specifications
COIL SPRING

=____
+

_~~Iied ~~~~.~

STRUT

diamete_r

CO~_~~~'~~~_____

-r
1-

F~~e lenglh

Identification color

Unit mm (in)

__A_II__ _ .

Applied mOdel
-----

__

Piston roc! diameter

131 (05_16_l

~!.~

~~

~ ~------_.
All
--

---

..

_._-

22(087)

FRONT STABILIZER BAR

\,1:

White x 1,

White

------------

Applied model

All

Stablille r d la meter

?G 5 (1 043\

Identl1 ic..ll lion color

Red

Inspection and Adjustment

WHEEL ALIGNMENT (Untaden*1)

LOWER BALL JOINT

SwmQlng force "A"

Except
Applied model

Europe and

Australia

Europe

(Measuflng point- cotler pin

Australia
Camber

degJ

Caster

degree

-1'30' to 0"

5'55' - 7"25'

6'00' - 7"30'

- -r - - - - - - - - - - - - - - .------

- - e-----

Toe-in
A

N (kg, Ib)
Turning torque "8"
~
N m (kg-em. rn-Ib)

Vertical end play "C"

1 - :3
(004 - 0 12)

Tolal angle 20

------------0(0)

1.5 -- 35

8' . 19'

Kingpin

1.2"50'

12'55' - 14'25'

nell nation

'-------------

(0.059 - 0.138)

5'-16~

degree

degree
---------

WHEEL RUNOUT (Radial and lateral)

Wheel type

14'20'

----

turning .::Ingle

39' - 43'/

InSide/outSide
degree _

-----

Steel wheel

Radial runout

Aiumillum wheel.
mm (In)

Front wheel

Full turn'2

'.,.tr

1 5 - 49
(15 - 50,13 - 43)

mm (In)
mm (in)

(2 4 - 81, 53 . 17 9\

--~._---

-1'35' to
-0"05'

235 - 794

hole 01 ball stud)

mm (in)

Lateral runClut

03 (0012) or less

-_.----~-_.---

07 (0028) or less

1.0 (0039)

01

39 - 43 /31 10

.I

Fuel, radiator coolant and engme oil lui!. Spare lire, Jack,
hand tools and mats in deSignated posllions.

"2

On power steering models, wheel turning force (at GHcurnferenee of steering wheel) ot 98 to 147 N (10 to 15 kg 22 to 33 Ib)
with engine al Idle

WHEEL BEARING
Wheel bearing axial end play
mrn (In)

0.05 (0 0020) or less

i:

------------_. ----+---Wheel bearing lock nul

Tightening torque
Nm (kg-m, ft-Ib)

206 . 284
(21 . 29, 152 - 210}

.i

FA-15

REAR AXLE &

REAR SUSPENSION

_RA

sE_c-rlo._N

CONTENTS
" ....
.......
....
__

PRECAUTIONS AND PREPARATION ..

Precautions ..
Special Service Tools .. "
Commercial Service Tools.

"

REAR SUSPENSION SYSTEM ...

.."
ON-VEHICLE SERVICE
Rear Axle and Rear Suspension ParIs.
Rear Wheel Bearing
"
..
Rear Wheel Alignment
.
Drive Shaft .......

"

2
2
2
3

Drive Shaft.."
REAR SUSPENSION

.
.""

Removal and Installation..

Coil Spring and Shock Absorber
Multi-link and Lower Ball Joint .. __ "."."..

5
5
6

7
7

Wheel Hub and Axle HOllsing .

5
"
..

REAR AXLE ... .. .

11
. .17

.... 1B

19
20

Stabilizer Bar
.. "....... .
" ".21
SERVICE DATA AND SPECIFICATIONS (50S) ""
22
General Specifications ... "
22
Inspection and Adjustment
.23

~
.

PRECAUTIONS AND PREPARATION

Precautions

When installing rubber parts, final tightening must be car-

ried out under unladen condition* with tires on ground.

*: Fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.
Use flare nut wrench when removing or installing brake
tubes.

~ GG94310000

SBR820B

After installing removed suspension parts, check wheel

alignment and adjust if necessary.
Always torque brake lines when installing.
Do not jack up at the lower arm.

Special Service Tools

Tool

num~er

Description

Tool name

Removing and installing coil spring

HT71780000

Spring compressor

NT144

------------ --------------~T356520CO

-------,------------------I:"ixing strut assembly

Strut attachment

NT145

3T30D310DO

Removing inner race of wheel bearing

Beanng puller

a: 50 mm (1.97 inl dia.

NT412

ST38280000

Removing and installing bushing or rear

Arm bushing remover

axle housing

.. - - - .. -

_._---

NT157

GG94310000

Removing and Installing brake piping

Flare nul torque wrench

a: 10 mm (0.39 in) dia.

NT40fi

RA-2

PRECAUTIONS AND PREPARATION

Commercial Service Tools

Tool name

Description

Equivalent to GG94310000

\..1')

Flare nut crows foot

(2) Torque wrench

~
~
~
~CD

Removing and installing brake piping

\,,1'

2'

NT360

Attachment
Wheel alignment

NT148

Rear wheel hub drift

NT073

Wheel beari ng drift

b~~

Measure rear wheel alignment

a: Screw M24 x 1.5

b: 35 mm (1.38 in) diaL
c: 65 mm (2.56 in) dia.
d: 56 mm (2.20 in)
e: 12 mm (0.47 in)

Installing wheel bearing

a: 49 mm (1.93 in) dia.

b: 41 mm (1.61 in) dia.

Removing rear wheel hub

~
a

NT073

a: 10 mm (0.39 in)

a: 40 mm (1.57 in) dia.

b: 26 mm (1.02 in) dia.

Inslalhng rear drive shaft plug seal

Rear drive shafl plug seal

drift

NT065

.~

RA-3

a~

85 mm (3.35 in) dia.

b: 67 mm (2.64 in) dia.

REAR SUSPENSION SYSTEM

- - - - - - - - - -------

with tires on ground

Fuel, radiator coolant and engine oil fulL
Spare tire, !ac'K, hand tools and mats In
designated positions.

I'-/ ........

tc:J

':...f
Front

Nm (kg-m, ft-Ibl
SRA706A

f,

Coil spring

(i)

_~

Shock absorber

(])

Member slay

3'

Lateral link

I])

Lower arm

'4'.

Suspension member

Drive shall

Fron\ upper link

~.

Rear upper link

'tV

Dynarric damper assembly

Stabilizer bar

RA ..4

ON-VEHICLE SERVICE

-l

Rear Axle and Rear Suspension Parts

Check axle and suspension parts for looseness, wear or damage.

Shake each rear wheel

Retighten all axle and Suspension nuts and bolts to the

specified torque.
Tightening torque:
Refer to REAR SUSPENSION (RA-17).

Make sure that cotter pins are inserted.

Check shock absorber for oil leakage or other darnagc.

Check suspension lower ball joint for excessive play
Check suspension ball joint for grease leakage and ball
joint dust cover for cracks or other damage,

Ball joint
SFAJ92S1

Rear Wheel Bearing

Check wheel bearings smooth operation.

Check axial end play,
Axial end play:
0.05 mm (0.0020 in) or less
If out of specification or wheel bearing does not turn
smoothly, replace wheel bearing assembly.
Refer to REAR AXLE - Wheel Hub and Axle Housing (RA7).

SRA227A

Rear Wheel Alignment

Radial

runDut

Before checking rear wheel alignment, be sure to make a

preliminary inspection.

PRELIMINARY INSPECTION

Inside

SFA575B

;' . Alignment

Make following checks. Adjust, repair or replace if necessary.

Check tires for wear and for improper inffation.

Check rear wheel bearings for looseness.

Check wheel runout.

Refer to SOS in FA section.

Check that rear shock absorber works properly

Check rear axle and rear suspension parts for looseness

Check vehicle posture (Unladen).
("Unladen": Fuel tank. radiator and engine oil full, Spare
tire, jack, hand tools and mats in designated positions.)

CAMBER
Measure camber of both right and left wheels with a suitable
alignment gauge and adjust in accordance with the following
procedures.
Camber:
Refer to SOS (RA-23).

gaug~

SRA036A

RA-5

.~:

ON-VEHICLE SERVICE
Rear Wheel Alignment (Cont'd)

1.

2.

If camber is not within specification, adjust by turning the

adjusting bolt.
Turn the adjusting bolt to adjust.
Camber changes about 4' with each graduation of the
adjusting bolt.
Tighten to the sppcified torque.
~: 69 - 88 N'm
(7.0 - 9.0 kg-m, 51 65 ft~lb)

SRA09BA

TOE-IN
Front

SFA6148

Measure toe-in using following procedure. If out of

specification, inspect and replace any damaged or worn rear
suspension parts.
WARNING:

Perform following procedure always on a flat surface.

Make sure thai no person is in front of the vehicle before

pushing it.
1. Move rear of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (196.9 in)_
3. Put a mark on base line of the tread (rear side) at the same
height of hub center to be a measuring point.
4. Measure distance "A" (rear side).
5. Push the vehicle slowly ahead to turn the wheels around
180 degrees.
If the wheels have passed 180 degrees, try the above procedure again from the beginning. Never push vehicle backward.
6. Measure distance "8" (front side),
Toe-in (A - B):
Refer to 50S (RA-23).

7. Adjust toe-in by turning adjusting bolts.

Toe changes about 1.3 mm (0.051 in) [One side] with each
graduation of the adjusting bolt.
8. Tighten to the specified torque.
toj: 69 - 88 Nm
(7.0 - 9.0 kg-m, S1 - 65 ft lb)
4

A.djUSII"\9 be,\t ~

RH
I

. . _~ch}J~

=~~ ~

Toe-m \ Toe-out

\. ,--H

.. I

.~~'~ .~----_

--:J-:"'.~

~~

Tce-cul

c;J

loein /

/
Lateral link-/

Drive Shaft
Check boot and drive shaft for cracks,wear,damage or grease
leakage.

SRA67BA

RA-6

REAR AXLE
Wheel Hub and Axle Housing
- - - _ . _ - - - -_.,-- -- - - - - - SEC. 396430

(f'

'i 4'
/

'.L5) ~

98 - 118
(10 - 12, 72 - 87)

Front

~' Nm (kg-m. H-Ib)

-------

~----

--------.-----

/.11

Ori ve shaft

(j)

Baffle plate

(i.2~'

Adj usting cap

~j

Axle housing

Wheel bearing with flange

':@

Cotler pin

@)
@
@

Bushing

(9)
@,

Wheel hub

Bushing

Plain washer

'.14
@

Wheel nut

Shock absorber pin

i!'

Insulator

:16)

Wheel bearing lock nut

@)

Bushing

Hub bolt

REMOVAL
1.
2,

Remove wheel bearing lock nut.

Separate drive shaft from axle housing by lightly tapping
it. If it is hard to remove use puller.
When removing drive shaft, cover boots with shop towel to
prevent them from being damaged.

SRA224A

3. Remove brake caliper assembly and rotor.

Suspend caliper assembly with wire so as not to stretch brake
hose.
Be careful not to depress brake pedal or piston will pop out.

.------------'

RA-7

I
I

REAR AXLE
Wheel Hub and Axle Housing (Cont'd)

--_._--

4.

Remove axle housing.

5.

Remove wheel bearing with flange, and wheel hub from

axle housing.

SRA680A

INSTALLATION

/~

;J,?/

/'

Install axle housing with wheel hub.

Tighten wheel bearing lock nut.
Before tighten'jng, apply oil to threaded portion of rear
spindle and both sides of ~lain washer.
~: 206 - 275 N'm
(21 - 28 kg-m r 152 - 203 ft-Ib)

3.

Check wheel bearing axial end play.

Axial end play: 0.05 mm (0.0020 in) or less
Make sure that wheel bearings operate smoothly.
Check toe-in - Refer to ON-VEHICLE SERVICE (RA-6).

4,

Jr(:jJ~
~:

1.
2.

S_RA227A

RA-8

REAR AXLE
--

Wheel Hub and Axle Housing (Cont'd)

-

-------------_.---,

SRA2LRA I

DISASSEMBLY
CAUTION:
Wheel bearing with flange usually does not require maintenance. If any of the following symptoms are noted. replace
wheel bearing assembly (including flange, and inner and outer
seals).

Growling noise is emitted from wheel bearing during operation.

Wheel hub bearing drags or turns roughly. This occurs

when turning hub by hand after bearing lock nut is tightened to specified torque.

After wheel bearing is removed from hub.

Wheel hub
Remove wheel bearing (with flange) and wheel hub as one
unit from axle housing before disassembling.

Wheel bearing

Press

,2.

Using a press and drift as shown in figure at left, press

wheel bearing out.
Discard old wheel bearing assembly. Replace with a new
one.

SRA229A

3.

Remove inner race from hub using a bearing replacer!

puller.
CAUTION:

Do not reuse old inner race although it is of the same

brand as the bearing assembly.

Do not replace grease seals as single parts.

5T30031 000

SRA 110AA

Axle housing
1.

Attach a drift on outer shell of bushing as shown in figure

at left. Remove bushing using arm bushing remover
When placing axle housing in a vise, use wooden blocks or
copper plates as pads.

:- A:.:le housing

SRA1'1AA

RA-9

REAR AXLE
Wheel Hub and Axle Housing (Cont'd)
r

2.

Bu~hlnQ

~~s;~r
/
Chamf~red

(..

3.

Ensure axle housing bore is free from scratches or deformities before pressing bushing into it.
Attach bushing to chamfered bore end of axle tlousing,
Then press it until it is flush with end face of axle housing.

ST3IJ2BOOQIJ

'Ir

SAA 112AA

INSPECTION
Wheel hub and axle housing

,-----------------

Check wheel hub and axle housing for cracks by using a

magnetic exploration or dyeing test.
Check wheel bearing for damage, seizure, rust or rough
operation,
Check rubber bushing for wear or other damage.
Replace if necessary.

ASSEMBLY

Press.

Place hub on a block. Attach a drift to inner race of wheel

bearing and press it into hub as shown.

Be careful not to damage grease seal.

SRA 1 13A
~---------

RA-10
'N

REAR AXLE
Drive Shaft
SEC. 396

~34

------ 44 (3.5 - '.5,25 - 3 3 1 ]

, I,

toJ: Nm (kg-m, ft-Ib)

G)
1]:\
@

Side flange
Drive shaft

(5.)

Insulator

Adjusling cap

Plain washer

(J)

Cotter pin

Wheel bearing lock nut

REMOVAL
When removing drive shaft, cover boots with shop lowel to
prevent damage to them.

Final drive side

Remove side flange mounting bolt and separate shaft

Wheel side
Remove drive shaft by lightly tapping it with a copper hammer.
If it is hard to remove, use puller.
To avoid damaging threads of drive shaft, install a nut while
removing drive shaft.

INSTAlLATJON
1.

SRA;>32A

2.
3.

Insert drive shaft from wheel hub and temporarily tighten

wheel bearing lock nut.
Tighten side flange mounting bolts to specified torque_
Tighten wheel bearing lock nut to specified torque.

'-----------~------

RA-11

REAR AXLE

Drive Shaft (Cont'd)

COMPONENTS

Final drive side

SRA/14A

,l'
,-:2.'

Plug seal

(~)

Slide jOint housing

i'fl'1

Boot

Spring

(ll

Boo/band

Spider assembly

(3)

Spring cap

~)

Boo!

@
@

I~)

Snap ring

~)

Drive shaft

~)

Hous I ng with shaft

,~)

Spider assembly

(1~'

Boot band

Snap ring

DISASSEMBlY
Final drive side
1.

Remove plug seal from slide joint housing by lightly tapping around slide joint housing.

2.
3.

Remove boot bands.

Put matchmarks on slide joint housing and drive shaft
before separating joint assembly.
Put matchmarks on spider assembly and drive shaH.

,1(0 L ' = = = = = r i

(\ \,,---~-

s,AlleD

---

1---

tT!~fi---, ll=r~
L
\A1\r ~ ~

If

4.

(~:

~-~~

Matchmarks ';RA1181\

---------------'

RA-12

REAR AXLE
Drive Shaft (Cont'd)
--------------------,

5. Pry off snap ring, then remove spider assembly.

CAUTION:
Do not disassemble spider assembly.
6. Draw out slide joint housing
7. Draw out boot.
Cover drive shaft serration with tape to prevent damage to the
boot.

SAA119A

Wheel side
Malching marks

1.
2.
3.

/ _ _-

Remove boot bands

Put matchmarks on housing together with shaft and drive
shaft before separating joint assembly.
Put matchmarks on spider assembly and drive shaft.

96----.J
3!
S_F_A_

,.! :

4.

Pry off snap ring, then remove spider assembly

CAUTION:
Do not disassemble spider assembly.
5. Draw out boot.
Cover drive shaft serration with tape to prevent damage to the

boot.

SFA964

INSPECTION
Thoroughly clean all parts in cleaning solvent, and dry with
compressed air. Check parts for deformation or other damage

Drive shaft
Replace drive shaft if it is twisted or cracked.

Boot
Check boot for fatigue, cracks, or wear. Replace boot with new
boot bands.

RA-13

REAR AXLE

Drive Shaft (Cont'd)

Joint assembly

Check spider assembly for bearing, roller and washer

damage. Replace spider assembly if necessary.

Check housing for any damage. Replace housing set and

spider assembly, if necessary_

When replacing only spider assembly, select a new spider

assembly from among those listed in table below. Ensure
the number stamped on sliding joint is the same as that
stamped on new part.
Housing alone cannot be replaced. It must be replaced
together with spider assembly.

~_.-

Stamped number
00

Part No.

--------+-

01

02

ASSEMBLY

After drive shaft has been assembled, ensure it moves

smoothly over its entire range without binding.
Use NISSAN GENUINE GREASE or equivalent after every
overhaul.

Wheel side
1. Install new small boot band and boot on drive shaft.
Cover drive shaft serration with tape to prevent damage to
boot during installation.

SFABOO

2.

Install spider assembly securely, making sure marks are

properly aligned.
Press-fit with spider assembly serration chamfer facing shaft.
3. Install new snap ring.

SFA31P

RA-14

REAR AXLE
Drive Shaft (Cont'd)
4_

Pack drive shaft with specified amount of grease.

Specified amount of grease:
135 - 145 g (4.76 - 5.11 oz)
5. Install slide joint housing, then install new snap ring.
6. Set boot so that it does not swell and deform when its
length is "L 2 ".
H
Length "L 2 :
95 - 97 mm (3.74 - 3.82 in)
Make sure that boot is properly installed on the drive shaft
groove.

-----1

7.

Lock new larger and smaller boot bands securely with a

suitable tool.

~Boot

band
SRA542AI

" ~fr((Jo/!~_

~\Y----

------------

1.

~~
- - - - - . .".-----_.--:..:.~
...~

Install new small boot band, boot and slide joint housing
to d rive shaft.
Cover drive shaft serration with tape to prevent damage to
boot during installation.

~. I,'

-----=:::::

f -~

T,pe

L.

Final drive side

'S_FA_8_00

2.

Install spider assembly securely, making sure marks are

properly aligned.
Press-fit with spider assembly serration chamfer facing shaft.
3. Install new snap ring.

r',

:.

',- Chamfer

Press.
SUitable

.~_ tool

"-

---

-",

SFA397

4.

Install coil spring, spring cap and new plug seal to slide
joint housing. Press plug seal.
Apply sealant to mating surface of plug seal.
CAUTION:
a. When pressing plug seal into place, hold it horizontally.
This prevents spring inside it from tilting or falling down.

RA-15

I .-

REAR AXLE
Drive Shaft (Cont'd)
,..---------------

b.

Move shaft in axial direction to ensure that spring is

installed properly_ If shaft drags or if spring is not properly
installed 1 replace plug seal with a new one.

t
S"lA123A

5.

Pack drive shaft with specified amount of grease,

Specified amount of grease:
155 - 165 9 (5.47 - 5.82 02)
6. Set boot so that it does not swell and deform when its
length is "L 1 ".
length "L 1 ":
95 - 97 mm (3.74 - 3.82 in)
Make sure that boot is properly installed on the drive shaft
groove.

7.

Lock new larger boot band securely with a suitable tool,

then luck new smaller boot band.

SAA542A

RA-16

REAR SUSPENSION

SEC. 380 396431

.~ ~

CAUTION:
n - 98
Do not Jack up at lower link.
~~ 69 88
(7.9 " 10.0,57 - 72)--".
_.
(7.0 9.0, ~1)
//
When Installing rubber parts, final lightening
must be carried out under unladen condition' ~. '1.l~
51 - 65) -~
/~ //-'
1
with tIres on ground.
;.;. ~~=_
,,~~. /
Fuel, radiator coolant and engine 011 full (~~~~
'l
Spare tire, Jack, hand tools and mats
:Yf'
_'----":-,\ ~-J 98 - 118
Iiil
In deSignated positions.
~~ 12 _ 14
,~(10. 12,
81)
~
.'

J)'J

~r
~"

(1.2. 1.4,
9 - 10)

_ \-.J

.'

. r~Jt~ ~\k~C "

~~
,
'_

r,11 \~
\

I
.\
..t.l"",-....L>-:"=--!

if;;=~_-~;~

J /..-.- ~~~9(',18
~ I ~_/

)( /

i ,\

!!

"_"

.-

~ 43 - 55

~~

"\J'"r
.

(4.4 - 5.6, 32" 41)

f..J

"

'.~ ~;:::

,L~

\~~

57 - 72)

,lJ ,
t~

~~~CJn
~~ "

t@'

~~--"'

~
\

~ 72)

,..=-

(10 - 12,
12

.1

"

~
. ~ ,,>..._~
\.

~~

~:

N,m (kg-m. ft-Ib)

I".:::

r--

'!v
10'

6.5 " 8.7)

'

-~n-I!

./

---------.~~ ~ 43 - 55 (4.4 5.6. 32 .41)

(10"12.72-87)~

9.(::;0:5:~:...~)_

p."I.;

jill

~ 98 - ~,8

-~ 34 .44

~ 71

- 86
(7.2 - 8.8,
52 - 64)

19

@/

............

COl,,'

r~

!i{4c 'liti'C::~- :, /~(O.J

v

..'!./

i \~ -1 / I"':" .. '.
V /1 ~=--=-==:~-<1.) ~

~'

7)~

1" '

{',~ ~~
~/AW?-~"".
. ~""

", ~~ .'--.. .
:

13.17)'

~\~\

".

~@J

- 24
(1.8 - 2.4

~,

@""

OJ~'~~
/// );5;~
~'--""_
&/
&
Front

'

uQ/~.=.~ 18

(09 -1.2,

_1~ 9

12.14)'

~':V'

88
(70 - 90
.
. ,51 65)

(7.9 - 10.0. ~
/
57 _ 7 2 ) - / . / ,

eli

16 _
(1.6

/ -1.

(1.

fJ @
!~"
~.'~69. .

,/

98 " 118
(10 12,

.~~ 77 - 98

/'>

~~

n - 98
(7.9 - 10.0, 57

'"

(~!ii:

/~~-:-_--"
/\~''''-_I

~- P
)r..r--

'

(10 12, 72 87)

72)"

~ ~ n

,-~.~~ ,/O~4~n ...: ~~.,

0" ~.
10.0.~

\.

" ,

,~

1
" <.!.~

-
f
.
~-J
L
d /2'

--yj/ /

':f,--:~~}~ ~ ~

__
/ ( I'

.,7)

1,~~.'

----- '&yi7i.. .
l/ :00/

'/~ f

17

".."
~-..

206 - 275

(21 - 28, 152 203)/

@ ~J

.:.

~ ,

SRtdOf11\

--------------

---_.-

CD

Cap

r1~.1

,}i

Gasket

11_1)

@
(4)

Upper plate
Bushing

6"tl
Q))

Upper spring seal

~4)

Upper rubbe, seal

Lateral link

(j)

Bushing

Plate
Bumper rubber With dust cover

@
@
ri'?)
@

~~

Drive shaft

Shock absorber

~Q)

Connecting rod

Suspension member

.f~

Final drive

Rear upper link

i~1

Stabilizer bar

Front upper link

Bushing
Member stay

Protector

~
~J'
@

Axle housing

~D

Coil spring

Lower arm

;J .
: I

Insulator
Adjusting cap
Dynamic damper assembly

RA-17
cd

REAR SUSPENSION
Removal and Installation

SRA684~
CAUTION:
Before removing the rear suspension assembly, disconnect
the ABS sensor from the assembly. Then move it away from
the rear suspension assembly. Failure to do so may result in
damages to the sensor wires, making the sensor inoperative.
1. Remove exhaust lube.
2. Disconnect propeller shaft rear end.
3. Disconnect hand brake wire front end

4. Remove brake caliper assembly.

Suspend caliper assembly with wire so as not to stretch brake
hose.
Be careful not to depress brake pedal, or piston will pop out.

SFA110A
1

5.
6.
Do
7.

Remove rear parcel shelf. Refer to BT section.

Remove upper end nuts of shock absorber.
not remove piston rod lock nut.
Remove suspension member fixing nuts. Then draw out
rear axle and rear suspension assembly.

RA-18
-fl'

REAR SUSPENSION
Coil Spring and Shock Absorber
REMOVAL
Remove shock absorber upper and lower fiXing nuts,
Do not remove piston rod lock nut on vehicle.

'----.:::::I
~I

:I
L
.

DISASSEMBL V
1.

Set shock absorber on vise with attachment, then loosen

piston rod lock nut.
Do not remove piston rod lock nut.
2. Compress spring with Tool so that the strut upper spring
seat can be turned by hand.

~.
.~

5T35652ooo

_SR_A_5_87_A___JA

',<

3.

Remove piston rod lock nut.

~
~~

~/~'L
I

l--

INSPECTION
Shock absorber assembly

Check for smooth operation through a full stroke, both

compression and extension.
Check for oil leakage on welded or gland packing portion.
Check piston rod for cracks, deformation or other damage
Replace if necessary.

Upper rubber seat and bushing

Check rubber parts for deterioration or cracks
Replace if necessary.

Coil spring
Check for cracks, deformation or other damage. Replace if
necessary,

RA-19

REAR SUSPENSION
Coil Spring and Shock Absorber (Cont'd)
-----

----------Upper end7

ASSEMBl Y

When installing coil spring. be careful not to reverse top

and bottom direction (Top end is flat)
When installing coil spring on strut, it must be positioned
as shown in figure at left.

Sattorn

Front

{t

Spring
lower end POSition

When installing upper spring seat, make sure that it is

positioned as shown.

RH
SRI\686A

--------------~

Multi..link and Lower Ball Joint

REMOVAL AND INSTALLATION

SRA "29A

Refer to "Removal and Installation" of REAR SUSPENSION

(RA-18).
Before removing, put matchmarks on adjusting pin.

When installing, final tightening must be carried out at curb

weight with tires on ground.

After installation, check wheel alignment.

Refer to "Rear Wheel Alignment" of ON-VEHICLE SER~
VICE (RA-5).

--------------~

SRA678A

RA-20

REAR SUSPENSION
Multi-link and Lower Ball Joint (Cont'd)
INSPECTION
Rear suspension member
Replace suspension member assembly if cracked or deformed
or if any part (Insulator, for example) is damaged

Upper and lower links

Replace upper or lower link as required
deformed or if bushing is damaged.

,1

..~

or

Lower ball joint

'aA

t
~

if cracked

Check ball joint for play. Replace transverse link assembly if any of the following cases occur, Ball stud is worn,
play in axial direction is excessive or joint is hard to swing.

Swing force and turning torque

Before checking. turn ball joint at least 10 revolutions so that

ball joint is properly broken in.
Swing force "A
(measuring point: cotter pin hole of ball stud)
7.8 - 54.9 N (0.8 - 5.6 kg, 1.8 - 12.3 Ib)
ll
Turning torque "B :
0.5 - 3.4 N'm (5 - 35 kg~cm, 4.3 - 30.4 in-Ib)
Vertical end play "e":
o mm (0 in)
lt

SFAB5BA

Stabilizer Bar
REMOVAL

Remove connecting rod and clamp.

INSPECTION

Check stabilizer bar for deformation or cracks. Replace if

necessary.
Check rubber bushings for deterioration or cracksReplace if necessary.

INSTALLATION

Vehicle

When installing connecting rod, make sure direction (s correct

(as shown at left),

AtoP
1.S r- Lower link

~/-conn'Cling

cod

/ - Stabilizer

l!1

SRA 1?8A
- - - - - - - - --

-----

RA-21

',j:

SERVICE DATA AND SPECIFICATIONS (50S)

General Specifications
SHOCK ABSORBER

COIL SPRING
Unit. mm ('n)
Appll ed model
Wire diameter

'-~f--

1\11

Applied model
Piston rod diameter

1-----12
I

mm (In)

All
5 (0492)

11 5 (0453)

Coil outer diameter

Large diameter

123.5 1265 (4 86 - 4.98)

Small diameter

1123- 1153(442-4.54)

Free length

350 (1378)

Ider1tlflcatlon color

Red x 1

DRIVE SHAFT
Joint type

final drive side

Final drive side

TSB2F

Wheel Side

TSB2C

Grease name
Nissan genuine grease or
equivalent

Final drive side

t=

Nissall genuine grease or

equivalent

Wheel Side

~-------------

Specified amount of grease

9 (oz)
Fiflal drive side

Wheel side

.~----~

SRA133A

Wheel side

155 - 165 (547 - 582)

135 - 145 (4 76 - 5 11)

mm (in)

800.1__
18_n_gt_h

F_lnal drive side (L , )

95 . 97 (374 - 382)
SRA543A

REAR STABILIZER BAR

Model
Stabilizer diameter
rnm (In)

Identl fica lion color

LHD

RHO

17.3 (0.681)

18.0 (0 709)

Light green

Orange

RA-22
[II

SERVICE DATA AND SPECIFICATIONS (50S)

Inspection and Adjustment
WHEEL ALIGNMENT (Unladen*1>
Ex:cept ALlstralla

Auslralla

Applied model
Camber

degree
._---

LOWER BALL JOINT

-,' 40' to -0'40'

___ .

SWlf1g force

(Measuring rOln! cottCt (II"

- 1"35' to -0"35'

,_L.--

hole of ball stud)

Toe-in

A - B

Turf1lng lorque

0 - 50 (0 - 0 197j

mm (In)

.---Total ang Ie 20
degree

------

"1

~; (kg. Ib)

-- - - - - -

------0' - 28'

N m (kg-em. 1I))bj
-

Vertical end play

--~01~ I

i B - 54. 9
(08 - 5 6, 1.8 - 12 3)

0.5 - 3 4 (5 - 35, 4 3 - 304)

0(0)

Fuel, radiator coolant and engine all lull

SpaTe tire. lack, hand tools and mats ,n deSignated pOSitions

WHEEL BEARING
Wheel bearing axial end play

o 05 (0 0020)

mm (In)

or less

Wheel bearing lock nul

206 - 275

Tightening torque
N m (kg-m. ft-Ib)

(21 28. 152 - 203)

WHEEL RUNOUT (Radial and lateral)

Radial runout

Wheel type
Aluminum wheel
Steel

whe~l

mm (in)

o3

(0,012)

o 7 (0028)
or less

Lateral runout
OT

less

1.0 (0039)
or less

II

RA-23

--- -

---

--

."-

-_.-

-"--

BRAKE SYSTEM

--~-

--'

----8--------R-

--_.--

SECTION

PRECAUTIONS AND PREPARATION.,- .....

rrccautions- ,

., ..... 2

__

,2

Commercial Service Tools

BRAKE HYDRAULIC LINE/CONTROL VALVE

Brake Hydraulic Line.

Proportioning Valve _."
CHECK AND ADJUSTMENT

3
4
5

..

_..

Checking Brake Fluid Level

_.... .....
-

BleedIng Brake System _." .

-5

.. ... 7

BRAKE PEDAL AND BRACKET ,,,_, __ .

Removal and InstallC'\tion Inspection

Adjustment .... MASTER CYLINDER,

'

--

-- --- .. ' -

"
-- .. -_

.......... 7

...... 8

--'

.. , ,8
..... 8
_9

Removal,
Disassembly ..
Inspection
Assembly

_ .... 9

_9

Installation -BRAKE BOOSTER/VACUUM HOSE

..... 10

__ 10

Brake Booster

Disassembly
Inspection - ,- -

..... 7

.7

--

Vacuum Hose .. ,. -" " ....... -".

FRONT DISC BRAKE (OPF25V)
Pad Replacement
-Removal and Installation,
.

5
. - 5
5
..

Checking Brake Line

Changing Brake Fluid _

.11

__ 12
,

.12
...,,13

.. 13
... 14

15

Assembly .. ,,Inspection (On-vehicle),

15
16
___ 16

REAR DISC BRAKE .

Pad Replacement..
Removal

18

Disassembly ..
Inspection - Caliper .. _

18

Inspection -

Rotor ...

Assembly -'"

.. --

19

_20

20
__ ... 21

Installation .. --

.22

PARKING BRAKE CONTROL

__ 22

Removal and Installation .. ,

Inspection Adjustment - .
ANTI-LOCK BRAKE SYSTEM
Purpose .,
,.--,.,.,.,- ,
,

-I

23

24_
23

.. 24

24

Operation. ,
ASS Hydraulic Circuit.. .. -

System Components
System [J8scription
Removal and Installation .. -- .. Wiring Diagram -- ASS -

.. 25

25
___ .27

--. - -

TROUBLE DIAGNOSES,

Contents,
Component Parts and Harness Conneclur
Location, SERVICE DATA AND SPECIFICATIONS (50S)-General Specifications
Inspection and Adjustment -...

__ ,24

29

39

39
,43
,66
66

66

PRECAUTIONS AND PREPARATION

Precautions
\\

\\.-- --- ;/
-

..

',- C0n11l1ercral service 1001

SBR686C
'----------------- - - - - -----------'

Recommended brake fluid.

For Europe: OOT3 or DOT4
Except for Europe: 00T3
For Europe, never mix different type brake fluids (DOT3
and DOT4).

Never reuse drained brake fluid.

Be careful not to splash brake fluid on painted areas.

To clean or wash all parts of master cylinder, disc brake

caliper and wheel cylinder, use clean brake fluid.

Never use mineral oils such as gasoline or kerosene. They

will ruin rubber parts of the hydraulic system.

Use flare nut wrench when removing and installing brake

tube.

Always torque brake lines when installing.

WARNING:

Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.

Commercial Service Tools

Tool name

Deser ipI ion

(1) Flare nut crows fool

(1) Torque wrench

Removing and installing each brake piping

a: 10 mm (0.39 in)

NT360

Brake fluid pressure

Measuring brake fluid pressure

gauge

NT151

BR-2
r"

BRAKE HYDRAULIC liNE/CONTROL VALVE

Brake Hydraulic Line

;,1

T?

Rear LJra~e

i
Proportioning valve

~ : Flare nut 15 18 (1.5 . 1.8, 11 - 1J)

Connecting bolt 17 - 20 (1.7 - 2.0, 12 - 14)

, Secondary line
: Pnmary line

Nm (kgm fl- tJj

Si:lH99UC

.-,

i'

REMOVAL
CAUTION:
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.

All hoses must be free from excessive bending, twisling

and pulling.
1,

2.
3.
4.

Connect vinyl tube to air bleeder valve.

Drain brake fluid from each air bleeder valve by depressing brake pedal.
Remove flare nut connecting brake tube and hose, then
withdraw lock spring.
Cover openings to prevent entrance of dirt whenever disconnecting brake line.

\' "

IIII
I

INSPECTION
Check brake Jines (tubes and hoses) for cracks deterioration
or other damage. Replace any damaged parts.

BR-3

f" :
{

BRAKE HYDRAULIC LINE/CONTROL VALVE

Brake Hydraulic Line (Cont'd)
INSTALLATION
.- ,'1
,l

l_

Commercial serviCe 1001

SBR68E-C

--------------------,

,t11)~:~-}\
-Brake fluid pressure
~/, :(~-,
, ~

!.l

-,-

'b"-~--'~'

1)

gauge

SBRB22BA

/
. -,,;/.- - -

Brake fluid pressure gauge

-'1

CAUTION:

Refill with new brake fluid .

For Europe: 0013 or DOT4
Except for Europe: 0013
For Europe, never mix different type brake fluids (DOT3
and D014).

Never reuse drained brake fluid.

1. Tighten all flare nuts and connecting bolts.
Spec ifica tion:
Flare nut
15 - 18 N-m (1.5 - 1.8 kg-m, 11 - 13 ft-Ib)
Connecting bolt
17 - 20 Nm (1.7 - 2.0 kg-m, 12 - 14 ft-Ib)
2. Refill until new brake fluid comes out of each air bleeder
valve.
3,
Bleed air. Refer to "Bleeding Brake System" (BR-5).

Proportioning Valve
INSPECTION
CAUTION:

Carefully monitor brake fluid level at master cylinder.

Use new brake fluid.

For Europe: DOT3 or OT4
Except for Europe: DOT3
For Europe, never mix different type brake fluids (00T3
and DOT4).
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_
1, Connect Tool to air bleeders of front and rear brakes on
either LH and RH side.
2. Bleed air from the Tool.
3. Check fluid pressure by depressing brake pedal.
Unl" kPa (bar, kg/cm 2, pSI)

Applied pressure (Front brake)

------+--Output pressure (Rear brake)

7.355 (736.75, 1,067)

---

5.100 - 5,492
(S 1 0 - 54.9, 52 - 56, 739 - 796)

SBRB23BA

4.

Bleed air after disconnecting the Tool, Refer to "Bleeding

Brake System" (BR-5).

BR-4

CHECK AND ADJUSTMENT

Checking Brake Fluid Level

Check fluid level in reservoir lank, It should be between

Max and Min lines on reservoir tank.
If fl uid level is extremely low, check brake system for
leaks.
If brake warning lamp comes on, check br'ake fluid level
switch and parkIng brake switch.

OK

L-

SBR418CB

1---------------

~,~((). .

@:~~ ~

. . ? -W

rl

Checking Brake Line

CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running,

(L/

S8R389C

-------------

':'.-1'1

Changing Brake Fluid

CAUTION:

Refill with new brake fluid.

For Europe: DOT3 or DOT4/Except for Europe: DOT3
For Europe, never mix different type brake fluids (DOT3 r:
and 0014).

Always keep fluid level higher than minimum line on reservoir tank.

Never reuse drained brake fluid.

Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on :,,'
painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and refill with new b r a k e .
fluid.
: ..
2. Connect a vinyl tube to each air bleeder valve
3. Drain brake fluid from each air bleeder valve by depress'I
Ing 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" (BR5),

Bleeding Brake System

1

'

CAUTION:

Carefully monitor brake fluid level at master cylinder dur

ing bleeding operation.

Fill reservoir with new brake fluid.
For Europe: 00T3 or 00T4/Except for Europe: DOT3
For Europe, never mix different type brake fluids (DOT3
and DOT4).
Make sure it is full at all times while bleeding air out of
system.

SBR995J

BR-S

,'"

CHECK AND ADJUSTMENT

Bleeding Brake System (Cont'd)

Place a container under master cylinder to avoid spillage

of brake fluid.
Turn ignition switch OFF and disconnect ABS actuator connectors or battery ground cable.

Bleed air in the following order.

Right rear brake ---.. Left rear brake ---..
Right front brake - Left front brake

1.
2.
3.

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.

4.
5.
6.
SBR419C

BR-6

..,

BRAKE PEDAL AND BRACKET

Removal and Installation

SEC. 465

r Slop

Cfevis pin -,-

~: Nm (kg-m. tt-Ib)

'.

~~

/r:Y

~~

~ ~,." ..~~

'<Imp sWItch

13 ,. (\.3 . 1,6, 9 ' 121

'

13 16 (1.3 1.6. 9 - 12)-/

SBR565CC

Inspection
Check brake redal for following items.

Brake pedal bend

Clevis pin deformation

Crack of any welded portion

Adjustment
Check brake pedal free height from dash reinforcement panel.
Adjust if necessary.
H:
Free height
Refer to SDS (BR-66).
0:
Depressed height
Refer to 50S. (BR66).
Under force of 490 N (50 kg, 110 Ib)
with engine running
el , C 2 : Clearance between pedal stopper and
threaded end of slop lamp switch and ASCD
switch
0.3 - 1.0 mm (0.012 - 0.039 in)
~

Nm (kg-m. H-lb)
SBRO]10

--------------------,

-----1 r--I

Stay5 inSide

----nll-I~
I

C~/-ttJ[~~
Input rOd)/

~ ~

1.

Loosen lock nut and adjust pedal free height by turning

brake booster input rod. Then tighten lock nut
2. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3. Check brake pedal's depressed height while engine is running. If lower than specification, check for leaks, air in
system, or damage to components (master cylinder, wheel
cylinder, etc.). Then make necessary repair.

Cle'Jls

i Lock nut
SBR8<48

BR-7

c'l'.

MASTER CYLINDER

C 460
.

(U------9
(1)-----

---@

IT! Reservoir C;lP

Ii) 01) filter
:~, Reservoir la"k
if; Seal
(~ Cyl'lnder body
(ID O-ring
(V Piston stopper
(~) Secondary plslon assembly

Primary piston assembly

@! Stopper cap

@ Proportioning

valve -(Do not disassemble.)

* LUbricate piston cup with brake

fluid or rubber grease when
assembling master cyllnoer

f] , Brake
~

flUid

Nm (kg-m. tt-lbl
SBAB51CA

Removal
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
1. Connect a VInyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve. depressing
brake pedal to empty 1\uld from master cylinder.
3. Remove brake pipe flare nuts.
4. Hemove master cylinder mounting nuts.

-------:------------------,

Disassembly
1.

Bend claws of stopper cap outward.

BR-8

MASTER CYLINDER
Disassembly (Cont'd)
2. Remove valve stopper while piston is pushed into cylinder
3. Remove piston assemblies.
If it is difficult to remove secondary piston assembly. gradu~
ally apply compressed air through fluid outlet.
4. Draw out reservoir tank.

Inspection
Check for the fol/owing items.
Replace any part if damaged.
Master cylinder:

Pin holes or scratches on inner wall.

Piston:

Deformation of or scratches on piston cups.

SBR231C

Secondary pislon

Assembly
1.

Primary plsto'"

1]1]
SBR354C

Insert secondary piston assembly. Then insert prfmary piston assembly.

Pay attention to alignment of secondary piston slit with
valve stopper mounting hote of cylinder body.

,,~

2. Install stopper cap.

Before installing stopper cap, ensure that claws are bent
Inward.
3. Push reservoir tank seals.
4. Push reservoir tank into master cylinder.

,.-,

,
L:

5.

Install valve stopper while piston is pushed into cylinder.

Installation

/
/
/

SBR222B

CAUTION:

Refill with new brake fluidFor Europe: 0013 or DOT4/Except for Europe: 00T3
For Europe, never mix different type brake fluids (DOT3
and DOT4).

Never reuse drained brake fluid.

1. Place master cylinder onto brake booster and secure
mounting nuts lightly.
2. Torque mounting nuts.
12 - 15 N'm (1.2 - 1.5 kg-m, 9 - 11 ft-lb)
3. Fi II up reservoir tank with new brake fl uid.
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.
(OJ: 15 ~ 18 N-m (1.5 - 1.8 kg-m, 11 - 13 ft-tb)
8. Bleed air from brake system. Refer to "Bleeding Brake
System" (BR-5)

BR-9

'

BRAKE BOOSTER/VACUUM HOSE

{j~

\\~o

.~

SBROJ2A

Brake Booster
ON-VEHICLE SERVICE

Operating check

Stop engine and depress brake pedal several times. Check

that pedal stroke does not ctlange.

Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.

Airtight check

,--------------------------,
OK

NG

Start engine, and stop it after one or two minutes. Depress

brake pedal several times slowly. The pedal should go
further down the first time, and then it should gradually
rise thereafter.
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.

SRR365AA

REMOVAL
CAUTION:

Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
Be careful not to deform or bend brake pipes, during
removal of booster.

INSPECTION
Output rod length check
1. Apply vacuum of -66.7 kPa (-667 mbar, -500 mmHg, -19.69
2.

inHg) to brake booster with a handy vacuum pump.

Check output rod length.
Specified length;
10.4 mm (0.409 in)

INSTALLATION
CAUTION;

Be careful not to deform or bend brake pipes, during

installation of booster.
Replace clevis pin if damaged.

Refill with new brake fluid.

For Europe: 00T3 or DOT4/Except for Europe: DOT3
For Europe, never mix different type brake fluids (00T3

and 0014).
Nev~r reuse drained brake fluid.
Tak~ care not to damage brake booster mounting bolt

BR-10

BRAKE BOOSTER/VACUUM HOSE

Brake Booster (Cont'd)
thread when installing. Due to the angle of installation,
threads can be damaged by the dash panel.

.'11

'I

1.

2.

3
4.
5.

6.

(0.94 In)

--

-~

I'

-+,------

- ---- ........... _ ...

Connect hose until it contacts

protrusion on vacuum tube

c."

CAUTION:
When installing vacuum hoses, pay attention to the following
points.
Do not apply any oil or lubricants to vacuum hose and
check valve.

Insert vacuum tube into vacuum hose as shown.

SBR225B

Intake manifold

.C'.

REMOVAL AND INSTALLATION

~re then 24 mm
I

Vacuum Hose

.-Lill ----------?O.,.-l--

Before fitting booster, temporarily adjust clevis to dimension shown.

Fit booster, then secure mounting nuts (brake pedal
bracket to booster) lightly.
Connect brake pedal and booster input rod with clevis pin.
Secure mounting nuts.
Specification: 13 16 N'm (1.3 - 1.6 kg~m, 9 ~ 12 ft-Ib)
Install master cylinder. Refer to "Installation" in "MASTER
CYLINDER" (BR-9).
Bleed air. Refer to "Bleeding Brake System" (BR-5).

Install check valve, paying attention to its direction .

Brake booster

;;~.:;ded

S8R49BA
L-.

~---------

INSPECTION
1-; ;

Hoses and connectors

Booster side

Check vacuum lines, connections and check valve for

airtightness, improper attachment chafing and deterioration.

Check valve
Check vacuum with a vacuum pump.
Connect to booster side
Connect to engme side

BR-11

Vacuum should exist.

Vacuum should not eXist.

n,
Ir,:'

FRONT DISC BRAKE (OPF25V)

SEC. 440

~7 - 9 (0.7 - 0.9. 5.1 6'5)~

rJ~ ~ C

'--l

(OJ 72

~? -:.:J ----.---,--/
-:'1

- 97 (1,J - 9.9. 53 71)

B~: PBC (Poly Butyl Cuprysill grease or

silicone-based grease point
!!:i!@: Rubber grease point

[]@.

Brake flUid point

~: Nm (kg-m. ft-Ib)

r :J.

~ -t~-~-l~'-~

~o r:~ve

not
or
loosen the" bolls.

i\

~______

toj72-97
(7.3 - 9.9, 53 71

-~

~J

~~

{ \

Do not remove or
loosen these bolts. ~

14

~
0

J5

Front
SBR991C

CD

Caliper

'1)

Retaining ring

(1)

@
'~

Dust seal
Piston seal

'~~~'

Piston

@
@
@

Outer pad

Pad pin
Outer shim A
Cross spring

Outer shim B

~']

Pad retainer

Inner shim A
Clip

Inner pad
Inner shim B

Pad Replacement
CAUTION:

When pads are removed, do not depress brake pedal

because piston will pop out.

Be careful not to damage dust seal or get oU on rotor.

Always replace shims when replacing pads.
1. Remove clip from pad pin and then remove pad pin.
2. Remove cross spring.

SBR992CJ

3.

4.
5.
6.
7.
8.
9.

Pullout outer pad and insert it temporarily between lower

piston and rotor as shown.
Push back upper piston with a suitable tool and insert new
pad so it contacts upper piston as shown.
Pullout old pad.
Push back lower piston with a suitable tool.
Pull out new pad and reinstall it in the proper position.
Repeat step 3 to 7 for inner pad.
Install cross spring, pad pin and clip.

'--------------------'

BR-12

FRONT DISC BRAKE (OPF25V)

Removal and Installation

1
2.

Disconnect brake tube.

Remove brake pad.

3.

Remove brake caliper mounting bolts.

Disassembly
1.
2.

Remove retaining ring.

Push out piston with dust seal using compressed air.

,,,",,1

;,.n
3.

L - -_ _-

Remove piston seal.

--------'

CAUTION:
Be careful not to loosen or remove bolts joining both sides of
caliper.
IIlhere is any fluid leakage, replace caliper assembly.

III
:
. [

S8R995C

I; '.

BR-13

FRONT DISC BRAKE (OPF25V)

Inspection
CALIPER

Check dust seals for damage.

Check calipers for damage, rust or foreign materials.
Check inside surface of cylinder for scoring, rust, wear,
damage or foreign materials. Replace if any such condition
exists.

Eliminate minor damage from rust or foreign materials by

polishing surface with fine emery paper
CAUTION:

Use brake fluid to clean.

PISTON
Check piston for scoring, rust, wear, damage or foreign materials. Replace if any condition exists.
CAUTION:
Piston sliding surface is plated. Do nol polish with emery
paper even if rust or foreign materials are stuck \0 sliding
surface.

PAD PIN AND CLIPS

Check for wear, cracks deformation, deterioration, rust or
other damage. Replace if any such condition exists.

RUNOUT
Secure rotor to wheel hub with at least two nuts (M12 x
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 "Front Wheel

1.

Bearing" in FA section.

3
SBR0198

----------------

Maximum runout:
0.05 mm (0.0020 in)
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 t=l. to c so that minimum runout position
can be found.
If the runout is still oul of specification, turn rotor with
on-car brake lathe ("MAD, DL-8700". "AMMCO 700 and
705" or equivalent)

THICKNESS
Thickness variation (At least 8 positions):
Maximum 0.01 mm (0.0004 in)
If thickness variation exceeds the specification, turn rotor with
on-car brake lathe.
Rotor repair limit:
28.0 mm (1.102 in)

S8R02CB

BR-14

FRONT DISC BRAKE (OPF25V)

.r

Retaining
ring -7

Piston seal

Assembly
1.
2.
3.
4.

Insert piston seal into groove on cylinder body

With dust seal fitted to piston, install piston into cylinder
body.
Secure dust seal properly.
Install retaining ring.

I,:

SBR743A

Inspection (On-vehicle)
DISC PAD

.~

Q~

Check pad shims for deformation or damage.

Check disc pad for wear or damage.
Pad standard thickness (A):
10.0 mm (0.394 in)
Pad wear limit (A):
2.0 mm (0.079 in)

SBR744A

~ ',-

I-! .

_.

BR-15

REAR DISC BRAKE

Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:

When cylinder body is open, do not depress brake pedal

because piston will pop out.

Be careful not to damage piston boot or get oil on rotor.

Always replace shims in replacing pads.

If shims are rusted or show peeling of rubber coat, replace

them with new shims.

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.
1. Remove master cylinder reservoir cap.
2. Release parking brake.
3. Remove brake cable mounting bolts from the rear suspension.
4. Remove pin bolts.
5. Remove cylinder body_ Then remove pad retainers, and
inner and outer shims.
Standard pad thickness:
9.5 mm (0.374 in)
Pad wear limit:
2.0 mm (0.079 in)

6.

When installing new paris, push piston into cylinder budy

by gently turning piston clockwise, as shown.
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.

__

___J

Commercial
service tool
SBR868C

BR-16

REAR DISC BRAKE

SEC. 441

~-,

Nm (kg-m. tt-Ib)

.;

; .

1.'1

PSC (Poly Butyl Cuprysil)

grease or silicone-based

1E3!'_~!'

f}'g:-

grease pomt
Rubber grease point
Brake flUid pOint

area
SBR859C

O-ring

2j)

Adjusting nut

Washer

@
@

Push rod

~jl

Return spring

~!)

Key plate

I~.'

Cup
Piston

Parking brake lever

(1])

Ring C

'~~I

Dust seal

f~
@)
@
@
@
@
@
@
@
@

Seat

Inner shim

Spring

CD

Nul

(1)
@
@

Cam boot

',[1
(jj

Cam
Brake hose

(8)

Connecting boll

~-)

Copper washer

Bleed screw

~D
~t
@\

Pin bolt
Cable mounting bracket

Strut

Cylinder

Ring A

f~
@
@
@
@

Spacer

Pad retainer

Wave washer

@')

Torque member

Spacer

@1)

Torque member fixing bolt

Spring cover
Ring B
Piston seal

Ball bearing

BR-17

Inner pad
Ouler pad
Ouler shim
Pin
Pin boot

/1

:-'"

:::':::"'.

II
,-

REAR DISC BRAKE

Removal
WARNING:

Clean brake pads with a vacuum dust collector to minimize the

hazard of airborne particles or other materials.
1 Remove brake cable mounting bracket bolt and lock
spring.
2, Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis4
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not 10 stretch brake
hose.

SBI=l860C

Disassembly
1.

Remove piston by turning it counterclockwise with suitable

commercial service tool or long nose pliers.

2.

Pry off ring A from piston with suitable pliers and remove
adjusting nut.

3.
a.

Disassemble cylinder body.

Pry olf ring B with suitable pliers, then remove spring
cover, spring and seat.
Pry off ring C, then remove key plate, push rod and strut.

Commercial
service tool
I

SBR868CI

-" "\
\

SBR646

b.

L-

SBR08BS

BR-18

t,.

REAR DISC BRAKE

Disassembly (Cont'd)
c. Remove piston seal.
Be careful not to damage cylinder body.

4.

Remove return spring. nut and parking brake lever

(1

SBR877

Inspection -

Caliper

CAUTION:
Use brake fluid to clean cylinder. Never use mineral oil.

CYLINDER BODY

Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above
conditions are observed, replace cylinder body.
Minor damage from rust or foreign materials may be el iminated by polishing surface with a fine emery paper
Replace cylinder body if necessary.

TORQUE MEMBER
Check for wear, cracks or other damage, Replace if necessary.

PISTON
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign matter is stuck to sliding surface.
Check piston for score. rust, wear, damage or presence of
foreign materials
Replace if any of the above conditions are observed.

PIN AND PIN BOOT

Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.

BR-19

.' I

;.' ';"

REAR DISC BRAKE

Inspection -

Rotor

RUBBING SURFACE
Check rotor for roughness, cracks or chips.

RUNOUT
1.
2.

Secure rotor to wheel hub with two nuts (M12 x 1.25).

Check runout using a dial indicator.

Make sure that axial end play is within the specifications

before measuring. Refer to "Rear Wheel Bearing" in RA sec-

tion.
SBR219C
'--------------------~

3.

Change relative positions of rotor and wheel hub so that

runout is minimized.
Maximum runout:
0.07 mm (0.0028 in)

THICKNESS
Rotor repair limit:
Standard thickness
9 mm (0.35 in)
Minimum thickness
8 mm (0.31 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)

-----------

Assembly
1.

Install cup in the specified direction.

2.

Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.

3.

Install ring C with a suitable tool.

SB_R_8--J92

Concave ponion

Convex portion

SBAS93

SBA878-A

'---------------'-----------

BR-20

REAR DISC BRAKE

Assembly (Cont'd)
4.

!nstall, seat, spring, spring cover and ring B while depressIng with suitable commercial service tool or press and
drift.

Spring cover-m

spnng-l

Seal---

Press

~
Spring cover-,

Spring

---I

L"'-

_ _ _ _----'-

R'lng A

Spacer

'.1
SBR679-A
----1

-0
----J:J

5.

Install cup. adjuster, bearing, spacers, washers and ring A

with a suitable tool.

6.

Fit parking brake lever and tighten nut.

Fit return spring in the order shown.

Wave washer --Q)

Spacer -iQJ
Ball bearing

---@

Adjuster--i

e
l
Cup ------@

P;s'on

SBR1DDB

7.
I~

SBRS77
L-

--------------l

Installation
CAUTION:

Refill with new brake fluid "DOT 3" (Except for Europe)
and "00T3 or 00T4" (For Europe). For Europe, never mix
different type brake fluids (00T3 and 00T4).

Never reuse drained brake fluid.

1. Install brake hose to caliper securely.
2. Install all parts and secure all bolts.
3.
Bleed air. Refer to "Bleeding Brake System" (BR-5).

BR-21

PARKING BRAKE CONTROL

SEC. 443

control lever

Ii.~.,j

8 . 11 (0.8 1.1,5.8 _ 8.0)

~. .

-~i

(O.33 0.44,2.4 -

3.2)~

'i

-1
I

(O.33 0.44. 2.4 3.2)

RH rear cable

L~3'2'
4.3
(0.33 0.44, 2.4 3.2)

r/r-q;=

~-:l

L--

/~ 3.24.3

Fr~on!
cable : ,

~
I

3.2 4.3

Lock plate

==,.
LH Ie., c.ble

~ 8 - 11 (0.8 . 1.1, 5.8 8.0)

L.~

Nm (kg-m, ftlb)

_________
sBA996cl

Removal and Installation

Adi",hng nut

j~

-<~-~~~L~~ \H~

~~'
Warning lamp

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.

Remove lock plate, then disconnect cable from caliper.

c~~

SBR01501

BR-22

PARKING BRAKE CONTROL

Removal and Installation (Confd)

When installing
parking brake cable at rear calir\Ar
k
1 ' - , rna e
,
sure to a I Ign matchmark on cable guide .

.--/ 'Cablo guide

\,':

SBR4B9A

--------'-------

Inspection
1.

2.
3.

4.

Check control lever for wear or other damage, Repl ace 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 found
deformed or damaged, replace.

/:""1
~

\.,-/!'.1

Adjustment

,,- Pdt'k'ng brake lever

""

\Stopper bolt

Pay attention to the following points after adjustment.

There is no drag when control lever is being released.

Parking brake lever returns to stopper bolt when control

lever for rear disc brake is released.

SBA26<1R

.----------------.,r--

Box wrench

1.
2.
3.
4.
5.

6.
7.
SBA490A

8.

Pull control lever up by 4 or 5 notches.

Insert a box wrench into opening in control lever and
loosen self-lock adjusting nut to slacken cables.
Completely push control lever down.
Forcefully depress brake pedal about five times (so that
caliper is automatically set in position.).
Pull lever up by 4 Dr 5 notches.
Turn adjusting nut as shown in figure and adjust lever
stroke to specified value.
Pull control lever with specified amount of force. Check
lever stroke and ensure smooth operation.
Number of notches: 7 - 9 [196 N (20 kg, 44 Ib
Bend warning lamp switch plate to ensure the following.
Warning lamp comes on when lever is lifted "A" notches,
and goes out when fully released,
Number of "A" notches: 1

J,~

:', :

;.

Pdf ki ng bra ke

warning lamp switch

plate
SBR493A

BR-23

Purpose
The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of braking force so that locking of the wheels can be avoided.
The ASS.
1) Improves proper tracking performance through steering wheel operation.
2) Eases obstacle avoidance through steering wheel operation.
3) Improves vehicle stability.

Operation

The ABS will not operate at speeds below 5 to 10 km/h (3 to 6 MPH) to completely stop the vehicle.
(The speeds will vary according to road conditions.)
The ASS has self-test capabilities. A mechanical noise may be heard as the ASS performs a selftest the first time the vehicle reaches 10 km/h (6 MPH). This is a normal part of the self-test feature.
If a malfunction is found during this check, the anti-lock warning lamp will come on.
During A8S operation. a mechanical noise may be heard. This is a normal condition.

-----.

ABS Hydraulic Circuit

__

._-----------------------------------------------,

Proportioning valve
(Do not disassemble)

'~

Master cylinder

Rear RH wheel

Brake booster /

~~eel

r=== -

ABS actuator

~~s~~alve

(Front R-H-)-+---+-S-ypas-s-ch-e-c-k-valv-e-(R-e-ar-) -

-==_-+--------,
Caliper

Lca"Per

(Front RH)

Outlet
solenoid valve

Outlet
solenoid
valve (Rear)

(Front RH)
Inlet
solenoid
valve

r---_~

Oullet
valve
(Front)

Damper /

:D~~----(Front LH)

_------if

~- ,

'-------cFront

LH wheel

Inlet [
(Front LH) valve
L........OMr-------'

(Front)

Bypass check valve ('mnt LHI

Pump

(Front)'

BR-24

(Rear)

.~ Pump
t,,1

(Rear)

Motor

(Front)
- --- - --- - _-- _

Outlet valve

Reservoir
_

Inlet valve

(Re~~_---, I
(Rear)

-.JI

SBR862C

ANTI-LOCK BRAKE SYSTEM

System Components
ASS conslsls of
Wheel sensors (3)
ACluator

p
Slop lam \

Warning lamp

SWitch

"Actuator

Control unit

/~

//

_--I

\
- _::....-------::..:-.:-~ --

- - . Harness

- ' Piping

For RHD models. actuator and

actuator connectors are
located at opposite sides.

Front wheel sensors

"1

_ _ _ _ _ _-5_BR0430>

':/!l=-;

System Description
SENSOR
The sensor unit consists of a gear-shaped sensor rotor and a
sensor element. The element contains a bar magnet wound
with a coil. The sensor is installed on the back side of the
brake rotor or the final drive. As the wheel rotates. the sensor
generates a sine-wave pattern. The frequency and voltage
increase(sl as the rotating speed increases.

I.

CONTROL UNIT
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 alsu controls ON-OFF
operation of the solenoid valve relay and motor relay. If any
electrical malfunction should be detected in the system, the
warnIng lamp is turned on. In this condition, the ABS will be
deactivated. and the vehicle's brake system reverts to normal
operation

BR-25

'7

ANTI-LOCK BRAKE SYSTEM

System Description (Cont'd)
ACTUATOR
The actuator contains:

An electric motor and pump

Two relays

Six solenoid valves, each inlet and outlet for

- LH front
- RH front
- LH and RH rear
These components control the hydraulic circuit. The ASS Con~
trol unit directs the actuator to Increase, hold or decrease
hydraulic pressure to all or individual wheels.

ABS actuator operation

Inlet solenoid
valve

Outlet solenoid
valve

I--

Normal brake operation

-Pressure hold

ABS operation

Pressure
decrease
Pressure
increase

~OFF (Op~~(Closed)
I

ON

(Close~l OFF (Closed)

r:rosedl

ON (Open)

1---

Masler cyl i nde r bra ke fI u i d press ure is directly

transmitted 10 caliper via the inlet solenoid valve.
Hydraulic circuit is shut off to hold the caliper
brake fluid pressure.
-naliPer brake Iluid is senl to reservoir

via~ Ihe

outret solenoid valve Then it is pushed up to the

master cylinder by pump.

; OFF (Open)

~FF (Closed)

BR-26

Master cylinder brake fl uid pressure is Iransmitted 10 caliper

ANTI-LOCK BRAKE SYSTEM

Removal and Installation
CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
When removing the front wheel hub or final drive assemblies
first remove the ASS wheel sensor from the assembly. Failur~
to do so may result in damage to the sensor wires making the
sensor inoperative.

'II!~,

WHEEL SENSORS
SEC. 476

Front sensor

~-!

r-

-=:'c
-",C..

1
J

~: Nm (kg-m, fHb)

SENSOR ROTOR

Removal
1.

2.

Remove the front wheel hub or final drive companion

flange. Refer to FA and PD sections.
Remove the sensor rotor using suitable puller, drift and
bearing replacer.

~l

~~
;~) I

I
I

L-

SBA873C

,--------------------,

Front sensor

Press

I nsta II ation
Install the sensor rotor using suitable drift and press.

Always replace sensor rotor with new one.

Pay attention to the direction of front sensor rotor as show

in figure.

r->' :

Il

,>

I [, .;:

2:'

.:>-

~::;

Whee) hub

\~~
BR-27

ANTI-LOCK BRAKE SYSTEM

Removal and Installation (Cont'd)
Press

SBR982C

CONTROL UNIT
Location: Under trunk side finisher LH.

ACTUATOR
Removal
1.
2.
3.
4.

Disconnect battery cable.

Drain brake fluid. Refer to "Changing Brake Fluid" (BR-5).
Apply different colored paint to each pipe connector and
actuator to prevent incorrect connection.
Disconnect connector, brake pipes and remove fixing nuts
and actuator ground cable.

InslaII ali on

S3R'l9BC

CAUTION:
After installation, refill brake fluid. Then bleed air. Refer to
"Bleeding Brake System" (BR-5).
1. Tighten actuator ground cable.
Place ground cable at a notch of mounting bracket
2. Connect brake pipes temporarily.
3. Tighten fixing nuts.
4 Tighten brake pipes.
5. Fix actuator harness clip on the mounting bracket.
6. Connect connector and battery cable.
ACTUATOR RELAYS
1.
2.
3.

Disconnect battery cable.

Remove ar.tuator relay cover.
Pull out relays.

BR-28

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram -

ASS -

LHD MODELS

BR-ABS-01
Refer to El-POWER.

OR/G

G/Y

I$~ ~)- ------1ciJi

G/8

I$~

G/W

-:!} 1~~ - - -1$1

G/Y

OR/G

GIB

G/W

G/Y

OR/G

CEID .....L,
........
~-af53) ~ - - - ~

OR/G

G/W

GIB

G/W

IciJ~ _<e;O:~_ - - - - - G/Y

@)

...I-.

$
I

$_~j$h_$
G/W I

rm

OR/G

r@ ,

IGN

BAT

CONSULT
DATA IN
(RX)

G/Y

GND

GND

GND

GND

GND

12.21

28

GIB

ri2'1il '

CONSULT CONSULT
DATA OUT
DATA
(TX)
elK

ASS
CONTROL
UNIT

@)
1

111

Ll-l-l..J

(tTI)

2
I~

8 73

gIIRTIIIJ CHID

L::IflITIIl.J

GY

II I 131415~~
I I _

~
2

19
20 12

1 ~

I
I

Refe~

to last

page

(Fo Idout page) .

:
I

1 I I I I~
[ I I
W

SBRODID

BR-29
L.

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram - ASS -

(Confd)

BR-ABS-02
ASS

FA
WHEEL
SEN RH

FR
WHEEL
SEN RH

FA
WHEEL
SEN LH

FR
WHEEL
SEN LH

RR
SKID
SEN

(+)

(-)

(+)

(-)

(+)

lYJ=ll

Wf

st

pt

Lf

~l[~~~~11

SEN

(-)

LJ

~l[~~~~l~

/1
I

f'

$~$-Jl----Lrn$ $
---AI----[)
I ---- l
---- J

!
,I
:

I
I

I
I
I
I

W~B

(.....

T'~

____

~nL

r,

B~

.-.

----p)

!: *~
~(8QQ) ~
! !

I."

'I

M
rv

__ --

CED

::

rv

I
1

I
I

I
I

I
r

\
I

r-

\
I
,I
)

,I

FRONT WHEEL
SENSOR RH

----

[L --- PI

I ..

I
I
I
I
I
I

, . -----

.-.

I
!
I

I
I

8""'" t~-f---~

!l

lI

/1

~~;-] t~rcpI~=~=~;:['1
f'--- ----)
w CE[) 8

CONTROL
UNIT
C@

AR
SKID

FRONT WHEEL B
SENSOR LH
~

I~

C@

B/W

~ICITJ)
I

rv

~~

REAR SK 10
SENSOR

Refer to last page

(Foldout page) .

~8
~~

<Hill'>

GY

~ ~

@JTI) GY

KJl CITD

@lID

GY

I' I II I 9 I 181911Oj~
I

1 _

1 I

CITIJEJIIJ ~

[lli[ILll]

SBR0020

BR-30
,

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram - ASS -

(Cont'd)

BR-ABS-03
Refer to

EL-POWER.

TACHO

~
LIB

R/Y

R/Y

II!'I

LAMP
USWITCH

21

METER
COMBINATION

(ASS WARNING
LAMPl

lLjdJ (~)

I1?JdJ ~

RIG

L/R

I
$

RIG @)

_
-

L/R ~

RIG @)

L/R cr::g)

Next page

L/R ~

1-------1

LIB

RIG

1-

LIB

L/A

12

231

STOP

FAIL

ECCS

LAMP

SW

f:>

lbP
LIB ~

$L/R ~

I
I
LIB
$-------------------

LAMP

L/R

YIR @)

RIG ~

C"::'

To tacnometer
(Refer to
EL-METER.)

1.

RIG (ffiJ)

C,-'

. - LIB

':,.'1,'

em

1
~
n STOP

ECM
(ECCS
CONTROL
MODULE)

TACHO

'C'i'
r' ,.

RIG

To
stop tolamp
(Refer
EL-TAIL/L. )

ABS

CONTROL
UNIT

i.-' -

Refer to last page

(Fa Idout page) .

U2! I I K)f I I I I I
D I I [ I I I .

Ie- .

~-----------------------,

:II3nIJTil
l.tt:1:11TI
I

~]
~
21
W

:
J

SBROOJO

BR-31

'r,:':

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram - ABS -

(Cont'd)

BR-ABS-04
ASS

FR AH
SOL v
IN

SOL"
IN

lYJlJ

RIB

R/B

Preceding

RR
FR RH FR LH
RR
SOL V SOL " SOL II SOL V SOL V
IN
OUT
OUT
OUT MONITOR

1l!J1--.-lT?fJf

GY

8R

S/Y

@Z) GY

SR

S/Y

L/Y

L/Y

~
Y

UNIT

@)

~
Y

$~ i$--$--1J--$--$--t$J

<:@-

page

FR LH

CONTROL

1 Il Il Il Il Il Il It
RIB

L/R

GY

SR

B/Y

l/Y

L/R <HQ) RIB ~

GY

SR

S/Y

L/Y

CEID

GY

SR

S/Y

L/Y

BR/Y

I$~- --~$~--t6]~--~~~- -tOJ~--J~~--l$l

L/R

CE!) R/8

L/R

AlB

GY

SR

m m m

rrTIi1

B/Y

l/Y

BR/Y

rr3l1

FRONT

FRONT REAR

FRONT

RH

LH

RH

FRONT REAR

LH

ASS

ACTUATOR

(ffi)
'-~

SOLENOID VALVE IN

r------

'---y-------'

SOLENOID VALVE OUT

~~11111~11111~
~

r------

ti 12 1131 ~5[161171181
1

Refer to last page

(Foldout page) .

111~MI
2 24
9 8 ~
:

I
7
[S
L

10

SBA004D

BR-32

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram - ABS -

(Cont'd)

BR-ABS-05
I BAT.ERT I

ASS

Refer to
EL-POWER.

J:~~30A

~ITJ
~OJ
R
R/L
@) R/L

SOL V
RELAY

MOTOR
RELAY

MOTOR

lift
A

G/A

I em>

I(@

~~------1Lp
LG/A

LCfll@)
A

G/R

ti'25"

MONITOR ~

~t

LG/R

ILC1Jt-----mI
R

CONTROL
UNIT

qJ---------fP--------fCt4ll

AIL

LG/RCEID

G/R

1--_---

To 8R- ~ G/Y _ _- - - ABS-01 -.......:::r

R/Y

G/Y~

',1- 1

(IT)

ASS

ACTUATOR ~

Prec ed i ng

CL---------l---.......,

page

~
t
rm rn

G/A

a/y

LG/A

R/L

rF@

SOLENOID
V~LVE

/]

RELAY

A/Y

m
MOTOR
RELAY

~
B

t 1

(QZ>

Refer to
(FoJl1out

~ast

page)

page

r------------~---------'

II

(ffi):

:@@tW~!

B
_

~~

illS'

GY

__

BY
-

11
I

1 I I a6171 I I ~
I

l14/

@)

I
.J

~n@ID
tttJDj B
S8ROO:,D

BR-33
!D

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram - ABS -

(Cont'd)

RHD MODELS

BR-ABS-06
Refer to

EL-PO~ER.

DR/G

G/Y

j"""---

- - - - - - - - - - - - G/Y

CONNECTOR
FOR CONSULT
. (BID

DR/G

G/Y ])

DR/G

,
I-If1
-------,.-LfJ------=-LjJ-I

l$t - -:1-------1COJI

_ _ _.

GIB

G/W

GIB

G/W

BAT

CONSULT
DATA IN
(AX)

~
B

IbjJJ
B

12~1

~
B

21

CONSUL T CONSUL T
DATA OUT
DATA
(TX)
ClK

A8S
CONTROL
UNIT

~ ~

---:-r-G-,::N'"""D,------------;rG-=N,..."D,----------:TG=N"'""'O:----:TG=N::TD:-------:TG=N",.,.O,....--

~
B

G/W

~~+---+
+~~---~
J
t
J

12-91

IGN

GIB

OR/G

8R-ABS-10

DATA LINK

G/Y ~

G/Y

~ To

2..s I
B

~.-.-.--I

t 1

2
19
1
:~
20212

:L
1~[ill[I[lTl (BID

L::l.JNII.IIJ

GY

I I I
I

r 9617181

I
I

BiiE
2

2 73
W

Refer to last page

(Foldout page) .

:
I

~I

j@)
W

SBR0060

BR-34

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram - ASS -

(Cont'd)

BR-ABS-07

(+l

ILtJr

tlJj1JJ

~l

ASS

FA
FR
WHEEL WHEEL
SEN LH SEN LH

FR
FA
WHEEL WHEEL
SEN RH SEN RH
(+)
(-)

AA

(-)

SKID
SEN

RR
SKID
SEN

,.

t
,-1
I
I
I
I
I
I
I
t
I
I

t
/;
I

I
I

I
I

I
I

I
I

I
I
I
I

L ~ P

f,

CEID

I
I
I
I

----

C..

1 1

~5~~

I
I

I
I
I
I
I
I
I
I
I

1
,I
)

"

,I
)

rv

~B/W

----

,-

~B/W

I
I
I
I

I
I....

FRONT WHEEL
SENSOR RH
(ffi)

\ L

..

I
I
I

I
I
I
I

rv

:I

I
I
I

I"

II

I~

"

B!W

,.

1
rtJ---$!m
$---4ltl
.-.

;, -,I ~

UNIT

(-)

(+)

~j

CONTROL

B/W

FRONT WHEEL
SENSOR LH
(ffi)

rv

I=lEAR SKID

SENSOR

CITD

Refer to last page

~(lli)

~
~ <ng)

ilil..@

GY

~ ~

CI!!l.fl)

GY

--.&LL <TI:D

C!l

GY

1112/31 1
1 1 I

9 I 1 I I J ~w

(Foldout page) .

I 1 I

~1<62.)
~

SBFl007D

BR-35

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram - ASS -

(Cont'd)

BR-ABS-OB
Refer to
EL-POWER.

G;]

ECM
(ECCS

TACHO

CONTROL
MODULE)

em

LIB

R/Y

I!l
G

m
I]
lhiJl

STOP LAMP

SWITCH
C@)

EL-METER.l

L/~

I
.------__--_.1_
I

I @)

L/R~

RIG

qJl

l@

L/A~

RIG ([g)
~_--

L/A ~ Next oage

LIB IT.[)

~l

._~

. - LIB. To tachometer
(Refer to

(ASS WARNING

~~

__

METER
COMBINATION
LAMP)

RIG

RIG

A/Y

..I--_-_-

LIB

RIG. To stop lamp

RIG ~

QJl
RIG

(Refer to
EL-TAIL/L.)

RIG

L/A

LIB

ri1'2u
FAIL

ECCS

LAMP

TACHO

ABS

CONTROL

UNIT

~
-1

23

r~-----------

:~][gmE]@
tL

I I I
I I

12

~
B

Refer to last page

(Foldout page) .

9
[I 191 I@)
__ I I . w

~_J

EEtf~fEE
~
19
W
SF3ROOBO

BR-36

ANTILOCK BRAKE SYSTEM

Wiring Diagram - ASS -

(Cont'd)

BR-ABS-09
ABS

FI=l I=lH

SOL V

IN

P~eceding ~
L/R
page
~

HI LH

RR

FA RH

FR LH

RR

SOL V SOL V SOL V SOL V SOL V SOL V

IN
OUT
OUT
OUT MONITOR
IN

4JJ
RIB

Iki=JJ

GY

SA

24
Blv

[2.61
L/Y

~n

L/R~R/B~ GY

SA

B/v

L/Y

L/R CI1) RIB <[) GY

BA

B/V

L/Y

CONTROL
UNIT

ro)_u r$--~~~--t~~--~$~--~$~--$

t
L/R

RIB

GY

BIY

SR

m mrn

FRONT

rr!6TI~

FRONT REAR

RH

L/Y

LH

~m

FRONT FRONT REAR

AH

LH

AB~

ACTUATOR

~
Next

page

SOLENOID VALVE IN

SOLENOID VALVE OUT

Iti1121131
~) I f a I I I I I~
85116117118

Refer to last page

(Foldout page) .

:~ ~ill):
ItillW~

I
GY
GY
I
~---------------~

SBP0090

BR-37

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram - ASS -

(Cont'd)

BR-ABS-10
, SAT.ERY

ASS

~1
i T
30A

30A

IT]

IT]

Refer to

EL -POWER.

SOL V
'-R;r:EL:::-AT':"'"Y

MOTOR
~
MO.. ,.,N-;-I.,. .,. ,TO_R.. . J

MOTOR
R-:rE-=:L......
AY

Ili=U

LG/R

G/R

11

R/L

LG/R ~

G/R

R/L

LG/R (@

G/R

~-----~

CONTROL
UNIT

It
R

~---------~qp~--------~

1-----

,
G/Y~

LG/R

rm

Preceding
page

$
G/Y (IT)
IJ
G/Y
rFh

SOLENOID
VALVE
RELAY

G/R

R/L

rmru

m
MOTOR

\]

RELAY

MOTOR ASS
ACTUATOR

<EM>

~
8

-=-

Refer to last page

(Foldout page) .

~~

WSJ
r------

:~
I
IL

~
B

...LI-.l-14~1~5 OLL-..,L....l.,I.....I.I.....,JII--! ~)
. I I It{[
I I .
I~J.....-I
n

~ ~ffi):
CilltW
GY
GY

tftj

I
I

SBRQ10D

BR-38

TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair
..
Self-diagnosis
Component Parts and Harness Connector Location
.
Preliminary Check
"" __
..
Ground Circuit Check
.
Circuit Diagram for Quick Pinpoint Check
..
Diagnostic Procedure 1 Warning lamp does not work
..
Diagnostic Procedure 2 Control unit or ground circuit
__
""'"
Diagnostic Procedure 3 Actuator solenoid valve
"
Diagnostic Procedure 4 Wheel sensor or rotor
Diagnostic Procedure 5 Motor relay or motor
.
Diagnostic Procedure 6 Solenoid valve relay....
"
Diagnostic Procedure 7 Power supply
"..................... .
Diagnostic Procedure 8 Memory volt stop
Diagnostic Procedure 9 Pedal vibration and noise
Diagnostic Procedure 10 Long stopping distance . ---DiagnQstic Procedure 11 Unexpected pedal action
"."
Diagnostic Procedure 12 ABS does not work
Diagnostic Procedure 13 ABS works frequently
"
Electrica I Component Inspecti on
'" .

BR-39
BR-40

BR-43

BR-44
BR-45
BR-46

'

BR-47

.
_

..

..

" ..

..
"'"

.
..
.
'''''''
'.
.

BR-49
BR-51
BR-52
SR-54
BR-57
BR-60
.. BR-61
.. BR-62
.. BR-63
BR-63

.-,

BR-64
. BR-64
. BR-65

L,

How to Perform Trouble Diagnoses for Quick

and Accurate Repair
INTRODUCTION

SEF?33G

_ _ _ _ _SEFn<lG!

The ABS system has an electronic control unit to control major

functions. The control unit accepts input signals from sensors
and instantly drives actuators It is essential that both kinds of
signals are proper and stable. It is also important to check for
conventional problems: such as air leaks in the booster or
lines, lack of brake fluid. or other problems with the brake
system.
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 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 problems,
so a road test should be performed.
Before undertaking actual checks, take just a few minutes to
talk with a customer who approaches with a ABS complaint.
The customer is a very good source of Information on such
problems; especially intermittent ones. Through the talks with
the customer, find out what symptoms are present and under
what conditions they occur
Start your diagnosis by looking for "conventional" probl ems
first. This is one of the best ways to troubleshoot brake problems on an ABS controlled vehicle.

r -

(.

BR-39

TROUBLE DIAGNOSES
Self-diagnosis
FUNCTION
Wtlen a problem occurs in the ASS, the warning lamp On
the instrument panel comes Orl_

A maximum of three malfunctions are stored in the mel11,

ory of the ASS control unit.
Erase the self-diagnosis results stored in the control unii after
malfunctions are repaired (See next page).
The self-diagnosis results are identified by Consult or LED
on the control unit

I~
I

'---..---06<'

-cj

-~!3)

=--wa,~

)')

SELF-DIAGNOSIS PROCEDURE
Start engine.
Drive vehicle over 15 km/h (9 MPH) for at least one mlnute_

1
Stop vehicle with engine running.
Make sure thai Ihe ASS warning lamp aclivales.

__

_~J

SBRM

The LED on the ABS control unit flashes to indicate the malfunction code

No

Venty the tocatlon 01 the malfunction with the malfunction code chart
Then make necessar-y repairs following the diagnosqc procedures

- _.- - - - - __ J

After the malfunctions are repaired, erase the self-diagnostic resulls

stored in the control unil
Disconnect connectors for ABS control unit or the baltery negative 'erminal for at least one minute.

BR-40

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
HOW TO READ SELF-DIAGNOSTIC RESULTS (Malfunction codes)

Determine the code No by counting the number of times the LED flashes on and off
The malfunction code chart is given on the next page.
Example

Mal1unclion code No 12 and 23

I'"

LED ON - - - I

_I
a
b

LED OFF

3 seconds (Clearance between code No.)

0 6 second (Ten digits)
03 second (One digit)

saRene I

~'~~
~--r'

,==

HOW TO ERASE SELF-DIAGNOSTIC RESULTS (Malfunction codes)

Disconnect ASS control unit connectors or battery negative terminal for at least one minute.

BR-41

TROUBLE DIAGNOSES
Self..diagnos;s (Cont'd)
MALFUNCTION CODE/SYMPTOM CHART
Malfunctioning part and circuit

Code No (No at LED flashes)

---

Diagnostic procedure

Fro nt r igh I sen s,)r (open -c ircu it)

01

4
--.---

Front left sensor (open-ClrcUlt)

02
----~-----

--

----------

-- f - - - - - - - - - - - - - - - - - -- - -

- - ---

-------- -

~._-

- - - --------_._---

03

Rear sensor (oppn-clrcuII)

OS

Front right sensor (short-circul!)

Jj

06

Front left sensor (shorl-circuit)

07

Rear sensor (short-circuit)

--

---

Actuator front right inlet solenoid valve (open-crr-

11

cuill

12

,A,ctuatar front left inlet solenoid valve (open-circuit)

13

Actuator rear inlet 'Solenoid valve (open-circuit)

Actuator front right

15

ou~let

solenoid valve {open-cir-

Actuator lr01\ left outlet solenoId valve (open-cir-

cui!)

-17

Actu ato r re ar out \el sole no id va hie (open-cireui I)

Actuator front right in lei solenoid valve (short-clT-

21

--

cuil)

16

cuit)

---

22

Actuator front left inlet soler,oid valve Ishort-circult)

-_.-

---------

23

----------,- 3

Actuator rear inlel solenoid valve (short-circuit)

Actuator frorJt rigr.t outlet solenoid valve (short-cir-

25

cuit)
r--

Actuator front left outlet solenoid valve (short-cir-

26
27

Actuator rear oullet solenoid vr:llve (short-circuit)

41

Solenoid valve relay circuit (unable to turn off)

42

,.-

Solenoid valve relay circuit ('Jnable to turn on)

43

Actuator molor or motor relay (unable to turn oil)

44

Actuator motor or molor relay (unable to lurn on)

tl

47

Power supply (High voltage)

48

Power supply (Low voltage)

-- ---------------

-----

cui!)

L..--._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ L . . - -__. _ _ _ _ _ _ _

45. 46. 77

Conlrol unit

LED deactivation or continuous

Ground cireui!

activation

----- ...-

,----------Warning lamp does not come on

Fuse. warniny lamp bulb or warning lamp cir:::uit

when ignition switch is turned on_

Control unit power supply cirCUit

Pedal v,bratlon and noise

--

1--'--

Long stopping distance

Unexpected pedal actio"

'---------

A8S does

no~

---,-

work
"-

ASS works frequently"

10

A _ _ _ _ ___
~--~

--

--------

-_._-,---------f - - - -

11
--- -- - - " . -

12

13

BR-42

----~.-

_.-

TROUBLE DIAGNOSES
Component Parts and Harness Connector
Location
ASS consists of Wheel sensors (3)
Actuator
Conlrol unit

~.

Actuator and

~~CIU'IO' connec~~_

---- ----------

LHD models

Stop lamp
switch

-----

[!I
---'-...

Control unit and

control unll connectors

_/

Rear sensor
Rear wheel
sef\sor connector

For RHD models. actuator and

actuator connectors are located
at opposite sides

- - - - : Harness

- - - : Piping

~'fi:

N C-

", I

L
"

/J ,

_______________ ASS control unit IS located

under the trunk side finisher LH_

J----------------'

_--L

SBR011D

BR-43

M
,

TROUBLE DIAGNOSES
Preliminary Check

,~-

- Max line

-----'------ ---

Check brake fluid level

MA~

OK

Min line

In

reservoir tank

Low fluid level m;.jY indicate brake pad

wear or leakage from brake line

__-T-

SBR418CB

r--, _
_~

Check brake Iine tor leakage,

I~he'k

Repair

~Reprace

brake boosler lor operation and

OK

00

Check brake pads and rotor. Refer to

SBR389C

---.J

air tightness. Refer fo (BR-10)

NG

Replace

NG

FiJI up brake fluid.

-I

(BR-12, 16)
OK

m
Check brake fluid level in reservoir tank

-,-

again.

-~

OK

(I

SBR058C

NG

Check warning lamp activatloil.

When ignition switch is turned on,
warning lamp turns on.

-Check fuse. warnIng

lamp bulb and warning

lamp circuit

'OK

NG

CheCK warning tamp for deactivation

after engine

Go to Self-diagnosis (BR-

40)

i~ s1arted

OK
Dr ive

ve~Cle at speeds

over 15 km/h

(9l

.--------------=r----MPH) for at least one minute

j
NG

Ensure warning lamp remains off wl-Jile

driving,

Go to Self-dIagnosis (BR40)

OK

END

BR-44

-I

TROUBLE DIAGNOSES
Ground Circuit Check
ACTUATOR MOTOR GROUND
Actuator motor ground is secured with actuator mounting
bracket bolt.

Check resistance between actuator motor ground terminal

and body ground.
Resistance: approximately

on

,-------------------,

CONTROL UNIT GROUND

Check resistance between control unit connector terminals

and ground.
Resistance: approximately

on

SBR879C

---------------,

Actuator 8-pin connector (body side)

ACTUATOR GROUND

Check resistance between actuator harness 8-pin connector (body side) terminal ,@ and ground.
Resistance: approximately

on

BR-45

TROUBLE DIAGNOSES
Circuit Diagram for Quick Pinpoint Check

I~

STOP LAMP

LHO models
RHO models

SWITCH

FUSE
29

To stop lamp

~---

12

--8'

cD:@
:~

IGNIT ION SWITCH

ON or START

-~r-T-

I--+-------i..------

ABS WARNING
LAMP

FRONT

WHEEL
SENSOR

23

RH

--i

-1=-m-----;d

cD:(@)
:@&

ECM(ECC:S

co~module:

FRONT
WHEEL
SENSOR
LH

To

ACTUATOR

ABS

17

ta~hometer

Ivl0TOR

18

A8S
CONTROL
UNIT

e&

FUSIBLE
LINk

11

REAR
SKID
SENSOR

15

10

----0
"

16

FUSIBLE

{2}-

~--

19

DATA LINK

LHH(

20

SOLENOID
VALVE

CONNECTOR
FOR CONSULT

t-

'

l1
~

I:lELAY

10
FL

21

26

24

22

27

25

OUT

~TI''-----

FR HJ

'QlT'--

FR OUT

rnr---

R IN
_---.fQlT'----

-1
~

SOLENOID
VALVE

-1

,R OUT
,
---'010'-- -- I

28

CD:@

@:@)

SBR999C

BR-46

TROUBLE DIAGNOSES

Diagnostic Procedure 1 (Not self-diagnostic

item)
Warning lamp does not work when ignition switch is turned
ON.
~RNING LAMP CIRCUIT CHECK -----~~-R-e-Pl-a-c-e-fu-s-e---- - - -

, ,!" -

,,-~

Check 7.5A fuse

] for warning

lamp.

ror fuse layout. refer to POWER SUP-

PLY ROUTING in EL section.

OK

Replace bulb.

~ Check warning lamp

Install 7.5A fuse

bulb

Disconnect connectors from control

unit and actuator.

lOK

Check voltage between control unit

Actuator 6-pin

~~~~:~~::~

,-------------'-------

connector terminal @ and ground

after turning ignition switch "ON".

SBR891C

connector Ibiide l

6f9 ltb

Repair harness and con-

Ballery voltage should exist after

"'eetars between ballery

turning Ignillon swllch "ON".

and control unit connector terminal r~ (includ-

OK

ing CO'T\bination meler)

DISCOO~CT

~0
Turn ignition switch "OFF"
Disconnect actuator 6-pm connector.

NG

-------..

-----------------~

[!1

Actuator B-pin conneclor (body side)

EffB ~ ~5

Repair harness and connectors between warning

lamp (combination meter)

Check continuity between control unit

SBR881C

conneClor terminal ([i) and actuator

and actuator 6-rin con-

E-pin connector (body side;' terminal

dl\ .

nector (body side) terminal (1)'.

Continuity should exist.

OK

o,sconnect actuator 8-pln connector.

R.-----JOK

Check continuity belween aCluator

harness 8-pin connector (body side)

II

_ _ _ _ _ _ _ _ _ _ _S_B_R_8_8~______')C

to

~erminal
and body ground
Conti nu ity shou Id exist.

~)

(Go to next page)

BR-47

""l,
":-=;

NG

Repair harness and con]

neelars.

:; I

[!]

Actuator connectors (actualor side)

TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Not self-diagnostic
item) (Cont'd)

e,aY box .lliJ EfRIj ~

~-~~

i5

,---------------------.

~[ill

I00o 1r1~.I

Disconnect solenoid valve relay

Replace actuator

Check continuity between actuator

bly

<I5Sem-

connector (actuator side) terminals

and solenoid valve relay box terminals.

S_B_R_88_3--'C

Actuator

Relay box

11 (fI

30

87a

21

Continuity should exist.

Note: Pay attention to tester polarity.

~OK
~ Replace solenOid valve

CHECK SOL ENOID VALVE RELAY.

relay.
Refer to SOLENOID VALVE RELAY in

Electrical Components Inspection (8R-

65).
\

-lOK,_ _
[G-o-to-I!)--;n-O-ia-g-nostic Procedu re 2.

; Specifications may vary depending on the type of tesler.

Before per'ormlng this inspection, reter to the instruction manual of the
tester.

BR-48

TROUBLE DIAGNOSES

Diagnostic Procedure 2

Actualm B-pin connector (body side)

ElftB '~ i5

CONTROL UNIT OR GROUND CIRCUIT

(Malfunction code No. 45, 46, 77, LED deactivation
ous activalion)
---_._-_. -- -

No

Disconnect can neclars from control

unit and actuator Check terminals for
damage Of connection Then reconnect connecto rs.

C/Unil connector
~

I'W5

~12

6 19
13 151729 4 ]
22 2120 14 16 le~

~i5

Actuator 6-pin
connector (body_side)

rfh
\I.t.LD

rtb~
~

DISCONNECT

-"-

f----+

Replace solenoid valve

relay

Refer 10 SOLENOID VALVE RELAY in

Electrical Components Inspection (BR65).

18

Actuator 6-pin
connector (actuator side)

~
bOle

e_~_-_"_J

! .'

NG

SOLENOID VALVE RELAY CHECK

. Relay

continu-

I
Carry out self-diagnosis again._~
Does warning lamp activate aga~

SBR882C

Inspection

Or

SOLENOID VALVE RELAY GROUND

CIRCUIT

NG

Repair harness and connectors

II

Disconnect actuator B-pin connector .

Check continuity between actuator

E8:W ~

B-pin conneclor (body side)

@ and body ground.
Continuity should exist.

DISCONNECT

18

ter~inaJ

-~ "~~"

Disconnect control unit connectors

and actuator 6-pin connector.

S8R884C

NG ...

RepaIr harness and conneelors.

Check continuity between control ~nil

connector terminal @ and actuator
6-pi n connector (body side) termi nal

~.

@.
Continuity should exist.
-~.-

_L

,---------

--

- - - - - , NG

Check continuity between actuator

6-pin connector (actuator side) ler minat @ and solenoid valve relay box
terminal .~Ol
Actuator

Relay box

Continuity

30 '.]

Yes

11 8

30 <:B

No

11
I

... Replace at::tuator assembly.

Note: Pay attention to tesler polarity'.

~
(1\)
(Go to next page.)

': Specificalions may I/ary depending on the type of lesler.

Before performing this inspection, refer to lhe instruclion manual of the
tester.

BR-49

TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)

00

CONTROL UNIT

[-RePlac~=J

POW~'~ SU~~~Y CIR- ~1Z~eck~A fuse OJ

for

I ~~ontrol unit. For fuse

CUlT

layout, refer to POWER

Check voltage between control unit

connector terminal

CD

SUPPLY ROUTING in EL

and body

ground after turning ignillon switch

SBR8B5C
~---------

section

L-

"ON".

0K
1

~--~-

8allery voltage should exist after

I Repair harness and con-

lurning ignilion switch "ON:'.

nectors.
OK

"

CONTROL UNIT GROUND CIRCUIT

Refer to CONTROL UNIT GROUND
Ground CIrcuit Check (BR-45)

-=--~_OK

~ to Diagnostic Procedure
,

.~
Replace ABS control unit

BR-50

InJ

4 (BR-52).

NG

Repair harness and connectars.

TROUBLE DIAGNOSES
.--------------,

Diagnostic Procedure 3

CiUnil connectors

6"

" '5 "

ACTUATOR SOLENOID VALVE

(Malfunction code No. 11 - 13, 15 - 17, 21 - 23. 25 - 27)

f@..oIIIIII
~

.LJ 8 lj

11 12222120 14 1 18 23 7

SBRJ

Actuator conneclors
(actuator side)

~-~

Code No
(LED flashes)

cIDl

Actuator connectors
(body side)

rJFT,\~

OISC(JN'IE'CT

10

11, 21

([)

C~I

12,22

(j)
(1)
(f)

(~Ol

15,25

SBA8B7C

769 1024.25.26,

..

Terminals

13.23

\1m/ttEV

...l-----..J

. - - - - - - - - - -

--_.

'6,26

\.1)

17, 27

(J)

.1
--

--

(9)

:81

ResIstance: 3.7 - 8.0n

m---~

__
NG

1.2.3.6.25.2627,

L~

~-- R epi ace ca nIra I u ~~--J

Disconnect control unit connectors.

Check resistance between control unit
connector terminals.

1 :1 3252627

-E- '.

m-

r-_A_C_T_U_A_T_O_R__S_O_L_E_N_O_1.0
__V_A_L_V_E_C_H_E_C_K----1 0 K

~~i5 ~
'--------l-...

No

Disconnect connectors from control

unit and actuator Check terminals for
damage or loose connection Then
econnect connectors
Carry out self-diagnosis again
Does warning lamp aclivate again?

DIsconnect actuator connectors

Check t esistance between ac!uator
connector (actuator side) terminals.
Code No
__
(LED flashes)

Replace actuator

Terminals
,~~ - ':~)

11, 21
SBR8BBC

--I----_ _-------"!)=::.....--_'~)

_ _ _ _1_3.2_3

16,26

(~ - ~~---@) . 'i~---

17.27

,,6) -

15, 2S

rif :

Reslsfance: 3.7 B_On

~.---

[!]

Check continuity between control un!!

connector term inals and actuator connectar (body side) terminals
Code No
(LED flashes)

._.

Control

Actuator

lJnl[

11, 21

(~)

'-2,\

12, 22

..1~'

13,23

\.9)

15, 25

"~1

'2_6~'

ofs

.--

1----_ _

.l~)

\6. 26

,~

1? 27

,t~

ti.,1

42

(1)

\6.. .

Conlinuily should exist.

i~,'1

(Go to next page)

BR-51

___

~
I

N~tepair i1arness and rOI~Inector

-----

TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Cont'd)

00

Go to
In Diagnostic
Procedure 2

Carry out self-diagnosis again.

Does the malfunction code No. Indicate actuator solenoid 'Jal'Je?

No
Go to applicable diagnostic procedure
tor malfunction codp, No

Diagnostic Procedure 4
WHEEL SENSOR OR ROTOR
(Malfunction code No. 01 - 03, 05 . 01)
Disconnect connectors from control

No

unit and wheel sensor of malfunction

Inspection end
~l
'------~

code No. Check terminals for damage

or loose connection. Then reconnect
connectors.
SBA6t\9G

Carry out self-diagnosis again.

Does warning lamp activate again'?

Yes

WHEEL SENSOR ELECTRICAL CHECK

t-------------------1

OK

----+@ I,See next page

Disconnect control unit connector

Check resistance between control unit
connector terminals.
Code No. 01 or 05 (Front RH wheel)
Terminals

and @

Cede No. 02 or 06 (Front LH wheel)

Terminals @ and @J
Code No 03 or 07 (Rear wheel)
Terminals

@ and @

Resistance: 0.6 . 3.3 kO

Note: If the result is OK, check it again
while moving sen!'>()f harness

~NG
:81

(Go to next page.)

Note: Wheel position should

be distinguished by
code No. (LEO

flashes).

BR-52

TROUBLE DIAGNOSES
Diagnostic Procedure 4 (Cont'd)
Sensor connectors
(body side)
Front

Rear

dfu dID
I

'2

'-------..-..J

I
m--~_
Disconnect wheel sensor

conne~l OK

Note

~~ECK WHEEL

Check continuity between control unit

-------1

connector terminals and wheel sensor connector (body side) terminals

Code No
(LED

f~ashes I

I
"'~

01, 05

\l)

(Front LH)

<~)

03, 07
(Rear)

I'----~

f----

Clearance

~)

=J

JNG

wheel sensor connector.

I

L-

[!J

Note
-----WH.EEL SENSOR MECHANICAL CHECK

Note
Clean sensor fixing
portion, reil1stalt or
replace sensor

Check for any foreign materials and

------------

Clearance:
Front
Make sure the sensor is installed
of minimum clearance.

Rear

L~-~0.31 - 0.82 mm

I!J Note
~
~eCk se~so~ortee~;';age

, Rear sensor

L_ _

Note

-lNG .lRe~a~~ ~e-ns~~-rntor

10K

L __
:J~'~

Carry oul self-diagnosis agail1.

~oes he malfunction code No_ (LED

LaShes) indicate wheel sensor?

~~---

Go to applicable diagnostic procedure

for malfunction code No. (LED flashes)

Nole: Wheel position should be distinguished by code No. (LED flashes).

BR-53

j
I

NG

clearance between sensor and rotor.

//

---------

0---

Repair harness and connectors

between control unit connector and

[;] A - B

rJ)

Continuity should exlsl.

Not_e

In Electrical Components
(SR-65)

~ection

Wheel sensor _

!_~;

02, 06

I
I

=r=
I

I----~

(Front RH)

Refer to WHEEL SENSOR

Control unit

SENS;-;-l

TROUBLE DIAGNOSES

Diagnostic Procedure 5

rl1Acluator connectors (body side)

Eflj@ ~i5
[yY~
"'----....&...-----4<+

'-----------------

MOTOR RELAY OR MOTOR

~
_

SBR892C

Actuator connectors
(actuator side)

~ ~Ef!tjUID

i5

(Malfunction code No. 43. 44)

NG
------+-

MOTOR POWER SUPPLY CIRCUIT

8 (Skip page)

,'---------------------1

I-

OJ

Check 30A fusible link

and 10A
fuse rTlfor actuator_ For fusible Iink
and 'use layout, refer to POWER SUPP_L_Y_R_O_U_T_I_NG in EL section_,__,__'

I_ _

r---,------~---------,No
Disconnect connectors from control
unit and actuator. Check terminals for
damage 01' loose connection Then
reconnect connectors
Carry oul self-diagnosis again
Does warning light activate again?

Inspection end

Yes
NG
----... Repai r harness and connectors between ballery
and actuator connector
(body side) terminals

Disconnect actuator connectors

Check voltage between connector
(body side) terminals and ground
Terminals

Ignition SWitch
ON position

\.51 . ground

Batlery voltage should exist

---

0K

Ii]

NG

MOTOR RELAY CIRCUIT

~i} -------"

85

Ground

SBR893C

Relay

.!!)

Yes
Yes ...
--'~--- f-------'
,~
Yes
--~Yes
___'5" ____
~
,~',
Ground
No

'4'

--

---

SBRgOOC

--

OK

[!)

Continuity

connector

,'\0,
---_.,---

Ch-~~~--~~ntln~i;~ between aCI-:~-t~r - connector (body side) terminal ..~

and ground
Continuity should not exist.

.'J

I!l

NG

-~OK
(Ai (Go to next page)
-

Disconnect control unit connectors_

Check continuity between control unit
terminals (control unit side) and
(~,

I),

~~I, ff), ~8),

Conlinuity should not exist.

~~~_~~_~NG
~_~ C~~~_lrOI

U_n_I_I

SR~90 I CA

BR-54
rtl

assem~1

Remove motor relay

Disconnect actuator conneclors
Check continuity between actuator
connector (actuator side) terminals
and relay connector terminals or
body ground_
Actuator
connectfJr

-------

Replace actuator
bly

l-

--~

OK

Repair harness
and connectors
---- -

---~-

TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Cont'd)
-----.-----

.~-=J

I MOTOR CHECK

Connect actuator connectors.

Connect suitable wire between relay

ING

connector terminals @ and @Q).

SBR89dC

'------------

Motor should operate.

Do not connect wire for more fhan 5

-----

-I-_

seconds.

Actuator
connector (body side)

DISCONNCl

, " I

e~

;.

DISCONNECT

10

10

-M-O-TO-R-RE-LAY CHECK

ie-I

I Reter to MOTOR RELAY-i-n-E-I-ec-t-ri-caI

~omponents

l.
Inspection (B_R_-6_5_

S8R895C

(j
CIRCUIT CHECK

'I':;

---.J

-------

NG

l-----+

Disconnect control unit connector.

Repair harness and connectars,

~J

"

Check conlinuity between control unit

connector terminals and actuator connector (body side) terminals.
Control unit

Actuator

(2)

~)

- - - - - - - - - 1--.

I Co.li.uily should exlsl.

r: '

I!. "

BR-55

TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Cont'd)

I!J

Actuator connectors (body side)

8ili@j~i5

'11

_1

t[il--l =-

~o
Inspeclion end
-l
---------~

8ePIace fusible link or fuse

Is n blown out when it is replaced or

I
I

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _S_BR896C I

ignition switch is turned "ON"?

NG , - - - - - - - - - - - - - - 1
Repair harness
----------------------,
neclor

and:J0n-

MOTOR POWER SUPPLY CIRCUIT

Actuator connectors (actuator side)

6GB Eft) c1ID ~ 10

and control unit.

~ ...

Check continuity between actuator

connector (body side) terminals and

LEJS1

ground
Terminals
Fuse/Fusible link
---------+----@) - ground Fusible link

~BR"BCI,

- ground

Fuse~

(~) - ground

Continuity should nol exist.

~==I

Control unit termmals

Remove motor ground.

---~~G
I Replace actuator

Check continuity between aclualor

10

and ground.
~mlnals_ _

_Fuse/Fusible link

SBR89~

FUSible link
(~)
~_I~I

[l]

___
F_us_e_~

. ground
-

ground

'"S) - grou'ld

r---

Conlinuity should not exist.

con~lnuity between CO~lrO' un~ ~G I~~ace control

~

Check
terminals.

Fuse/Fusible Imk

Terminals

iii") - 12,
~?).

i~l. '?~'.

rf6'

-~

SR-56
fl.

assemJI

bly.

connector (actuator side) terminals

OISCONNECI

-----

Discon neet can nectars from actu ala r

unl!

TROUBLE DIAGNOSES

Diagnostic Procedure 6

Actuator connectors (body side)

Effi3cm ~ i5

SOLENOID VALVE RELAY

(Malfunction code No. 41, 42)

_lr
NG

f------.-- (Se e n ext

SOLENOID VALVE POWER SUPPLY

CHECK

era

S_BA_9_D_2C....J

Actuator conneclors
(actuator side)

~ ~ElBclD

Check 30A fusible link rKl and 10A

fuse f1]for actuator- Fo'rT'usible link
and fl:JSe layout, refer 10 POWER SUp
PLY ROUTING in EL section.

L
~

5-6-7921

18

=F ---NO~
~

Disconnect connectors from control

unit and actuator. Check terminals for
damage or loose connection. Then
reconnect connectors
Carry out self-diagnosis again.
Does warning lamp activate again?

DISC et.INE C1

;', '1 ~

page)

~OLENOID

Yes
VALVE POWER SUPPLY

I--C_H_E_C_K

- 11

Inspection end

L-

Repair harness and oon-

IL....-n_e_c_to_r_.

1. '

I {:L
---1

~.'~I

Disconnect connectors from actuator.

Check voltage between actuator 2-pin
connector (body side) terminals and
ground_

Actuator

~~=i~dj: 55} --------/

~ 0 Gro~~~
@J

30

~rn~

~~

Terminals

Ignition switch

- ground
- ground

ON position

Battery voltage should exist.

,________________

SSROOJGI

=J

~OK

SOLENOID VALVE RELAY CHECK

1------------------11

Replace solenoid valvel

relay

Refer to SOLENOID VALVE RELAY in

I Electrical Components Inspection (BR65).

[;]

I SOLENOID

r~

VALVE RELAY CIRCUIT

NG

Replace actuator.

CHECK
Check continuity between relay terminals and actuator connector (actuator
side) terminals
Relay
terminals

Connector
terminals

@
@

(ID__

Yes
I----

Yes

@!)

~6)

(/)

Yes

Yes

Yes

Ground

Continuity

No

-----p<-

(Go to

BR-57

cAl
n~-~t

page)

- J,;
-Ii!;',

TROUBLE DIAGNOSES
Diagnostic Procedure 6 (Cont'd)
III

Actuator connector (body side)

~---~----JOK-

EB ~io

[j~

Check continuity between actuat~r

connector (body side) terminal, 7
and ground,
Continuity should not exist.

00 - S8R904C

--r

~NG

--

~('---C) (See below)

Disconnect conlrol unil connectocs

Check continuity between control wnl!
terminals (control unit side) (:" and
(1), (3) ~2), @. @
Continuity should nol exisl.

.----------~

---

Replace control unit.

---

NG

CIRCUIT CHECK

L----.+

SBR9C5C

I!IControl uml conneclor

CJ
1\ \2 2221

141618

Actuator
connectors (body side)

1ft,
\1IJ::D \:iJY

~ ~

Control Ullit

('!J

([)
Ground

liS
SBR9C6C

Actuator

~~~

J''''~

rn

i{)

Repair harness and Connectors

Disconnecl control unit connector

Check cont'lnuity between contl'ol .mil
connector terminals and actuator connector (body side) terminals

r=5::;:6=;=:19~;='3~1::::;5 1729 41 ~

r;=:::;,

----,
Repair harness and Connectors,

(~)

f1)

Continuity should exist.

r~ I!J
~

=:E

in Diagnostic Procedure

-2-l
I

(!J

Actuator connectors (body side)

E1jOb ~i8

jUS'bl~~jUSe

-f~[

;ePlace
.. Is it blown out when il is replaced or
ignition switch is turned "ON"?
~-

_L~

---'JG

ACTUAT OR POWER SUPPLY CIRCUIT

SBR9J7CAI

Jiscon nect connectors from actualor

and co ntrol unit.
Check continuity between actuator
canne ctor (body side) terminals and
ground
Terminals
ground
'~'. - ground

Fuse!i= usible link

Fusib Ie link

Fuse

(~I -

lD

(~)

- ground

Contin uity should not exist

OK
(0)
(Go to next paqe )

BR-58

Inspection end------J

-~

Repair harness and

nectar,

TROUBLE DIAGNOSES
Diagnostic Procedure 6 (Cont'd)
Actuator connectors (actuator side)

~cU~i5
~

Check conlinuity between actuator

connector (actuator side) terminals
and ground.
Terminals

Fuse/Fusible link
Fusible link
Fuse
SBR90BC

Replace actuator assembly.

\,::'1 ,~,

'1') - 9 ro und

~) . ground

[!]

(~) - ground

Continuity should nol exist.

OK

Check continuity between control unit

terminals (control unit side).
Fuse/Fusible link
Fusible link
Fuse

[E]

[!]

Terminals
(f) . r~. @. @.
@.@
ill - C~. (~). @.
@.@

Contlnuily should not exisl.

OK

Replace actuator assembly

u;

I 1 ,'~,

BR-59

TROUBLE DIAGNOSES
Diagnostic Procedure 8
MEMORY VOLT STOP
Disconnect control unit connectors.
Check terminals lor damage or loose

~_~_ .. ~~_spection end

--=_l

connection. Then reconnect connec-

',', '

tors
Turn ignition switch ON and OFF
more than two limes
SBR911C

Carry out self-diagnosis again

Does warning lamp activale again?
IYes

...L-~

,=m=,'-------

CONTROL UNIT POWER SUPPLY

NG

---...

Check harness and connectors between battery

Disconnect control unit connectors

and control unit connec-

Check voltage between connector terminal @ and ground

tor terminal ~~ or 7,5A

Battery voltage should exist.

~OK

fuse

G]]

For fuse layout.

refer to POWER SUPPLY

~,

/ .

,
1

ROUTING in EL section
_._------------,

Repair harness and connectors

Refer to CONTROL UNIT GROUND in
Ground Circuit Check (BR-45)
OK

Replace control unit.

Note: MEMORY VOLT STOP is always indicated after disconnecting conlrol unit
conneclor.

~.

BR-61

TROUBLE DIAGNOSES
Diagnostic Procedure 7
POWER SUPPL V
(Malfunction code No. 47, 48)
Disconnect control unit conneclors
Check terminals lor damage or connection. Then

reconnec~

InspectIon end

connectors

Carry out self-diagnosis again.

Does warning lamp activate again?

res

SBR910C

E1

CONTROL UNIT POWER SUPPLY

NG
Check harness and con~
nectars between battery

Disconnect control unit connectors

and control unit connec-

Check voltage between connector terminaf (i) and ground when ignition

tor terminal

switch is turned ON.

SUPPLY ROUTING in EL

CIRCUI~ Repair
nectars

, Refer to CONTROL UNIT GROUND in

~round

Circuit Check (BR-45).

______E

~ep\ace control

unil.

BR-60

10A fuse

section

0K

CONTROL UNIT GROUND

CD,

or battery. For fuse

layout, refer to POWER

Batlery voltage should cliClst.

[1]

harness and con-

TROUBLE DIAGNOSES

Diagnostic Procedure 9
Brake pedal

SYMPTOM: Pedal vibration and noise

Check whether the symptom appears

Carry :;;~elf~d;agnos;sJ

only when engine is started.

(See page BR 40.)

No

-Yes
For such conditions. ASS
----+
will work due to differ-

Check whether the symptom appears

when brake is applied gradually under
SAT797A

ence of wheel speeds

the conditions helow.

Shifting
Operating clutch
Passing over bumps/potholes
,----.

--

Check if there are any conditIons.

~-------------.

For such conditions. ASS

among those listed below, when symp-

will work due to differ-

lorn appears,

ence of wheel speeds

Low friction road

High speed cornering
Passing over bumps/potholes

Yes

Check whether the symptom appears

f-----+

when engine speed is over 5,000 rpm

with vehicle stopped

~---.-

switches are operated.

-----.--

--.J

gr'OUI1C

~or

location of shield ground, refer to wiring diagram and "HARNESS LAYOUT"

In EL seetior.

~-=r
E a c e control unit
--------,,-

BR-62

----,-

Check whether electrical equipment

~heck INheel sensor shield

sor may caL;se ASS

operation

r~_O
l--

Vibration related to sen-

--

---

Go to [;] in OiagnofJSiC
Procedure 11 (BR-63l.

TROUBLE DIAGNOSES

Diagnostic Procedure 10
SYMPTOM: long stopping distance
-------------~--

Check If road condition is sll!='pery with

1 Yes

snow or gravel

Stopping

d,stanc~~~l

~-

---_.~-

Disconnec! actuator connector a nd

I No

check whether stopping distance is sti II

-----+ Procedure 11 (See

long, _ _. _

_ .

be longer than venicles

without A8S

Go to [;) In Dlag')ostlc
below)

Yes

Perform Preliminary C~eck and air

I bleeding,

[' I' ~
"

Diagnostic Procedure 11
SYMPTOM: Unexpected pedal action

m
Check whether brake pedal stroke

Ives.Uedorm Prehmina;;-

IS

excessively larJ~ "__--~

SBR540A

C~k~R~~I_.

f yes

Check thai brake pedal force is lirm but

brake is effective
No

Normal condillon

-]
i

Check (BR-44) _

Yes

rn

~-s-u-re-w-a-r-n-in-g-la-rr---'1P-re-malns

l_d~V~

"

N~rrY-OLJtsetf'dlag~OSI~

off while

LI:ee pag~~R~I

~~~'"TledY,

connec~~

Check wheei sensor

lermiral daMage or loose conneclior
Perform wheel sensor meehan'cal
check
Refer to ~ and 00 in Diagnostic
Procedure 4 (BR-53)

t~----~.p-I-a-c-e-c-o-n-tr-o-I-u-n-It

BR-63

IJ

OK-- - - - -

CHECK WHEEL SENSOR

pe~;~rrelimlnClry--J

Disconnect actuator con nector and

check whether brake is effective

-------------,----

-l

".

_'_J

TROUBLE DIAGNOSES

Diagnostic Procedure 12
SYMPTOM: ASS does not work.
I
~Yes
LCheck whether warning activates _~. -----.. Carry out self-diagnosis.
(See page BR-40.)

~--------------,

---

.
h
.
Ch ec k symptom condition whet er vehlc/e speed is under 10 km/h (6 MPH).

Yes

ASS daes net work in

this condition

-----,----------

No

00

Go to
(SR-63).

in Diagnostic Procedure 11

------._-----

Diagnostic Procedure 13
SYMPTOM: ABS works frequently.
CHECK BRAKE FLUID PRESSURE.
_.;-

NG
~

Perlorm Preliminary
Check (8R-44)

Check whether brake fluid pressure

distribution

IS

normal.

Refer to OP valve inspection in "CONTROL VALVE" (BR-4)

~----,

CHECK WHEEL SENSOR.

Y_
NG [Reme_d_

. _.

---------~-----j

Check wheet sens.or conneclor for

terminal damage or loose connection

Perform wheel sensor mechanical
check.

Refer to ~ and

I!J

In

Diagnostic

Procedure 4. (BR-53)
OK
Check

fr'Orlt

dxles for excessive

IOOS~-~medY, ---~

ness. Refer to "Front Wheel Bearing"

in FA sectiol1
--~~_._-

----

---~~----

OK
Replace con:rol un'L

BR-64

------

TROUBLE DIAGNOSES
Electrical Components Inspection

i~ !E~S
Front sensors

WHEEL SENSOR

Rear sensor

G;~Q

Check resistance for each sensor

Resistance: 0.6 . 3.3 kO

SBR013D

_ _ _ _ _ _ _ _ _--------l

ACTUATOR MOTOR RELAY AND SOLENOID VALVE

RELAY
Solenoid valve relay
Continuity existence
Condition

L--

- -

between terminals

1.ID

Actuator motor relay

solenoid valve relay
Continuity existence
between terminals 'fo~'

and@

and ~~

Yes

No

Battery voltage not

applied between terminals ~) and @.

._-

.~

--

Ballery voltage applied

between terminals @

No

Yes

and @

;- r

.- ;

II
._,

BR-65
~.n

"

':

11

rII

SERVICE DATA AND SPECIFICATIONS (50S)

General Specifications
Without ABS

Front brake
Brake model
Cylinder bore diameter

rflm(ln)~

Pad

mm (m)

mm (In)

1',60 x 500 x 10,0

Lenglh x width x thlcl<ness

mm (in)

x 30 (11 02 x 1 18)

-t---------l

=t

Split point
kPa (bar, kg/cm L , pSI) x
CL 11H disc brake
38 18 (1.5031)

mm (In)

3.923 (392,40.569) x 0.4

reducing ralio
-----------+--Brake boost.er
M23 or G23
Boosler model

--1-------------

Cylinder bore diameter

25.40 (1)

-------

Rear brake
Brake model

Proportioning valve
(huilt into master cylinder)

Valve mode!
280

23.81 (15/16)

Control valve

(4 57 x 1 969 x 0,394)

Rotor outer diarneter x lhlCk-

ness

Gyll nder bore d I arneter

40 -t (1 59) x 2

With ABS

-I

Master cylinder

OPJ=25V disc brake

--f------------

Pad

75

mm (in)

a l(

Primary 205

400 x 9.5

Length x width x IhlCkn~ss

(2953 x 1 575 x 0,374)

--------

Diaphragm diarneter
mm (in)

-----------

Rotor outer diameter

x thickness
mm (In)

258 x 9 (10.16

l(

230 (9,06)

(8.07)
Secondary: 180

0.35)

(7,09)

Recommended brake fluid

00T3 or 00T4

For Europe'
Except for Europe

~L-I

0_0_T_3

'For Europe. never mix difierent type brake fluids (DOT3

and DOT4)

Inspection and Adjustment

DISC BRAKE
Brake model

PARKING BRAKE

-------1

Pad wear limit

mm (in)

OPJ=~~_

Number at notches

Minimum thickness
Rotor repair limit

Center lever
Type
-------------.---f------

20 (O,079)

[u11der

forc~

of 196 N

(20 kg. 44 Ib)J

mm (In)

Minimum IhlcJ,ness

28 (1 10)

Number of notches

8 (0.311

when warning lamp switch

comes on

BRAKE PEDAL

~~:~C~.:i::ld~~--=:]m_~O

RHO

(In)

181191
n . 752)

MIT

(7

179 - 189
(705 . 744)

---------+----All

191-201

17 52 - 791)

189 - 199
(744 - 783)

Depressed ~Ieight "D" mm (In)

(under lorce of 490 N (50 kg
110 IbJ with engine running]

Clea

110 (433)

f~-r~;:~c'~etw--;~ ped;~

stopper and lhreaded end of

slop lamp switch or ASCD

switch

03 - 10 (0012 - 0039)

BR-66
f"

7-9

STEERING SYS-rEM

---------_.----

Sr J .:

SECTION

_:I:.,!

L---------------.-----------~----------------

CONTENTS
PRECAUTIONS AND PREPARATION .. '
Precautions
"",.,
Special Service Tools.
'
"
Commercial Service Tools
,...........

,.,2

2
3

,,,,

ON-VEHICLE SERVICE ...... "..

Checking Steering Wheel Play ..... ., ........ "....

,5

Checking Neutral Position on Steering Wheel

Checking Gear Housing Movement.

PR24AC)

,.. "".

--

".''''

Removal and Installation

Disassembly...

Checking and Adjusting Drive Belts (For

" ..
,.... .

.." 6

Adjusting Rack Retainer.

Inspection." ..
POWER STEERING GEAR AND LINKAGE (Model

Disassembly and Assembly "

.5

Front Wheel Turni ng Angle

__ . 12

Disassembly and Assembly

..

__ "

"

13
. . 14

14
16
.17

Inspection,

17

Assembly

18

24

Disassembly and Assembly ..

Checking Fluid Level ......

Checking Fluid Leakage

Disassembly

25

Inspection .. '

... 25

Bleeding Hydraulic System

Checking Steering Wheel Turning Force
(For power steering)

""

"......

Checking Hydraulic System"" .. "".,.'

STEERING WHEEL AND STEERING COLUMN.... .
Removal and Installation

"..

,.8

9
9

..... 24

Pre-disassembly Inspection

" ..

26
27
. 27

,27

Assembly.
SERVICE DATA AND SPECIFICATIONS (50S)-General Specifications
Inspection and Adjustment

'

.24

6
6

power steering)." .. ,

22

Adjustment"
POWER STEERING OIL PUMP

..

",

:,

.. . II
ii'-'

PRECAUTIONS AND PREPARATION

Precautions
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR
BAG" AND "SEAT BELT PRE-TENSIONER"
The Supplemental Restraint System "Air Bag" and "Seat belt pre-tensioner", used along with a seat
belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The Supplemental Restraint System consists of air bag modules (located in the center of the steering
wheel and on the instrument panel on the passenger side), seat belt pre-tensioner, a diagnosis senSor
unit, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely
is included in the AS section of this Service Manual.
WARNING:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system.

All SRS electrical wiring harnesses and connectors are covered with yellow outer insulation. Do r
use electrical test equipment on any circuit related to the SRS.

STEERING SYSTEM

*.

Before disassembly, thoroughly clean the outside of the unit.

Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
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..1Iammabie
solvent.
Before assembly, apply a coat of recommended ATF* 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.
Automatic transmission fluid

Special Service Tools

TOOl number

Desc r i ption

Tool name
KV48100700

Measu ring pi nion rota ling torque

Torque adapter

~JT

5T271800;)1
Steering wheel puller

169

--+----------------~ M10 x 1.25 pilch

'f

f\',\ \'\
\\
\

'i~

\'

M8 , '25 pilch

5T-2

Removing and installing steering wheel

PRECAUTIONS AND PREPARATION

Special Service Tools (Confd)
Tool number
Tool name

Description
Removing ball joint

HT72520000

Ball jOint remover

a: 33 mm (1.30 if'l)

b: 50 mm (1.97 in)
r: R11.5 mm (0.453 in)

NT546

ST27091000

To all pump
outlet Pl=3/8" ~\
(female)

Pressure gauge

NT5.47

Measuring oil pressure

To control Yalve

II / ))

"'..,
PF'3/B"
(male)

\~;/

Shul-oH valve

.KV4B 102500

PF3/B"~

'Pressure gauge adapter

Measuring oil

PF3/B"~ ~,

'.5 p"e"

Measuring turning torque

ST31?7S0QO

GG91 C30000

HT62940000

pre~slJre

M16 )( 15 pilch

NT542

\1'

. '.'i

Torque wrench

{j)-~_.. ~

Socket adapter

CJ)------{}"'-......

@ HT62900000

___

1'3'
:~~
~j-

Socket adapter

"

114'"
114" to 3/8"
318" to 1/2"

;:

Tmo"e wlenc"
with range of

2.9 N.m

(30 kg-em,
,
2611"1-lb)

NTSdl

------------+--_._----------------------------------KV48104400

Reforming teflon ring

Rack seal ring re10rmer

a: 50 mm (1.97 in) dla.

b: 36 mm (1.42 in) dia.
c; 100 mm (3.!l4 in)

NT550

Commercial Service Tools

Tool name

Description

Installing rear oil seal

Rear oil seal drift

a: 28 mm (f .10 in) dia.

I. NT063

5T-3

.,1
{C., L'r

Commercial Service
Tool name

TOOJ~ '(Cont'd)

Description
Installing pinIon oil seal

Pinion oil seal drifl

.: 40 mm (1,57 In) dl.

NTD6.l

Disassembling and assembling oil pump

Oil pump attachment

NT179

Unit: mm {In}

ST-4

Checking Steering Wheel Play

1.

2.

With wheels in a straight-ahead position, check steering

wheel play.
,
Strlng wheel play:
.
3S mm (1.38 In) or les8
If at is not within specification, check the following for loose
or worn components.
Steering gear assembly
Steering column
Front suspension and axle

SST45SC

Checking Neutral Position on Steering Wheel

OK

NG

U:

Pre-checklng

Make sure that wheel alignment is correct

Wheel alignment:
Refer 10 SOS In FA .ectlon.
Verify that the steering gear is centered before removing
. the steering wheel.

If~

Checking

SST456C

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 MY
wheet and reinstall It correctly.
If the neutrai position is between two teeth, loosen tie-rod &1
lock nuts. Turn the tie-rods by the same amount in opposite directions on both left and right sides.

Front-Wheel Turning Angle

Rotate steering wheel all the way right and left; measure ~1Rl
turning angle.
Turning angle of full turns:
Refer 10 5DS In FA section.

1IIIIIIII

StdAI27

,s

If It
not within specification, check rack stroke.
Measured length "S":
Refer to SDS (S1-27).

SST086BA

ST-S

ON-VEHICLE SERVICE
Checking Gear Housing Movement
1

2.

Check the moc/eme!)1 of steering gear houslIlg during stationary steering on a dry paved sur/ace
Applya force of 49 N (5 kg, 11 Ib) to steering wheel to check
the gear hOllslng movement.
Turn orf ign itlon key wh i Ie checki ng
Movement of gear housing:
2 mm ( 0.08 in) or less
It movement exceeds the limit, replace mount insulator
after confirming proper installation of gear housing
clamps,

Adjusting Rack Retainer

1,
2.

Perform this driving test on a flat road

Check whether vehicle moves in a straight line when steering wheel is released
Check whether steermg wheel returns 10 neutral position
When steering wheel is released from a slightly turned
(approx 20") pOSition
\f any abnormality is tound, correct it by resetting adJusting screw.

Checking and Adjusting Drive Belts (For power

steering)
Refer 10 Drive Bell Inspection in MA section,

- - - .. -----,----

G:",

o g"
~ ~I
I.

'"

'"
.

'I

II

I
1

J:\(l;-:'~T:'
o"

Checking Fluid Level

i
I

U~I
e <"l
~
'"

I ....
10

(.OLDI' 0
I

!I~

u:-,

;t
ti,-

!21.-.::
_
! ;{ \

IN
0

Check fluid level with dipstiCk on reservoir cap

Use "HOI" range for flUid temperatur es of 50 to BOC (122 \0
176F).
Use "COLD' range for fluid temperatures of a to 30C (32 to
86"F)

IJ B 'I'

~STls'cl
..:::J

I
.--- - - _ L
_.

CAUTION:

Do nol overfill.

Recommended fluid is Automatic

"DEXRON Tl\II .. type or equivalent.

Transmission

Fluid

Checking Fluid Leakage

Check the lines tor improper attachment and for leaks, cracks.
damage, loo';e connections, chafing or delcriol aiion
1, r-lun engine al Idle speed or 1,000 rpfT1.
Make sure temperature of fluid in oil tank rises to 60 to 80'C
(140 to 176'F).
2 Turn steering wheel r Igl1t-\o-left several times
3. Hold steering wheel at each 'lock" DOSltlon for five seconds and carefully check for fluid ',eakage
.~,l

51-6

ON-VEHICLE SERV'CE
Checking Fluid Leakage (Cont'd)
CAUTION;
Do not hold the steering wheel in a locked position for more
than 15 seconds.
4, II IIU\d leakage at connec',ors is noticed, loosen flare nul
and then (tlghten
Do not overtighten connector as this can damage O-ring,
washer and connector.

:,i
,cr.i

Bleeding Hydraulic System

Raise lronl end of vehicle unlil wheels clear ground
Add fluid into oil tank to specified level. Then, quickly lurn
sleertng wheel iul1y to right and left and lightly louch steering stoppers.
Repeal sleering wheel operation until fluid level no longer
decreases,
3 Slart engine
Repeat step 2 above

Incomplete air bleeding will cause the following to occur,

When this happens, bleed air again,
a Air bubbles in reservoir lank
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 the steering wheel slowly. This does not affect the performance or
durability 01 the system
1,
2,

,L

1"'1

Checking Steering Wheel Turning Force

(For power steering)
Park vehicle on a level, dry surface and set parking brake,
Start engine,
Bring power steering /Iu.d up to adequate operating temperature, {Make sure temperature 01 i1uid is approllimately
60 to 80'C (\40 to 176f\ I
Tires need to be inflated to normal pressure.
4 Check steering wheel turning force when steering wheel
has been turned 360" ~rom the neutral position,
Steering wheel turning lorce:
39 N (4 kg, 9 Ib) or less
5. 11 steering wheel turning force IS out of specification. Gheck
rack slIding force
a DIsconnect steering column lower jOint and knuckle arms
Irom the gear
b Start and run engine at ,die to make sure steef'.ng fluid has
reach~d normal operating temperature
Pull tie-rod slowly to move it from neutral position to 11 5
mm ( t-O 453 'n\ al speerl 0135 mm (0,138 In}/'S Check fhat
rack sliding force 15 within specification

1
2
3

, '.

,.,::

Ii"

':!

A_erage value = (Max value +M;;;--;aluej

Checking Steering Wheel Turning Force

(For power steering) (Cont'd)

~
~murn \'alue

Average rack sliding rorce:

186 - 245 N (19 25 kg, 42 - 55 Ib)
Maximum force deviation:
98 N (10 kg, 22 Ib)
II rae\( sliding force is not within specification, overhaUl
steering gear assembly

Checking Hydraulic System

High.
pressU'6
hose

Before slartlng, check bell tenSion. driving pulley and tire

pressure.
1. Set Tool. Open shut-off valve Then bleed air (See "Bleeding Hydraulic System". ST-?)
2 Run engine.
Make sure temperature of fluid in tank rises to 60 to 80C (140
1017S"F).

WARNING:
L...

Direction of 011 flow

Warm up engine with shut-off valve fully opened. If engine is

started with shut-off valve closed, fluid pressure in oil pump
increases to maxirnum. This will raise oillemperature abnor-

mallv
3.

Check pressure with sleering wheel fully turned to left and

right positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a Jocked position for more
than 15 seconds.
Oil pump maximum pressure:
8,630 9,219 kPa (86.3 - 92.2 bar, 88 94 kg/em:!,
1,251 - 1,337 pSI)
4. If oil pressure is below the standard pressure, slowly close
shut-off valve and check pressure
When pressure reaches standard pressure, gear is dam-

aged.
When pressure remains below slandard pressure, pump is
damaged.
CAUTION:
Do nol close shut-Off valve for more than 15 seconds.
5. If oil pressure is higher than standard pressure. check oil
pump flow conlrol valve.
6. After checking hydraulic system, remove Tool and add
fluid as necessary. Then completely bleed air out of sys

tem

I
\

STeERING WHEEL AND STEERING COLUMN

Removal and Installation
SEC.488484

\{O:J24 - 29
\

(VI - 3.0, 11 22)

.~

ll'l
'1

~-

Jl

.f

\] ~ "'.,

Without llI'r bag

~-to.] 13 - ,. (1.3 - 1.8. 9 13)

:J''i
L..-fiP ~

~,

~~
D

-A13

-18 (1.3 .18, 9-13)

~ Nm (kgm, tHb)

LHD model

A 3.4 - 4.4 (0.35 - 0.45. 2.5 3.3)

RHO model

~9 12 (0.9.1.2,6.5 - 8,7)

fA;,

(iJ Air bag module

@ Horn pad

Spiral cable

("5) Column cover

SST494C

Steering column assembly

!J) Lower joint

@ Steering wheel

CAUTION:
The rotation of the spiral cable (SRS "Air bag" component
part) is limited. If the steering gear must be removed, set
the front wheels In the straight-ahead dlrecllon. Do nol
rotate the steering column while the steering gear Is
removed.

Remove the steering wheel before removing the steering

lower Joint 10 avoid damaging the SRS spiral cable.

---------- - l

\.""'"'~.~

/~~\~
-

~~:

III
p;~

STEERING WHEEL

Wilh air bag type _

I'C

Remove air bag module and spiral cable Refer to

"Removal-- Air Bag Module and Spiral Cable", "SUPPLEMENTAL RESTRAINT SYSTEM" in RS section

SSI'~'C

51-9

Removal and Installation (Cont'd)

a
b.

AI i gn spiral cable correctl y when install i ng steering wheel.

Set the front wheels in the straight-ahead position.
Makf! sure that the spiral cable is in the neutral positioll.
The neutral pasHian is detected by turning left 2.5 revolutions from the right end position Align the two marks (I)

CAUTION:
The spiral cable may snap due to steering operation if the
cable is installed in an improper position_
Also, wilh lhe steering linkage disconnected, the cable may
snap by turning the steering wheel beyond the limited number
of turns. (The spiral cable can be turned up to 2.5 turns from
the neutral position 10 both Ihe right and left.)

Without air bag type-

Remove horn pad.

Insert a crosshead screwdriver into hole on lower side of
spoke and remo\le screw Uft horn pad off by hand

Remove steering wheel with Tool

When installing steering wheel, lubricate with mUlti-purpose grease. Apply grease to entire surface of turn signal
cancel pins and horn contact slip rings.

SST'6~C

!
I

ST-10

I
I
I

Removal and Installation (Cont'd)

Cutout portion

STEERING COLUMN

'I

tJr

~
o

./.

I#f

When Installing sleering column, fingertighlen all lower

bracket and clamp retaining bolls, then tighten them
securely, Do nol apply undue stress 10 steering column
When atlacl1ing coupling joint, be sure tightening boll
faces cutoul portion.

~i
;'.'j,

'1

Lower joinl

SSTBOOA

Align slit of lower joint with p~ojection on dust cover. Insert

joint until it stops.
CAUTION:
After Installation, turn steering wheel to make sure II moves
smoothly. Ensure the number ot turns arc the same from the
straight forward position to left and right locks. Be sure that
the steering wheel Is in a neutral position when driving

V
~(,

straight ahead.

SST489C

II
~ I

"I

ST-11

Disassembly and Assembly

SEC. 48-8--

WlthOU.S")

Nm (kg-m. HlbJ
SSTd95C

ill
~
@

Combination switch
Lock nul
Tilt lever
Washer

<!I

TIlt lever stopper

(!'I

(J)

tJ)

Steering column mountmg

Jackel lube assembly

bracket

@
@

Jackel tube bracket insulator

Adjust boll
Adjust bolt stopper
Push nut
Tilt spring (Air bag "lodel)

Band

Hole cover

Slee(lng column sl1aft

(l])

Lower joint

When disassembling and assembling, unlock steering lock

with key
Install lock nul on steering column shaft and tighten the nul
to specification
~: 25 - 34 N'm (2.5 3.5 kg-m, 18 - 25 ftlb)

ST-12

Disassembly and Assembly (Cont'd)

a,
b,

Sel f -,h

Steering lock
Break self-shear type screws with a drill or other appropriate tool.
Install new self-shear type screws and then cut off selfshear type screw heads,

:11

.a, Ie,"""

L-~---------

>~

Inspection

---------

When steering wheel does not turn smoothly, check the

steering column as follows and replace damaged parts,
a, Check column bearings for damage or unevenness. Lubricate with recommended multi-purpose grease or replace
steering column as an assembly, if necessary.
b. Check steering column lower shaft for deformation or
breakage, Replace if necessary.
When the vehicle comes into a light collision, check length
"L," and "L2 ",
Steering column length "L,":
lHD model 630.7 mm (24.83 In)
RHO model 610.0 mm (24.02 In)
Steering column lower shaft length "l2":
LHO model 323.7 mm (12.74 in)
RHO model 341.0 mm (13.43 In)
If out of the specifications, replace steering column as an
assembly

';l

p;

Till mechanism

After installing steering column, check tilt mechanism operal;an,

-sH~i

20 (0.79)

SST~28A

~l

ST-13

Removal and Installation

SEC. 483-492

Rack mounting mSulator~

V"""" "00'

~l'

G...... "".,. ......,

~aa

,~~-

;<

..

{,,-,o,,,j

~J

- 108 19.0 - 11.0,65.80

(Cj

N'm Ikg-m, Hlbj

SST.~C

CAUTION:

The rotation of the spiral cable (SRS .. Air bag" component

part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rolale the steering column while the steering gear is
removed.
Remove Ihe steering wheel before removing the 5teering
lower joint to avoid damaging the SRS spiral cable.
Detach tie-rod outer sockets from knuckle arms with Tool.

ST-14

I
II
.Ill

Removal and Installation (Cont'd)

Install pipe connector.

Observe specified tightening torque when tighteninQ highpressure and low-pressure pipe connectors. Ex~ess'ive
tightening can damage threads or damaged connector ji'

O-ring,
Connector lightening torque:
low-pressure side "1"

27 - 39 N'm (2.8 - 4.0 kg-m, 20 - 29 f1-lb)

High-pressure shle "2"
1525 N'm (1.52,5 kg-m. 11 - 18 ft-Ib)

The O-ring in low-pressure pipe connector is larger than

that in high-pressure connector. Take care to install the

iF,'?

~',:(;,
1.'=,

proper O-ring.

Initially. tighten nut on tie-rod outer socket and knuckle

arm to 29 to 39 N'm (3 to 4 kg-m, 22 to 29 ft-lbJ. Then tighten
further to align nut groove with first pin hole so that cotter

:S,',

pin can be installed

CAUTION;
Tightening torque lTlust not exceed 49 N'm (5 kgm, 36 It-Ib),
.

Before removing lower joiot from gear, sel gear in neutral

(wheels in straioht-ahead position). After reMoving lower
joint. put matching mark on pinion shaH and pinion housing to record neutral position
To IOslall, sellell and right dust boots to equal deflection,
Attach lower joint by aligning matchmg marks of pInion
shall and pimon hous'ng.

Tighten gear housing mounting bracket bolts in the order

shown,
Temporary tightening torque:
78 N'm (8.0 kg-m, 58 ftlb)
Secure tightening torque:
88 108 N'm (9.0 - 11.0 kgm, 65 - 80 ftlb)

II
~i, f"'

f, "i

I~

If'.'

T4!mpJrd,(Y

Se~ure

t'9htenmg
SST46~l-

51-15

I'
~

POWER STEERING GEAR AND LINKAGE (Model PR24AC)

Disassembly and Assembly

SEC.

W.~92

~: Nm (kg-m. IHI

f1

Apply automatic Ir9nsml~sIO"

flu,,:! "DEXRO"'.. type
or EtQu'06.lellt

SST'iQOC

(1)

Rear housing cover

Washer

@
@
(4)

Rear housing assembly

Sprong seal

Bool clamp

Pinion seal ring

AelalJ'\el

~'

Dust boot

Pinion assembly

tf~:

Gear hOLis il19 assembly

Bool band

lID

a-ring

~j)

Cenler bushing

,~~

Lock plate

~61

Shim

n7)

Rack 0,1 seal

~I

Tie-rod inner socket

'!.'

Pinion all seal

Aack assembly

~8)

Tie-rod
Tie-rod ouler socket

End cover assembly

/8)

lock nul

I\.!!
';9'

Raelo. seai ring

19)

AdJusllng scre'"

~O)

O"ng

Coller pin

ri~

Spnng
Spring d,sG

Rack od seal

Gear housing lube

~i)

5T-16

POWER STEERING GEAR AND LINKAGE (Model PR24AC)

----,----------

Disassembly
1

55T131C

Prior to disassembling, measure pinion rotating torque.

Record the pinion rotating torque as a reference.
Before measuring, disconnect cylinder tube and drain ;Qj[
fluid.
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.
3. Remove tie-rod outer sockets and bools
4. Loosen tie-rod inner socket by prying up slaked portion,
and remove socket.
5. Remove retainer
6 Remove pinion assembly,
7, Use a 2 to 2,5 mm (007910 0.098 in) diameter drill to com- c';
plelely remove slaked portion of gear housing end

B
9,
10

Remove gear housi ng end cover assem bly with Tool,

Draw out rack assembly.
Remove rack seal ring,
Using a heat gun, heat rack seal to approximately 40C
(104F),
Remove rack seal ring.
Be careful not to damage rack.

~_
"'~'~'
J::tenSion bar

Rack 011 1eal

Center buShin g

11 Remove center bushing a nd rack 011 seal us ing tape

wrapped socket and extension ba r.
Do not scratch Inner surfaces of pinion housing.

..

29 mm socket

SST472A

Inspection
Thoroughly clean all parts in cleaning solvent or automatic
transmission fluid ''DEXRON .. type or equivalent Blow dry
with compressed air, if available.

{,"

"I

BOOT
Check condition of boot. If cracked excessively, replace it

'i'

RACK
Thoroughly examine rack gear. If damaged, cracked or worn,
replace it

ST-17

POWER STEER.NG GEAR AND LINKAGE (Model PR24AC)

Inspection (Cont'd)
PINION ASSEMBLV

Thoroughly examine pinion gear. II pinion gear is

damaged, cracked or worn, replace it
Check that all bearings roll freely Ensure that balls, rollers and races are not cracked, pitted or worn. Replace it
necessary.

GEAR HOUSING CVLlNDER

Check gear housing cylinder bore lor scratches or other damage. Replace if necessary.

TIE-ROD OUTER AND INNER SOCKETS

,I Inner
/ ball joinl

Check ball joints lor swinging force.

rlerod outer and inner ball joints swinging force "A";
Refer to SOS (ST-27).
Check ball joint for rotating torque.
Tie-rod outer balljo/nt rolating torque "B";
Refer to 50S (Sr27).
Check ball joints for axial end play.
Tie-rod outer and inner ball joints axial end play "e":
Refer to 50S (5T-27).
Check condition of dust cover. If cracked excessively,
replace ouler tie-rod

Assembly
1.

la,

, Rack s.. ~1 rin9

SSTOB)!l!

Rack leelh./

D'

,~-- "~1-

2. Using Tool, compress rack seal ring securely onto rack

Always inserf the 1001 from the rack gear side.

KV481044()()

Rack seal rinQ

t==-:

tPos;tton and
secure seal

Using a heat gun, heat new teflon rack seal ring to approximately 40C (104"F). Then place it onto rack.

.1D

SST132CA

ST-18

POWER STEERING GEAR AND LINKAGE (Model PR24AC)

Assembly (Cont'd)
3.

Insert rack oil seal,

Place plastic film Into rack all seal to prevent damage by
rack teelh.
Always remove plastic film after rack 011 seal Is positioned
properly.
Make sure lips of rack oil seal face each other.

'}'f

SST20'A

4_

Install center bushing and rack oil seal with rack assembly
~'

aCk

~
End

--------........

---------

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.

0,( seal

co~e-'

a,sembl.,.

-~
---U

SSTJ;/1B
.-----._-----------.~

23 mm

(0.08 . 012 In)

~~

End COlier
assembly

Gear
_

_h_OU_s_t"_9

SSTO)~8

7,

~._

Set rack gear in the neutral position.

Measured length "S":
Refer to SDS (ST-27).

..

~"-):-~~1~~ .__- ';-li.!-j~--=-1\jdllllB

-~.-

J,---t:-. -~

_I

~'1"

1_

S -,

SST066BA

ST-19

"
"

POWER STEERING GEAR AND LINKAGE (Model PR24AC)

Assembly (Cont'd)
8.

Coat seal lip of new pinion oil seal with multi-purpose

grease. Install it into pinion housing of gear wilh a suitable
1001.

Make sure lip of oil seal faces up when installed.

9. Install pinion bearing adjusting shim(s}_

Whenever pinion assembly, gear housing and rear housing
are disassembled, replace shlm(s) with new ones. Always use
lhe same number of shim(s) when replacing.

10. Install new pinion seal ring (made of Teflon) on pinion gear
assembly.

Using a heal gun, heat pinion seal ring to approximately

c
40 C (104F) before installing il onto pinion gear assembly.

Make sure pinion seal ring is properly settled in valve

groove.

5_5_TO_85---1
B

1----

Gear housing -

11. Apply a coat of multi-purpose grease to needle bearing

roller and oil seal lip.

-~--

Rack assembly

Needle bearing

-~
-

SSTD7SB

- ---------------------,

----

12. Install pinion assembly to rear housing

Be careful not to damage pinion oil seal.

- - - - - - -SST552
ST-20

Assembly (Cont' d)
13. Apply a coat of mUlti-purpose grease to rear oil seal lip
before installing rear housing.

14. Ensure that the rack is centered. Install rear cover cap so
that protrusion of rear housing cover is positioned as
shown in figure
Be careful nollo damage worm ring and all seal.

:..f;

;:of-,

15. Install diaphragm spring at retainer.

Always install retainer, spring washer and diaphragm

spring in that order

Make sure convex end (painted white) of diaphragm spring

faces outward when installing.
16. Install relainer spring and adjusting screw temporarily.

17. Install new lock plate.

Attach lock plate to side rod inner socket d)

Apply locking sealant to inner socket threads @.
Screw inner socket into rack @ and tighten to specified
torque.

Clinch two places of lock plate at rack's groove.

CAUTION:
To prevent scratching the boot, remove burrs from lock plate.

',i1

r',~:,

SSTl35C

18. Tighten outer socket lock nut.

':J:-"lL-~--~~
-- - .J!':"_,
-,
L
'--,f
~.
.- ..~
w

Tie-rod length "l":

Refer to SOS (ST-27).
19. Measure rack stroke.
Rack stroke "S":
Refer to SOS (ST-27).

l-'I.

'['

_ _.

SSTOJ9CA
.:......J

ST-21

::

POWER STEERING GEAR AND LINKAGE (Model PR24AC)

Assembly (Confd)

<-::l

20. Before installing boot, coat the contact surfaces between

boot and tie~rod with grease

I~~~=@~I

~==:J-

SSH67A

~------

ga ti '10 kg, 22 Ib}

hi

1/(~l.
MO

98 N (10 kg, 22 lbl

//1

/ ~,
~'"'

21. Install boot clamps.

To install, wrap boot clamp around boot groove twice. To

tighten clamp, place a screwdriver through both rings.
Twist rings 4 to 4-1/2 turns while pulling with a force of
approx 98 N (10 kg, 22 Ib).
Twist boot clamp in the direction shown in figure at left.

SST440A

Place twisted ends ot boot clamp in the range shown (This

will prevent interierence with other parts.)

Fro"t

After twisting boot clamp, bend twisted and diagonally so

it does not contact boot.

SSTl26B

Adjustment
Adjust pinion rotating lorQue as tollows'
1. Set gears to Neutral without fluid III the gear
2. Coat the adjusting screw with locking sealant and screw it
in
3 Lightly tighten lock nut
4. Tighten adjusting screw 10 a torque 01 4 9 to 5.9 N'm (50 to
60 kg-em, 43 to 52 in-Ib)
5 Loosen adjusting scr~w. then retighten it to 0.2 N m (2
kg-em, 1.7 in-Ib).
6 Move rack over its enlire stroke several times

ST-22

POWER STEERING GEAR AND LINKAGE (Model PR24AC)

Adjustment (Cont'd)
7.

8.

9.

Measure pinion rotating torque within the range of 180

from neutral position.
Slop the gear at the point of maximum torque.
Loosen adjusting screw, then retighten it to 4,9 N'm (50
kg-em, 43 in-Ib).
Loosen adjusting screw by 70 to 110,

~r

'. -- ST3127S000
SST072BII

10, Prevent adjusting screw from turning, and tighten lock nut
to specified torque.

U-;

SST557A

SST090B

11. Check rack sliding force on vehicle as follows:

a. Install steering gear onto vehicle, but do not connect tierod 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 115
mm ( 0.453 in) at speed of 3.5 mm {O.138 in)/s. Check that
rack sliding force is within specification,
Average rack sliding force:
186 245 N (19 2S kg, 42 55 Ib)
Maximum force deviation:
98 N (10 kg, 22 lb)
g, Check sliding force outside above range at rack speed 01
40 mm {1.57 in)/s.
Maximum rack sliding force:
294 N (30 kg, 66 lb)
Maximum force deviation:
147 N (15 kg, 33 lb)

If rack sliding force ;s not within specification. readjust by

repeating adjustment procedure from the beginning

If rack sliding force is still out of specification alter

readjustment. gear assembly needs to be replaced,

ST-23

~:.i\

III'
)'Jg{

~'T

SST497C

CD

Pulley

(21

Snap ring

@
@

Joint

Drive shaft assembly

@
@
@

Oil seal

@
5i)

Rolor
Pn

Washer

~i)

Cam ring

Hose

"4)

Eye bolt

~)

Gasket
Rear cover

(~

Suction pipe
O-rine;

Casing

t5)

front bracket

(1)

Spring

O-(lng

(~)

Power steer,ng pump brackel

Flow control va ve
D-rlng

\fi)
@

a-ring

~~

Adjusting bar

Front Side plale

~I

~)

A~jusljng

Connector bolt

@J

Vane

.~~

Adjusting bolt lock nul

l
1

O-ring

boil

Pre-disassembly In spection
Disassemble the power steering oil pump only if the following
items are found_

Oil leak from any point shown in thl'! figure

Deformed or damaged pulley

Poor performance.

__ ~. ssnJ

I
1

ST-24

;,

Disassembly
CAUTION:

Parts which can be disassembled are 91rlcUy limited.

Never disassemble parts other than those specified.
@[
Disassemble In as clean a place as possible.
Clean your hands before disassembly.
00 nDt use rags; use nylon cloths or paper towels.
Follow the procedures and cautions In the Service Manual.
When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

Remove snap ring, then draw pUlley shaft out.

Be careful not to drop pulley shaft.

ssro,oa
Remove oil seal.
Be careful not to damage front housing.

Remove connector.
Be careful not to drop flow control valve.

Inspection
Inspect each cornponent part for wear, deformation, scratches.
and cracks If darnage i~ found, replace tile parI.

ST~25

-{:.

~_

TEERING OIL PUMP

R-----

__

Assembly

{r':::~
~ {I
~
~ ~

~~&h
"

n,~ '00....

"d,

"';;'

=
~

'r
,'_,

m nng, ro'o,
"ecloon,
necessa,\"
and "nes must
ATF
Coat e apa"
c h"'Ih
'
be replaced "'
when a

Pay attention to th e direction

'
of rotor

en 8s5embl'
Wh
vanes must f acelog
vanes
to'd e,
r 0 I or, rounded surfaces
cam
ring 51

Insert
pin t2' mto
'
s'd
p rn groove
cam (i~g
,~ront
housing
I e plate, '6J
Then'Install
(11 of
. f as shown
at and
left fr ani

' ",_

F'onl hoUSIng side

SSTB4)~

'
Always install n gs and oil seal a 9 instructions
Be
ew 0 ' gs
re prop
Ca coeel"' of oil se,it
and olt seat e<ly'Ostalled

-c:J

"

/-----r

oil p"
:Assemble
Make suee
o:~~ noling llie tollowln

a sel iI

ssembling

01

General Specifications
Applied model

11I1

Steering mOelel
PR24AC

Steering gellr lype

t72

$t.. e,,1\9 overall gear ral,o

--

Turns of sleerlng wheel

(Lock to lock)

3 t
Coliapsi ble, tj It

Steering column Iype

1,-

Inspection and Adjustment

STEERING GEAR AND LINKAGE

GENERAL
Steeflng wheel a.,al play

5lee''''g gear type

IlIm (onl

T'f!' rlJd outer ba II ioonl

Steering wheel play lim,t

mm(lnl

Sw,ng,ng fo'ce al cotler

p,n hole A"
N (kg. Ib)

35 (t 3B)

Allowable movement of gear

houSIng
mm (in)

2 ( 0 DB)

69 - 657
(0 1 - 6 7, 1.5 -

RotatonQ torque "B"

N m (kg-em. m,lb)

~3,O

'4 8)

0,29 - 2.94
- 30 0, 2 6 - 26 0)

o (0)
''(r

STEERING COLUMN
Applied mooel

-----------+----_
Stee"n9 column lenglh l,"
mm (in)
Sleering column lower Shalt
length "L;'
mm (Inl

LHD

S"",ngmg lorce', "A"

N (kg. IbJ

RHO

-1-._----

6307 12483)

323 7 (\274)

69- Sf> 9
(0.7 - 5 B, , 5 - 12 B)

---------+-------------

A.'al end play "C" mm (in)

0(0)

--+-----------

610 0 (24,02)

Tie-rod sta nda rd length '"L"

mm (In)

t69 (6,65)
'----------------

3410 (1343)

Measurmg po,"l

I r

'37 mm (5 39

mil

w&::Lr==v
Rack
SST49JC

SI'O~-

mm (In)

68 5

~2,6971

S5T4Bac

I
", ,~
rl'_~

\' i

,";-

ST-27

'

Inspection and Adjustment (Cont'd)

POWER STEERING
SIQe"ng gear type
-I
-------------+-k sliding force
Rae

PR24AC

N (kg Ib)

u"der

normal operating oil

p rI~ssu'e

Range within 1 t 5 mm
I 0 453 in) trom !he neutre. I
pos'llon at rack spe~d Df
3 5 mm (0 138 jnlls
t86 - 245
(19 25, 42 - 55)

Allerage torce
f--

Ma~imum torce devieli~n

98 (10, 22)

E nepl for the abOve range

MaXimum slldrng tarce

294 (30, 66)

Maximum force dellial'"n

147 (15,33)

Rela ,nIH 6djustment

A dJUShnQ screw
I"ilial tightening larql'e
N m (kg-em. In-1tll
Retightening torque after
loosening
Tightening I01QUA aller gear
has settled
Retu, n,'ng angle

degree

Siae Img Wheel turning lorce

(Mea sured at one lUll turn 'rom the
position)
N (kg, Ib)

n@u(, al

4,9 - 5.9
(SO - 60, 43 - 52}
():I (2

1 7)

4,9 (50, 43)

70'" IIC"

---

39 (4. 9) or less

Fluid capaCity (Approximatel

- - - - - - - - - r (Imp ql)
0,1 pump maxu-num pressure

kPa (bar, kg/cm', pSll

0.91:l/ 4)

8.630 " 9.219

(86 J - 92,2, 88 - 94,
1,251 - t ,337)

ST-28

-------

----

_______________
RE~TRAINT SYSTEM

--. ---.---":l m

SECTION

R~

1'(>
.",

CONTENTS
PRECAUTION.
,2
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BEL T PRE-TENSIONER",
.2
SEAT BELTS
3
Front Seat Bell,
3
Rear Seat Belt.
. " ...
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) , "" .. 5
Precautions for SRS "Air Bag" and "Seat Bell
Pre-tenSloner" Service
.5
Special Service Tools
5
Commercial Service Tool
.5
Description.
6
SRS Component Parts LocatIon
.6
Maintenance Items
.7
Removal and Installation - DiagnOSIS Sensor
Unit and Seal Bell Pre-tensioner
,8
Removal - Air Bag Module and Spiral Cable. . 9

Removal - Fron1 Passenger Air Baq Module

Installation - Air Bag Module and Spiral
Cable
Installation - Front Passenger Air Baq
Module
Disposal of Air Bag Module and Seat Belt
Pre-1ensioner.
TROUBLE DIAGNOSES - Supplemental
Restraint System (SRS}
-'
Wiring Diagram - SRS - .
Schematic
Sell-diagnosis ..
Diagnostic Procedure 1 ,
Diagnostic Procedure 2 .
Diagnostic Procedure 3
Collision Diagnosis.

~.~

10

':'i.
11
i.:..

12
12

.j.Cf
;

.17
17
20
21

~ Li

I
i
l

-= I~':

':!7

27
28

~~ .. ~

,29
~:',

1
~

When you read wiring diagrams:

Read GI section. "HOW TO READ WIRING DIAGRAMS"
See EL section, "POWER SU PPL Y ROUTI NG" for power distribution ei reu it.
When you perform lrouble diagnoses. read GI section, "HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT"

~
I,

F',

Of;

I,

i
l

PRECAUTION
Supplemental Restraint System (SRS) "AIR
BAG" and 'SEAT BELT PRE-TENSIONER"
The Supplemental Reslraint System "Air Bag" and "Seat Bell Pre-tensioner". used along wilh a seat
belt, help to reduce the risk or severity of Injury to the driver and front passenger in a frontal collision.
The Supplemental Restraint System consists of air bag modules (located in the cenler of the steering
wheel and on the Instrument panel on the passenger side), seat belt pre-tensioners. a diagnosis sensor unit, warning lamp, wiring harness and spiral cable
WARNING:
To avoid rendering the SRS inoperative, which could Increase the risk of personal injury or death
In the event of a collision which would result in air bag Inflatfon, all maintenance must be performed
by an authorized NISSAN dealer.

Improper maintenance. including incorrect removal and Installation of the SRS, can lead to personal
Injury caused by unintentional activation of the system.
All SRS air bag electrical wiring harnesses and connecfors are covered with yellow outer insula
tion. Do not use electrical test equipment on any circuit related to the SRS.

RS-2

SEAT BELTS
CAUTION:
Before removing the seat belt assembly. turn the ignition swItch ott, disconnect battery ground cable
and wait for at least 10 minutes. (For Europe model)

Do nol disassemble buckle or seat belt assembly.

Replace anchor bolls if they are deformed or worn out.

Never oil longue and buckle.

If any component of sea' belt assembly Is questionable, do not repair. Replace as seat belt assembly.
If webbing is cut, frayed, or damaged, replace seat belt assembly.
When replacing seat belt assembly, use a genuine seat belt assembly.
After any collision. Inspect all seat belt assemblies, including retractors and other attached hard-

wares (I.e., guide rail set).

Front Seat Belt

CD

Remove rear seat. Refer 10 "SEAT" in BT section for details.

Remove rear pillar lower garnIsh. Refer to "INTERIOR TRIM" in BT section for details.
@ Disconnect seat bell pre-tens1oner connector. (For Europe model)
@ Remove floor anchor cover and the anchor bolt_
Remove pillar anchor cover and lhe anchor bolt.
Remove the screw and the anchor bolt securing front seal belt assembly
SEC. 868

8eJ - S5
(44 - 5 S,

32 ell"

""'<
, ..~

N.m Ikg m ft-Ibl

':;";'1

SEAT BELTS
Rear Seat Belt
1.
2.
3.
4.

Remove
Remove
Remove
Remove

rear seat Refer to "SEAr' in BT section tor details

rear pillar lower garnish. Refer to "INTERIOR TRIM" in 8T section for details.
each anchor bolt
the anchor bolt securing rear seat belt assembly,

\R43.

S5

~ (4.' - S. " . "I

prj

Anchor

00

~@
..I,

\'

\~\)
..~
' ;;'':~-~-rlJ:;,-fl$

I \
I
I

~(;O

\',,-.. ~--

'.

, R43 55 (4.4 .

~.6.

32 . 41)

~<BF497BA

RS-4

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Precautions for SRS "Air Bag" and "Seat Belt
Pre-tensioner" Service

Do 1"01 use a circuit tester to check SRS circuits.

Before servicing the SRS, turn ignition switch "OFF", disconnect battery ground cable and wait tor
at feast 10 minutes.
For approximately ten mInutes alter the cables are removed. it is still possible for the atr bag and
seal belt pre-tensioner to deploy, Therefore, do not work on any SRS connectors or wires unlll al
least ten minutes have passed.
Diagnosis sensor unit must always be installed with their arrow marks
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 <::olumn alter removal of steering gear.
Handle air bag module carefully. Always place it with the pad side facing upward,
After removing any SRS parts, discard old bolts and replace with new ones. Conduct self-diagnosis
to check entire SRS for proper function.
After air bag inflates, the front instrument panel assembly should be replaced

"Q"

Special Service Tools

Tool number
Tool name

-i""

CI

Description
Disposing of

KV99106400

air

bag module

Deploymenllool

f'HJ57
.:,1,

KV991065$O
Deployment tool

adEiple-rs

Anchor th& passenger air bag module

KV99105300
Passenger air bag brackel

Commercial Service Tool

Tool name

DesCription
Use lor special bolts

Special Ion. bit

(TAMPER RESISTANT TOAX (Sim T50J!

a: 3.5 (0.138) dla,

b: 8.5 . 8.6 (0,335 - 0,339) dla.

c: appro . 10 (0.39) sq.

,I
Urlol

RS-5

mm {lnl

SUPPLEMENTAL RESTRAINT SYSTEM (SRSI

Description
The air bag deploys jf the diagnosis sensor unit activates while the ignillon switch is in "ON" or "ST ART"
position_

-----------------------

r----------- -----------

'grulla"

Dla~"os;s

~W1lcn

sensor unit

Driver
air bag module

(Or-l 0' STAAT)

AuxJilary power source

Ico"denserl

r-f------<.---~~;~r I

.--.. . .- - - - J - - - - - +..
P8,9se"ger
air bag modulel
seat bell pretensioner

-------

SBF281HA

SRS Component Parts Location

Seat belt pre-Illnsioner fetraclor

I
I

----

-_._-- - - - - -

------ - - - - - - - - - -

l-t8FSJOB

I
I

RS-6

SO'~PLEMENTAL

RESTRAINT SYSTEM (SRS)

Maintenance Items
1.

Check "AIR BAG" warning lamp (Models equipped with air

bags)
After turning ignition key \0 "ON" or "START" position :~r
"AIR BAG" warning lamp illuminates for about 7 seconds:
The "AIR BAG" warning lamp will go out after about 7
seconds, If no malfunction is detected.
When a warning lamp flashes, check and correct cause of
the problem

2.

Visually check SRS components

Airbag
Check case and bracket for dents, cracks or deformities,
Check connectors for damage, and terminals for deformities.

IAlRl
L~

L-_ _.

SBF805E!

I,

(1) Diagnosis sensor un it -

(2) Main harness and air bag harness

Check connectors for poor connections

Check harnesses for binding, connectors for damage. and

terminals for deformities.
(3) Spiral cable

Visually check lock (engagement) pins and combination

swi'ch lor damage

Check connectors. flat cable and protective tape for damage.

Check steering wheel for noise. binding or difficult operation.

(4) Air bag module and steering wheel

Remove air bag module from steering wheel or instrument

panel, Check harness cover and connectors for damage.
terminals for deformities, and harness for binding.

Install driver side air bag module to steering wheel to

check fit or alignment with the wheel.

Check steering wheel for excessive free play.

Install passenger side air bag module to instrument panel

to check fit or alignment with the instrument panel.

,i

','11

;1 '

CAUTION:
Replace previously used screws with new ones.
(5) Seat belt pre-tensioner

Check harness cover and connectors lor damage. terminals for deformities, and harness for binding,

Check belts for damage and anchors for 100".e mounting,

Check retractor tor smooth operation,

Perform self-diagnOSIs for seat belt pre-tensioner using

circuit tester Refer to "Self-diagnosis" for detai Is (RS-21)

RS-7

I;,"

SUPPLEMENTAL RESTRAINT SYSTEM (51.6)

Removal and Installation -

Diagnosis Sensor

Unit and Seal Belt Pre-tensioner

CAUTION:

Before servicing SRS, turn the ignition switch of/, disconnect battery ground cable and wait for al
least 10 minutes_
The special bolts are coated with bonding agent. Discard old ones alter removal; replace with new

ones.

Check diagnosis sensor unit for proper installation.

Check diagnosis sensor unit to ensure they are hee of deformities, dents, cracks or rust. Il they show
any vIsible signs of damage, replace them with new ones.
Check diagnosis sensor unit brackets to ensure they are free of deformities or rust.

00 not attempt to disassemble seat belt pre-tensioner.

00 not drop or impact seat bell pre-tensloner. If any portion is damaged, replace the seat belt pretensloner.
00 no! expose seat belt pre-tensioner to temperatures eKceeding 80'C (176"F).
Whenever seat belts (equipped with pre~tensioner) are moved, ensure thai cVltnder faces down. Do

not hold cylinder.

REMOVAL OF DIAGNOSIS SENSOR UNIT

1
2.

Disconnect driver ::Ind rassenger air bag module connectors Also, disconnect seat belt pre-Iensioner connector
Remove rear seat assembly Refer to "ReFlr Seat" in 81

section.
3
4,
S.

Remove cover.
Disconnect Ulagnosis sensor unit connector.
Remove boll and also remove special bolts IJsing the
TAMPER RESISTANT TORX (SiLe T50), from diagnOSIs
sensor unit,
Then remove lhp. dirlgl'\osis sensor un:'
NOTE:
To install, reverse the removal procedure sequence.

REMOVAL OF SEAT BELT PRE-TENSIONER

For removal 01 seat bell pre-\ensioner. reler to "Front Seat
Belt" for details, (RS-3)
NOTE:

To install, reverse lhe remo~al procedure sequence.

After replacement, perform self-dIagnosis for seat bell pretenstoner using circuit tester. ReIer to "Self-diagnosis" for
details. (RS21)

RS-8

Removal -

Air Bag MOdule and Spiral Cab1e

SEC. 253484

\~~\
' - SpeclBI POll ..~
15 25 (l.5 2.5, 11 - 181

\.. Side lid lH

CAUTION:
Before servicing SRS, furn fhe Ignition swItch on. disconnect
battery ground cable and walt for at least 1() minutes.
1 Remove side lid LH from steering wheel, nnd disconnect
air bag module connector.

2.

;'.1

Remove side lid. Using the TAMPER RESIST ANI TORX

(Size T50\. remove left and right special bolts. Air bag
module can then

be removed

~:. /:

II
CAUTION:

Always place air bag module with pad side facing upward.

Do not att~mpl to disassemble air bag module.

Ttle special bolts are coaled with bonding agent. Discard
old ones after removal; replace with new ones.

:1'
:

(c~, :

RS-9

SUPPLEMENTAL RESTRAINT SYSTEM (SR'5)

Removal - Air Bag Module and Spiral Cable
(Cont'd)

,-----------~------

3,
4.
5.
6.
7.

Do not drop or impact air bag module. If any portion is

deformed or cracked, replace the module.
Do not expose the air bag module to temperalures exceed
lng 93C (199F).
00 not allow oil, grease or waler to come in contact with
the air bag module.

Set steering wheel in the neutral position,

Disconnect horn connector and remove nuts
Using steering wheel puller. remove steering wheel Be
careful not to over-tighten pUller bolt on steering wheel.
Remove steering column cover,
Disconnect connector and remove the four screws. The
spiral cable can then be removed,

SBFnQF

Removal -

Front Passenger Air Bag Module

CAUTION:
Before servicing SAS. turn the ignition switch off, disconnect
battery ground cable and wall for al least 10 mlnules.
1, Remove connector bracket from air bag module and disconnect air bag module connector.

SEC. 680

2.
3.

Front

-~pedal DOll.:. ~--- -

- --

~J
_.:c~. :.~,.-.=~
~fr~~~~~.~ -.
\_ (1.5 2.5, ~
;A1S.25

=31~(

--\
__ -<"

-~~'~j
l A

__

i"(n-~I
' I~I :~.5 ~~.5.rc:~
I~

Nm (kgm. It-Ibj

,Idi

1119)

MBI"~

CAUTION:

Always place air bag module with pad side facing upward.

Do not attempt 10 disassemble air bag module.

The special bolts are coated with bonding agent. Discard

old ones after remollal; replace with new ones.

Up

- - I &~~~~~??
---S-pecral bOI~~
.

Remove instrument panel.

Remove the special bolts from leH and right sides 01 (ronl
passenger air bag module, Then remove the air bag module from the steering member.
Air bag module is heavy and should be supported using
both hands during removal.

Front

II

I
t

I
I
I

MBF<l86B

RS-10

SuPPLEMENTAL RESTRAINT SYSTEM (SRS)

Removal
Front Passenger Air Bag MOdule
(Cont'd)

1.

~Ilil!,

Air Bag Module and Spiral Cable

Set the front wheels in the straight-ahead posit ion.

Make sure that the spiral cable is in the neutral Position.
The neutral position is detected by turning left 2 5 revolutions from the right end position. Align the two marks (i:),

CAUTION:
The spiral cable may snap due to steering operation If the
cable is Installed In an improper position.
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 lurned up to 2,5 turns from
the neutral position to both the right and left.)
3. Connect spiral cable connector and tighten with screws,
Install sleering column cover.

(.1[

Do not allow oil. grease or waler to come in contact with

the air bag module.

Installation -

!Sec. 253

Do not drop or impact air bag module. If any Portl

deformed or cracked, re.p1ace the module.
on Is
Do not expose the air bag module to temperatures e
jng 9JoC (199F).
xceed-

/~
,~~\\

l,~
~~

{~l

lUff

",rr

Altgnment mark

I.<BF4878

4.
5.

6.

Install steering wheel setting spiral cable pin gUides, and

pull spiral cable through
Connect horn connector and engage spiral cable with
pawls in steering wheel.
Tighten nuts.

S8F8,aE

--~

Position air bag module and tighten with new special bolts
Connect air bag module connector.
9 Install all lids.
10 Conduct self-diagnOSIs to ensure entire Sr:tS [>perates
properly. (Use CONSUL T or warning tamp check J
7.
8.

h,
\

~~;k~ -Ibl

-"_

_~.>J

RS-11

'~M'

SUPPLEMENTAL RESTRAINT SYSTEM (Sn~)

Installation -

Front Passenger Air Bag Module

1.

Install front passenger air bag module on steering mem-

f:.nsure harness (s riot caught between rear 01 air bag module and steering member.
Install instrument panel

ber.

2.

3.

4.
5

Connect air bag module connector to body harness connector,

Install air bag module connector on connector bracket.
Install connector bracket on air bag module.

MBf41\.1R

Disposal of Air Bag Module and Seat Belt

Pre-tensioner

Make sure to deactivate air bag modules and seat belt prp.-Iensioners before disposing of them. Also,
befure disposing of a vehicle equipped with an SRS system, deactivate air bag modules and seat
bell pre-tensioners. Jf such systems have already been deployed due to an accident. disposp. 0 1 as
indicalF.!d in "DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONEA",
When deploying the air bag module and seat belt pre-tensioner, always use the Special Service Toot;
Deployment tool KV99106400
When deploying the air bag modul e and seat belt pre-tensloner, stand at least 5 m (16 ft) away from
the deployment component
Due to heat, do not touch air bag module for at leasl 30 minutes after deployment. Also do not touch
seal belt pre-tensioner for at least 1{) minutes aller deploymer.t,
Be sure to WP.<H gloves when handling a deployed air bag module and seat belt pre-tensioner
Never apply water to a deployed air bag module and seat bell pre-tensioner.
Wash your hands clean after finishing work,

RS-12

I
j

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Disposal of Air Bag Module and Seat Belt
Pre-tensloner (Cont'd)
CHECKING DEPLOYMENT TOOL
Connecting to battery

Place vehicle outdoors with at least 8 m (20 It) of open

space on all sides

SRSOO!>

Use a voltmeter to make sure the vehicle battery is lully

charged.
CAUTION:
The battery must show voltage of 9.6V or more.
Remove the battery from the vehicle and ptace it on dry wood
blocks approximately 5 m (16 tt) away from the vehicle
Wail 10 to 12 minutes aller the vehicle battery is discon-

'1.1:;:

nected be/ore proceeding.

Connect red clip of deployment too! to LJallery po~il:ve terminal and black clip \t) negative terminal.
CAUTION:
Make sure the polarity is correct. The rlg"'l side lamp in lhe
1001, marked "deployment IDOl power", should glow with a
green light. tf the right side lamp glows red. reverse the connections to the battery.

~t

~~

'r;;t

Deployment tool check

Press the deployment tool switch to the "ON" position. The teft
.<;ide lamp in the tool. marked "air bag connector voltage'
should illuminate. 1/ it does nol illuminate, replace the tool.

~\T

Air bag deployment tool lamp illumination chari

(Banery connected)

Left side lamp, green'

"AlA BAG CONNFC
TOR VOLTAGE"

Rig'" side lamp,

green'
"DEPLOYMI:N J IOOL
POWER"

OFF

OFF

ON

ON

ON

ON

SWlte~

operation

S_BF2----J66H

1/ this lamp glows red. the tool is connected to the battery Incorrectly
Reverse the conneclions and make sure the lamp glJ)ws green.

RS-13

'~)I

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)'-'

Disposal of Air Bag Module and Seat Belt
Pre-tensioner (Cont'd)
M6B

6 . B /0,2' - 0,31)

DEPLOYMENT PROCEDURES FOR AIR BAG MODULE

AS A UNIT
Deploying air bag module while it is mounted in vehicle may
damage vehicle, Deploy air bag module as a unit except when
disposing or vehicle,
Anchor air bag module In a vise secured to a firm foundation
during deployment
Deployment of driver's air bag module as a unit

Unit; mm 1;1'1)

SBnBlH

Prepare two sets of nuts and bolts (see figure at left).

These bolls are required to secure driver's air bag module to 'he vise.
2. Install one sel of nuts and bolts to each side of the air bag
module.
CAUTION:
Make sure to Install two bolts and nuts on each side.
,.

SBF267H
----------------------'

3.

Firmly place two nuts (secured to air bag module) in the

vise.
CAUTION:
Ensure these two nuts are equally placed In th~ vise. Never
finish the Installation with just one nut.
4. Connect deployment lool (SST: KV99106400) to air bag
module connector.

Bolt (nwll

[ Aor bag module

connector

5.

Connect red clip of deployment 1001 10 ballery posilive terminal and black clip to negative terminal
6. The lamp on the right side of the tool, marked "deployment
tool power", should glow green, nol red
7. Press the bullan on the deployment tool The left side lamp
on the tool, marked "air bag connector vollage", 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.

Air bag module

SBF26~H

Deployment of passenger air bag module as a unit

Using wire, secure air bag module to passenger air bag
bracfo<el (SST. KV9910S300j at two places.
CAUTION:
Use wire of at least 1 mm (0.04 in) in diameter.
1

RS-14

SU':"PLEMENTAL RESTRAINT SYSTEM (SRS)

Disposal of Air Bag Module and Seat Belt
- - - - _ . , . _._-Pretensioner (Cont'd)
2.
3

Firmly anchor passenger air bag bracket in a vise.

Connect deployment tool adapter (SST: KV991065S0) to
deploymenltool (SST: KV99106400) connector and connec-\r(
tor on either side of air bag module,

4.

V:

SBF21IHA.

'--------------

----~

Atr bag module

SBF269H

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 gtow green. not red.
6. Press the button on the deployment tool. The left side lamp
on Ihe 1001, 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 It)
away from the air bag module.
CAUTION:
Always activate one inflator at a time.

t'~:
~~

{.I,

lij( '

Deployment of seal belt pre-Iensioner as a unit

Firmly place pretensioner
an d web blOg ,n the vis e

1. Firmly anchor seat belt pre-Iensioner in a vise

CAUTION:
Ensure bracket and webbing are placed in the vise.

:-,\

SBF272H

2.

Connect deployment {Dol adapter (SST, KV991065S0) to

deployment 1001 (SST: KV99106400) connector and seat
belt pre-tensioner connector.

~l1-:'

S8F273HA

Connect red clip of deployment tool to battery positive lermina' and black clip to negative terminal
4. The I.amp on the right side of the tool, marked "deployment
tool power", should glow green, not red.
S. Press the button on the deployment 1001 The left side lamp
on the tool, marked "air bag connector voltage", will illuminate and the seat belt pre-tensioner will deploy.
CAUTION:
When deploying the seat bell pre-tensioner, stand at least 5 m
(16 ft) away from the seat bell pre-tensloner.
SIlF2/."

RS-15

I(

!'l.

c't

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Disposal of Air Bag Module and Seat Belt
Pre-tensioner (Cont'd)

~\

DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT

PRE-TENSIONER WHILE MOUNTED IN VEHICLE

MBF4B1B

1-

When disposing 01 a vehicle, deploy air bag modules and seal

belt pre-tensioners while they are mounted in vehicle.
CAUTION:
When deploying air bag module or seal bell pre-tensloner,
ensure vehicle Is empty.
1. Disconnect battery ground cable and wait 10 minutes
2. Disconnect air bag modules and seal belt pre-tensioners
connector.
3 Connect deployment tool connector (SST' KV99 106400} to
air bag module or seat belt pre-tensioner.
For front passenger air bag module and seat belt pretensioner, attach deployment 1001 adapters (SST:
KV991065S0) to the tool connector.
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 bullon on the deployment tool. The left side lamp
on the lool, marked "air bag connector voltage"'. will illuminate and the air bag module or seat belt pre-tensioner
will deploy.
7. Alter deployment. remove them from vehicle and seal
them up in plastic bags, then dispose of them.

DISPOSING OF AIR BAG MODULE AND SEAT BELT

PRE~TENS lONER

SllF216H

Deployed air bag modules and seat belt pre-tensioners 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:

Never apply water 10 a deployed air bag module and seat

belt pre-tensioner.

Be sure 10 wear gloves when handling a deployed air bag

module and seat belt preIensioner.

No poisonous gas is produced upon air bag module

deployment. However, be careful nollo inhale gas since it
irritates Ihroat and can cause choking.
Do not attempt to disassemble aIr bag module and seat
belt pre-tensioner.

Air bag module and seal bell pre-tensioner can nol be

re-used.

Wash your hands clean after finishing work.

RS-16

TROUBLE DIAGNOSES -

Supplemental Restraint System (SRS)

Wiring Diagram -

SRS -

RS-SRS-01

~-~-A-~~] ~f.Ho a-p~

mIT]

Moaels with

(b):

Ll-{) mode 15
RI-() mode 15

pl"'e-tens1onel"'
system only
@: Except

Ifl<I) RIL,
1f2"'@

~TER

(AIR BAG
WARNING
LAMP)

,R/L

Ibi=U
RIG

R/G@

~
B

$---1$

l@t~~~B .,
A/G.

IGN

!t

r@l

A/BAG
LEO

GNO

DIAGNOSIS

SENSOR

.....

-=

-=

r ' 1.-.1
"="

UNIT

~ <M@ CHI)

aD:@
aID: @

rJ::TI:TIITI CID

CDID...J!QLLJ

[--ffiimi~]-~1
W

~G

~w

...

FletaI' to la9t page

(Foldout page) .

~,1 f'~

~'; I

IIJ~
"

~--------------------------~

: -

r-----------------------------~---------------~

: rTITCI::IJQIIIJ aD:
I
II

~
ITIIIIJ.IJ
~

__ -

ill):
W

:
:

i .

I
~

~-----------------

SRSOO7

RS-17

~~

TROUBLE DIAGNOSES -

Supplemental Restraint System (SRS)

Wiring Diagram - SRS - (Cont'd)

RS-SRS-02
Preceding page

<.D;

<:@-

II

"L.!

l...;-.......

LHD mode 1s
RHO models

R.

~-,......-;::;--;---~:---;--------...,..-::;......,.....~

LIB ~

SO-

(DR)

I.

GIB

GIS

viS

I.

It
G

G/8

It

fi21TI

ff21m_

PIT

SSS

SSS

WARN

TX

RX

DIAGNOSIS
SENSOR
UNIT

aD:

SQ-+-

50-

(PASS)

(PASS)

@
aID:@

~t~

It

~~

SPIRAL
CABLE

$B

em

o _"'_3_ 11

--

---iGlt---$
viS

(DR)

I
8

*4

rm PASSENGER

~2
t MODULE
AlA BAG

AI~ BAG
MODUlE

it

SIDE

DRIVER'S

(SQUIB)

SIDE

em

(SQUIB)

gmr::IT::I:J7l

\IJOIJill aID

l:J1II.IIJ!gj

Refer' to !lIst page

(Fa Idout Dace) _

~GV

~---------------------------------------------~

:
:

~cm:@
~

~ill)::

l.IIJ..J-l.TI..

loll

:
I

~---------------------------------------------~

cwm em
~W

CONSUL T

LiJ
Gis

I I I

OR

SQ+

l-iJ
G

LIB

Models with
pre-t8nsiQnersystem only
@: Except @

LINK

CONNECTOR

~:

*-4'.'

IOATA

~lf3
tilly

~@
w

\l..@

TROUBLE DIAGNOSES -.~uppl~mental Restraint System (SRS)

Wmng Diagram
SRS - (Cont'd)

c:=
~

GV/R

GY/R@

GY/R

P/T+

p/TlOR)

(PASS)

(PASS)

IYJJl

lYj1I

L/R

It

I~

OR

LG

OR

LG

II
L/R

OR <[!g)

Ui
~'(~;

'-s

OR ~ lG

SlOe:

L/R

C';I,
1

"~:rr

it:,'T
~

I. I.

~ ~:
BELT
TENSIONEFl
DRIVER'S

00

M~:BELT
rENSIONER

~~\ 'i:

J~

PASSENGER

SIDE
~ ~\

@: Models wun pre-tensionel'" system on1';

@: Except @

r---------------------------------------------,
I

: ~l CID:
l~y
I

cr:F<::>rTl

Li

;,'k

LG

SIDE
~

CID ])

~_~_$

LG ~

LR-.J@
~

DOOR

RHO models

It

r~=}t

SWITCH
DRIVER'S

~\:)l

---$ ----------1~ - - -1$

I
GV/A

LHD mode 1 s

aID:@

LG

LJR ag)

lHW

(C>:

P/T-

OR

I%~,~~,

aD:@

(OR)

P/T+

GY/Fl CID

OPEN

~~c

DIAGNOSIS
SENSOR
UNIT

(ill
GY/Fl@

RS-SRS-03

@:

~w

Refer to last page

(Foldout pagel.

(
I

~-(@)

~w

"I

-'.

GY

SRSOO9

RS-19

TROUBLE DIAGNOSES -

Supplemental Restraint System (SRS)

Schematic

CAUTION:

Do not use a circuit tester to check SRS "Air Bag" harness connectors. The wiring harness and
connectors have yellow outer insulation for easy Identification.

Do not attempt to repair, splice or modify the SRS "Air Bag" wiring harness. If the harness is
damaged, replace it with a new one.

Keep ground portion clean.

--

-------------------;:::---=-=--========~--------------

DATA LINK
CONNECTOl'l

FOR CONSuLT
CDM8INA TION
METEI'!
(AU' Ddll
",arnlr'lg

lamel

DIAGNOSIS
SENSOR UNI T
2\ 20

r------+--_-----+--...-------+-~..._---<>

10

11

12

0---__.----,

Saf lng
sensor

17

_~

SPIRAL
CA8LE
DOOR SWITCH

DRIVER"S SIDE

Mode Is '" til ore-tens loner

system only
Except

---- -----------

SRS010

l
I

I
\

RS-20

TROUBLE DIAGNOSES -

Supplemental Restraint System (SRS)

Se If-diagnosis

The air bag and seat belt pre-tensioner can be put under self-diagnosis by the fOllOwing methods,

USING CIRCUIT
TESTER

USING CONSULT

RS-21

Seat bell pre-tenSloner

RS-n

AS.;?4
---- -

,',

-.

co

'"

(Standard equipment)

Equipped with driver a,r bag

Equipped Wllh driver air bag and passellger

CI
<--~

air bag

.20.0'0."

'1{

USING "AIR BAG"

WARNING LAMP

._.- f - - - - - - . - - - - - 1 - - . _ - - - - - -

--~._----

._-(1

Equipped with driver air bag

(_I

'.." w~
<)

;,

Equipped with driver air bag and passel1ger

air bag

_.

For Australia

(\

USING CfRCUIT TESTER

Seal belt pre-tensioner self-diagnosis results can be read by
using a circuit tester as follows:
1, Measure resistance between data link connector for CONSUL T and body ground

..: ~

2.

<.D

Visually check the oscillation of circuit tester needle.

0-----

Normal

"'"

6 sec

~"'"'em

The seal bell pre-tens loner

-J

~--------i

IS In

good

order

SRSOOJ

-------~-.
(2)

M~lfunction (Including when seal

bell pre-tansioMr

IS

deployed)

Seat belt pre-tens,oner CircUit

1$

oper"l

or shorted to some power supply

~~~I~llllllllil

cirCUli, or shorted to ground

Visually check wiring ha, ness

~onnec

lIons
Replace seal bell assemhly (8"lore
disposing, it muSl be deactivated)
R".,lace diagnos,s sensor

lin

'I

ReplaGe air bag harness

5 Replace main harness

S<lSOO~

!Recheck seat belt prelenSIQrler

y .:
USing

c!fcud tester al each replao~mcrl! I

RS-21

TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Self-diagnosis (Coord)
USING CONSULT
The self-diagnosis results can be read by CONSUL T. as follows:
1. Connect "CONSULT" 10 dala link connector tor CONSULT.
(Data link connector for CONSULT is located in left or right
d ash side panel)

L~

Turn ignition switch to "ON" (When CONSULT is

connected. the "AIR BAG" warning lamp will be turned to
present diagnosis mode 1

OJ

3.

Touch "START" to operate "CONSULT"

I
~

4.

Touch "AIR BAG" to choose air bag system.

Touch "SELF DIAG RESULTS" to read self-diagnosIs

results.

6.

Problem codes are displayed on "SELF DIAG RESULTS".

7.

When "PRINT" is pressed, information displayed on "SELF

DIAG RESULTS" is printed out

SELECT SYSTEM

LENGINE
CAIRBAG

~_~----=:J

=:J

I
I

SBf88JF

SELF-DIAG RESULTS.

.. NO SELF DIAGNOSTIC
FAILURE INDICATED

...

...
...

...
...

WARNING:

FAILURE DETECTED

FURTHER TESTING
MAY BE REQUIRED.

...

2.

*
8.

9.

While CONSULT is displaying this "SElF-DlAG RESULTS"

information, do not disconnect CONSULT from data link
connector.
When finishing diagnosis, make sure fo change CONSULT
display to SELECT SYSTEM mode by using BACK KEY.

...

After repairing malfunctioning parts, press "ERASE" to

clear self-diagnosis results.
"ERASE" function requires selecting "ERASE". and completing step 9.

...

Push BACK KEY of CONSUL T until SELECT SYSTEM mode

appears to make "SELF-DIAGNOSIS" user mode.
If malfunctioning paris are not completely repaired, "AIR
BAG" warning lamp will blink every 0.5 seconds .

....

10. Push the power off switch

11 Tum off ignitiDn sWitch, disconnect CONSULT.

12. Turn Ignition switch to "ON"

"AlA BAG" warning lamp should come on lor about 7 seconds and then go off.

RS-22

TROUBLE DIAGNOSES -

Supplemental Restraint System (SRS)

Self-diagnosis (Cont'd)

Self-diagnosis results
Repair or(ler
Diagnostic Itern

E. pIan a tionl PDS 5 Ib Ie

caLlS es

Reclleck SRS using CONSULT at each

replacernenl

NO SELF DIAGNOSTIC

Normal SAS system is in good order

FAILURE INDICATED
-- --

AIRBAG MODULE

Driver's air bag module circuit

's open

I Visually c:heck wiring harness connections

2 Replace spiral cable

Ilncluding the Spl ral cable)

[OPEN]
AIRBAG MODULE

Driver's air bag module circuil IS shorted to

:I Replace driver's air bag module

(Before disposing 01

some power supply circuit (including lhe

IVB-SHORTI

spiral c:able)
AIRBAG MODULE

--

Driver"s air bag module circuit is shorted to

[GND-SHORT]

ground (Ir"lcludlng lhe spiral cable)_

AIRBAG MODULE

1(.

It must be

deployed)

_._.-.---

4 Replace diagnosis sensor unit

5 Replace air bag harness

S Replace main harness

Driver's air bag module circulls are shorted

to each other

lSHORT]

--

- - - - - - - - - - - - - - ~---- - - - - _ . - - - - - - -

ASSIST AlB MODUlE'j

[OPEN]

Fronl passenger air bag module CirCUli is

2, Replace fronl passenger air bag module

open

ASSIS"'! AlB MODULE"

,-_.- ---_ .. _ - - - - - 1 Visually check wifing harness connections

Front passenger air bag module clrcuil

(Before disposal 01 it, It musl be deployed)

IS

[GND-SHORTI

3 Replace diagnOSIs sensor unil

shorted to some power supply circUlI
.- - - - - - - - - - - - - - - - - - 4 Replace air bag harness
Fronl passer>ger air bag module circuit IS
5 Replace main harness
shorled to ground_

ASSIST AlB MOOULE'l

Fronl passenger air bag module Circuits are

IVB-SHOATj
ASSIST AlB MODULE"

[SHORTI

CONTROL UNIT

sharted to each other

--

Diagnosis sensor unit IS oul of order

1 Visually check wiring harness connections

2_ Replace diagnosis sensor unit.

3 Replace air bag harness
4 Replace main harness
----------------

INDEFINITE FAILURES
[AIR BAG)

because more Ihan two parts are out 0/

Visually check wifing harness connections

2 Replace diagnOSIS sensor unit

order

3 Replace spira! cable and air bag n'odules

A problem which cannot be specified occurs

4 Replace air bag harness

5 Replace main harness

',- For Australia model only

P',-;

,~

.'

r',,--

RS-23

TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Self-diagnosis (Cont'd)
USING "AIR BAG" WARNING LAMP
Air bag self-diagnosis results can be read by Jsing the 'AIR
BAG" warning lamp,
The "Air bag" warning lamp operates as shown below:

WARNING:
When the "AIR BAG" warning lamp is flashing, compare the
flash time to the chart below.

How 10 alternate self-diagnosis

W'tr,n 7

se~onds

dUer '91 itlon

~ey 15

lurned "ON" press

driver s door SWitch at least 5 lomes

---

With n 7 seconds

~It",

ignit,on k.,y is ILrned "ON"_ press

-----J

~,':~;OSiS

---------------+'t

---

driver's docr switch at least 5 I,mes

Problem codes are displayed in diagnosis mode (self-diagnosis results)_

Warning lamp indication

Aher repairing malfunclloning part, use driver's door switch 10 return the system 10 user mode. This
will clear self-diagnosis results from memory.

If a malfunctioning part is not completely repaired, self-diagnosis fesults will not be cleared.

User mode

------r-------No proolem.

(i) Noonal (OFF)

IGN ON

Ughl check

ON~
OFF

I 7 sec. 1
t-----l

------------.-------SSF29IlH

The system has

problem Perform

0: S1IlJU1JUlJ1J1JU1J1JlJlJlSLll
sillksec

self-diagnosis with
010'191"105'5 mode"

05

SSF299,.A

----------------------------------,1) A" bag is i:lep1oved

ON
OFF

0(

disono,is &on<or unil ,~ mlllruPlctionlflg and continuously sends all "ON" signal

,---_

--.J

RS-24

-----t--------I he system needs 10

be repai'ed
(Refer to pi:lg~
RS-;>6 )

Self-diagnosIs (Cont'd)
DiagnosIs mode (Sell-diaQ"o5Is result!

:l?,' SIart
,a

~,

11)

5;9nal, Start s,gn,,1 Idenlilies display maCles

(3;

(6)

(c)

@ i~ through t~; are

reoealeCl

o::FLJLIIJlJlI1Jl_nJlJLJlJu
~1
l I
f::Ij0s
as

.eo..

2. ~C,

2 iee,

sac.

sec

Varies wUh I'oubled part

SBfJOOH

I. l

No manunclionlng (or ;nterrnfltenl troublelrep~lIr compl"t":m)

ON
OFF

(~'

Cli'

'1:

~;.

',a:,li!

lld
2s&c.

WARNING:
After 'he malfuncllonlng pam have been repalr<!d. relurn Ute syslem to "User mode",

Self-rlii'lgnosis rp.suHs in diagf10sls mDde can be identified by

number of flasl1es @ Refer 10 Table on nelCt page for troubled
parts

~. i~

~. ~I,

II
,' I
I .,

RS-25

~"

,I

TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Self-diagnosis (Cont'd)
Warning lamp flashing limes and repair
Warning

Flash codeCdJ

_I_'~''-OC''",""''

Explanation/Possible causes

-------- -----------+---------------- Normal SRS "A,r Bag" '5 ,n good

order_

)----------

Rep"''' order
Recheck SRS at each replacemenl

--"-,

Driller's air bag module circuit 's oLlt of

order_

_._----.-_.-. ------

1. Visually check wIring harness conneclions

2 Replace sp"al cable

3 Replace driver s air bag module

(Before disposal of It, ,t musl be

r-------------

deployed_)
4 Replace diagnOSIs sensor unit

5 Replace air bag Ilarness

DI.goo,;, ""''' om' " '"' of

tlons

g'

2 Replace diagnosis sensor unit

~;l:
r-,

III

m," """."

6 A.pl",
-----------,---.-

O'd~ V""", ,"oc' w"'''g h,mm ,o,,"~

- - - - -..- - - - - - -

::I Replace aPr bag harness

4 Replace main harness
- - - - - - - - - -f--------

f---

Front

pas~enger

air bag module Clrcuil

,s out of order

_._---

1 Visually check wiring harness connections

II:

2 Replace front passenger air bag mod-

ule
(Belore disposal, it must be deployed)

3 Replae" diagnOSIs sensor un,t

4, Replace air bag harness

5_ Replace main harness

More than two Pilfts groups are out 01

1 Visually cheel< wiring harness cannec-

tlons

order

2 Replace diagnOSIs sensor unit

3 Replace all sensors, spiral cable and
OIl( bag module
4 Replace "l" bag har"ess

5 Replace main harness

RS-26

TROUBLE DIAGNOSES -

~~J/ 'uP .,~:.~'-- -~t~ 11~;COI'I~eCIOr

II \

'I

\1

,!

'
IL.II

Supplemental Restraint System (SRS)

Diagnostic Procedure 1

'~"'~lor CONSULT,~

SYMPTOM: "AIR BAG" warning ICimp flashes.

WARNING:
'~i
Determine If the flash rate Is every 0.5 seconds, or 3 seconds
"ON" and 2 seconds "OFF".
If every 0.5 &econds, perform self-diagnosis.
y~),~:
It 3 seconds "ON" and 2 seconds "OFF". the system Is In
Present diagnosis mOde. refer to page RS-24 for Instructions.

(iJJ1I1I:

~Jill
Brake

p~dal

Connectlhe CONSULT and oper-

SB~~

Refer 10 SELF-DIAGNOSIS
RESUL TS and repair

ate it Read the "SELF-DIAGNO

SIS RESULTS"
RS-22 ,

-----~

r - - - - - - - - OR
I

r------------

Reier 10 the number

warning lamp flashes
Repair as necessary,

~ Diagnosis using wa<nlng lamp

~) (Refer to page

OJ

(Reter 1o page

AS24 )

It
f.t

"-------------

Diagnostic Procedure 2
SYMPTOM: "AIR BAG" warning lamp does not come on.
, Check 7 SA fuse (No

'
l

~.

localed in

NG

Replace the !use----]

fuse block)

Broke

pedal

--~--

-----

Connect the CONSUL r

~NG
~ unil and begin diagnosis,
.Is AIR BAG" displayed on

Replace rhe diagnosis

sensO' unit.
L-

the CONSULT screen?

-------F----

L' (~

Read the SELF-DIAGNOSIS

NG

~) AESUL TS

--fK
-1~

'S-r-<O'\-,--C-h-eC-k-t-h-e warning

e---------r~

~ NG

~,
~

ness GOnnecliofl

Replace the dIagnOSIS sensor

uno!

--~

RS-27

~.

lam~~~acethe harness

K- - -

/6

,~If!;

--------

r; Check the warning lamp bulb.

L-=-.

Reter /0 SELF DIAGNOSIS]

t:lESUL TS and repair

I
;gtf

I.;, ,

TROUBLE DIAGNOSES -

Supplemental Restraint System (SRS)

Diagnostic Procedure 3
SYMPTOM: Warning lamp does not go off.

Ellie

air bag module deployed?

~ Re~-;;;;'he air bag

--r~------

r~eCk lOA
~

3,

fuse No,

and 7.5A fUi>e

'--u_le

mod---J

Replace the fuse

NG

Replace Ihe

@lL.,'---------

-yT

::J

Connect the CONSUL T unit and

~)

operate II
Is "AIR BAG" displayed on

d;ag(lOS~

sensor unl(

-J

the CONSUL T?

~-

!4 ~
I ~

~
~

Read the

RESULTS

SELF-DIAGNO~ISNG
OR--

.~eler to the warnIng lamp self-

~J diagnosis

NG
~----

0K

1 ----

Check the harness connecflon

L~ne_c_e_s_sa_r~

the diagnosis sensor unit

.'."'"
Ih. "'9 ';' """'
ur"t

-----

RS-28

_l

.--~,R_ eplace the h;,~J

between rhe warning lamp and

16 tiii\
~

Refer \0 Ihe warning lamp

flashing times and repair

TROUBLE DIAGNOSES -

Supplemental Restraint System (SRS)

Collision Diagnosis
To repair the SRS, perform the following steps
When air bag deploys In a collision:
cD Replace the diagnosis sensor unit
(?> Remove the air bag modules and seat belt pre~tensioners
@ Check the SRS components uSing the table shown below
Replace any SRS components showl{)~ visible signs of damage (dents, cracks, deformation)_
@ Conduct self-diagnosis. Refer to "Self-diagnosis" far details (RS-21). Ensure the remainder of the
SRS is operating properly.
~ Install new air bag modules,
I.J Conduct self-diagnosis again.
When air bag does not deploy in a collision:

CD

Check the SRS components using the table shown below:

Replace any SRS components showing visible signs of damage (denls. cracks, deformation)_
Conduct self-diagnosis Refer to "Self-diagnosis" for details (RS-21). Ensure entire SRS operates
properly

SRS inspection
Part
Air bag module

Air ba<l deployed

REPLACE

(dr;ver and passen-

Install with new

ger Side)

bolls_

Air bag did NOT deploy

1 Remove a" bag module_ Check harness cover and CDnnectors tor damage.
termll1als lor deformities, and harness for binding
Iflstall driver air bag module into Ih~ steering wt'eel 10 check rtt and align-

2-1

ment with the wheel.

2-2 Install passenger air bag module Into the instrument panel to check fit

With Ihe Instrument panel.

3 No damage found. reinslall with new bolts

,-----Instrument panel

-+-=-=,------~==------+_4-'-------'It'---d=-:a"-'m.:.=.ag;z:e::..:d::...----'---Rc:::EPLACE
Air bag mu~t be deployed before discardll1Q_
REPLACE
I 1 Check Instrument panel for bending, deformities. or cracks_

,Install with new

2 If no damage IS found, reinstall with new bolts

_ _ _ _ _ ___ ~ " - -__-----1----'3:::-----'I-'---f.::.doo.am=il:JIl.ge:::d"--.------'-R"'E'---P..::L-'---A"'C:.:::E'----Seat bell pre-lenREPLACE

1 Remove seat belt pre-lensioners
sioner assembly

Inslal! With new

Check harness cover and connectors for damage, terminals lor deformities,

I bolls

;:Ind harness for binding

2 ChE'Ck bel'!s

Chec~

-1 II

'ar damage and anchors 'or loose mounting,

relractor for smooth operation

no damage is lound, reinstall wilh new bolts

5 If dama ed-REPLACE_
DiagnOSIs sensor

REPLACE

1 Check case and bracket lor dents, cracks or deformities,

unit

lostall with new

2 Check connectors for damage, and terminals tor deformities

3 IJ no damage is lound, reinstall wilh new bolts,

bolls

_ _ _ _ _ _ _ ~ 11 damaged-REPLACE,
_
1 Check harness (buill miD sleNing wheElI] and connectors for damage, and terminals for deform i-

lies

2 Install air bag module

to check

fit or alignmel'\t wi1h steering wheel

3 Check steering wheel for excess've free play

4 If no damage is found. reinstall wllh new bolts

_ _ _ _ _ _ _-+-=5.. ---:1--':-'--=d-=-a:..:..ffic::a"'9-=-e=--d-_-_R.:.=E:.:..P..::L-'---A:;:C:=E'----SpIral cable

1 Visually check lock (engagem-en1)

pinS

and combination switCh 'or damage

2 Check connectors, f1al cable and prolec!lve tape lor damage

J Check steerll1g wheel for nOise. bindll1g or heavy OpNal.on

4 If 00 damaglJ is found, remstll.'l With new bolls
Harness and Conneelors

5 II damaged-REPLACIO
1 Check con"ectors lor pmi-;-connecllon. damage. and termll1als for deform.ties,
2 Check harness lor bll1d,ng, cha'lI1g. cuts, or deformities
3 If no damage '5 found_ reinstall
4 Damaged-REPLACE damagt'd section of harness Do nol attempt to repa", splIce
SRS harness

RS-29

<Jr

modify any

I.:",

CONTENTS
GENERAL SERVICING .. , '
""." .. ,2
2
Precautions,
Supplemenlal Restraint Syslem (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER",
2
,3

Clip and Fastener.

BODY END ..
Body Fronl End
Body Rear End and Opener,
DOOR
Door Glass Fitting Adjustment.,
INSTRUMENT PANEL
INTERIOR TRIM,

6
6
,8
,,10
, .. 11

, , 14

EXTERIOR TRIM

* For seal belt. refer to MA and RS sections.

17

,22

* For body eleclrical systems, refer to EL section.

SEAT
Front Seat..,
Rear Seal,.,
SUN ROOF .. , .. "." ..... " ...
WINDSHIELD AND WINDOWS
Windshield and Rear Window
Side Window,
DOOR MIRROR.,
..
FRONT AND REAR AIR SPOILER
Front Air Spoiler
Rear Air Spoiler
BODY ALIGNMENT
Engine Comparlmenl
Underbody

27
27

',1

30
31

35
35
36

... 37
38
,38

38

39
39
41

'..'1"1

;','r

1\

GENERAL SERVICING
Precautions

When removing or installing various parts, place a cloth or padding onto the vehicle body 10 prevent
scratches.
Handle trim. molding, instruments. grille, elc carefully during removing or installation 8e careful
not to soH 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, elc.), be sure to take rust
prevention measu res.

Supplemental Restraint System (SRS) "AIR

BAG" and "SEAT BELT PRE-TENSIONER"
The Supplemental Restraint System" Air 8ag" and "Seal Bell Pretensioner". used along with a seat
belt. help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The Supplemental Restraint System consists of air bag modules (located in the center of the steering
wheel and on the instrument panel on the passenger side), seat belt pre-tensioners. a diagnosis sensor unit, warning lamp, wiring harness and sprral cable Information necessary to service the system
safely is included in the RS section of this Service Manual.
WARNING:

To avoid rendering the SRS Inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inllal/on, all maintenance must be performed
by an authorized NISSAN dealer,

Improper maintenance, Including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system.

All SRS air bag electrical wiring harnesses and connectors are covered with yellow outer insulalion. Do not use electrical test equipment on any circuit related to the SAS.

BT-2

GENERAL SERVICING
Clip and Fastener

Clips and fasteners in BT section correspond to the following numbers and symbols
Replace any Clips and/or fasteners which are damaged during removal or installation
Symbol

Shapes

No

@i)

fJ

Removal &. Inslallation

T i cv

Removal:
Remove by bend Lng up with
f1al -bladed screwdrivers or
clip remover

f~r'
SBF302H

SBF:l61B ....

~-,

~
lfwT~' ~
'--

Removel:
R"mOV9 Wlth a clJp remover.

r---

SBFJOJH

@.D

fOi

@)

11

i?

S8F423H

Push

e
C:J

...

Push center pin to /

calchlng position.
(Do '101 remove
center pin by hilling 11.)

lr: T...

Push

.0.

Installation,

SBF1C11lE

SBF25BG

Removel:

11
BT-3

r~'
Clip

FInisher
""SFSISB

SBF636C

GENERAL SERVICING
Clip and Fastener (Cont'd)
Symbol

Removal & Installation

Shapes

No.

MBFS1911

MBf520e

RemDval:

SBF10dB

Remove1;
Type 1

C1l Then oeM up

.. (;t.~~~~
il"

Push

Type2

SBf653B

SBF9\4B

Removel:
Holder porhon of clip must be
~pread oul to remOve rod

SBf7668

BT-4

SAF7708

GENERAL SERVICING
Clip and Fastener (Cont'd)
Symbol

Shapes

Removal & Inslallation

No

Removal,
1, Screw out with a Phillips

<@i)

i f
~~r 8fp

~ 1

~
~/

~
SBF076B

screwdriver.
Remove temale
portion wIth (,
flalbladed
screwdriver [ ___~

~.

SBF992G
~

L-

,.1

",'1"f

, I'

'I

BT-S

BODY END
Body Front End

When removing or Inslal'ing hood, place a clOlh or other padding on hood. This prevents \/ellicle bOdy
rr om being scratched
Bumper fascia is made 01 plastic. Do not use excessive force and be sure to keep oil away from iI.
Hood ad: ustrnent Adj ust at hmge portion.
Hood lock adiustment: After adjusting. check hood lock control operation Apply a co.:!t (If grease to
hood locks engaging mecllanisnl.
Hood opener: 00 not attempt to bend cable iorcibly. Doing so 'lncreases ellart require(1 10 unlock

hood.

REMOVAL -

ill
('1
@
@

(f)

@)
@

Front bumper assembly

Remove DOlts securing bumper li:1scia to engine undercover.

Remove screws and clips ~ securing left and right sides of front fender protector Then remove
the front fender pr()lectof.
Remove clips @ill) securing Iront grrlle, then remove the front grrlle.
Remove clip ~ securing bumper fascia bracket to hood lock stay
Remove screws located at wheel opening.
Remove the screw securing each side of fronl cle>arance lamp Dsscmbly. then remove the front
clearance lamp assembly.
Remove the screw securing each side of front turn signal lamp assembly. Then remove the fron~ turn
signal lamp assemb:y.
Remove bolts securing each side of front fender bracket.
Remove nuts securing left and right Iront fenders to bumper fascia bracket
Remove nuts and bolls securing bumper assembly to fronl side member.
Extract bumper assembly,
Remove bolls securing bumper fascia bracket to bumper fascia.

m.

@
@ Disassemble bumper tascia and bumper fascia brack.et

BT-6

se

c.

.....

,~

MO~!S:~~\
,at hood

Adjust
mesl,e,., .1 a
0059

,otter
When

10 \ 5

sec\J'lT1~ ~ood

Ie

'

onl d)

m,... (003Q to

arJj\Js\rre(\(, ad usl 0

urnper

not till SInker "'us, 00(.1<, ertSLJre

~7t:'rHa;'

ronl End

pnmary 10 k

\
~~D~~:rl<po,,""'''
man lender.

ruboer

Body F

250.'61.25' '6
" ,
3.6,..6".630.6"'.147

II

does

l"'''\"'~ 1~~~'!lOn"'d at lhe

o~.'ale
IBtc~

1'1000

and ,.e~~,,~me,,' enSur. thai h(}()ll

'
r1 primary
Hood lock
ary locI<
seconaary
pr1>pe1..y.,gll>
hOoid"1l

r ~o:.:"",
or. th.n 5.0 n1m {O.H1 In}

t~:ent

8umpef ",11M' ad

Adjust so thai
\er>d..., <\t that '1m IS ahgnell with
appro. 2 m
e deflection i
'<JOb "' (008 in)
5
t:l mm (0 51 ,~;, ;ree neigh' IS approt,

IElum~(

I~{~"

<II
~

BT-?

Bumper
N.no (kg.",samb'
II Ibr rrlCunllng bolls,
m

"ul~ a~d

clIps

BODY END

Body Rear End and Opener

When removi ng or install ing trunk Iid, place a cloth or o~her padding on trunk lid _ Th is prevents
vehicle body from being scratched
Trunk lid adjustment: Adjust at hinae-trunk lid portion for proper :runk. liJ fit.
Trunk lid lock system adjustment: Adjust stnker 50 that it is In the center of the lock After adjustment.
check trunk lid lock operation.
Opener r.able do not attempt to bend cable L'sirlQ e~ceSSI\ie force
After installation, make sure that trunk lid and fuel filler lid open smoothly.

REMOVAL -

Rear bumper assembly

G) Remove
Remove
@ Remove
@) Remove
Working

trunk trim. Refer to "TRUNK ROOM TRIM" in "INTERIOR TRIM" for details. (BT-21)
clips csm securing rear panel upper to bumper fascia_
clips CS101 securing rear panel lower to bumper fascia_
bOlts from lower side of each side bumper
inside trunk, remove nuts securing left and right rear fenders to bumper fascia [i1
() Extract bumper assembly II) .

----_._------

\~~
\~/J :;;
L

Fuei ',lIer t'd

apul\er & control

(OJ

BT-8

Nm (kg-m. f1-lbl

BODY END
Body R ear End and 0 pener (Cont':i\d)---- .SEC. 843-850

i.L

8T-9

For removal of door trim. refer to "DOOR TRIM" in "INTERIOR TRIM" lor details (BT-19)
After adjusting door or door lock. check door lock operalJon.
SEC. 800803.805

Door g'.tu -topper

adjullmen!

Door

II'." slIb-channa' adlulIlmBnl

:- I~~

L
t

~/~13-16

~-t

(1.3 1.6, !I. 12\

~-,

"' 'Z

I~.-Door
~t6 .dlulIllNnl

~ .:~:u 28

(2.1 2.9,15 - 21)

i(OJ1t. --'~
1l~
15

(1

t 1.5, 8 -

____J

BT-10
_

(1.8 2.4. lJ 17)

~ N-m (kg'" Itlbl

---------.-J

.l;IJ.

__

r~~~
-_/~~

Striker adlustment

~\\

~:.,'1

~~~18.2..

..::::=rr~)

HI" ....,

Door Glass Fitting Adjustment

The door glass is properly adjusted using the following five
methods:
In-oul adjustment (at the glass waiSI)
[;] Fore-aft tilt adjustment
[!J In-out tilt adjustment (at the glass Upper slop)
1!1 Up-stop adjustment
Fore-all adjustment
NOTICE:
When adjusting the door glass, it is nol necessary to remove
the outside door molding.

~1':Vl

Adjustm_ent locations

Front

Adjustment standard clearance

SEC. 803
t - 5 (0.04 . 0.20)
Weatherstrip
Afttalner hoiller

A
Front

o - 3.5

Secllon A -

(0. 0.138)

=::=:j

~. Side window molding

-

Glass

Una. mm (in)

, --t-;5. 1.5 {O.1n 0.2'95)

Sec110n B -

B
SflfJ94HA

..

- ~ ~ _ _----~------

8T-11

8..

DOOR
Door Glass Fitting Adjustment (Cont'd)

m IN-OUT ADJUSTMENT (at the glass waist)

Outside moldmg with

outer stabilizer

1.

Raise door glass until glass stopper is in contact with inner

stabilizer, just before the window stops.
2. Loosen adjusting bolts
3. Lightly press door glass upper end outward so that glass
outer surface contacts outer stabilizer. With glass held in
that position, press inner stabilizer to glass inner surface
and tighten adjusting bolt.
CAUTION:
Make sure nap portions of stabilizers are clean and free from
011. grease, elc.

Dutstae

@) FORE-AFT TILT ADJUSTMENT

rm-;:nt

1- ::JrhV'OdY';d'
/L~W".""'"
r.~

Adjust door glass sub-channel so thal the adjustment standard clearances A - A and B - B (Refer to BT-11) are
obtained at the glass and retainer holder/body side weatherstrip locations.

Door glass
sub-channel
MBF500B

r~u 2:J
R~

~<}

Upward
Door 111118& aub--chllnnlll

I
[!J

:' Correct

For sub-channel adjustment procedures, refer to figure at

left as a guide
CAUTION:

Make sure door glass sub~channel is horizontal.

The fore-aft tilt adjustment musl be made at the same time
the fore-aft adjustment II Is made.

Downward
~

.&

' Incorrect
MBF501B

l!I

IN-OUT TILT ADJUSTMENT (at glass upper stop)

1.

Adjust door glass-Ie-holder clearance to 0 to 3.5 mm (010

0,138 in) (A) with the adjusting bolts
CAUTION:

Turn adjusting bolt clockwise 10 move door glass upper

end outward,

Turn adjusting boll counterclockwise to move door glass

upper end Inward.

For sub-channel adjustment procedures, refer to figure at

left as a guide
CAUTION:

Make sure door glass sub-channel is horizonlal.

The fore-aft lill adjustment must be made at the same time
the fore-aft adjustment ~ is made.

BT-12

Door Glass Fitting Adjustment (Cont'd)

I!J

UPSTOP ADJUSTMENT

Adjust panel stopper height so that clearance at upper

edge of door meels the adjustment standard clearance
A - A (Refer to BT-ll). Make sure front and rear glass @/
stoppers lightly contact front and rear panel stoppers. then
tIghten adjusting nuts.
If stoppers do not contact each other, adjust sub-channel
nut. Refer to "fi] Fore-aft tilt adjustment",
Open and close doors to make sure upper end of door
glass does nol contact holder.

lower panel side

slopper [Upper
end of door glass
moves downward I

2.

Adjusting nut /

3
Glass s,de
stopper
(Front. Rear)

[;J FORE-AFT ADJUSTMENT

Fronl~
<:: ,./\,'

QRear

3
55.

loosen
Jock nuts

then adjust.

Gu><le (ail

L.----______

MBF!;04B

Adjust guide rail in lhe fore-aft direction so thai when door

is closed or opened the clearance between upper edge of ~(G
door glass and holder conforms to the .adjustment standard clearance A - A (Refer to 8T-11).
2 If ouler perimeter of door glass interleres with holder when Fia
door is opened or closed, refer to "Ii) Fore-an tilt
adjustment" for procedures.
CAUTION:
When loosening guide rail lock nut, prevent adJusllng bolt
from turning by holding It with a standard screwdriver.

3.

Lower the glass slightly until the glass side stopper comes
off the panel side stopper.
CAUTION:
Do not lower the glass excessively.

~ 1lI~CoN.O'' '!
Glass s,de stopper

After completing door glass adjustment, rellghten all lock

nutS.
CAUTION:
While lightening lock nuts, hold adjusting bolts using a standard screwdriver to prevent them from turning.

flat -bladed

...

" ~""~

~~~'(,
M8FOIlO.l\

BT-13

INSTRUMENT PANEL
CAUTION:

Disconnect ground terminal from battery in advance.

Disconnect air bag system line in advance.

Never tamper with or fOfce air bag lid open, as this may adversely affect ai, bag performance.

Be careful not to scratch pad and other parIs.

REMOVAL -

Instrument panel assembly

Audo &

A/CCO~

Remove air bag module (driver] and steenng wheel Rerer to "' SlJPPI F.
MtN" A\. RESTRAINT S'iSTEM"' In AS secl,on lor de\~lls

(D SIl?~Tln9

-------------'---------

column cover and comlJlnalloll sWlIcn

AemOlle scr(!W$

'----~-_-_-----TI-------------~--

I~
1

A,'T iinisher or MiT shiH

In.l,um,,,,' low,,'
side

~r

\~er bools

On drive'

Remove screws

I'@ Instrumen! lower reinforcement

1_
<ID

Remove

bol'"

Cluster lid A
Remoll'! screws :hen disconnect harness conneclors

~~ ~nTlbH'\al.. t:<n mmQf

Remove .crews then disconnect harness conr>eclors

r----

- - .- - - - . " - - - . _ - - - -

Ceol@r ve,,"ilat;orl assemblt

P,J II oul wah a r1all>laded sc' ewdflver_

~oo

--~~

-- -----==c
(!'i Ale or healer conlrol
Rp,movp. ,,-:rf'wc;.
---r-l~--~~-

Glo~e bo~ ~;sombly

Hemove serews

BT-14

Glove box

SEC. 241l.487680685969
~[!

~~
~~~
l.~

~t

iJ"E

,t11jn
/~'.~!

,~l}

,l'ffi!,

ll'sl'umel'll panel

ass~mbty

flIOUrltlnq bolts and nuts

f.l.t~\

pj~

~T

rl~
Mell.' cUp

INSTRUMENT PANEL

MBr52~B

8T-16

INTERIOR TRIM
SiDE AND FLOOR TRIM
CAUTION:

Wrap tl1e tip of f1albladed screwdriver with a clolh when removing metal clips from garnishes.

REMOVAl- Body side trim

(f) Remove front and rear seat Refer to "SEAT" tor details (8T-27),
Remove dash side finisher,

Remove kicking plate.

@ Remove front pillar garnish.

@) I1cmove rear side finisher.
Remove rear pillar finisher,

Remove rear parcol shelf

welt. Refer to "TRUNK ROOM TRIM" for details (8T-21)

Remove seat back finishers (Right. Center, Left).

Remove seat back finisher

BT-11

~,:~1r/~~1J. IJ-~~
<:::>
.-~ J
-r.-.-.-I

Heater un,i

~
~

-~--

f-------, _
Carpe

Instrument pan",1

BT-18

-_

DOOR TRIM
REMOVAL - Door trim
[l Remove screws securing inside handle escutcheon, then remove the inside handle escutcheon

m'

m.

Remove power window switch

@ Remove screws securing door finisher
@ Remove clips (@ securing door finIsher,
Pull door finisher to remove clips @) and metal clips [!J from door panel and remove door finisher Disconnect harness connectors,
Remove ventilator grille and ventilator duct assembly from door finisher I!]
SEC. B09

@ir,

~liI/~,

~11t!l

vc;

'---------------- '-------_._----- '-------------

81-19

TRUNK ROOM TRIM

SEC 799849

Well

~J

8T21

Mel.1 clip

MBF449B

BT-22

EXTERIOR TRIM

rID @

(1) Windshield upper and side molding

Cowl top grille and hOOd rear

sealing rubber

SEC. 660

Method 1

~;-:v

~\~c,~''''''"
Appl~

/~~~--

LCOWIIOP~@ /~
.

..

<I>

~J~/~''''

,ulan, to top pOll,on 0/

mold,ng

Cut all low~t jlO't,on

of new mold."~

MBF450B
------.J

...

@.

Hood fronl sealing rubber

SEC. 650

F HUlk well 10 gIve it a

good i!lppearanc.e

Method 2

1. Cut off sealant at glass end.

2. Clean the side on which panel was mounted.
3. Set molding fastener and apply sealanl to body

'~:. T

panel. and apply primer to molding and body.

- Doublebee<!
lIdhe"Vi! tape
MBfJ5111

Install molding by aligning the molding mark

located on center with vehicle center.
Be sure to install tightly so that there is no gap
around the corner.

(~

Body side well

SBF'6\F

Outs,(l~

MBF452B

IG.

BT-23

EXTERIOR TRIM

,..,
I.U

I
@ Body side
.
weath erstnp
. and
atner
SEC. 766
weatherstrip ret .

Retainer

w""

~~o.m,

\:

Body sIde
weatherstrip

MBf45J8A

BT-24

....

EXTERIOR TRIM

Door weatherstrip

Before removing door weatherstrip, remove door

trim Refer to "DOOR TRIM" lor details (BT-19).

Rear panel finisher

SEC, 265

SEC. 800

If

L-

MBF4s.tB

Back window upper and side molding

(SEC. 797)
Basically the same as windshield upper and side
molding

@ Back window lower molding (SEC. 797)

It is mounted with screws,

@ Trunk lid weatherstrip

'
1

" / Trunk I'd

,'"wealtlerSlr,p

~O

Butyl
seal

MBF456BA
_

@ Sun roof lid weatherstrip

SEC. 736

l:t~l

Body panel
MBF<!S7BA

p:o:

EXTERIOR TRIM
@

Rear combination lamp

------------------- ------

,com ~ ",

I
l
I

Heal gun

~~-

~-~---<;'~- (\\\'\ ~~

~~

jllm~\\(LJ
~~~-"-\1~ I \
-----------:::

----

L,.'....
)

()l

Butyl seal

II

Wnrm up lamp lISJembly a"'8 to a tempereture n IIttl"

'0

Apply butyl seol evenly II tellds 10 b.. "om~ thin I" th ..

corner._
Warm up ramp lIllSembly nrea to s temperature a lillie
below 60"C (HOOF).

,'wo.

MGf459B

@ High-mounted stop lamp

81-26

.
carefully han die it to keep dirt out an d avoid damage.
.
the seat trim.
or installing

.
von

When 'emo

Front Seal

SEC. 870

,I

L.-=r
t

L_-----~~
BT-27

r:oJ ',(4. .S:~ ..u, 32 - 41)

43

Front Seat (Cont'd)

Remove retainer from lower side of seatback with fingers

MBF494B

Roll up seatback trim all the way to gain access to headrest

holder pawls Disengage and push headrest holder pawls to
unlock holder lift off headrest holder.

[-~_-

MBF495B

8T-28

Front Seat (Cont'd)

HEATED SEAT

When handling seat, be extremely careful not to scratch healing 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.
--,'--- ,---,---'--"---/

Se~tback trim ~"d

~~

pad

Trim lemperature

0C (oF)

Increasing 10

DecreaslIlli' 10

35 ' 45

2535

/95 \131

(77 " 95)

Turns OFF

Turns ON

f-----

Thermos18t operation

(C!L.

ijIT
MBF332B

DiY

* For Wiring Diagram, refer to "HEATED SEAT" In El section.

~m

,r$).

~&:

~I~J

~'jj'

'R1~

BT-29

Rear Seat
SEC. 880

Striker installallon

Nom (kg.m, 1llbl

MBF461 SA

BT-30

SUN ROOF

* For Wiring Diagram, refer 10 "ELECTRIC SUN ROOF" In EL section.

ADJUSTMENT

Inslall motor & limit SW assembly and sunroof rail assembly in the following sequence:
1.

2.
3.
4.

6
7.
8
9.

Arrange equal lengths of link and wire assemblies on both sides of sunroof opening.
Connect sunroof connector to sun roof swi tch and positive ( +) power supply.
Set lid assembly to fully closed position
by operating OPEN switch and TILT switch.
Fit outer side of lid assembly to the surface of roof on body outer panel.
Remove motor, and keep OPEN switch pressed until motor pinion gear reaches the end at its rotating range
Install motor.
Check that motor drive gear fits properly in wires.
Press TILT-UP switch to check Iid assembly for normal tilting.
Check sunroof lid assembly for normal operations (tilt-up, lilt-down, open, and close).

SBF92QF

81-31

SUN ROOF

After any adjustment, check sun roof operation and lid alignment.

Handle finisher plate and glass lid with care so not to cause damage_

It is desirable tor easy installatIOn to mark each point before removal.

CAUTION:
Always work with a helper.
r

Link and
I aSSembly

w"~=:J

Sh ada

Sun rool trame

as~embly

L,d assembly

assembly

--=r==

~ass I'dup

___------'-

==r=___

(1) S'oe trim

Rl>mol/e s'de t'lm clIps

------..-J-_ _
- _~-_-====:r=

~-sun

'001 11<1 mour.1 nvls

==r==----~

----

l~emb\Y

=r=

I ~)

Aaa! dram moun! screws

[,~

Reay d/ain

-==r=

-----r==--------=r

assen\~ly

~~e sun rool switch to 1"1 glass lid down

i IID

==r=

:=r:::=-------,

--==::L

~_=r==

-----=r:=

..::::::r=

====:I

_ _------'1

Shade assembly

_
]

==r=

Sun ,oat switch/,nl""", accessories/headlining

ReIer to "ROOF TRIM \IH-20)_

===r:
I

(7)

MOlor sw,tch

b'ac~el

--=r:::::==
I~

--==::L

Molor assembly

[\ID w,nd~w

-----=c=J om----._----.

dellector hO-ld-e-r

---J------

L!:

Wmdow deffeeln! moun! sCrew

--J

-~----r--

W",dow deHector assembly

l: Dra~~s=-=-~
@

~:i)

'Rl

(15\ GUide

'ii) Rear

Sun 'oaf frame assembl)'

-=r=.

~,nk

I
I

'IO"P~

g~l

~-----.::r

I _

==-r=-

,-----c==
'I

=r=-

Sun roof un,l b'aLk"il

~----l

and w""
. ;ssemblV

---J

1.---------

BT-32

SUN ROOF

SEC. 264 736

1m.
o

t
F'on\

1f
I

.!h-~~

~C~ ,~ "J

~,--

-- Gu!de Slopper @

Rea' gUide@

SBTOO)

BT-33

I (1';"

SUN ROOF

m Using flat-bladed screwdriver, pry shade assembly holder

011 rail Then pull shade assembly forward to remove it
from rail

mDisengage pawls trom rail, then remove window deflector holder.

mUsing flat-bladed screwdriver, pry stopper spring off rail

groove. Then slide rear guide backward to remove it from
rail,

mRemove wire and link assembly from rail while pushing

link back with flat-bladed screwdriver,

t.1BF493B

BT-34

REMOVAL
After removing moldings, remove glass.
CAUTION:
Be careful not to scratch glass when removing.

INSTALLATION

-I/O
J

, ',\.',
/

\''\\

SBFOJ48

--------

Use genuine Nissan Sealant kit or equivalent. Follow

Instructions furnished wIth It.
After Installation, Ihe vehicle should remain stationary

untH Ihe sealant hardens.

WARNING:
Keep heal and open flames away as primers are flammable.
CAUTION:
Advise users not 10 drive the vehicle on rough roads until
sealanl has properly vulcanized.

Do not use sealant which Is past its usable term.

Do not leave cal1ridge unanended with its cap open.

Keep primers and sealant In a cool, dry place. Ideally, they

should be stored in a refrigerator.

Molding musl be installed securely so that it IS in position

and lea\les no gap.

~E

Windshield and Rear Window

Inslall dam rubber.
Windshield

1\

1==f~

'
);j

DMh upper panel

8 - 9 (0.31 - 0.35)

~j..

~j

~.~

~,~'II

8. 9

8 - 9
\
(0.31 - 0.35)
Joint portion

Glass

Rear wlndow

61~

f=

(0.31 0.35)

@ J o i n t portion

425 (16.73)

'iDS (15.94)

Reef wlndow
B
- 9 O.JS) ~eh'c1e center
(0.31

8(0.31
. 9 0.35)
Tjehicle
8 _ 9cenler

(0.31 - O.35)

Dam rUbber~GlaSS
Double/aced adheswe tepe-

8 9

Body panel

(0.31 - 0.35)

Unit: mm r,nl
Apply sealant 8enly.
WIndshield end rear wlndow

Inslall molding lastener.

When installing it. heat body panel and
fastener 10 approx. 3(J to 40C (86 10 104FI,

3f ~7
- 8 (0.28 - 0.311

Upper & side molding fasteners

.e
~

vF8SIener

Dam rubber

....

panel~

~"

)!.:.>

I-

Glass

:>:::._~

Doublefaced adhesive tape

~

MBF4638

Unit mm lonl
MBF464B

REPAIRING WATER LEAKS FOR WINDSHIELD AND WINDOWS

Leaks can be repai red WI thoul removing and rei nstall ing glass,
(fti:l
If water is leaking between caulking material and body or glass, determine the extent of leaking. This
can be determined by applving water while pushing glass outward.
To stop the leak, apply primer and then sealant to the leak point.

81-35

WINDSHIELD AND WINDOWS

Side Window
SEC. 830

Seiliant quantity

ill:
12 -

1~

-r--=r---

c-

7 8

lQ.26 . 031~ Umt: mm (in)

BT-36

DOOR MIRROR
*For Wiring Diagram. refer to "POWER DOOR MIRROR" In EL section.
CAUTION:
Be careful not to scratch door rearview mirror body.

REMOVAL -

Door mirror

CD

Remove door trim HeIer to "OOOR TRIM" in "INTERIOR TRIM" for details (8T-19)
Remove inner cover front corner of door fi1 .
@ Disconnect door mirror harness connector.
@ Remove harness clips
t]) Remo\le three bolts securing door mirror, Illen remove door mirror.
SEC. 963

~-==::::=:::=:::--

Remove

Wlap nal-hladllo <:J scre....driver "";ltl a cloth to

pr81lent seratchilly ,ea, 0' door mirror. 00 no!
insert screwdriver too tal

91-37

FRONT AND REAR AIR SPOILER

When installing, make sure that there are not gaps or waves at ends of air spoiler.
Before installing spoiler. clean and remove oil from surface where spoiler will be mounted.

Front Air Spoiler

SEC. 960

Rear Air Spoiler

SEC. 960

\~-

-~

~ lt~~o
,~ ~~
~::

I,

~
~~~~~~J

--

\ (e-Y)
\\...-.-:: ...-:::::--

V'~"'~~l7

""J~

-Double-faced adhesive tape

BT-38
2

Sealing 'ubbe'

BODY ALIGNMENT

All dimensions indicated in figures are actual ones.

When using a tracking gauge, adjust both pointers to equal length. 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 C") 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",

z
(+)

Imaginary base line

"Z": Imaginary base line
[200 mm below datum line
("Or at design planl]

C@ : LH

sIde

CffiD : RH side

/H

:'C. ~,

Front ule center

(0)

Engine Compartment

MEASUREMENT

II
623

Unit: mm

L-

MBF376B

._-----.---.--------------

BT-39

BODY ALIGNMENT
Engine Compartment (Cont'd)
MEASUREMENT POINTS

Unit: mm

----

--

Front

Radiator core support upper

and side

@ /

MBF473B

Radiator core support lower

7 die.

_-------~--I
o
0

ii:'
8

1_

,H, . .

dl,l._--L._---'--

----...--

MBF471 B

BT-40

__ 1--------------

BODY ALIGNMENT
Underbody

MEASUREMENT
...

IG
Q)

a:

jy

.i:

CD

c(

---1

::)

350
350

350

g\~:

~~,

2&3
805

@(~'

@(ci:!

-:- L'

,-

(102)
115

154

104

6)(:3
C~l

@r)

Q)

..

...J

_-+----73-1__ (~} .

255

@(~:'

..

0>

~
....

co
u:

co
u:

M8F375B

BT-41

(-

BODY ALIGNMENT
Underbody (Cont'd)
MEASUREMENT POINTS
Rear

Front
coordi nates:

Rear
coordinates:

@,@

@
G ..m
ID

X : 378
y : --635.5
Z : 214.5

X : 422.5
: 1,650
Z : 103.9

@, (~)

@,@

X : 185.3

X : 564

: -630
Z : 179

: 1,900

Z : 154

@,(C)

G),CD

X : 370

X : 540

: -196.5

Z : 254.9

: 2,100
Z : 115.2

@.@

X : 384.2

Z : 254.9

X : 308
: 2,690
Z : 262.8

@,@

: 32

X : 380
y : 510
Z : 106.2

X : S40
: 2,955

Z : 350

.(D

CD

X : 420
; 1,150
Z : 106.2

RH side

c)

: soo

: 2,955
Z : 350

X : 580

y : 3,245
Z : 350

@
X : 530
y : 3,250
Z : 350

Front and rear strut tower centers

~-w-,
Coordinates:

,(PJ
X : 545.1
Y
Z

: 63.6
: 730.9

@.@
X : 479.8
Y : 2,608
Z : 804.6

Front:
Rear:

. @
@.

82.2 dl.
66 die.

Unit: mm
Front
MBF477BA

BT-42

HEATER &
AIR CONDllllONER
@f

SECTION

HA ~j2

CONTENTS
1=

.1

MANUAL AND AUTO

L __

TROUBLE DIAGNOSES
-...--J

... 3

PRECAUTIONS AND PREPARATION

Supp Iemental Res tra; nt Syste m (S RS) "A' R

BAG" and "SEAT BELT PRE-TENSIONER" ....... :.... 3

,.. 76

Contents

Wiring Diagram -

A/C, A -

127

Overview of Control System

Control System Input Components

COlltrol System Automatic Amplifier (Auto

General Refrigerant Precautions

Precautions for Refrigerant Connection

amp.}................
Control System Output Components

Precautions for Servicing Compressor

Special Service Tools

5
,

Precautions for Service Equipment

"

DESCRIPTION
Refrigeration Cycle

'

Component Layout..

10
10
,

Discharge Air Flow

'-_-------=:1-

"

..

_ _ _~J
DESCRIPTION
Introduction
Features

Control Operation

13
13

'

TROUBLE DIAGNOSES
Contents
Wiring Diagram Wiring Diagram -

12

c=~- ::=J

MANUAL

DESCRiPTION.......
Control Operation

..
,........

14
14

..

HEAT A/C, M _

AUTO

11

37
.45

:===J

72
72

.
,

--

72

73

'------_ _-----.J:I

.Ic;t

104

SYSTEM DESCRIPTION

Precautions for Working with HFC-134a (R134a)

HFC-134a (R-134a) Service Tools and

Equipment

76

127
128
...130
130

MANUAL AND AUTO

SERVICE PROCEDURES

"

"'-,
~'r.;

-:;/~".

"

138
138

HFC-134a (R-134a) Service Procedure

Maintenance of lubricant Quantity in
Compressor.........................................
Refrigerant Lines

C ompressor M ountlng
Belt Tension

~j
.

140

142
4
14

~~~;

144

Fast Idle Control Device (FICO)

"
144
Compressor - Model DKV-14C (ZEXEL make) .. 145

c---~

l-I~_~~-==:J ~~~~

MANUAL

SERVICE PROCEDURES
..
Overhaul - Push Control Unit Assembly ..

Disassembly

'---------

--JI

--

MANUAL AND AUTO

SERVICE DATA AND SPECIFICATIONS (50S).

General Specifications..
Inspection and Adjustment

... 148
148
.148

=:=J
149
..149
149

f{L

CON-rENTS

(Cont'd.)

When you read wiring diagrams;

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

Supplemental Restraint System (SRS) "AIR

BAG" and "SEAT BELT PRE-TENSIONER"
The Supplemental Restraint System "Air Bag" and "Seal Bell Pre-tensioner", used along with a seat
belt, help 10 reduce the risk or severity of injury to the driller and front passenger in a frontal collision.
The Supplemental Restraint System consists of air bag modules (located in the center of the steering
wheel and on the instrument panel on the passenger side), seat belt pre-Iensioner, a diagnosis sensor
unit, warning lamp. wiring harness and spiral cable Information necessary to service the system safely
is included in the RS section of this Service Manual.

'11

WARNING:

To avoid rendering the SRS inoperalive, which could Increase the risk of personal injury or death
In the event of a collision whIch would result In air bag Inflation, all maintenance must be performed
by an authorized NISSAN dealer.
Improper maintenance, including Incorrect removal and Installation of the SAS, can lead to personal
injury caused by unintentional activation of the system.
All SRS air bag electrical wiring harnesses and connectors are covered with yellow outer Insulation. Do not use electrical test equipment on any circuit related to the SRS.

L":,

Precautions for Working with HFC-134a (R-134a)

WARNING:
CFC-12 fR12) refrigerant and HFC134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor failure is likely to occur.
Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC134a (R-134a) components. If lubricant other than that specified is used, compressor failure Is likely to occur.
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, Immedlatefy cap (seal) Ihe 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
lubricant. Without proper sealing, lubricant will become moisture saturated and should not be
used.
d: Avoid breathing AIC refrigerant and lubricant vapor or mist. Exposure may Irritate eyes, nose
and throat. Use only approved recovery/recycling equipment to discharge HFC134a (R-134a)
refrigerant. 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 Ale System Oil Type S) to come in contact with styrofoam parts.
Damage may result.

l,r(

,L,"(

~i:~

General Refrigerant Precautions

WARNING:

~Ik.

~~

~1

f:i
~n

Do nol release refrigerant inlo the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
Do not store or heat refrigerant containers above 52"C (125 F).
~I_
Do not heat a refrigerant container with an open !lame; if container warming is required, place the
boftom of the container in a warm pail of water.
Do not intentionally drop, puncture, or incinerate refrigerant containers.
In, ':,:
Keep refrigerant away from open flames: poisonous gas will be produced If refrigerant burns.
Refrigerant will displace oll:ygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
Do not introduce compressed air to any refrigerant container or refrigerant component.
D

HA-3

;:5\

0'

- - - - - - - - - - - - - - - _.. _ - -

I
I
I

PRECAUTIONS AND PREPARATION

_' MANUAL AND AUT<U

Precautions for Refrigerant Connection

WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure In the system is
tess than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.

When the compressor is removed, store it in Ihe same position as it is when mounted on the car.
Fa II Lire to do so will cause lubricant to enler the low pressure chamber.
When connecting tubes, always use a torque wrench and a back-up wrench.

After disconnecting tubes, Immediately plug all openings to prevent entry of dirt and moisture.

When installing an air condilloner in the vehicle, connect the pipes as the final stage of the operation. 00 not remove the seal caps of pipes and other components until jusl before required for connection.

Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming Inside AlC (;ompanenls.

Thoroughly remove moisture from Ihe refrigeration system before charging the refrigerant.

Always replace used a-rings.

When connecting tube, apply lUbrIcant to portions shown in illustration. Be careful not to applV
lubricanl to threaded portion.
Lubricant name: Nissan Ale System Oil Type R
Part number: KLHOO-PAGRO

O~ring must be closely attached to inflated portion of tube.

After insertina lube into union unW O-ring is no longer visible, tighten nut 10 speCified torque.

After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect lhat line and replace lhe O-ring. Then lighten connections ot seat seat to 'he specified torque.
I

TorqiJe wrench

~/iJ).
/'
--_/.-

'\

.~.

1.~~71{

I
I.

,-~.

/)f-

Plug
SHA~?5DA

- - - - - - - - . _ - ------------------'

HA-4

Precautions for Servicing Compressor

Plug all openings to prevent moisture and foreign matter from entering.
When Ihe compressor is removed, slore it in the same position as It is when mounted on Ihe car.
,~u
When replacing or repairing compressor, (oHoIN lubricant - CHECKING AND ADJUSTING procedure
exactly. Refer to HA-140.
Keep fricllon surfaces between clutch and pulley clean. If Ihe surface Is contaminated, with lUbricant, ~:l~
wipe it
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 t\,~
installed, let the engine Idle and operate the compressor for one hour.
After replacing the compressor magnet clutch. app1v voltage 10 the new one and check for normal
operation.
l

0"

r:

Special Service Tools

DKV-14C mode1
TOOl number

Tool name

Descflpl10n

KVg9n1162

Removing shalt nul and cluler. disc

ClutCh disc wrench

NllS~

KIIS9232340

------------

Removing clutch disc

Clutch disc puller

Installing ;Ju\\ey

KV99234330
Pulley Installer

'it207

HA-5

PRECAUTIONS AND PREPARATION

HFC-134a (R-134a) Service Tools and
Equipment
Never mix HFC-134a refrigerant and/or its specified lubricant wit'" CFC-12 (R-12) rotrigerant and/or Its
lubrication oil
Separate and non-inlerchangeable service equipment must be used fer each type of ,'efrigerantl
lubricant.
Rp-trigerant container titting5, service hose fillings and service equIpment fittings (equipment which
handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134al This
is to avoid milCed use of the re1rigeranls/lubricanl.
Adapters that converl one size fitting to another must never be used: refriqerantllubricant contamination will occur and compressor lailure will resurt.
Tool name

Description

Note
COnUI;nPr ,olor" light blue

HFC-13-4a (R-134a\ refrigerant

Container marking HFC-134a (R-134a)

Filling size: Thread size

large CO'l\alner 1/2"-16 ACME

Type Poly alkyline glycol oil (PAG), type R

Nissan A/C System Oil

Appl<cal,o" HFC-134a (A-134a) vane rotar)'

Type R

compresscrs (Nissan only)

lubnclty. 40 mf (14 Imp tl oz)

NT197

Recovery/Aecycl'ngl

Funclion Refrigerant Recovery and Recy-

Recharging equipment

cling and Recharging

NT195

Electrkal leak deleclo(

Power supply
DC 12 V (Cigarelle lighter)

Mamiold gauge set (with

I,oses and couplers)

Identlfica tlOn
The gauge face indicates R-134a.
Filling size Thread size
1/2"-lb ACMl:

NT'9q

HA-6

[ MANUAL AND ~

PRECAUTIONS AND PREPARATION

HFC-134a (R-134a) Service Tools and

Equipment (Cont'd)
TOOl nome

Ocscripl1on

Note

Service hoses

Hose color:

High side hose

low hose: Blue with black stripe

tllgh hose: Reo wllh black stripe
utility hose '(811ow with black stripe or
green with bl2lck stripe
Hose lilting to gauge'
.1/2'16ACME

I nw sid hose
Utility hose

NT201

Service cOl/piers
High side coupler
low Side coupler

TX.2

Refrigerant weight scale

NT2tlO

Vacuum pump
(Including
valve)

'he isolator

Q
~i

&I
~

-----

For measuring of refrigerant

Filling size: Thread size
112'16

c:l

ACME

-~

_'~' cJ

"IT203

Hose filting to service hose'

Ml~ II 1 5 lilting i$ optional or
permanently attacl\ed

.. _--Capacity:
Air displacement: 4 CFM
Micron rating' 20 mk;'rom.
all capacity: 482 9 (17 Ol)
Fill Lng size' Thread size
1/2"16 ACME

~'~"

,';1,

HA-7

PRECAUTIONS AND PREPARATION

Precautions for Service Equipment

RECOVERV JRECVCUNG EQUIPMENT
Be certain to follow the manufacturers instructions ~or
machine operation and machirlP. maintenance. Neller introduce any refrigerant other than that specified into the
machine.

ELECTRONIC LEAK DETECTOR

Be certain 10 follow the manufactures instructions for tester
optJration and tester mainte"lance

VACUUM PUMP

Wjrnout isolalt>r valve

The lubricant contained inside the vacuum pump is 1'101 compatible with the specified lubricant for HFC134a (R-134a) A/C
systems. The vent side of the vacuum pump is exposed 10
atmospheric pressure. So the vacuum pump lubricant may
migrate out of the pump into the servico hose. This is possible when the pump is switcl'\ed 01/ after evacuation (vacuuming) and hose is connected to it.
To prevent this migration. use a manual valve placed near the
hosp.-lo-pump connection, as follows.

Usually vacuum pumps have a manUel isolator valve as

part of the pump Close thIs valve to isolate the servIce
hose from the pump.

For pumps without an isolator, use a hose equipped with

a manual shu\-olt valve near the plJmr end. Close the
valve to isolate the hose irom the pump

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 lubricant may mlgratB
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.

MANIFOLD GAUGE SET

Be cerlain that the gauge tace indicates R134a or 134a. Be
sure the gauge ,>et nas 112" -'16 ACME threaded connections
for service hoses Confirm the set has been used only with
refrigerant HFC-134a (n-134C1) and specrfled lubricants.

SERVICE HOSES
Be certain that the service hoses dispLW the markings
described (colored hose wl\h black stripe) All hoses must
include positIVe s"lut elf devices (ellher manual or au!OmatiL)
near the end of the hoses opposite the mani~old gauge.

HA-8

Precautions for Service Equipment (Cont'd)

SERVICE COUPLERS

M14 x 15 fltlnq

/
b;:5:

cl'lIO(la i

. Ale servIce

/'

I
valill

,,_ '

Ho~e may

be

J.~rrnim~nt''Y

anached to

Never attempt to connect HFC-l 34a (R.134a) service couplers

to an CFC12 (R12) Ale system The HFC-134a (R-134a) couplers will not Droperly connect to the CFC-12 IR-'2) system.
However, if an improper connection is attempted, discharging
and contamination may occur
Shut all va've ratatlon

- ,---C_Q_UP_le_'_1_ _--------'

'

,:_~[

Ale service valve

Open

GOllr1ter(;/ockwise

Close

AHA2130

REFRIGERANT WEIGHT SCALE

/ - I'letllgeral)\ t:on\~lf\"
(111'C 134a)

Hose Illllngs:
\/2"-16ACME

Verify thai no refrigerant olher than HFC-134 a (P-134a) and

!'.pecilled lubricants have been used with the scale If the scale
con!rols refrigerant flow electronically, the hose fiUinq must be
1/2"-16 ACME

1:[':
~'r::

/-

I WeIgh: scao1e

RHI\2140

.;.iJ1
CHARGING CYLINDER
Using a charging cylinder IS /lot recommended l1e'rigerant
may be venled into air 'rom cylinder's top valve when Iilling
the cylinder with refrigerant Also, the accuracy ol l he cylinder
is generally less than that of an electronic scale or of quality
recycle/recharge equipment.

,~"T
".r

f' ~I,

HA-9

DESCRIPTION
Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant flow is in the standard patttorn. Refrigerant 1\ows through the compressor, condenser
liquid tank, evaporator and back to the compressor.
'
The refrigerant evaporation through the evaporator coil is cDntrolled hy an externa'ly equalized expdn
sion valve, located inside the evaporator case.

FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specilied point. the thermo control amplifIer ;nterrupt5 lhe
compressor operation. When the evaporator coil temperature rises above the specification, the thermo
control amplifier allows compressor operation.

REFRIGERANT SYSTEM PROTECTION

Triple-pressure switch
The triple pressure switch is located on the Ii quid tank. 11 the system pressure pses or tails out of
specifications, the switch opens to interrupt compressor clutch operation Trinle-pressure switch closes
10 lUI n on the cooling fan and reduce system pressure.

Fusible plug
Open at temperature above 10S'C (221~F), theret>y discharging refrigerant to the atmcsphere. It this plug
is melted and opened. check the refrJgerant line and replace liquid tank.
z=) ~~~".pressIS6 c=::::::J ~;'dPressu,e

==:J ~~~~~p,esS\Jre wz::.l ~~;-preS5ure

t
Outside al/

11...-----~'jJ

1.~
_~- =/"'"~/~~r'.,,,,,'.====:= : :E: :~=:a, , po: : [: :;at~or~ ~! ~ "'-""'~
,1F~~~===~Condense.

..

Fusible

~Iug

---./

._________

. '...,'.
.

Uquld tank '.........

U
[x.paus\(}f\ \lmt,ve

T--'r;p'---le.;...--"--pr_e:..:ss:..::u_re.;...SWl~t_ch _ _.,

SHA5040A

I MANUAL

AND AUTO]

Com ponent Layout

SEC. 270-271. 272-273685

S,oe delroster duct

~.

f/l-Ie3ter un.'\

Inlake ul"\it

f"'

._'.

'1."-,
IHlAJT7F

HA-11

-i MANUAL

DESCRIPTION

AND AUT<Q

Oischarge Air Flow

Fool

....J

Foot end defroste,

BI-level

Oelrost",

'-'---~
-------.yJ

~_

(?) ---------./

(Il

-'

~---/./

To 'see

l~ To tcol
(3) To defroster
;.;

Wher, AECIRC !w'(ch is 0 ....

t"1,,,

FDr ..I, rio,", "II,

10 "Opl!r..tlone' Check".
"TROUBLE DIAGNOSES".

DESCRIPTION
Control Operation

L.".

~I

AHA]')'

FAN CONTROL SWITCH

This switch turns the fan ON and OFF, and controls fan speed.

MODE SWITCHES
These switches control the outlet air flow.
In "OEF" or "FlO" mode. the intake door is set to "FRI:SH"

The compressor turns on in the "DEF" mode.

TEMPERATURE CONTROL LEVER

This lever allows adjustment of the temperature of the outlel air.

RECIRC SWITCH
OFF posilion"
Outside air is drawn into the passenger compartment
ON posItion"
Interior air is recirculated inside the vehicle
REC1FlC is canceled when OEF or FlO is selected, RECIRC resumes when another mode is chosen

AIR CONDITIONER SWITCH

The air conditioner switch controls the Ale system. When the switch is depressed with the fan ON. the
compressor will turn ON The indIcator Jamp will RJSO light
The air conditioner cooling function operates onlv when the engine Is running.

HA-13

TROUBLE DIAGNOSES

MANUAO

Contents
How to Perform Trouble Diagnoses for Quick and Accurale Repair

HA-15

Operational Check. ,

,HA-16

Symptom Chart...

..

HA-18
,HA-?O

Preliminary Check ...

PRELIMINARY CHECK 1

(Intake door is not set at "FRESH" in DEF or FlO mode.)

...... HA-20

PRELIMINARY CHECK 2
(Ale does not blow cold air,)
PRELIMINARY CHECK 3

.. HA-21

{Magnet clutch does not engage in DEF mode.}

PRELIMINARY CHECK

.. HA-22

Ij

(Air outlet does not change.)

PRElIMINARY CHECK 5
(Noise}
__
..

..

...... ,HA-23

.. ........ HA-24

PRE'J.IMINARY CHECK 6

(Insufficient heating)
Performance Test Diagnoses

..
HA-25
.
HA26
..................... " .. HA26
"
HA-28
HA-28
,.. ,.,

.
..
,

INSUFFICIENT COOLING
Pet10rmance Chart ...
TEST CONDITION
TEST READING ' ...
Trouble Diagnoses for Abnorm81 Pressure

Harness Layout...........

"

..

.HA-33

..

Circuit DIagram -

Heater.

..

Wiring Diagram -

HEAT -

Circuit Diagram -

Manual Air Conditioner

..

."

Circuit Diagram -

Push Control Unit"

Wiring Diagram -

A/C, M - ' .. ,,'"

................ HA-36
HA-37

.
__

Maln Power Supply and Ground Circuli Check .....

Oiagnnslic Procedure 1
(SYMPTOM: Blower motor does not rotate.)

HA-2B

........... HA-29

__
__

.HA-43

..
.

__

HA-44

...................................HA-45
................................. HA-55
................HA-56

Diagnostic Procedure 2

(SYMPTOM: Air outlet does nol ch;mge.) .

Diagnostic Procedure 3
(SYMPTOM: Intake door doe:> flU! change in VENT, B/l or FOOT mode.) .....
Diagnoslle Procedure 4
,
(SYMPTOM: Air mix door does no! change.).
Diagnos.tic Procedure 5
(SYMPTOM: Bi-level (B/L) door does not operate.)
Diagnostic Procedure 6
(SYMPTOM' Magnet clutch does nol engage when Ale switch and fan swit,~h are Or..' )
Electrical Componenls Inspection
Control Linkage Adjustment

.... HA58
." ..... HA-60
HA~61

......... HA-63
..HA-64
HA-6B
HA-70

How to Perform Trouble Diagnoses for Quick

and Accurate Repair
WORK FLOW

r-

J --- ~terence -ite-~~

C_H_E_C-,----K_I_N

-_-_.

llSTEN TO CUSTOMER COMPLAINT AND CONFIRM BY

PERFORMING OPERATIONAL CHECK

(1,~"

Operational check
(Refer to HA-16.l

---

Symptom Cl'1a't IRele.

\0 HA-18)

WUCATE CuSTOMER ON
CORRECT OPERATION OF

svsnM

'------------INVESTIGAT E JlEMS

you

SHOULO CAHHY OUT

AElA TED TO EACH SYMPTOM.

r-----------------1-

----------'.~\

ELIMINATE GOOD S'r'STEM{S)/PART(S)

CHfCK MAIN POWER SUPPLY AND GROUND CIR-

CUITS

Di~\lnoSlil.:

Pr<J<.t!-

dure(s} (Reier 10
HA-56.)

ELIMINATE GOOD PMH/Sj/HAflNCSSiES)!

CCNNEC10R(SJ ELECTRICAllY

Circuit Diagram
(Refer to HA43 J

J_

Ma"LJnc~~=rlng

Maltu f1 ctlonlng
harnesslesll

Sy"plom Chart

[ReIer 10 riA lB.)

Preliminary Check
(ReIer to HA-:?O)

Main Power Supply and

Ground Circuli Check
IRetAr to HA-SS)
Harne~:5

layoul :neler to

HA-33)

'-----

partfs)

COl\neClor{s\

,..-

Electrical Comp~nenls
Inspection
(Refer to HA-68 I

IREPAIR

L-

C_H_E_C_K_O_U_i

HA-15

=:J

---,

:-'1,

Operational Check
The purpose of the operational check is 10 confirm that the
system is as it should be. The systems which will be checkec
are the blower, mode (discharge air), intake air, temperature
decrease, temperature increase and Ale switch.

CONDITIONS:

Engine running and at normal operating temperature.

PROCEDURE:

1. Check blower
11 Turn fan switch to t -speed
Blower should operate on lew speed
2} Then turn fan switch to 2-speed.
3) Continue checking blower speed until all speeds are
checked
4) Leave blower on speed 4

2. Check discharge air.

1) Press each mode switch.
.

~.

Ic!'~~~rE

~ 4=~==
r~ /-""""';.
l:=JJf
- - -.
~
0-'

,--=-_._--

.'

!lI-lAJ75F

Confirm that discharge air comes out according to the air

distribution table al left.
Re1e! to "Discharge Air Flow". "DESCRIPTION" {HA-12)
2)

Discharge air flow

Sw,tch model
indicator

....

:;"
.. J
Ifil).

....if

<W

Air oUllel/di~lribullo"
Face

FOOl

O,,(rmlu

100%

60%

NOTE:

Confirm that the compressor crutch is engaged (ViSUClI inspection) and intake door position is at FRESH when the DEF
~ button is pressed.
Confirm thallhe intake door posHion is at FRESH when the FlO
button is pressed.
Intake door position is checked in the next step.

fJ

40%

80%

20'"

60%

40%
100'X.

HA-16

Operational Check (Cont'd)

3. Cheek recire
1) Press REC di) s""i'ch
Recire indicator should illuminate.
2) Listen for intake door position change (you should hear
blower sound change slightly)
""1',

""'1
RHAJllE

4. Check temperature decrease

1) Slide temperature control lever \0 full cold
2) Check for cold air at discharge air outlets.

'.1,
RHAJI6E

5. Check temperature increase

1) Slide temperature control lever to full hot.
2)

Check for hoi air at discharge air outle:s.

RHAJ79E

6. Check air conditioning switch

Move the fan control switch to the desired (1 to 4 speed}
position and push the Ale switch 10 tum ON the air condi-

tioner.
The indicator lamp should come on when air conditioner
is ON.

'~,

RHA160E

------

"',

HA-17

Symptom Chart
DIAGNOSTIC TABLE
Main Power
Preliminary

Diagnostic

Supply and

Check

Procedure

Ground Circuli

PROCEDURE

Check

r
N

0
N

REFERENC~

4::

PAGE

4::
I

4::
I

4::

....

tr>
N

<l:

<l:

<l:

4::

""

'1>

1:

<'I

<"'l
<1J

....
<l:

CD

M
CD

CJ:J

:r:

.I:

:r:

<J)

CD

<l:

<l:

<l:

en

'"<l:

'"'"4::

en

'it

VI

Ql

'"

lL

l/)

I:

I:

tr>

<J)

4::

'"
lfl

4::

.I:

I
......

<"'l

'<T

lr)

-"
<)

-"
<)

.><

{i

10

{;

-5

>.

:>.

-"
u
:>.

>.

,g
Qi
a:

'

<)

(I)

~
c::

SYMPTOM
Ale does nol bloIN cold

Qi

a:

:>.

~
:~
Qi

a:

4ll

Qi

a:

to
..><

l)

<I)

>.

;;;

"0

e
0

Cu

:>

'0
III
0

D-

'"

I ~ I ~ ~e~
~

"0

o.

OIl

IJl

,~

~
,

a::

a:

0
0

CJ

','

05

d)

a,r

:;

Insulllcient haating

V;

0>
III

iii
Q

C.

o-

u
-~

c::

g'
C

i
0

,~

i7)

'llo

..

iii

(jl

1Il

lL

CJ

0
to

'"
::J

'"

r...:

u..

"2
c:
3

f'--

a..

fi

III:J

U1

.c.

'"
::J

,;)

Blower molor does not

rotate,

f)

AlF outlel does not change

"

C'

,~

, I-----

Intake door does nol

()

change in VENT, BIL or

FOOT mode,
Inlake door is nol sel al
"FRESH" in DEF or FID

(l

<J

mode
Air mil< door does nol
change

fJ

BI-Iellel door does nol

change,
Magnet clutch does not
engage when Ale SWitch

and fan switch are ON

Magnet clutch does 1'101
engage

In

DEF mode,

,'-)

8
0

Noise

O. f)
/'j

\--

.,-f--

The number means checking order

Checking order depends on malfunctIOn

H)

E'ilch tlow chart

' ,

,"

"""
to

_I

i
-,

~)

- I

'I

,!

I
:

h'l

A1r m,x cloor mOlor

BI-LEVEL [SILl door motor

Ale relay

' ,; I Triple-pressure

i
1

I,

i -

cloor motor

:..

Fan sWitch

Inta~e

sWitch

,-

I Corrpressor

Compressor (Magnel clulch)

T
'-

:-

'.:

'J

""J(
_

-=:...c.)

-~:

,1::,

~!~

~nl

oc

unit

I1'-

J~

control

Mode door molor

!:'

'-

' Pusn

OEF sWitch

--'

VENT switch

FlO SWitch

!,~

,-

REC sWitch

'I

FOOT SWitch

'i :::,

Ale sWllch

B/l sWItch

II

,-

I
,
I

I I
I I

I,

:t

J
-

,-

i
i

I c I Resistor

Blower motor

:' I

I:

.,~

~~7~

:1

1 Thermal prolecto

C;

EeM (ECCS control module}

Harness
.,~)

--"

1-~

---,'

Q.-)l

,"

IJ'I
coJ

~n.'

,~..;;;)

Preliminary Check
PRELIMINARY CHECK 1
Intake door is not set al "FRESH" in DEF or FlO mode.

Turn ignition switch ON and set fan

speed at ' 4"

Set mode door at VENT mode.

T_Ur_I1_REC s_w_it_Ch OFF

'

No

Does intake door change from

when REC switch

IS

Go to DJagnoslic Procedure J, (HA-60)

"FRESH" position to "REC" posilJon

turned ON? (Make

sure the intake door has moved by listening for air flow sound from the
intake unit)
_ _ _ _ _ _ _ _-.--

--.J

Yes
Does Intake door change from "REC"
position to "FRESH" position when FlO
switch or DEF switch is pushed?
Yes

''''-'---l

r-----L_
INSPECTION END

HA-20

_~Place push control

"~It

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 2
Ale does nol blow cold air.
DOES AIR FLOW FROM VENTS?
Condition
Ignition switch, AIC switCh, and tan
switch are ON,
Mode switch is in VENT mode and
tempera lure leller is in full cold position,
~_

IS BLOWER MOTOR OPERATING NOA-

I MALLY?

NG

CHECK

CO~PRESSOR OPERATION

CHECK FOR EVAPORATOR COIL

FREEZE UP
Remove Intake unit Check it evaporator freezes

OK

NG
(Freeze
up)

OK

'----~.---_

~------.J

NG

CHECK REFRIGERANT
Connect manifold gauge
then check system pressure, Refer to HA-28.

OK
(Does not
freeze up)

CHECK VENTILATOR
DUCT FOR AIR LEAKS

CHECK REFRIGEAATION CYCLE

PRESSURE WITH MANIFOLD GAUGE
CONNECTED
Refer to HA-28

Adjust or
replace
compressor
bell. Refer
to MA section
("ENGINE
MAINTENANCE")

No

CHECK BLOWER
MOTOR OPERATION.
Perform Dlagnosllc Procedure 1. Refer \0
HA-56

.. ---~,---------Yes

CHECK COMPRESSOR
BEL T TENSION
Refer to MA section
("Checking Drive Belts",
"ENGINE
MAINTENANCE")

Yes

OK

CHECK THERMO CONTROL AMP

OPERATION,
Refer to HA-68.

Perform Performance
Test Dlagn-oses. Refer to
HA-26

'-

OK

,
CHECK
FOR
REFRIGERANT
LEAKS

VISUALLY CHECK AIR MIX DOOR

MOTOR AND LINKAGE OPERATION,
OK

NG

Perform OIagnoslic 'jrocedure 6. Refer to

HA-64.

VISUALLY INSPECT AIR MIX

DOOR
Access by removing instrument panel

~m. D;agnosll~ Procedure 4

~_tOHA-6t

I
.

,,

j'

HA-21

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 3
Magnet clutch does not engage in DEF mode.
Perform PRELIMINARY CHECK 2 before referring to the following flow chari.
With engine rUI)11lng. does magnet

No

Perlorm Diagnoslic Procedure 6. Reter 1o HA64

clutch engage normally when Ale

switch and fan sWitch are ON'?

Yes

I Push

SY:J

stem
Ale switch and turn Ale
OFF" Make sure Ihat magnet clutch IS
d;sengaged.

With engi ne running. does magnet

clutch engage normally when DEF
switch and fan switch are ON?

Yes
[

INSPECTION END

HA-22

No

Replace push tonfrol

unit

--

Preliminary Check (Cont'd)

PRELIMINARY CHECK 4
Air outlet does not change.
TURN IGNITION SWITCH ON DOES AIR COME OUT NORMALLY FROM EACH DUCT

No

Perform DIagnostic

}I:

Procedure 2. Refer

WHEN EACH MODE SWITCH IS PUSHED?

10 HA58
Air oullet/dlstributlon

Switch mode!

'.'

Indicator

..;
:;
..J
fJ

l , "..

Foot

Defroster

100%

40%

80%

20%

60%

40%

100%

60%

~-,~

Face

___r:=_-~-INSPECTION

E~

,______

i).i\

-\

...,:

!
I

..
HA-23

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 5
Noise

1
Check lor noise

Inspect Ille com'

in all modes and

pressor clulch

temperature set-

aod pulley and

tings.

Idler pulley

Noise

r
G

OK

IS

constanl
Check blower

Replace

1\'\e lIne IS

motor !Dr for-

compressor

fixed directly

eign particles.

clutch and

to Ihe body.

pulley
ReIer 10
HA-146

Chock blower

Check dlsc-Io-

F,x the

motor and Ian

pulley clearance

wilh rubber or

lor wear.

ReIer 10 HA-147

some vibration

OK

I<ne

Fit

the line

tightly.

ansarI'",,!:)
malerial

-.1- __
Check and adjust

lubricant

Refer 10 HA-140

Side of belt

IS

worn OJ!

NOISe IS

,ntermillent.

The pulley cenler does not

,-j'' ']

Check ai,
charge
duels

section

match
Readjus! the pul-

for obstruc

( 'Checklng

ley cenler

tions. lore'gn
materia's or

Drive Belts",
"ENGINE

air leakage

MAINrE-

-~--

NANCE' )

.J

TROUBLE DIAGNOSES
Preliminary Check (Conl'd)
pRELIMINARY CHECK 6
Insufficient heating

DOES AIR FLOW FROM FOOT

~~ ..

CHECK BLowER MOTOH

OPERATION

AREA'
Condillon,

PerforM OIagnosllc Proce-

Ignition sw"ch and f:ln

SWIlch are ON

dura 1. Refer 10 HA-56

Mode swilch IS in FOOT

mode and tempera/ure

lever is in lullhot position,

E.J

Check the fcllowing'

I::ng,ne coolant level (Reier

1 -I

Repaor!replace as neces-

~ary

\0 MA sec\,on)
Hoses for leaks or kinks
RadIator cap (ReIer 10 LC
section)
Air In coolmg system

Check ai, miX door adjustment

Refer 10 HA-71

Check by feel the heater inlet

and outlel hoses

Hot Inlet

Bolh hDses

Warm outlet

warm

Check lhermostat
Installation

Check heater hoses

for proper installation,
OK

\her~m-

stal ReIer 10 LC

Back Hush heater core.

lJ,ain and relill Loolanl

sect,on

Retest

Replace

("Ther mosl at" ,

"ENGINE COOLING
SYSTEM')
.-------

Hoi inlet
Warm oulle:

Sy~lem OK

HA-25

'---=J

Both hoses

warm

III

l,.-LA-e-~-'(l-c--e-, h-.e-a-l-e-,-co-r-e----,I [: 1

LMANUAL AND AUTO ]

TROUBLE DIAGNOSES
Performance Test Diagnoses
INSUFFICIENT COOLING

'------==r= INSUFFICIENT COOLING

.----....,~

[ECK AIR FLOW.

~-----

'-C-H-EC-K-C-O-M-P-R-E-S-SOR OPERATION

OK

Clogged blower mlet!

Clogged ducllLoose duct
connection! Air leakag
etc

(Go fo
ned page)

OK

CHECK HIGH AND LOW 51"DE P:JESSURE. USE PERFORMANCE CHART.

(Refer to HA-Z8.)

NG
I

RECOVER REFRIGERANT USING

RECOVERY AECYCLING RECHA~.GING
EQUIPMENT AND CHARGE SPECIFIf:O
AMOUNT OF REFRIGERANT

L.--.

CHECK HIGH AND LOW SIDE PRESSURE. USE PERFORMANCE CHAAT.

IIAf'fer to HA-28 l

Nole
NG

-----+

BOTH HIGH AND LO:]

PRESSURE SIDES AA.E
TOO HIGH

==:JOK
'-C-H-EC-K-O-IS-C-HARGE A-IR-r-E-M-PE-R-A--]
---

HIGH PRESSURE SIDE

1$ TOO HIGH AND
LOW PRESSURE SIDE
IS TOO LOW.

TURE USE PERFORMANCE CHART

(Refer to HA-28 )
NG

-I

E~~

-.-------- m
- . -... Gl

HIGH PRESSURE S I D E j
IS TOO LOW AND lOW
PRESSURE SiDE IS
TOO HIGH

------Malfunctioning temperature contro", operation (air ml~ door position improperly

adlustedl

Bor-H HIGH AND LOW-I

P~ESSURE SIDES ARE

......
~

TOO lOW.
-----~-

I LOW PRESSURE

I
Note

f..i.1-1ii1

correspond to those in TROUBLE DIAGNOSES FOR

ABNORMAL PRESSURE
[Refer to HA-29 )

HA-26

SOMETIMES

-~IOE _

.. r:;a
I:!I

BECOMES NEGA TlVE

LOW PF1ESSURE

SIO~-}

BECOMES NEGATIVE
-

-----

-_._-

..... r::2
III

TROUBLE DIAGNOSES
I MANUAL AND AUTO]
Performance Test Diagnoses (Cont'd)

,-------1r------~alfunctioning

~_

~-- J

electrical CirCUit

':1f

Mallunc.lloning blower moior

Internal CIrCU',t

Dlsconllnued wIring or componentlj

cirCUits Dr poor connectionl

I,~

Malfunctioning resislor, amplifier,

etc I Burned oul luse or low bat-

Lr.,.

voltage
----~

Magnel clutch

doe;~~

---~.-

[ Magnet clutch s.lipp,ng

.-----

- r

'-C-H-EC-K-M-AGNETCLUTc:J
(coil clfcuil, disc-lo-pulley clearance)

Malfunctioning internal paris of

clu\ch, comprC5sor

CHECK ACTIVATION OF SAFETYI

PROTECTION DEVICES [sllch as

___ .- Foreign partIcles

on

clutch frlc-

llonal surface or excessive diSC

pressure 5wllch, elc )

clearance
--------'

- - OJ

.------.- Malfunctioning electrical circuit

(poor connl!cllon, low oauerv
voltage. etc)

-----_.------

:1

HA-27

TROUBLE DIAGNOSES
Performance Chart
TEST CONDITION
T es: i119 m usl be pertormed as follows:
Vehicle location. Indoo's or In the shade (in a well ventilated place)

Doors. Closed
Door window: Open (Front driver s;de only)
Hood. Open
TEMP setting: Max COLO
Discharge Air: Face Vent
REC!RC switch: (Aecircu1allor ON
FAN speed: High speed

Ale switch: ON
Engine speed: Idle speed
Operate the air conditioning system for 10 minutes before
taking measurements.
TEST READING
Recirculating-la-discharge air temperature lable
lnsicle air
at blower assemb,y inlel for FlECIRC'

D,scharge air temperaturp. at center lentilalar

Relatil/e humidity

Air temperature

eJ~

'C ('FJ

20 {WI
25 (71)

50 - 60

,'FI

--

62 - 8 8 (43 . 48\

- - - -------------

104- 135 (51 - 56)

--~.

30 (86)

14,5 - 18.2 (58 - 65)

f--------

18. 7 - 23.0 (66 - 73)

35 (95)

--

B.~

20 (68)

- - - - -_.

- 11

f)

(48 - SJ)

._--

13 S - 168 (56 - 62)

25 {77)

60 - 70
30~86)

HI 2 - 22 0 (65 - ILl

- - I----

35 (95)
Thermometer

~hOLJld

230 - 272 (73 - 81)

be placod at mlake unit under AH Side of Ins!rument pa'1el

Ambient air lemperature-Io-operating pressure table

Ambient air
Ac:li:itive humldl!','
~c

Air temperature

'c

Hlgh-pressuro {D'9charge I>Idtl)

Low-pressure (Suction SIde)

kPa (bar, kg/em', psi)

kDa (bat, kg/cm~. psij

rF)
814 - 991 (8 14 - :191,

2S (77)

147 - 216 11 47 - 2,16, 1 5 - 2 2. 21 - 311

83 - 10 1, 118 - 144)
941 - 1,177 (9 41 - 11 77.

30 {B6)

157 - 245 It 57 - 245. 1.6 - 2,5,23 . 36:

96-120,137-171)
-

50 - 70

1. loe . 1,<102

35 (95)
1-----------

40 (104)

{I I Of) . \ 4 02,

11 3 - 143, 16! - 203)

177 - 284 (1 77 -

1,304 . 1,677 113 04 . 16.77,

\3 J - 17 \

HI9243)

84, 1 8 - 2 9, 26 - 41)

2 16 - J43 (2 16 . 3 43. 2 2 - 3 5, 31 . 50)

II prp.ssure Is not wIthin range, refer to HA-29, .. I rouble DIagnoses lor Abnormal Pressure

HA-28

._--------

f-------

.,

MANUAl. AND AUTO

TROUBLE DIAGNOSES

Trouble Diagnoses for Abnormal Pressure

Whenever system's high a.nd/or low side pressure is abnormal, diagnose using a manifold gauge The
marker above the gauge scale in the following tables IndIcates the standard (norma!) pressure range.
Since the standard (normal) pressure, however, diners Irom vehicle to vehicle refer to HA-28 ("Ambient dlf temperature-to-compressor pressure table").
Gauoe indication

Refrigerant cyc:e

80th l'1igh and 10w-preSSLre

~ides

are too high

~~
~

Probable cause

,-"I

Corrective action

---

--

.,

Pressure IS reduced soon

after water is splashed on
conc:lenser

Excessive relrigerat1l charge

In refrigeralion cycle

Air sudan lly ;;oollng Ian 's

InsuflicicJ'l\ CO"dC"llcr COoling CIon ... cond",ns'lr,

it'1sulficl~nt

performal1c~

Reduce relngera,'t unt , specil,ed pressure is- obtained

----

Check and repair cooling

1
G) Condenser

finS

fan as necesSBry,
are

cfoggec

(!l Improper Ian rOla\IO(\ 01

cooling Ian
Low-pressLJrc pipe

IS

not

cold

Flla(';(JaIA rP.c>ealedly and

den~er

recharge system

(After compre-ssor operation

stops. high pressure

When compressor is
stopped l'1igh-p r essJre
I.CJ59A

Poo' heal exchang@ in (';nn

value qUickly drops by

apprOximately 196 kPa (2 0

decreases loa slowly)

Dar. 2 kg/cm', 28 psi), \I

thon decrea.,,!'; grarflJ~1!v

Air

1
.r,

refrigeration cycle

theresHer
Engine tends Ie overheat

Engine cooling systems malfunction.

Check and repair each

engine coohnl) S.ysleln,

An area of the low-pressure pi~e i5 colder then

Excessive liqUId refrigerant

00 low.pressure sirl'"

Replace a,panslon "alve

areas near the evaporator

outlet
Plates are sometimes cov
ered wJlh frost

I'

Excessive refngerant

~ Q,

CIS-

charge !low

E,p,",lo" "',, ;, OP'" ,

litlle compared with
spec ,tical/on,

I (j)
\iJ

lmpror pr

\h~

1~P.fmal lIa've

installation
Improper e~pansio", vallie
adjustment

,-I

'I','.

HA-29

TROUBLE DIAGNOSES

MANUAL AND AUTO]

Trouble Diagnoses for Abnormal Pressure

(Cont'd)
Gauge mdicali~n

Ref"gerant cycle

Probable cause

---------+-----------t-------------+------ --'--Upper side ot conde~ser and

.-Jigh-pressure side is too

Hi!Jh-pr.. ~sure lube cr parts

high anl1 low pressure side IS nigh-pressure Side are hoi,

located belween compressor

too low

and condenser are clogged

10wever, liqUid tank

IS

not so

Check and I epa"

Or

replace 'llalfunct,onlng
paris,

hal

or crushed

Check lub"can1 tor con\amina lion

High-pressure side IS 100 low

Hgh and low-pressure sides

Compressor pressure opera-

Replace co.'npressor

and low-pressure Side

become equal soon aller

tion is Improper.

AG360A.

IS

100

high,

compressor operation stops

[!J

Camaged inSide compressor

packings

No temperature dlflerence
belween

hig~

and low-pres-

sure sides

Comprp-.. sor c4.scharge

Replace

compre~~Uf

capacity does 1'01 change

(Compressor stroke is set at
maximum)

ACh~A

Both high- <)nd

low-p~re

----- -----+-------------1---------

fhere ,,,, " big temperature

sides are loa low

difference between liquid

Ii)

tank oullel and ,nlet. Dutlet

Liquid tank inside is dogged

Replace liqUid tank

a little

Check lub,icanl

'0' c:>nlam-

,nation

temperalure is extremely
l;>w.

Liquid tank inlel and expansion valve a'e frosted

- - - - ----._--+----- - - - - - -

--------

Temperature DI expansion
valve inlet is extremely low
as compared Wllh areas

High-pressure pipe localp.n

belween IIQU,d tank aflC

eXDanSlon valve is clogged

Chp('k and 'apaJr rna'Iunc

tioning p8r:s
Check lub' canl 1o, cOlllamillation

flear liquid tank.

Fxp""",ion ,,;olv.. ,nlat may
be frosled
Temp'lralure dillerence
o::;curs somewhere In highI->' I:lSsur" side

HA-30

MANUAL AND AUTO

TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont'd)
Gauge Indication

Refrigerant cycle

Probal>le cause
E~pans'on valve closes a lit-

Both rugh- and low-pressure

There is a big temperature

sides are too low.

by uSing ccmpressed air

dllference bel ween e~pa"slon lie compared Wllh the spec,',valve inlet and oullet while
cation
Check lubricant lor contamIhe "alve ilsell is trosted
i,allo(\

l!]

Remove foreign particles

(1' Improper e~pan5ion valve

adjustment
12)

Maitunctioning thermal
velve

~ Oullet and Inlel rna} be

I"

cfogged
An area of the low-pressure
Pipe is coldel Ihan areas

LON-pressure pipe is cl~gged Check and repair mallunc0' crustled

tIonlng par:s

near the evaporator outlet

Check lub(Jcant for cOntamInation.

Air lIow volume

AC3S1A

IS

------+------------- -

Ev~porator is Irolen

not

Replace compressor

enough or is too low

Compressor discharge
capacity does not change.
IComp'eosso,

~trokc

is set al

maximum length.)
low-pressure Sloe somelimes becomes negative

lEi

Air cOf\(!\licning system

Refrigerant does no! dis-

does not lunctlon and does

not cyclically cool Ihe com-

charge cyclically

MOisture IS 'rozen at expanpartment a' r.

lhe system conslantly tunc- sion valve oollet and inlel

tlons 1m a cerlain period ot

lime afler compressDf is

Water is mixed with refriger-

slopped and restarted

anI

",C354A

HA-31

Olain water from refriger-

anI or replace relngerant

Heplace liqUid lank

I MANUAL

TROUBLE DIAGNOSES

AND AUT"]

Trouble Diagnoses for Abnormal Pressure

(Cont'd)
Gauge Indication

Refrigerant cycle

Probable cause

Low-pressure Side becomes

Liquid tank or 'ronl/rear side

High-pressure side is closed

negative.

01 expanS'('ln villve's pipe is

and refrigerant does

Ii

frosted or dewed

nol flow

Correcll\le action

L eave the system at rest un!i I

no frost

IS

present. Start it

again to check whether or

E1pansion valve or liqUid

not the problem is caused by

tank is frosled

water or foreign particles,

If water is the cause, initially

coolong

IS

okay. Then the

water freezes, causing a

blockage.

11 the problem is due to

water, drain water from
relrigerant or replace

refflgeranl
If due 10 lore,gn parllcles,

remove expanSion \lal\le

and remove Ihe paorllcles
wilh dry and compressed
air (not shop air)

If either of the above methods cannot correct the

problem. replace expansion
"alve
Replace liqUid tank
Check lubricant for contamination

HA-32

TROUBLE DIAGNOSES

MANUAL]

Harness Layout
ENGINE COMPARTMENT

:.,-

?1

,I' :',

SHA500E

TROUBLE DIAGNOSES
Harness Layout (Cont'd)
PASSENGER COMPARTMENT

LHD model

l!l Thermo

HA-34

control limp.

TROUBLE DIAGNOSES
Harness layout (Cont'd)
RHO model

SHAS27E

HA-35

TROUBLE DIAGNOSES

r----

Circuit Diagram -

Heater

~GNI TION SW! TCH

ON

F~EO

1
14

~~~~~R, M

22
23

AIR MIX

ODOR

!PBI'l

26f-

~OTOR

.~

r - -t-----

18
19

FAN

RE 5lSTOR

..

.........z

'---------

..J
0

.;:> f---

~
::z:

FI>N S.... ITCH

OFF

'0
(

:x:

UJ

I---

\---I----

--

'- 12

--l1f1
--tit!

--ll11-

DEF
F/O
FOOT

MODE
uao=l
MOTOR

B/l
VENT

~.1

0l-'

11
~1

27

F ~~~e~\lUmlnQtlQn~ _____ 15

12.4

16

(Jf) ..

-i1

,~
]1

20

25

~01Dn

-t-l

::l

BI-LEVEL
DOOR

INTAKE

-il

-411

:t

REe

DOOR
MOTOR

FReSH

iJ

17

--r

,Fer cleta i 1s. re fer to "pu<;n

C"ntr"'O 1 System"

HA-36

(See

page HA- 44) ,

TROUBLE DIAGNOSES
Wiring Diagram -

HEAT -

LHD MODEL

HA-HEAT-01
.---.~

dJlTI ~rn LVrn

Li

Lt

Refer to a-POWER.

LlLOR

L/"

DLOWE1=l

; :'

vrn0!9 Ne't .....

.--.------.

..... LG/~ ~

~
4

FAN

~STOR

LIB L/Y L/R

mrn

FAN

SWITCH

HA-31

Next page

TROUBLE DIAGNOSES

Wiring Diagram -

[ MANUAL]

HEAT -

(Cont'd)

HA-HEAT-02

FAN

IGN

SW

ElILL
PJSH

CONTROL

UNIT

O/F

I NPLJT

FOOT

INPUT

VENT

INPUT

~
L!Y

L/Y

,l

MOOE

',ioo
OfF

DOOR

MOTOR

VENT

~
14

17

1615

,
:
JI

SHA477(

HA-38

TROUBLE DIAGNOSES
Wiring Diagram - HEAT -

I MANUAL I
(Cont'd)

HA-HEAT-03

I
RIG

- I

Mo~E~g~OR @>

rrlW~

RIG

LG/W

' ' 'I,''

PU

1t

- -:.')

PU

mm
OPEN

-"1

19
I OPEN

~CLOSE

eCLOSE

PUSH

CONTRDL

?,I-'

\..JIIIT

lAEC

E&REC

I!JJlI
G/W

G/W

GIS

'(

GIS

I l It
m m

I
Y

6FAE

FRE

$FRE

It-PUT

<:9C L/OR,

PrecedIng
page

.~

-,

\'~'~1~

INTAKE

DOOR
MOTOR
~

AIR
MIX
DOOR
MOTOA

,:'r

f~

~
B

~--------"'IB

,.\.'

~-J

t,

CHD

r-------------------------,

:~~@):

: lilltj ~
I
I
L

mID:::QTI ~
~

I
~I

~<l@)
B

l&llJ

HA-39

~ ~

Cill.Iill

TROUBLE DIAGNOSES
Wiring Diagram - HEAT -

[MANUAL]

(Cont'd)

RHO MODEL

HA-HEAT-04

~ {SA ~~7.5A
l4-l OJ L:J rn ~ m
L/W

L/W

L/OFI

+ '

L/W

Iii
~

Refel' to EL-POWER.

BLOWER
:

L/OFl~Next

....

page

LG/R ~ Next page

~
rn
4=!'
LIB

FAN

~STOR

L!v L/Fl
2

FAN
SWITCH
~

SHA479E

HA-40

CMANUAg

TROUBLE DIAGNOSES
Wiring Diagram - HEAT -

(Cont'd)

HA-HEAT-05

FAN

IGN

SW

E!)ILL
PUSH

CONTROL

UNIT

eVENT
E!)DEF
8

GND

eILL

~~
B

'~"'T

MODE

DOOR

MOTOR
~

~@Ji
B
L

~_-

I
I
I

SHA.480F

HA-41

TROUBLE DIAGNOSES
Wiring Diagram - HEAT -

MANUAiJ

(Cont'd)

HA-HEAT-06

g6D~E~6ioR

@)

ITG/.~

PU

RIG

RIG

LG/H

It

27

rrTIrn

PU

lBOPEN

6 OPEN

eCLOSE

ED CLOSE

PUSH
CONTROL
UNIT

6FRE

mREC

PBR

GIW

G/B

I t It

G/W

~
~L/OR'

page

GIB

L/OR

rm

It

P/L

Preceding ~

P!L

rnm
INTAKE

DOOR

MOTOR

1 - - - - - - -1 I
8

~....J

t-,

CHI)

r--------~----~-~---------,

~~@)l
B

~-------

~@]>
~w

~~

[JIgIill

I
1

ITIQI]~

CITIIJ

SHA4BIE

HA-42

IG~l!rIDN

sWlreH

ON

COSE?

BATTER'(

('IIi)

fUSID1;

lIn,,)

Except RHO mooels tor Europe

'''I

FUSE~

For Cletal1s. refer to

"pusn Contro 1 System"
(See page HA- 44) .

I
14

THERMO
CONTROL

9LOWERf
MOTOR IV,

t~

r-

J:

FA.N

F1ESIST0>1

L
~

26

"2

PBR

AIR MIX
DOOR

Br -LE VEL
DDDfl.

MOTOM

n
o

~....
FAN SWITCH

OEF
FlO
FOOT
B/l
vENT

:!:

~I
~

~ELA,(

IACV-FICD
SOLENOlO
VALVO:

...

"::'"

L.-....--

AII'l

eOND I TI ONER

1-10TOR

::tt==@J

;?3

rr

---1

A~

MODE
ODOR
MOTOR

. ~ SWITCH
""ESSOAE
#'A'P"-

fTl

("')

3:

I
AS

~:

15

[16

17

INTAKE
DOOR

L __

MOTOR

241--1---j-":"

--r
'

~~:

~
-~

.~.~ ~_'~___

_...

~'.~-.....---

..0'

-.-,
'1.=,

WI'

~;

;&

'C'

,:;)

:;':".

"/?J
t~)

"

33

20 1-4 - - - - 1 - - - - - - - '

"'-?1~

~~~~e;lluI111ncJtlon

(")

\ 12

n
n

LBlmfgf------,

i11

:::OJ

-<

--

~!-'

III.

r'J'l

:lnJ

'~--~

E:l:HJ
15 ..
FUSE

PUSH CONmDL I)N]T

CD

FAN

RESISTOR

::t

@
REC

J:.
.;:.

SlOlTCH

t
From tl"lermo
contro 1
amp1 1 f ler

(Q

LHO maae ls

RHO mode

(~I

Is

Tl"lese sw I tCr"les are bu 1 H lr"lto push contro 1 vOl t

ana mechanically llnked to corresponding sWltcnes,

c:I:il&J71
l..lIIIillJ

AIC, M -

Wiring Diagram -

HA-A/C, M-01

LHO MODEL

.-.~
m
m
LlJ CD LtJ m []]
15A

L/W

15A

L/W

EL-POWER.

Refer to

"PI'I

7,5A

L!OR

.
' ._ _...-------~.-L/OR~Nextpage

'

LlOR

~5~~~R
~
M

w
I

L'2W

THER~ISTOR

THERMO

~~~~~~jER
@

~
mmm
I!4J! ~ Ibj.JJ
LIB

L/Y

FAN
RESISTOR

~e

LY/B~}TO
~c
LG/....
" '1/"

HA-A/C. M-03

I~I (8Q)

T'Cffi

LlR

~:'

4=Jl

~f~

FAN
SWITCH

~
AIR

ECIooI
(ECCS

CON

CONTROL
MODULE)

(ill
B

t,

.,"r

cMb
l""Ql@
[I@Q] w

~~
~
SR

Refer' to last page

(Foldout p8(Jel .

,Cffi

em

, n:",

SllA457E

HA-45

Wiring Diagram -

AIC, M -

(Cont'd)

HA-A/C.M-02
] Refer to

+@
2

8) ID-l
i

~@
3 4

,,8

a--...

Refe,. to last page

Ja>~

(Fol(lout page) ,

~~

~.

em

m~-2

SHA45eE

HA-46

Wiring Dlagram- AIC, M -

Preceding page <aL/OR

To HA-A/C. M-O 1

~ v/s
_

------e-e-

:;I-

~LG/A'
LG/A
12
FAN
SW

v!B

L/OA

(Conttd)

..... UOR HA-A/C. M-03

-t> Next page

l....=.L/OA-@> To HA-A/C. M-05

.-

AIL

To EL-ILL

.AIL

TtA040
AMP.

PUSH
CONTROL

UNIT

MODE

DOOR
MOTCIFl

r-------------------------'

SHA459E

HA-47

Wiring Diagram -

AIC, M -

(Cont'd)

HA-A/C. M-04
MD~E~6fDR @)

RIG

fiLG/w~PU

RIG

LG/W

1/
PU

eOPEN
$

CLOSE

PUSH

CONTROL
UNIT
$FRE
6REC

eFRE
tBFlEC

EflCOLO
eHOT

GIS

G/W

Preceding

I t It
m m
G/W

page

~L/DR'

L/OR

G/8

INTAKE

AIR

MIX

000fl
MOTOA

ODOR

MOTOR

<ID

~
8

~-------"'I
8

I
8

~....J

t-,

~
~-------------------------~

It
:~dIm
11
2018
@

..

I
I
I

:
I

I
f

rn::::ITJ@
~B

~~
B

rn..m:o

I
I

~-----------------~-------~

~~
~w

SHA~&OE

HA-48

Wiring Diagram -

To HA-A/C, M-03

AIC, M -

(Cont'd)

'---~ __~] HA-A/C, M-05

<:@- L/OR,

Refer to EL-POWER.

LlDR

~Oill)

I~I([W

LJ~:

1"1

1,~

I! ~leOOLING I! ~leOOLING
Tor I:: Li~I/Rl
LIOR

e/w

L/OR B/W

n FAN

IbiJl

OR/L

n FAN

U RELAY-1

I4=Jl

U RELAY-2

CID

~,

-:'L.,

L/G

~~$
OR/L
L/G
I

OR/L

COOLING
FAN
MOTOR

L/G

~&i$J

To

H,-,/e

.-02~~L:f

OR/L

LG

M1

rr13l1

RFFl

LO

L.......:".:,~--;r-.!;,;,.;:--.J~

RFR
HI

ECM
(ECCS

CONTROL

MODULE)

(IT)

Refel"' to 18st p8ge

(Foldout p8ge)

~~

L\.,

HA-49

TROUBLE DIAGNOSES
Wiring Diagram - AIC, M -

(Cont'd)

RHO MODEL

HA-A/C. M-06

m
~
-iffiili
LtJm
w
15A

L!W

15A

~m
L/W

L/OR

Refer to EL-POWER.

7.5A

- - - - - - - - - - - . - LlOR

L/W

~
2

IVI

~~

BLOWER
MOTOR
~

J1.jJI
L

~
4

I'=iJl

THERMO

FAN

RESISTffi

YI:. Vis
LG/Fl

Next page

;~~[~~ER

THERMISTOR

t-------..

-e>

~}

-f!>

To HAA/C. M-08

t@J lHW

LIB L/V LIP.

4mm

I
FAN
SWITCH

d6iI
AIR
CON

ECM

(ECCS

CONTROL
MODULE)

em

Refer' t.o last page

{Foldout page) .

[Q]@

HA-50

Wiring Diagram -

A/C. M -

( on

HA-A/C, M-07

~L~_-':;'oB> ~~~ I"~:~A

!'r.c.ding
page
~

ffi]

L/ORlHill)

$@Y
L/OR
I

'1f

Refer to EL-POWER.

G/B
_ _-

.....

l.t

~ :::IJ~6~DITIONER
RELAY
~ [I

3'

G/W

G!W

(lID ~ @Q)

L/R

L/A

t> To HA-A/C.

LlR
M-10

--1---'I
L/R

LIR

OR/Lrn
m ~~~-

~
AS.

L/R
"';i/L

em

I+~]
HHPLE0 'I PRESSURE

1!"jJl~

, SWITCH

G/V

$: L_-"_--'--~lHW

~CE.4)
G/Y
9

,tCy

1 TI-Em.1AL

SOLENOID
VALVE

1~~cs

~g~~~~
(ill

PROTECTOR

ffi-t

COMPRESSOR

~-2

rt t,
@ ffi
~ @

Refer to last p.ll!le

(Foldout page) .

~
~ B

~I

n.

@-1
8

SHA46JE

HA-51

I MANUAL]

TROUBLE DIAGNOSES
Wiring Diagram - AIC, M -

(Cont'd)

HA-A/C, M-08

To HA-A/C.M-10

Preceding page <19-L/OR-------.-.-LlOR~

Next page

To HA-A/c.M-06

~Y/8~~

~LG/A'
LG/R

Y/a

r@

FAN
SW

THERMO
AMP

~LlOR-e>

I~

L/OR

AIL

rrT4TI

mID

IGN

R/L

To EL-ILL

EflILL

PUSH
CONTROL
UNIT
@

ED VENT
8DEF

GND

8ILL

~~
8
a

MODE

DOOR
MOTOR
@

r---------------------------~

~:
~@):

I
I
I

SHA4&1E

HA-52

I MANUAL I

TROUBLE DIAGNOSES
Wiring Diagram -

AIC, M -

(Cont'd)

HA-A/C, M-09

~~E~5jOA~

rrG/W~

,~1!&\

RIG

RIG

LG/W

It

rrf5i1

Ii17iJ

18

19

PU

n~

PU

(BOPEN

l,:e

eOPEN

eCLOSE

mCLOSE

PUSH

CONTROL

~CC

UNIT

REC

INPUT

llJn
Y

Y/L

y/L

(BFRE

eFRf

eREC

EflREC

IYJM

G/W

G/B

It I~
m m
G/W

PBR

'F~

Preced ing

page

<8- LOR'
I

PIL

:e'l,

It

LIOR PIL

GIS

~,n

AIR

INTAKE
DOOR
MOTOR
<8l

:1\1

"'IX

DOOR

MOTOfl

<SaL>

~"I]

~I'A

---------.... I
B

f{l~\

&-1

~~l

t,

~
I
I
I

E::F=FEf.~r+--"

rzI6TIJ:J

4m> :

CBD

[I[Q]J~
B

ITITl

~l'
~}~~

W"OlIDl@>
[illll[J 8

rL

~W

i'G)\(

SHA46SE

HA-53

I
I

Wiring Diagram -

To HA-A/C. M-Oe

AIC, M -

(Cont'd)

<S- L/DR ,
LlOR

rtOJlID

LlOR lUQD

B!W

--

~-F:-"'-----I
~I~[NG
~tOL[NG

II

it

L/OR B/W

L!OR B!W

"\ FAN
\ RELAY-1

2~@

To

HA-A/~

-t

L/G

:=

OR/L

LlG

ORIL

l/G

I[Q)~
~ ~~J
':::y=r lHIQ) ""i"'"

ORIL

I-I..,::

+I

RHO models
for

EUf'~

Except <ED

BR/W

COOLING
FAN

MOTOR

L/G

1-.:.,r.~----:rc!cT.'-'

ffi:

~:<BD

OA/L

LlG

trf9il

RFR
LO

W!R

W/R

$~$
OA/l
LlG

FAN

lJ AELAY-2

t~(ill:@

OR/L BR/W

007 <fIo;;L

11

RFR
HI

ECM

(EeeS
CONTROL

MODULE)
CIT)

~531
T

Refer to last plIge

(Foldout page) .

ill) CD)
L'

~.m

@,

em

SHA~6lif

HA-54

..

==-------

Main Power Supply and Ground Circuit Check

POWER SUPPLY CIRCUIT CHECK

Push conlrol
unit conn&Clor @

~~"'(bo.'"

mugul.mIO
UOR

Check power supply circuit for air conditioning system

Refer to El section ("Wiring Diagram", "POWER SUPPLY
ROUTING").

JI

PUSH CONTROL UNIT CHECK

L':

Check power supply circuit lor push control unit with ignilion
switch at ON.
1. Disconnect push control unit harness connector.
2 Connect voltmeter from harness side.
3 Measure voltage across terminal No. @ and body ground.

oC'

Voltmeter terminal

e
Body ground

Push control

unit conneclor @

IFH:fllrn1 ~ 10

Gll
L

Voltage
Approx

12V

Check body ground circuit tor push control unit.

1, Disconnect push control unit harness connector.
2 Connect ohmmeter from harness side
3. Check for continuity between terminal No @ and body
ground.
Ohmmeter terminal
Contlnu l 1y

Body ground

Yes

... SKA428EA

[15 .

HA-55

Diagnostic Procedure 1

Flow char!

INCIDENT

No,

SYMPTOM: Blower molar does not rota Ie.

Perform PRELIMINARY CHECK 2 before referring to the

following flow chart.

Fan tails to mlale,

-1

Fan does not rotate at

1-speed.
Fan does not rolale at
2-speed.

Check it blower motor rotates properly

at each tan speed

Fan does not rotate al

3-speed

Cooduc' check" pet lIow '",,' " len

'--.

Fan does not rotate at

1r

4-speed.

m
ffi Blower motor
'lJ11f connector
LIW

~i'6
~

l]

-No

CHECK POWER SUPPLY FOR BLOWER

MOTOR
Discol1 necl blower motor harness con-

blower motor harness lerminal No.

1U'1

CHECK BLOWER
MOTOR
(Refer to HA-68 )

TNG

Replace blower motor

Reconnect blower motor harness connector

Disconnect resIstor harness connector

r!J
CHECK BLOWEA,.OTOR C'RCUIT
BETWEEN BLOWER MOTOR AND

~ ""'"""'"

l2D 10

~o
Disconnect blower m-~~".1
harness connectors

RESISTOR
Do approx. 12 volls exist between resis-

tor harness terminal No,

CD

ground?

and body
Check circuit continuity

Yes

-'

between blower motor

harness terminal No (1)
and resistor harness terminal No. CD.

SHAS31E

(Go to next page)

Note:
If Ihe re-sult is NG after checking circuit contlnultv. repair harness or connector.

connector

Il@

OK
~

..-

lNG

Blower motor

ReSistor
connector

and

L..--_ _.

~>i8r~

00

No. CD

body ground.

RHA3a2EA

ReIer to EL seclion

res

motor harness terminal

leJiWj
lY\

Check 15A fuses at fuse

block.

and body ground?

1AI Blower molor ~ """",,,,"

m1 connector@D I.m 10

@)ector

ROUTING").

Check circuit continuity between blower

"POWER SUPPLY

Do approx. 12 volls exist between

RHA381EA.

[l ill ResISlor

('Wiring Diagram".

nector.

l1J(Go tor~Jnext:9!page)
~J

fGt@

GcmLJ'

._-~

HA-56

Fan swilcl,
connector

~ CCJHiC'

Diagnostic Procedure 1 (Cont'd)

[lJ
~
- - [2J

lAm L \
~

~o~

.-----

CHECK RESISTOR AFTER DISCON-

@J

!JJ

NECTING IT
(Refer to HA-68 )
NG

OK
I

R,p1'"

,,,,,. -

tor
RHA385EA

Reconnecl resistor harness conneclor

l~

LJ.J
~

QJ

[5]

0J

CHECK FAN SWITCH CIRCUIT

Do approx 12 volls exist between each
fan switch harness terminal and body
ground?
RHA38aEA

Terminal No

Flow chart

Voltage

No

t!J

!2J

<!l

Ql

111

[4;

(!)

Body ground

Appro.
121,1

L--r-------

Yes

Ii

[~

[3!

RHA187EA

to

Nole

Check circuit continuity

between fan switch and

[4~

~J

resistor,

-CHECK FAN SWITCH AFTER DIS-

Replace

fa~ switch

CONNECTING IT,
(Refer to HA-68l
OK

[!t

Nole

Check circuit continuity between fan

switch harness termmal No @ and
body ground

~------I

Replace blower motor ,

_~

Note:
If the result is NG after checking circuit continuity, repair har-

:=i..,

i'ly::,

ness or connector.

HA-57

Diagnostic Procedure 2
Push conlrol
unit conneClor@

SYMPTOM: Air outlet does not change.

~i5

Perform PRELIMINARY CHECK 4, then Main Power Supply

and Ground Circuit Check before referring to the flow chart
below.

lOIR

CHECK MODE DOOR MOrOR POSITION

SWITCH
1 Turn VENT switch ON With Ignition

SHA429EA

~~

D,sconnect mode

dog

~otO' ha""'j 'O""""~o"

sWitch al ON position.

2 Turn ignlhoo SWitch OFF

Push control
connector @

Disconnect push ccmlrol

U'Ht

~16

connec-

CHECK BODY GROUND

CIRCUIT FOR MODE
DOOR MOTOA.

CD

or

C!>

of push control unit har-

Does conhnuily exisl

between mode door moior
I".arness termInal No
and bDdy ground?

ness conneclor and body ground.

Using above procedures, check for
continuity in any other mode, as indi-

cated In charI.

SH:29EB!

UI\\\

lor.
3 ChecK lor cOl'\linuily between termInal

Terminal No

Cont'
nU1ty

Mode door mOlor connllctor

~~Di8'

Note

VENT
BfL

00

Check circuit cDnlinuity

t1J

between each terminal on

or @

-------t----,
FlO
or
OEF
or
FOOT

@ or

Body

g.ountl

--o--rOK-o_..
flH ....369EA

push control unit and on

Yes

mode door motor.

'

Terminal No

_J

$
I'osh

CHECK SIDE LINK

(!]lHD model

f::)

\ Reier 10 Control L'f1kage Adjustmenl

(HA701

Mo~e

con!fol

doo'

unll

rnotof'

(1)

(!J

,~

11)

~)

Conll'
nUlty

I~)

I---

I~

'2\
'J'
't'

ll)

<!J

Yes

!J)

l
r-~:-----~---r--1---

__

'!l

\'~~~J- ~l~~ 1

_ '-.""r"';6"!S]

{13T2J.-rX[?W~,
1~8"
motor

Mode door

connectOf

"'l1>lI

(Go 10 nexl page)

Nole:
II the resull Is NG aller checking circuit continuily, repair harness 0' connector.

SllA530E

HA-58

TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)
~----------

-----

~)

RHO model

Pus'" control
UfHI COfmeclor

<

Reconnect push control unit and mode

door molor harness conneclors

CHECK FOA OUTPUT OF PUSH CONTROL UNIT

Change the mode from VENT 10 DEF, or
from DEF 10 VENT. Do approx. 12 volls

eltlsl between push conlrol unil harness

lerminals (!J and @ in both cases?

Terminal
No

~
Iifll~ ii:A
Each

Mode dOl)! moior

connector ~
~-':0

e Till
lfJle

RHO: G/OR
LHD: G/V
Push control
unit connector

~-~@

Repla~e

VENT

DH

OV
OEF

--

VENT

mODe dOD! motor

RHO GIY

LHO: GIOR

13

Voltage

Stop

side

SHA482E

Mode switch
operation

VENT

~I-DEF

SliA431EA

HA-59

Appro~

12V

I'

im~iD

l Irn-mm
I

Yll

Diagnostic Procedure 3
SYMPTOM: Intake door does nol change in VENT, B/l or FOOT
mode.
Perform PRELIMINARY CHECK 1, then Main Power Supply
and Ground Circuit Check before referring to the flow chart

Push control
unit corllwclor

below.

rJ
r---------------SHUl6EA

._-------

Terminal No

Rf.C
S\/\ll!c~

dOO~

r!l pu:

control unit
connector @

Inlake
conneetor"-'

miHm~ ~~8

"-I'

~:

iD

[ill

,-V

y/L

i:

I
I

BOdy

OFF

ground

I
j

eN

EEl
@

rrn
I

p.

~ rnJHrn ~ is

~ ~==~

Refer to HA71.

Push control un,t connector @

u""

Note
--

rv

OK

Note

~OK
Reconnect push control
unll and inlake door
molar harness conneclor

IE
Yes

f--

CHECK FOR OUTPUT OF

PUSH CONTROL UNIT
Turn REC swilch ON or
OFF. Do approJi. 12 \lolts
exist between puSh C(Hl'
Irol unit harness connec
lor terminals @ or @
and body ground?
flEe

Replace intake door melor

res

push control
unit be,"","
harness
<ool;,oil,
terminal @ (~~) and
in lake doer motor har
l1ess lerminal @ ((i))

S""i1c~

ON
OFF

L
(j

__

'---.

Note

CHECK BODY GROUND

CIRCUIT FOR INTAKE
DOOR MOTOR.
Does continuity exist
between Intake dODr
motor harness termmal
No. Sl'Id body
ground'>

Y"s

Check for continUity between push conIrol unit harness connector termrnal ~a!
{@) and intake door motor har'less
lerminal
()

raJ

r-----

CantinuII..,

L~~

,~~~

------r---

LlN~

r---'

ush control unil connector@

DlscorlOect inlake door

motor harness connect.:.r

CHECK INTAKE DOOR

SI--IA484

-J

NG

CHECK INTAKE DOOR MOTOR POSI

TION SWITCH
1 Turn AEC sw,tch ON with ignitiOn
switc h at ON position.
Turn ignition switch OFF
Disconnect push control unit connector.
3 Check for conlinuity between term 1nal @ of push control unll ha'fl~SS
connector and body ground
4 USing above procedures, chec~ for
REC switch OFF pOSition as indicated
In chaort.

Terminal No.

1)1 e

Vollag"

f~ I aody Approx
12V
(il\ \ ground
I

IlHA555EA

~@

Inla~8 door
motor@

illlillll

rEEEfffi

Push contlolunn COM ector

~~

\.
J
l P"~t~!D~~~

I
] NC

ePlaCepUShconlr;-'-J
uml

--------

Note:
If the result is NG after checking circuil continuity, repair har
ness or connector.

HA-60

Diagnostic Procedure 4
SYMPTOM: Air mix door does nof change.
Perlorm PRELIMINARY CHECK 2, then Main Power Supply
and Ground Circuit Check befare referring to the flow chart
below.

'il

"",'1,..:"
No

CHECK POWER SUPPLY FOR AIR MIX

r-----

DOOR MOTOA.
SHA4B&E

m InoIJ]
~

-@

and 7 SA fuse at fuse

Olsconnect air mix door motor harness

block

connector.

Reter to EL section

00 approx 12V eXist bet ..... een

Air mix door
motDr connector

Check power supply c,,

CUlt

( 'Wifing Diagram".

II" mil(

door molor harness terminal No

"POWER SUPPLY
ROUTING")

and body ground?

res

Note

Cl'Iack Circuit continuity between air mix

00

L_ _~~

ml~

Air
door molor
conneclor @

F",

ml

"t.. .

door molo' harness terminal No

(iJ

and body ground.

0K

Disconnect push control unit harness

connector.

Note
Check circuit continuity between each
terminal on push conlrol unit and air
mi~

door motor.

Terminal No

Contlnu.ty

G>

Push control

A"".. .. door
m'Jlor

unIt

Yes

!OK
c----'-------'------.-----~

Reconnect push conlrol unit harness

connector and air

door motor har-

In"

ness connector
--

_._------~

'f.)
(Go 10 ne~l page)

Note:
If the result is NG after checking circuit continuity, repair harness or connector.
,I,;',:

Diagnostic Procedure 4 (Cont'd)

I!J

COlO_HOT

:::::=:I

CHECK FOR PUSH CONTROL UNIT

OUTPUT,

Replace push conlrol

unit

Slide the temperature control lever

Push conlrol
unit
connector
@

from HOT to COLD and COLD 10 HOT

Do approx, 12 volts exist belween push
control unit harness terminals @ and
@ in both cases?
Terminal No.

(I)

Each side

Temp
control
lever
operation
HOT

Voltage

COLO
COLD

---+

Approx
12V

HOT
STOP

Appro.
OV

SHAd44EA

Yes
CHECK FOR PBR RESISTANCE IN AIR
MIX DOOR MOTOR
Refer 10 HA70
OK
CHECK AlA MIX DOOR LINK.
(Refer to HA-71 )

HA-62

--

Replace air mix door

motor,

Diagnostic Procedure 5
Bit door motor
conneClor ~

1i8>JI]

SYMPTOM: BI-Ievel (Bll) door does not operate.

~)
""'"'C,

-------------

PU

CHECK POWER SUPPLY FOR BIL

DOOR MOTOR
Turn BIL switch ON and OFF
Do approx. 12 IIOlts exist between Bil
door motor harness lerminals (1.:; and

LGNI

@ in bolh cases'
81L door molor
connector ~

~ ~

Terminal No

~ "W;J

~:-'l
~~

BIL
switch

B/L
door
operalion

(!)

(f)

ON

Open

ffi

OFF

Close

Note

Check circuil continUity

between BIL door motor
Voltage

I.'=:

harness terminal No (i)

((1) 1 and push control

Appro.
12V

unit harness terminal No

@(@l.

Yes

I),
SHA489E

CHECK B/l DOOA LINK, Reter to

Push control unit
connector @

BIL door molar

connector @

HA-71,

~I~~

~l'r~~':u
~C\
LGffl

"

:,

lGIW

!'

Note:
If the result is NG after checking circuit continuity, repair harness or connector.

J
~'; '~'.

SHA490E

HA-63

TROUBLE DIAGNOSES
Diagnostic Procedure 6
SYMPTOM: Magnet clutch does not operate when Ale
switch and fan switch are ON.

Perform PRELIMINARY CHECK 2 before referring 10 the

following flow chart.

CHECK POWER SUPPLY FOR COM

PRESSOR.
Thermal prolector UiD
conMctor

Disconnect compressor harness connector.

-,

RHO. @-1

~ ~'i5' ~

P.
No

00 approx. 12 volts eXist belween com

pressor harness terminal No

CD

,-

and

body ground?

SHA492E

LHD -t
connector RHD :@.,

'is'

CHECK THERMAL PRO-

_J

TECTOR.
Check circuit continuity

OK

belween thermal protec-

LHD :CE) 2
RHD -@-2

~ C0

[j] ~

LEU 'is'
00

[!J
Check magnet clutch coil.

Compressor
connector

l!JThermal
protector

Disconnect thermal proteclor harness connector

Do approx. 12V exisl
between Ihermal proleclor harness terminal No.
CD and body ground?

Yes

CHECK POWER SUPPL Y

FOR THERMAL PROTECTOR

Replace magnet clutch.

tor harness ler~inal No_

G) and compressor har-

Refer to COMPRESSOR (HA1461

ness terminal No.

CD-

Replace thermal protector

SHA493E \

(Go to nexl page

HA-64

TROUBLE DIAGNOSES
Diagnostic Procedure 6 (Cont'd)
I;]

\A)

Thermal
proleclor LHD.@)'
conneclor RHO @.,

-~-_.

AJC 'elay

~ ~

LIF'

cann;Clar@

C'~~
EO ~ [ill ~
.
15
ra
''''o....

Ale 'elay
conneclQr@

I D,,,,,,,n~1 Ale "'"

1!1

__J

~~eCk

c"cu,t cont,nUlty

-N:e

betwe~n Ale

\j; and
thermal prolector harness terminal Na

I ,clay harness term,nal No

(I)

'HEeK POWER

r_

CHECK POWER SUPPL Y

CIRCUIT AND 7 5A
FUSES AT FUSE BLOCK
(Refer \0 "POWER SUPPLY ROUTING" ,n EL
section and Wifing Diagram)

SUPPLY FOR AIC

RELAY
D,scannect AlC relay
Do approx 12 volls e.,st between A,e
relay harness termInal No jl. 5', and
body ground?

ea~~
___________

,,~l

---~

1lI

eir ~i5

h"nm

tor

.-----~-- - - -

RHA.Jg~J

~ ...... <'

~E)

Replace Ale relay

CHECK Ale RELAY AFTER DISCON

NECTING IT
(Reier to Elect"cal Compo"enlS InspecI,on) (HA-70)

OK

rr===E=C=M====!i'jO[ OONNECTOR II
v

.-~

Reconl\ect AIC relay

Nole

~
Ale felay
connector

TJlplepressure
switch connector

liD

~--:::;.j

~ ~i"o ~~~g:~
~
rnJ
lHD GN
RHD GTW

LHD GN
RHO GfIN

'--------------------'

III

Triple-pressure
switch connector
lHO'@ ~

LHD,SIP

No

Check C>fCUI! contrl\uity

betwee" AIC relay harness terminal No @
and triple-pressure
switch harness terminal
No (~

Yes
OK
Nole

IGo to ne.t page)

Check circuit continuity

betweel\ triple-pressure
switch harness terminal
No. CD and ECM (ECeS
control module) harness
lerminal No, .
~For terminal
arrangement, refer to
last page (Foldout page)

~ ~~

l.II!D ~V
=qs'~==~
RHO:@~GI
CECM JJi CONNEC1OA II
RHD GIY

CHECK COrL SIDE CIRCUIT OF AIC

RELAY
Do appro. 12 volls ensl between ECM
(ECCS control module) harness ter';i~I
nal No ~ and body grou"d~
~

em

AHD,GIY

~ LH~
SIlA496E

OK
CHECK TRIPLE PRESSURE SWITCH
Refer to HA-69
-----

- -_.-

-l.~;
-

Note:
II the result Is NG aller checking circuli contlnully, repair harness or connector.

Diagnostic Procedure 6 (Cont'd)

raj

[ D'''"Me'' ,he'mo <D"'" omp

ho'~

ness connector

Nole

belween;~rmo I

Check cirCUIt continuIty

control amp harness termInal No. lj)
and ECM (ECeS control module) har-

ness rermlnal No ~
Thermo control
amp.@

~~16

[~ j~";j}
L

SHA496E

e=lJ=--_ _

=r=_-_- - ,

CHECK POWER SUPPL Y FOR THERMO

No

Check 7.SA fuse al fuse

block

CONTROL AMP
Disconnect thermo control amp harness connector
00

appro~

Refer tQ EL section
"Wiring

12 volts e(ISl between

Dia9ram"

"POWER SUPPl Y

thermo control amp h:lfness terminal

@ and body ground?

ROUTING")

No

Yes

Thermo Ctlr"frol
amp.@

~~EO~
~or~

"(JJj

Ia

CHECK BODY GROUND CIRCUIT F ; ] R NG

THERMO CONTROL AMP

Disconnect push conlrol

unit harness connector.

Turn Ale sWllch or OEF SWItch ON

Check lor continuity between thermo
conlrol amp. harnes'S terminal @ and
body ground
L-

~_----_-_

OK

RHM03EA

(Go to ne(t page)

CHECK THERMO CONTROl.

AM~e Ihermo con~

~

ReIer to HA-66
~---

Check voltage between ECM IEees

control module) harness terminalS (~,

~_~

@ and body ground

Refer to EC sectIOn ("ECM Termlnals
and Relerencp- Valve" "TROUBLE
DIAGNOSES -

General Descrlplion

Note:
If the result is NG aller checking circuit continuity, repair harness or connector.

HA-66

Diagnostic Procedure 6 (Conl'd)

Th~rmo

control

Push conlrol unit G)

.mp@

& ~

i5

remEml

(I
I
Note
.------~~-------,
Check Circuit continuit)' between thermo
control amp harl1ess terminal No. l])
and push contra) unit harness terminal

No. @.

[ill

OK
rlHA404EA

r,

II Fan switch

Push control unit @

connector @

~I ~ 1trf8Jl]

l~

i5

JlGftl

Oisconnect fan switch harness conneclor,

~OK

Note

Check l;ircuit continuity betweel1 push

control unit terminal No @ and Ian
switch harness terminal No. @.

------,------OK

[ill

Nole

RHA405EA

CHECK SODY GROUND CIRCUIT FOR

FAN SWITCH,
Check lor continuity between fan SWitch
harness termmal and body ground,

----=e= -_-_~~~-_-.~laCe

Fan sW1tch
connectof @

~~~i8

'-C-H-E-C-K-F-A-N-S-WITCH.
(Reier to HA-68l

LfJlJl

L-

Ian switch

~'fJj

OK

~Place push::._O_I1_lr_O_I_U_I1_'I_,
RHA406EA.

Note:
If the result is NG after checking circuit contlnully, repair harness or connector.

HA-67

~ 1~:~M".OI
SWiIC~
~.=fi
o

un..ll

lOan

~ 1S17! _-:-_~Io

L-

~I
_

Electrical Components Inspection

FAN SWITCH
Checl< continuity between terminals at each position
TERMINAL

POSITION
OFF

(4) - 15) . @

--------+---------------.

(~

@ . (5) -

'J)

I~

(Jj -

RHA5S~E

(1) -

(~

-------

BLOWER MOTOR
Check blower motor for smooth rotation.
Ensure that there are no foreign particles inside the intake
unit.

AHA553E

BLOWER RESISTOR
Check continuity between terminals

THERMO CONTROL AMP.

1.
2.
3

Run engine, and operate Ale system.

Connect the voltmeter iram harness side.
Check thermo control amp. operation shown in the lable.
ThermD ~mD
Cperi\llOfl

Tesler

DecreaSing to ~ 5 . ) S (37 38)

TUrri OFF

ApprOJ l?V

Increasing 10 1 - 2 (34 . 36)

Turri Ot~

Evaporator cullet air temperature

'C I'F)

- - - - - - - - . - - - - -------1--------- - - - - - - -_._+----------- - - - - - - - . -

HA-68

Appro~

QV

Electrical Components Inspection (Cont'd)

TRIPlE~PRESSURE SWITCH

LHD model
High-pressure side Ime
Terminals

---

pressure
kPa (bar, kg/cm~. psi)

Opera-

Con Ii-

lion

nuily

ON

Exist

~r

IncreaSing 10
157 - 225 (1,57 226,

Low-

1,62.3,23 - 33)

pressure
side

G)-@

Decreasing 10
152.0 - 20'.0 (1520 - 2,010,

OFF

1 55 2.05, 22 0 - 29.2)

Does 1'101
eXlsl

,7"
1_'0

Increasmg 10
1,422 1,618 (14,22 - 16 18,

Mediumpressure

ON

Exist

14 5 . 16 5, 206 - 235)

@ .

(~)

side"

Decreasmg to
1,128 - 1,422 (11,2814.22,

OFF

11.5 . 14.5, 164 - 206)

Does not
exisl

Increasing to
1,667 - 2,059 (16.7 - 20.6,

High-

ON

Exist

17 21,242 - 299)

pressure

G)-@
Decreasing to

side

2,452 - 2,844 (24.5 - 284,

OFF

25 - 29,356 - 412)

Does nol
exist

For cooling fan molor operallOn,

H'j

RHO model
Terminals

Low-pressure side

Medlumpressure
sode'

Hlgh-pressure side

(1) -@

(2) . ~.~I

(1) . l4;

High-pressure side
line pressure
kPa (bar, kglcm 2 , psi)

Operation

Cont'f\ult'l

Increasing to
157 . 216 (1.57 - 2 16,
1 6 2 2, 23 - 31)

ON

EXists

Decreasing to
1520-2010
(I 520 . 2010,
1.55 - 2 05, 22 0 . 29 2)

OFF

Does 1'101
e)(ISl

IncreaSing 1O
1,442 . 1,697
(1442 - 1697,
14 7 - 17 3. 209 . 246)

ON

EXIsts

DecreaSIng Ie
1,1261.422
(11 28 . 14 22,
11,5145,164 - 206)

OFF

Does not
exist

ON

eXists

DecreaSing to
1,275 1,667
(12.7 - 167.
13 17, 185242)
Increasing to
2,452 - 2,644
(245 284,
25 - 29,356 412)

OFF

Does

U'i7

f\I-' ,

.':'1

'101

eXIsl

For cooling Ian motor operation

HA-69

J'

TROUBLE DIAGNOSES
I MANUAD
Electrical Components Inspection (Cont'd)
THERMAL PROTECTOR
Temperalure 01 compressor
'C ('F)

Operation

If'creasing to approx 145 - 155 (793 - 311)

Turn OFF

DecreasH1g to approx 130 - 140 (266 - 284)

Turn ON

Ale RELAV
Check circuit continuity between terminals by supplying 12
volts to coil side terminals of the relay.

AHA2U

AIR MIX DOOR MOTOR

Air mI. dOor

molor eonnector ~

~i5~ I

Check tor PBR resistance.

1. fum ignition switch ON and temperature control lever to
FULL HOT position.
2. Turn ignition switch OFF.
3. Disconnect air mix door motor connector
4. Check for resistance between air mix door motor harness
terminal @ and .
5. Using above procedures. check for each terminal as indicated in chart below

SHA5QJE

Terminal No.

Temp conlrol lever posihen

FUll HOT

(j)

,~

FULL COLD

CD

(?\

FULL HOT

eli

,J.j

f--.

FULL COLD

Resislance
ApprOl(.OO
Appro. 3

kn

Approx 3 kf.!

---.--------Approx on

Control Linkage Adjustment

MODE DOOR
1.
2
3
4
\

L_ _~

Install mode door motor on healer unit and connect it to

main harness.
Turn ignition switch to ON
Turn VENT switch ON.
Turn OEF switch ON. Check that Side link operates at the
fully-open position. Also turn DEF SWitch ON to check that
side link operates at the fUlly-open position.

HA-70

Control Linkage Adjustment (Cont'd)

AIR MIX DOOR
1.
2.
3.
4.
S
6.
RHA411E

Move air mix door link by hand and hold air mix door in
full cold position
Install air mix door motor on heater unit al'\d connect sub- ,~[
harness.
Turn ignition switch to ON.
Slide temperature control lever to ful! cold.
Attach air mix door motor rod to air mix door link rod
holder.
Check that air mix door operates properly when temperature control lever is slid to full hot and full cold.
Slide temperature control lever to full cold.

INTAKE DOOR
1.
2.
3.
4.
5.
6.

Connect intake door motor harness connector before

installing intake door motor.
Turn ignition switch to ON.
Turn REC switch ON.
Install intake door motor on intake unit
Set intake door rod in REC position and fasten door rod to
holder.
Check that intake door operates properly when REC switch
is turned ON and OFF.

~I/:,

BI-LEVEl (B/l) DOOR

1.
2
3.
4.

Connect B/L door molor harness connector before installing B/L door motor
Turn ignition switch to ON.
Install B/l door motor on heater unit.
Check that B/L door operates properly when bl-Ievel
switch : ; is turned ON and OFF.

RHA414E

HA-71

~:g(

DESCRIPTION

Introduction
The Automatic Temperature Control (ATC) system provIdes automatic regulation of the vehicles Interior
temperature. The operator selects "sel temperature", on which the regulation is based, regardless of
the outside temperature changes This is done by utilizing a microcomputer, also referred to as the
automatic amplifier (auto amp.). which receives input signals from several sensors, The automatic
amplifier uses these input signals (including the set temperature) to automatically control the ATC system's outlet air volume, air temperature, and air distribution.

Features
Air mix door control (Automatic temperature control)
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

Blower speed is automatically controlled based on temperature selling, ambient temperature, in-vehicle temperature, amount of sunload and air mix door position
With FAN switch sel to "AUTO", the blower motor starts to gradually increase air now volume
When engine coolant temperature is low, the blower motor operatIon is delayed 10 prevent cool air from
flowing.
Intake door control
The intake doors are automatically controlled by. The temperature setting, ambient temperature. in-vehicle temperature and amount of sunload.
Mode door control
The mode doors (defroster door, ventilator door and foot door) are automatically controlled by The
temperature setting, ambient temperature, in-vehicle temperature and amount 01 sunload

Bf-Ievel door control

The bi-level door is opened to increase amount of air discharge when the air discharge oullet is set at
bi-Ievel posi\lon. The bi-\evel door is also opened when the ian speed is high and the set temperature
is aI18C.
Except during the above condilions, the bi-Ievel door is closed,
Self-diagnostic system
The sell-diagnostic system is built IOta the automatic amplifier to quiCkly locate the cause at problems.

HA-72

Control Operation

l,'.'.

ll-lM:19A

----

AUTO SWITCH
The compressor, air intake ooors, air mix door, mode doors. and blower speed are au\omatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature.
,he air conditioning cooling function operates only when the engine Is running.

}:f

Ale SWITCH
Manual control of the compressor operation When the Ale mark appears on the display screen, compressor operation IS being carried out.

TEMPERATURE SWITCH
Increases or decreases the set temper ature.

OFF SWITCH
The compressor and blower are off, the air intake doors are set to the outside air posItion. Then, the
mode doors are set to the foot (80% foot and 20% defrost) position In the oil position the ATe system
uses the vehicle's "flow through" \lentilalion. It tries to maintain the interior temperature based on the
last set temperature of the system.

yr

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.

8r,

MODE SWITCH
Manual control at the air discharge outlets Four selectIons are available (as shown on the display
screen)'
face
,bi-Ievel ~J ,foot ....
defrost/foot

J.

fn

III
'I

fJ

1
I

HA-73

r:

~:

I
I
!

REC SWITCH

Control Operation (Cont'd)

ON position: Interior air is recirculated inside the vehicle.

OFF position: Automatic control resumes.
RECIRC is canceled when DEF is selected. RECIRC resumes when another mode ;s chosen.

OEF SWITCH
Positions the mode doors to the defrost position. Also positions the air intake doors to the outside air
position. With DEF switch ON, the compressor operates.

HA-74

NOTE

I];

'1';l

HA-75

TROUBLE DIAGNOSES

Contents
How to Perform Trouble DIagnoses for Quick and Accurate Repair.
Operallonal Check

." HA- /8
, HA- 79

Symp10m Chart ,.

HA- 82

Self-diagnosis

HA." .... HA... HAHA... HA-

CHECKING PROCEDURE
.
STEP 1: Checks LEOs and segments
..
..
STEP 2, Checks each sensor circuit for open or short circuit
STFP :'j' Checks mode and intake door positions
STEP 4: Checks operation 01 each actuator .. "."

88
88

89
HA- 90

STEP 5: Checks temperature detected by sensors

AUXILIARY MECHANISM: Temperature setting trimmer ..

... HA- 90

.. .. HA- 92

Preliminary Check ...... "

PRtUMINARY CHECK 1
(Air outlet does not change.)
.
PRELIMINARY CHECK 2
(Intake door does not change.)
.
PRELIMINARY CHECK 3
(lnsutficient cooling)
PRELIMINARY CHECK 4
(lnsufiicient healing) ...
PRELIMiNARY CHECK 5
(Blower motor operation is mallunclioning.)
PRELIMINARY CHECK 6
(Magnet clutch does not engage.) ." .....
PRELIMINARY CHECK 7
(Discharged air temperature does not change 1
PRELJMJNAny CHECK 8
(Noise)
Performance Test Diagnoses

.... HA- 93

HA 93
HA- 94

HA- 95
... HA- 96
.... HA- 9?
''' .. HA- 98

HA- 99
... HA-100
HA- 26

Performance Chart ..

. ". HA- 28
.. ...... HA- 29

Trouble Diagnose6 for Abnormal Pressure

.......... HA-101

Harness layout

..... HA-103

Circuit Diagram ., .....

Wiring Diagram -

84
85

AIC, A -

HA-104

..

Main Power Supply and Ground Clrcuil Check

. ,

Diagnostic Procedure 1
SYMPTOM Ambient sensor circuit is open or shorted
(21 or -2: is indicated on display as a result at conducting Self-diagnosis STEP 2 )
Diagnostic Procedure 2
SYMPTOM: In-vehicle sensor circuit is open or shorted.
(22 or -22 is indic<'l ted <'In display as a result of conducting Self-diagnosis S rEP 2 I
Diagnostic Procedure 3
SYMPTOM, Sunload sensor ClrcUlt is open or shorted
(2sor -25;s indicated 01'\ display as a result ot conducting Sell-diagnosis STEP 2 I
Diagnostic Procedure 4
SYMPTOM. PBR Circuit is DDen or shorted.
(C'b or -2fiis il1di~ated on display as a result of conducting Self-diagliosis STFP 2)
Diagnustic Procedure 5

SYMPTOM. Mode door motor does not operate normally

HA-110

.. HA-111

.. . HA-112
"

HA-113

HA114

" HA-115

Di"gnoslic Procedure 6

SYM?TOM Intake doer motor does not operate normally

HA-76

HA-1 ~ 7

,~o

Contents {Cont'd}

DIagnostic Procedure 7
SYMPTOM Air mix door motor does not operate normally.

Diagnostic Procedure 8
SYMPTOM Bi-Ievel (B/l) door mOlor does not operate normally.
Diagnostic Procedure 9
SYMPTOM: Blower motor operation IS malfunctionmg under oul ot
Starting Fan Speed Conlrol ..
Diagnostic Procedure 10
SYMP' OM' Magnet clutCh does not engage after performing
Preliminary Check 5
"
,..
Control Linkage Adjuslment .

HA118

HA-119

jl

'.,'\:,
HA-120
~I\')

HA-122
HA-125

I.,

i'1

CI.

HA-77

How to Perform Trouble Diagnoses for Quick

and Accurate Repair
WORK FLOW

~~~-==--=_l--

LISTEN TO CUSTOMER COMPLAINT AND CONFIRM BY PERFORMING OPERAriONAL CHECK

~:~'i~~ed

Operational Check (Rerer to HA-79)

Symptom Chari (Refer 10 HA82 I

~;~'~r~~~
EDUCATE CUSTOMER ON
CORRECT OPERATION OF
SYSTEM

~~VL~s;~g~~E ~:~~Ss~~~i'~$ULD CARAY

OUT

------,~

L---PE_R_F_O_R_M---,--S_E_LF_"_O_IA_G_N_O_S_I_S_,

--

~rr:,::~~~:_~~

----

Selldlagnosis
(Refer to HA~4 )

Cannol be
conti/med

Can be
contirmed

Maio Power Supply and Ground Circuit

Check
(ReIer to HA-ll0,1

CHECK MAIN
POWER SUPPLY
AND GROUND CIR
CUlT

+_

Diagnostic Proceaure(s) (Reier

to HA-ll t.)
Wiring Diagram
- AIC, A (Refer to
HA-l04l

[R*rence Item

Preliminary Check
(Refer 10 HA-93 )

-----~
----------l

-+--_ L_H_ar_n_e_SS_L3_Y_O_U_1
(Refer to HA-101 )

MalfunctIon mg
hamess(es)!

Malfunction I ng
part(s)
~

conrleclor(s)

1
-:=J

[REPAIR

INSPECT EACH
COMPONENT.
~---

~EPAIR/REPlACE

- - - - -----..:.;Nc;:Gc..;----'----F-IN-A-L-C-H-E-C-K-5
OK

CHECK OUT - - - - - ' - ,

HA-78

Eleclncal Components Inspection

TROUBLE DIAGNOSES
Operational Check
The purpose of the operational check is to confirm lhat the
system is as it should be, The systems which will be checked
are the blower, mode (discharge air), intake air, temperature
decrease, temperature increase, AIC switch and the memory
function.

:~r'

CONDITIONS:

Engine running and at normal operating temperature.

~l;',1

PROCEDURE:
1. Check blower

EEJ

1)

~c.......:=::::::::=,----..:::r~=o:::1Q=o~l

cv

AUTO. OFF -

,(I@,

-,.t~
'-),) -

~~

~
~
I

2)
3)
4)

Press fan switch one time,

Blower should operate on low speed.
The fan symbol should have one blade lit ~ ,
Press fan switch one more lime.
Continue checking blower speed and fan symbol until all
speeds are checked,
Leave blower on MAX speed" .

ZHAOJOA

2. Check discharge air.

1)

AUTO, OFF - - ..;

-- ;; -

...

Press mode switch four times and DEF switch one lime.
When OEF switch is ON, DEF indicator should illuminate,

J- S

I
ZHA031A

DrAcharge elr flow

Swilch mOdel
indIcator

..

Air OLillelldlslrlbLilion

Face

.....

100%

....

60%

'I

Fool

Defroster

rr

40%

....i

80%

20%

@.
......

60%

40%

2) Confirm that discharge air comes out according to the air

distribution table at lefl.
Refer to "Discharge Air Flow", "DESCRIPTION" (HA-12),
NOTE:
Confirm Ihatthe compressor clutch Is engaged (visual inspectlon) and intake door position is al FRESH when the DEF
switch is pressed.
Intake door position Is checked in the next step .

Fl .

100%

RHA429EA

HA-79

TROUBLE DIAGNOSES
Operational Check (Cont'd)
3. Check recirc

1\ Press REC
2)

~ switch
Recife indicator should illuminate.
Listen for Intake door position change (you should hear
blower sound change slightlYJ.

4. Check temperature decrease

1) Press the temperature SWItch (COLD) until 18T
played.
2) Check for cold air at discharge air outlets.

IS

dis-

lHAOl4AI

S. Check temperature increase

1) Press the temperature switch (HOT) until 32"C is displayed
2) Check for hot air at discharge air outlets.

------.

ZHA03~~

6. Check AUTO mode

1)
2)

::J ~~
-'~~
~ 2S c
r:;-o
L.:---.C.:.J
_

~-"-

00 ....

[TI

_C>_

Press AUTO switch.

Display should indicate AUTO and A/C.
Confirm that the compressor clutch engages (audio or
visual inspection).
(Discharge air will depend on ambient. in-vehicle, and set
temperatures)

i
)

ZHA03TA I

---------"-_._--~

La f~~~fi}--I;

0\:) ....- ,;25t

L_.J
\.'-,-- - /

ELlQcI~-

7. Check AIC mode

1) Press A/C switch
Display should indicate AUTO (Ale goes oUI).
Confirm that the compressor clutch is not engaged (visual
inspection)
(Discharge air will depend 01) ambient. in-vehicle. and set
temperatures)
3) Repress A/C switch. Display should IlIdicate A/C and the
compressor clutch is engaged

2)

-- ..
HA-80

Operational Check (Cont'd)

-----~----------

8. Check memory lunction

1) Press OFF switch
2) Turn the ignilion off,
3} Turn the ignitIOn on,
t,) PresS the AUTO switch,
5) Confirm that the set temperature remains at previous temperature

ZHA036A

HA-81

:i~
~"~,,i~

TROUBLE DIAGNOSES
Symptom Chart
DIAGNOSTIC TABLE
Sf-II diagnosis

PROCEDURE

OJagnOSllc Procedure

PreJmlrnary Check

a-

<:

'"
:l;

~~

::f

0'"

":

~ffi

;.

UJu0",
Zr:<

SYMPTOM

"-

l:}o

...

UJ

"';z

(/J

0<:(

0
0,

A.ir oullel dot.s I'1ot l;;:hiJoge.

Intake door

~c.:ll~S

nol change

lnsuflic I'lint l.oollng

~
~

":
f.
"-

UJ
....

'"
f)

MaQI1611 dulCh <1061,$ not engage

Ol'icna,ged

~,t

1~mperalure

does

nol

cna"qe

0
0
0

~;:

..,

.;;

f.

"-

"

"-

f-

:;;

UJ
f-

(/J

(/J

UJ

"'

.:J

."

:J

()

l)

':)

':.l

f)

f)

:J

<:

:I::

~
::;

'-'
~

"-

UJ

f)

In',luPrlc;i1n1 heal/flg

Blowe' maIm ope/a.tion is maHu,.ctioning

g;

>-

r:<

Vi"

~.

~
0:

,.c

<:(

..

"
,.

.,.;
X
::>

:'II

t.:
"0-

.. Q:~..

ti:

22
25

-=-.

f-

If>

~ 26

~
~

(;

a:

-2 :
-22
-25

-t='6

f)

f)

f}

cuit itt: shor1ed

In-vehicle Sensal CiT

cuit is shorted

f)

{)

f)

f)

SunlQao S,i1nsor circuit

is open
PBR cln:uit is open
Ambient sensor Clt-

Suntoad s,enSOr c.rc.urt

is shorted.
PBR crrcuil is shorled

Mode dOOf molor does not operate norITlally

)nt,alc:e door motor does not operale

1"10'-

mally
mix door motor does nol operate
matry
A.ll

nOT-

Bi-leweJ door molor does not operate florrnally

Blower mOlor operation tS m8JlUl'lClionln~
under out 01 SlarHng Fan Speed Conl,ol

Magnet clutch does not I)oerate .aller Qar.

'?,mlng Pretjminary C"edl 6
Serl-dragnt)s,~ cannot

be

'"

t::.

'",..

t::.

..

"

0;

~
0:.

!.

'"

d-

4:

:s

.. ..

<:(

.{

!.

f.

":>
"c

"c..

..,
~

'-'

il.

'C

"-

iL

il.

e''""

e'"

":>

il.

"
<:;

<:;

C>

'"

0'"

C>

.:;

()

.,
0

/)

~ -~

-- ._- --.

"

"-~

0
@)

@
----

--~

..

0
@
,-

, , -- - ' - - -

0
"-

-'

f)

:J

f}

@)

'-)

@)

'l

f)

.(

CUllls open

"

il.

5
<:>
<:>

.~

I---

I" -...ehlde sensor Clr

..:I::

rs open

.(

"

CUlt

"

NDI~l!!.

Ambient SenSOr cir

- - f - - r-'" f------ -

--

0
@

/,

._,,'---

~er'o(rnetj

0-6

The Ilumber means ctleck,ng otder

As lor checkmg order, reler 10 each Ilaw chart (It depends on malfunctioning portIOn)

HA-82

'--

", I Dia

Dia

Ol~

-'.I I

(.JII'I

Q
Q

Dla

1,01

D'~

I I I'; -,' I' I-I ~' IA~

7,S
-'

-j

'-'
r~,

I'

r_,

1..1

7,5
C

.J

()

-<-, IIJ I,",

'J

Iln.

(~

I $u

,-, I

Th

L'

~
I
ClO
W

T5

1-) I Am

J:

,5

P6

At<

Mo

Inl

() I

1_ \ _ I

I '_' I B.-

Bl

Fil

L'

,)

r...

Tr
fj

M
IH

c) I 0

10 101 Au

o
0\ [,

()

:J

'J

~j

l) IC,Ic,

I>

Al

010

EG

C'l

CO

I
'='
~

.......=.=-~,.""'mNi" '

,"1'

R
-

;wJ

0-l

(0j)

:w"
~

.gw
29

I GO

: I

(; I G
~

'I ~

~,

"&

,9

') I c;

rJ

!3J

~
---"'1

\,!,"")\

1,_, I ') I Co 10 I Ha

-llLl

.rliU

ron,

,"lJ

TROUBLE DIAGNOSES
Selfdiagnosis
The self-diagnostic system diagnoses sensors. door motors
blower motor, etc by system line. Refer to applicable secliol'l~'
(items) for details. Shifting from normal control to the sell-di_
agnostic system is done as follows, Start the engine (turn the
ignition switch from "OFF" to "ON") And press "12 "switch
for at least 5 seconds. The "
switch must be pressed
within 5 seconds after starting the engine (Ignition switch is
turned "ON"), This system will be canceled by either pressing
g 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 shifling from STEP 5 to AUXILIARY MECHANISM
is accomplished by means of pusning Ea (fan) switch

a "

.~

!7'QnJilon sw,leh OFF

ON)
L--,-

tion sw,leh IS turned "ON"). presS

,-

switch lor at least:; seconds

..L-

' -_ _--...

r-----r---

__ _T_.

T__

AUXILlAR,' MECHlI.NISM ' - T('moeralure

selhng l/.'mmer (Reier 10 HA~2 I
L-

Within 5 ,econcls after starling engone /'9 n ,.

Ign'I,<>n

~wileh,

OFF

'~
I

Iqnn,on SWitch OFF

Note:

fo, S fEP 4 &nd :;, engine must be 'Ullnll'9 lor eOl1lpres-

' - - --',-

$0'

HA-84

to operate

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
CHECKING PROCEDURE
(Igoilioo

'.,"Ii o~

t"'--

J __

Selin self-dlagnost,c mode

]
(Within 5 secol\ds aller starling engine (Ignition swllcn IS
turned ON"). press l!lD swilch ON for 5 seconds J
I

STEP 1

~LEDS

No

and segments L1lurninate.

~-------,---

Ess I I
_.-

~Yes

switch, LED or fluorescent

STEP 27

------.-[ Mallunctionlllg

1:1 (HOT) switch

-J

(COLD) sWitch

___==r=

, Return to self-diagnOSIS STEP P

-E~c-tioning 0

(COLD) switch

i.f,,1

~Yes
L:ress

+DiSPlay

STEP 2

All sensors are

good order.

1:1 (HOT) sWitch

---" -

In

--]--Yes

Em

L--

(HOT) SWIlch

~dvance 10 self-diagnosis
Press

Malfunctioning
dIsplay tube

-.J

'1: Conduct sell-dIagnosis STEP 2 under sunshine.

When conducting indoors. direct light (more
than SOW) at sunload sensor or Code No
25 will Indicate despite Ihe tact that sunload
sensor IS functioning properly

Sensor(s) is(are)
mal1unct oning
1

MlIlfunctioning sensor

Code

(including circuits)

No.

Code No of ma)lunCllonlng
sensor IS mdlcated on display

--

--

21

Ambient sensor

22
25

Invehicle sensor

26
Note:
Al any Ume, you can relurn 10 a previous step In the selldlagno5ls
by pressing (he
(COLO) switch.

HA-85

Sunload sensor\
PBR

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
@

I
I

STEP 3

All mode and intake door

molor position swilches are
good order

D'splay

No

Mode door and inla"'e

molor posiliorl sWJtch(es)
is(are} malfunc1toOl'lQ

,1'1

Dj,pla,

Code No. of maltunchoning

mode door molor pos'!JO'l
switch is indicated on dlsplay_

_ _------:T
[ Press

(HOT\ switc h

~
STEP 4

Mallunctlcning part or circuit

Code

Displav

Code No of actuators test pattern is iOd,e.ated

on display

r- --

Nole:
For STEP 4, engine must be running lor compressor 10 operate.

HA-86

--

VENT
Btl

33
3Y

FOOT

35
36
38
39

DEF

Mode door motor

-FOOTtOEF

-FAE
20% FRE

Intake door molor

REC

A<::luato's test pattern

COde
No.

Ai,

Mode
door

Intak",

y:

VENT

REC

Full
Cold

OPEN

45V

ON

Y2

Bil

REG

Full
Cold

OPEN

9 11V

Of.!

Bil

20%
FAc

Full
Hot

CLOSE

1- 9V

ON

Y3
- -yy

31
32

Position sWitch

dOD'

mb:

doo'

aileve l Blow""
mOlD,
docr

Comp(ess~,

r--------- - -

---

FOOT

FRE

Fuil
Hot

CLOSE

7 - 9V

OFF

YS

~!O

FRE

Full
HoI

ClOS!::

7 - 9V

OFF

Yf,

DEF

FflE

Full
Hot

CLOSE

10 12V

ON

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
l'

[~

15~

STEP 5

--1

l __I
Press (DEF) sWitch

.~empe,alure delected
cated 01'1 olsplay

Oisplay

.----]

:J-

by each sel\sor is indl-

--r=00

'---_II\-_V_e_h_ic_le_se_n_s_o_'

.------------=-:'

Press FAN swilc;h

r--:sPlav

" " I

~
=-c=--

XILI ARV MECHAN'SM --r-e-m-p-e-r-a-tu-re-s-et----.

t,l\g trimmer

Turn ignition sWItch OFF or

_~I-(-A-U-T-O-)-~I

switch ON,

_ _,J'-----I

E_N_D____

, Ambient sensor

HA-87

--,

1,(

TROUBLE DIAGNOSES
Selfdiagnosis (Cont'd)
HOW TO INTERPRET THE RESULTS
STEP 1: Checks LEOs and segments
When switch's LED and segments are in functioning properly
in STEP 1, LED and display will come on.

l
[

I It

A/C

- - - - - - - - - - - - - _.. _ - - _ . _ - - - - - - - - - - - - -

ZI-IAQ19A

If LEOs or segments malfunction, LED will not come on or display will show incomplete segment.

Display malfunctJon

" ,-;.i-RBc

<~,~

..... "' ..._ ......

illuminate.

lHA040A

STEP 2: Checks each sensor circuit lor open or short

circuit

Display (when all sensors afe

In good order)

\m""" \

\ IlIumlnale~ S seconds

'M" . ~ . " ,"C","""

Display shows "2 .. in STEP 2 mode.

When al J sensors are in good order, display shows "20".
It takes approximately 5 seconds to check all sensors.

~,,'

eLI

RHA499AA

Display (when sensor malfunctions)

BlrnkS (Indicating

I'

~hortc"cult)

\,m1nates ~ Code No

--,--,

--

(blinks)

~I"'I"
~

---------.--

--ZHA04ZA

If a sensor is malfunctioning. the corresponding code No.

bl inks on dispJ ay. A short circuit is identified by a bl inking "_"
mark preceding mode number

, ,,
..,...,

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)

..

If two or more sensors malfunction. corresponding code Nos

respectively blink two times

,~
~

Each code No.

blink$ two tim.

I"I~
~~

AHASOtA

Sensors and abnormalities

If a circuit is opened or shorted. dIsplay shows its code No,
when input corresponds with any of following conditions_
Code No.

Sensor

:)1

Ambient sensor

LI

22

Short circUli

Open cifCUil=1
Less !han
---41 g'C (-43'1')

-Sunload sensof'2

26

PBR'l

lO<tC (212'Fl

Less than

In-vehicle serlsQt

2S

Greater lhan
Greater than

__ ---41 g'C (--43'F)

IOO'C (212"F)

Less Ihan

Greater than

4,5 rnA

192 rnA

Greater than 50%

Less than 30%

'I' "50%" and "30%" refer 10 percentage with respect to full stroke of air
mix door (Full cold: 10%. Full hot: 90%)
'2: Conduct self-diagnosis STEP 2 under sunshine.
When conducting indoors, direct light (more than 60W) at sunload sensor.

Dl&play (when ell doors ere

In good order) IIlumlnaters 20 seconds atler

.. 3'
1I,\,nates

,s shown an dISplay

",n

=.u

Display (when 8
ut of order)

Illu\"ales

~,

..,

Code No, (blinksl

=t.:l

- - - - - ------

Display shows "3 "in STEP 3 mode.

When all doors are in good order, display will then show "3D"
It lakes approximately 20 seconds to check all mode and
Intake doors.

AHAJ8JD

oor s
\

STEP 3: Checks mode and intake door positions

When abnormalities are detected, display shows a code No.

correspDnding with malfunctIOning part.
Code No

31 32 33
-1--

Mal/unt:tlonlng part

VENT

f1l1A"9/A

----

HA-89

Brl

FOOT

3E. 38 39
F~o~135
i
DEF

OU

FRE

20%
FRE

REG

F,\.

[IX'

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)

=-,
!

-~-

If two or more mode or intake doors are out of order, corresponding code numbers respectively blink two times.
If mode door motor harness connector is disconnected, the
following display pattern will appear
3: ----> 32---" 33---> 3'--1--->35

Eac" code No

=-=,

L-

lIm~s

bliflk; lWO

4alt:

Change; t, 0'"

":" to

STEP 4: Checks operation 01 each actuator

"(,".

Display shows "y: " in STEP 4 mode.

When ~ DEF switch is pressed one time, display shows
"Yi? ". Thereafter. each ti me the switch is pressed, display
advances one nu mber al a time. up to "YEi ", then returns to
"y: ".

rOm,""" \

1_' ,

IL.

_--.--J

If intake mode door harness connector is disconnected, the

following display pattern will appear
36 --4 3B ---to 39
r
I
If any mode door mOlor position switch is malfunctioning,
mode door motor will also malfunction.

.~.~

.,

..J

During inspection in STEP 4, the auto amp. will forcefully

transmit an output to the affected actuators The corresponding code Nos. are shown on display as indicated in the table
below.
Checks must be made visually, by listening to any noise, or by
touching air outlets with your hand. etc. for improper operatIon.

Of.charge elr ftOt'f

Air outletidistrlbuUOfl

SWllc~ mQdel
indicator

-.
-.
.....

Face

Detro~'~r

Fool

100%

Code No.
GO'll.

Actualor

40%

VENT

Mode door

",j

60%

60%

REC

Intake door

20%

Air mtx door

40%

Blower motor

1_-

_100%

\"'P""

RHA429E ...

all

REC

Bil

20%

FRE

L: Lf
FOOT
~AE

'-IS 'if,
F/D

DEF

FRE

FRE

--

Full

Full

Full

Full

Cold

Cold

Hot

Hoi

Hal

Hot

4-5

9 -11

79

7- 9

7 - 9

10 - 12

Full

full

CompreSSO I

ON

ON

ON

OFF

OFF

ON

Bi-Ievel door

Open

Open

Shut

Shut

Shut

Shut

OperaUng condition 01 eiJctl aclUalor cannot be checked by Indicators.

1

STEP S: Checks temperature detected by sensors

P"

d"p'"

Checks temperature detected by sensors

Display shows "5" in STEP 5 mode

When
DEF switch is pressed one time, display shows
temperature detected by ambient sensor

When
DEF sWItch is pressed second time, display
shows temperature delected by in-vehicle sensor.

When ~ DEF switch is pressed third time. display

returns to original presentation "5".

CD

CD

LI: '-:2 Lf3

HA-90

Self-diagnosis (Cont'd)
L-------------- ~- :pm~"(.t0(e

delected b~ senSDr

~orr~S?Ondi"g will'1 switch ope' .."""

"-

"",..-

~,~,
~,

.....

RHM93 ...

!
Ii

:;

- _ Temperatur&
detected by

ambient .enlOr

Display

""
Temperatura
detected by
In-vehicle

I-----

len.or

If temperature shown on display greatly diHers from actual

temperature, check sensor circuit at first Then inspect sensor
itself according to the procedures described in Control System
Inpul Component. Refer \0 HA-128.

{"!

Self-diagnosis (Cont'd)
AUXILIARY MECHANISM: Temperature selling trimmer T
This trimmer compensates for differences between temperaY
ture setling (displayed digitally) and temperature felt by driverH
in a range of 3'C
r
Operating procedures for this trimmer are as follows:
_
Starling with STEP 5 under "Self-diagnostic mode", press!
(fan) switch 10 sel air conditioning system in auxiliary:
mode Then, press either
(HOT} or
(COLD) sWitch as
desired. Temperature will change at a rate of 1'c each time a
switch is pressed

Initial display

D'~

,-----

~c_ I'~

~~

Ir-:,

~i

l~I~-i-~
~--=_~[jiJ1
-IL__--_-~~----l IL_-~ JfjJJ
l

lHA045A

- - When battery cable is disconnected. trimmer operation is canceled and temperature set becomes thaI of initial condition,
I.e. GOC.

HA-92

Preliminary Check

PRELIMINARY CHECK 1
~Ir outlet does nol change.

Perform Self-diagnosis STEP 1 before referring 10 the flow chart.

JING

CHECK SENSOR CiRCUIT

Set up Self-diagnosis STEP 2
Is each sensor cirCUli normal?

CHECK SENSOR CIRCUIT iN DETAIL ACCORDING TO THE DIAGNOSTiC PROCEDURE BELOW CORRESPONDING TO EACH CODE
NO

Code No. 20 should be Indlcaled on Ille display alter appro . 5 seconds.

page

2J

Go 10 Diagnostic Procedure 1

HA.l11

CC

Go to Diagnostic Procedure 2.

HA-112

25
26

Go 10 Oiagnost,c Procedure J.

HA-113

Go 10 DiagnostiC Procedure 4

HA-114

-2:

Go 10 Diagnostic: Procedure 1

HAl11

-22
-25

Go

Diagnostic Procedure 2.

HA-112

Go to Diagnostic Procedure 3

HA-113

-26

Go 10 Dlagnoslic Procedure 4.

HA-114

10

f--------

Are sensor circuits for ambient sensor and in-vehicle sensor operating normally' If malfuncllon IS suspected, check temperature
dele-cled by each sensor using Selt-diagnosis STEP 5, Conlirm the
temperature is wilhln normal range before performing Diagnostic
Procedures

Go
~G
- 10 Olagnosllc Procedure 5.

- CHECK MODE DOOR MOTOR

Set up Sell-diagnoSIS STEP 3

Reference

How 10 repair

Code No

OK

(HA-115)

l
I

Is mode door molor operaling normally?

Code No. 3D should be Indicated on the display alter apprOl(. 20 seconds.
~

-p

CHECK MODE DOOR OPERATiON

Set up Seltdlagnosis STEP 4
Does al1 outlel change according 10 each code

NG CHECK SIDE LINK MECHANISM.~~ Repair.

ReIer to CONTROL LINKAGE ADJUSTMENT, p-IA-125)

No?

%
'-I:.-+-----+---+---+----1--VENT

DEF

ReIer 10 Discharge Air Flow. (HA-121

=-----~OK.

Air Dullet conlrol syslem 's normal. Reier 10

Mode door control speel/icallon. (HA-133)

HA-93

Preliminary Check (Cont'd)

PRELIMINARY CHECK 2
Intake door does not change.

Perlorm Self-diagnosis STEP 1 before referring to the following flow chart.

- - - - - - - .-._-"-- - - - _ . _ - - - - . NG

CHECK SENSOR CIRCUIT

r--

Set up Selfdiagnosis STEP 2.

Is each sensor circui! normal?

--~

CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO THE DIAGNOSTle PROCEDURE BELOW CORRESPONDED TO EACH CODE
NO.

Code No. 20 should be Indicated on the display alter apprOIL 5 seconds later.

Reference

How to repair

Code No

page

---_. f - - - "

OK

21

Go lo Diagnostic Procedure 1.

22

Go 10 Diagnostic Procedure 2.

HA112

25
26
-2:
-22
-25

Go to Diagnostic Procedure 3.

HA-113

~26

HA-ll1

Go to Diagnostic Procedure 4.

HA-114

Go to Diagnostic Procedure 1.

HA-l11

Go to Diagnostic Procedure 2.

HA112

Go to Diagnostic Procedure 3.

HA-113

Go to DiagnostiC Procedure 4

HA-114

Are sensor circuits for ambient sensor and invehicle sensor operating normally? If malfunction is suspected, check lemperature
delecled by each sensor using Selfdiagnosis STEP 5. Confirm the
temperature is withm normal range before performing Diagnosfic
Procedures.

NG

CHECK INTAKE DOOR MOTOR.

--

..

Go to 0 i ag noslic Proced ure 6 (HA-117)

Sel up Self-diagnosis STEP 3.

Is intake door molor operating normally?
Code No. 30 should be Indicated on Ihe display after approx. 20 seconds.
OK

CHECK INTAKE DOOA MOTOR OPERATION

Set up Sell-diagnosis STEP 4.
Does inlake air change according to each
code No?

I
No
CHECK INTAKE DOOR ROD or LEVER
~ MECHANISM.
Refer to CONTROL LINKAGE ADJUST
MENT (HA-1261

OK

l{1

Y2

REC

REC

yy

YS

FRE

FRE

FRE

'-13
20%
FRE

Q----

------~

Go 10 Dlagnosllc Procedure 6.

Yes

I
,..--'

Intake door control system is normal

Refer 10 Inlake door conlrol specification. (HAt34)
L--.

HA-94

(!-iA:117)

Repair or adjust.

Preliminary Check (Cont'd)

PRELIMINARY CHECK 3
Go 10 Preliminary Check

InsuHicienl cooling

I.~HA

93)
L-

Go to Preliminary Check -;. {HA "]

94)

Go to Preliminary Check 5.

(HA-

(''I.:i'-

1 ~i::~

97)
L-

~8~ 10 Preliminary Check 6. (HA-

Adjust or replace compressor

~"::
~2

bell.

Go to Preliminary Check 7. (HA99)

---~~:_----]
CHECK REFRIGERATION CYCLE
PRESSURE WITH MANIFOLD

Go to Performance Test DIagnoses. (HA-26)

GAUGE CONNECTED
Refer to Performance CharI. (HA28)

~,F,

Check thermo control amp operallon

PERFORM TEMPERATURE SETTING TRIMMING

1 Set up AUXILIARY MECHANISM mode in self-diagnosis
2 Press

(COLO) switch at

desirable times

c:'1

:.' ,.

HA-95

Preliminary Check (Cont'd)

PRELIMINARY CHECK 4

---=

---J

CHECK MODE DOO;:;-OPE RA=rNGf ",,101m .",,;;;;;;:,;,

InauHiclent heating

TION

Check 1. ReIer to HA-91

CHECK BLOWER MOTOR

Perfcrm

OPERATION

Check S. Refer \0 HA97

r--------=r:=_I CHECK THE FOLLOWING -

I
MA
I Hose~

- , NG

l ___ J~

Repair/replaC" as neces

Engine coolant level (ReIer

to
section)

prellmlnarY~

sary.

lor leaxs 01 10nilS J t

Ra. d.iato r cap (Refer to lC

seellcn)

Air

III

cOOling system.

-,

CHECK AIR MIX DOOR OPERATION.

Reier 10 'iA125
OK

OK
CHECK BY FEEL THE

-J

HEATER It~LET AND OUTLET

HOSES
Hot inle!
Warm

Both hoses

tl~!let

Check heater hoses

ter DlO[ler j>1s1alla-

lion.

1_ ~~ _ ,
Replace thermoSIal. ReIer 10 LC

10K

'.'ENGINE L:OOL!.:JG
SVSTEM"}.
----.---

'~ote

---

To aVOid unnece<;sary servIce of heatIng syslp.m,

fIrst perlDrm TEMPERATURe:: SETTING TRIMMING.
ReIer 10 'AUXILlAfW MEChANISM", '"Sell.diagnosis"

CO'C'l

, Back flush healer

dram and refill coola,l

section

t 'Thermosla I" .

Noll~

r:---- L - Retesl
Hoi ,,,let
Warm Dullel

Both hoses

warm

il~a;OK =-J [A~;"~;h~~ ",>I"J

Preliminary Check (Cont'd)

PRELIMINARY CHECK 5
Blower motor operation is malfunclloning.

Perform Self-dlaOl1osis STEP 1 be-fore referring 10 the following flow chart.

CHECK SENSOR CIRCUIT.

----

NG

~ NOSTle PROe EDURE BELOW CORRESPONOING TO EAr.H (';ODE

NO

5e! up Selt-diagnosis STEP 2

15 .,dell

Sell::iO'

<.:1Icull normal

CHECK SENS OR CIRCUIT IN DETAIL ACCORDING TO THE DIAG.

Code No. 20 should be Indh::aled on Ihe d Is

play after approlC, 5 seconds.

Cl'lrl~

How to ropllir

No

OK

.-

---------~-------

Reference
page

21

Go 10 Diagnostic Procedure 1

~A-ll1

22

G,[) I" Diagnoslic Procedure 2

IIA112

cS

G o to Diagnostic Procedure 3

HA-113

26
--

Go !o Diagnostic Procedure"

----------------.

-2:

G o 10 Diagnostic Procedure 1

-22
-25

G o to Diagnostic Procedure 2

-26

Go

G o ID DiagnostiC Procedure J
10 Diagnostic Proce~ure 4.

CHl;.C\,\ BLOWER MOTOR OPERATION

Are sensor clr cuils for ambient sensor and in-vehicle s~nsor oper-

Set up Self-diagnosis STEP 4.

ating normally , If malfunction is suspected, check temperature

Does. blower speed change according to each

detected by ea ch sensor using Self-diagnosis STEP 5 Confirm the

lempera!ure IS within normal range before performing Diagnostic

code No,?

Procedures
Code
No.
Blower
motor
speed

y;

lfC'

Low

MIddle
high

r~ngine coolant

HIgh

MIddle low

NG

temperature belowso~

~-

---F-

E'FJ?

IS BLOWER MOTOR CONTROLLED UNDER

No

--_._------------,
Blower moior operat,oPl IS normal.
Refer to Fan speed control speclflcalion. (HA-1J6)

Check
~Ol

Refer to STARTING FAN SPEED CONTROl.

~erer

__

{HA-116)
- '

- - - - ~ - - _ .

ePlgll1~

"nol;H)t lemperatura

~cn

(;ol"l\rol CirCUlI

ST AATING FAN SPEED CONTRO\.. ')

to EC sectIOn

'ii':o:'
r',.:

..

+Yes

.-l"

~.~

[Blower
molor operation is lormal
~
__________________..---.---l

HA-97

TROU BlE DIAGNOSES

Preliminary Check (Cont'd)
PRELIMINARY CHECK 6
Magnet clutch does not engage.
Perform Self-diagnosis STEP 1 before referring to the following flow charI.
NG

CHECK SENSOR CIRCUIT

CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO THE DIAG-

r----

Set up Self-diagnosis STEP 2.

NOS Tie PROCE QURE BELOW CORRESPONDED TO EACH CODE

Is each sensor circuit normal?

Code No. .20 should be iodicaled

NO
00

Ihe dis-

play Bller lIpprOtl;. 5 seconds.

Code No

How to repair

OK

page

"

Go 10 Diagnostic Procedure 1.

HA-l11

22
25

Go to Diagnostic Procedure 2.

HA-112

Go to Diagnostic Procedure 5.

HA-113

c6

Go 10 Diagnostic Procedure 6.

HAtt4
HA-l11

(,

Reference

-21

Go 10 DiagnostIc Procedure 1.

-22
-25

Go to Diagnostic Procedure 2

HA-112

Go 10 Diagnostic Procedure 5

HA113

-25

Go to DiagnostiC Procedure 6

HA-114

Are sensor clrcu, ts for ambient sensor and in-vehicle sensor operaling

norma"Y~

If malfunction is suspecled, check temperature

detected by each sensor using Self-diagnosis STEP 5. Confirm the

temperature is wi thin normal range belore performing Diagnostic
Procedures.

NG

CHECK MAGNET CLUTCH OPERATION.

Sel up Self-diagnosis STEP 4

l----+

Does magnet clutch operate according 10 each

code No ~
Code No.1
Compressor

y:

T---

system pressure

I 42 I 'H I '-1'-1 I L/5 I Y6

! ON I ON

I I I I
ON

OFF

OFF

JNG

CHECK REFRIGE RANT

Check refrigerant
Connect manifold gauge, Ihen C h e c k - leaks.

ON
Go to Diagnostic
122)

OK

.-

Magnet clutcn control system is normal

Refer to MAGNET CLUTCH CONTROL (HA137)

HA-98

procedU::':J

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)

PRELIMINARY CHECK 7

Discharged air temperature does not change.

Perform Self-diagnosis STEP 1 before referring to the following flow chart.
_ _ _ _ _ _ ,___ , M'. __

'_~

,-,_._---

NG

CHECK SENSOR CIRCUIT

f--------.

Sel up Self-diagnOSIS STEP 2,

Is each sensor Circuit normal?

CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO THE DIAGNOSTle PROCEDURE. BELOW CORRESPONDING TO EACH CODE
NO,

Code No. 20 should be Indlcaled on the display afler approx. 5 seconds laler.

Reference

Code No
OK

Sel up Self-diagnosIS STEP 4

Does discharged air temperature change
according 10 each code No.?

I 'i2

Full cold

I 'i3

,;y I YS

I Yfi
NG

OK

21

Go to Diagnostic Procedure 1.

HAl11

22

Go to Diagnostic Procedure 2,

HA-112

25

Go to Diagnoslic Procedure 3,

HA-t13

25
-2:
-22

Go to Diagnostic Procedure 4.

HA-114

Go 10 Dlagnoslic Procedure 1,

HAl11

Go to Diagnostic Procedure 2.

HA-112

Go to Diagnostic Procedure 3,

HA-113

Go to Diagnostic Procedure 4.

HA-114

-25
-26

Full hal

page

._---

---,

CHECK AIR MIX DOOR OPERATION,

';:

How to repair

Are sensor circuits for ambient sensor and in-vehicle sensor operating normally? If malfunction is suspected, check temperature
detecled by each sensor using Self-diagnosis STEP 5 Confirm lhe

Air mix door control sys-

temperature is within normal range before performmg Diagnostic

tern is normal

Procedures

Aefer 10 Air mix door

control specilicalion.
(HA131)

CHECK AIR MIX DOOR MECHANiSM.

--

ReIer to CONTROL LINKAGE ADJUSTMENT

(HA-125)
OK

NG

Repair or adjust

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 8
Noise

Ehere

nOise

~ome~

J _ _ ~_~
CBel~

Compressor

1
Check for noise

Inspect the com-

in all modes and

pres s()r cl uteh

t~mperalure

arld pulley and

sel-

,dler pulley,

ti"y5,
Noise is

~~J

tJ
G

OK

constant

Check blower

The line's

R.p,""
compressor

motor lor fere,gn p;:l.rticl~s

"Ked d irecll y
(0 the body

dutch an<!

pulley,

Aels' to
HA146,

I Chec~

- J

blower

mOlor and

Fix the line

Check disc-to~ulley

t~n

with rubber or

clearance

some vibration

Refer to HA-147

for wear

--

!Ibsorbing

__I
Check

L:nalerlal

rl
--=r ---r=-

~n(l adl~s\

lubrrcal't
[ ReIer to HA-140

-L._

rl

Heplace com]
p'eS50r alld Ilcllid ta"~_

Noise IS
rnterm,ttent

Check

~"

dis-

belt~

The bet: vibra-

I Side 01

t,an IS Intense

torn out

p~lIey cenJ

Readjust belt -tension

The

Refer to MA

match

te. does not

charge ducts

section

Read,ust the p~l-

10' obst'uc-

{ Check.ng

ley center

lions, foreign

Drive Belts'.

materials

ENCINE

Dr

MAtNTE

air leakage

NANCE"i

HA-100

Harness layout
Engine compartment

HA-101

Harness Layout (Cont'd)

Passenger compartment

Sunload sensor

-Intake door motor

B,-Ievel door mOlor@

Aula amp

@
Mode door motor

ZHAO~7A

HA-102

THERMO
CONTROL
AMP

19l

L
I

8H"" I

om
~TI~

ODOR
MOTOR

1
~

>

I
~

C#.)

AIR MIx
DOOR
MOTOR

~I

~7
~
PSR

:IlJ:

-iII

rnJ:

()~

-ir
0

lJ

OEF
FlO
FOOT
B/L
VENT

S
0

......

lACY-FICO
TSOLENOID
YALYE

!-lODE
DOOR
MOTOR

T)

~ ~~~5RE

29

SWITCH

~~

SUNLOAO SENSOR I
26
AMBIENT SENSOR I

23
32

3<l
IN-vEHICLE
SENSOR

~;

"U"-,~Ht

l:

J.

I INTAKE

1Ti
n
n

DOOR
MOTOR

Ul

n
0

FRESH

46

~0
3

25

a
c:

From water temp.

gauge

17

From lllumlnat lon ~

system
13

;n

1~

THERMAL
TRANSM ITT ER

0j

:!:2./
l'!/2'

5~

.2:'

.-.

-;.:.::,

,,-

'I
.-~,

T::"j

j~;:

{~I}

,-

'rl)

not

'r n..~

,-II

Wiring Diagram -

Ale, A -

HA-A/C, A-01

~7-.5-A-'--'--~~15A]Refer to E:L-POWE~

o:1/G

LtJrn

l+1rn~rn

L/OA

L/W

Llw

e - eII

"--"_-I_LlaR~A/G'A::::05
-

J;;-... T

HA

L/W

~2 BLOWER

L/OR

THERMO
CONTROL
AIoIPLIFIER

f> r~C~:05

OR/G LlOR

ViS

L!W

Ifffil~

19

rFt\iJ

BAT

rGN

. ._-J;-

MOTOR

A!e

IGN
I e FAN)

SIGNAL

FAN

CONTROL
AMPLIfIER

~l

~
t

L/Y

r=n

10

FAN
FIB

FAN
OUT

AUTO

Ale
UNIT
@

.'-----:,
8

rtl8@

J::Ql@
[IlillJ w

~l8W
~

S"A-1Ij,olf

HA-l04

Ale, A -

Wiring Diagram -

r-

(Cont'd)

HA-A/C. A-02

AIL. To EL-ILL

AIL

~-

...---

'~"="ITIJ:tJ'-------.----,

E!)ILL

AUTO

Ale

SEN

SUN

INC

AI43

OR/L

OR

I
I
I~- I'NO~/L

OR

VEHICLE
SENSOR

LOAD

SENSOR

~~
B/Y

OA/B@Q}

GNO

WIT

l!JJJl
y

8/Y

~(lliD

IAMBIENT
SENSOR

To Water temp.
gauge

(~E!~J~.)

W~

~<TI)

2~

~ffi

1~1<ffiD

t$J<OOl
B/Y

~
-

Iy

B/Y

Blv

6ILL

._

OAIB

~~

UNIT
@])

<'on

cEIID

I
y

0
1

~.,

THERMAL
TRANSMITTER

7):

ffiD

...

.1

- ._

B/v

Ne)(t page

;-------------------------------~

i
:

EHiHrn
e

~@

[gIII

EtHh~
B

[Q]~
B

r.m:J

g~

(ill) B

~ru>
! W:t7
GY

Rrul)
L!J B

HA-105

Refel"' to last page

(Foldout pagel"

. iUQD
@.@

'I

Wiring Diagram -

AIC, A -

(Cont'd)

HA-A/C. A-03

<

INTAKE INTAKE INTAKE

1

V/B

G/Y

l rI

rnmrn

[NTAKE E& fRE

.,

6AEC

e FAE

EflREC

Q:n Ikp

r"lt Tl
Y/R

G/W

rnm

G/B

INTAKE
DOOR

ArR
MIX

MOTQl=l

MOTOR

DOOR

Preceding_~
p~ge

slY

-I

B Y

~;
~@):
B

lZ!6lQ
---0 <ffi>

rnrnmJ :

mIN]@

[JJ&TIJ

SHA470E

HA-106

HA-A/C, A-04

eOPEN

tBOPEN
eCLOSC

$ CLOSE

Aura

,~

1,.\.

Ale

UNIT

MODE
1

MODE
'3

MODE
2

MODE
41

,-I~i~f
T-I------..

fiJOEF
eVENT

eDEF
QlVENT

~~~~

Ll/e

L!W

L/R

L!W

,".
",,-

LIB
5

.:-{

MODE

'. J

aOOR

MOTOR
@

ii',.,
1""';"

I
B

t-,aID

<EZ>

r-------------~----~------------,

:~
i

:
I

IL

~I,

~@):
B

~
1817/ ItTI415161GI

I
I
~

riUT]@

mID

~
BA

HA-107

sri

TROUBLE DIAGNOSES
Wiring Diagram - AIC, A -

(Coot'd)

HA-A/C, A-05
./Ai. To !-IA-A/C. A-01~L/OR_._L10A~

Next
page

to EL-POWER.

L/OA@

$m

L/OR

i
GIB

l/OA

...._
_

!r

IX
l!:jJI

'1 CONDITIONER

RELAY

@)

LL/

G1/W

lillD 0ill)@<E)
~ LlR ~ L/A

L/R

11
~
T

HA

A~C,A=01<@-

G/Y

1R

r o~~

~rIPLEn

~L;A Mg~-

PRESSURE

L/R
THEI=l~AL

SOLENOID
VALVE

U SWITCH

$~
G/Y <ffiQl

I~L~~u1J1

Next page

_ _- - - - ,

1 PROTECTOR
~-1

COMPRESSOR

0-2

I9Ff <E) =r='

R

C6~

L
+e
5

(1)
1

rn>-1

G/Y

m
t~y

ECM

(ECCS

CONTROL
MOOULEI

em

~
3
B
<4

.....

=
(ffil

~~
1
PU

Rete,.. to last PlIt;le

(FlII(JlIut page)

@Q),~

@,Cffi

ITI1 (ffi)-2
W

(IT)

~HA47LE

HA-108

TROUBLE DIAGNOSES
Wiring Diagram - AIC, A -

(Cont'd)

HA-A/C. A-D6
preceding.--1iL /Ofl

p.g'

"'I"L,

BATTERY

L/DR

I]

(Via

fU""[~fnk)

$@Q)

Refer to EL-POWER

uu

L/os:l~

---------,1
,-r - I I

8/W

L/OA B/W

L/OR B/W

m. FAN
COOLI~

'4JJ3<ill

OAIL 8R/W

L/G

ORIL

::

.,=@~

LlG

OA/L

LtG

BR/W

II 111

db

~~ ~~SLING
~OTOR

(ffi)

~ @L:::j='
OA/L
L/G

ORIL

LtG

19

rrTIiJ

r~

W/R

~\

I~ ~ ~~,

l-Il
W/R

L/G

I[Q]~ ~ ~r!1J1

ORIl

t::,-'

URELAY-2

RELAY-1

~3@)

~~~~'d'n, ~;;L_t

c,:",

~5n COOLING
FAN

~t"

Eel-!

{ECCS
CONTROL
\otQ()ULE}
(IT)

to bst D<!Ige
(Foldout pllge) .

Refer

rfr4\ffi

III
I
L

SllA47JE

HA-109

Main Power Supply and Ground Circuit Check

POWER SUPPLY CIRCUIT CHECK FOR AUTO AlC
SYSTEM
Check power supply circuit lor auto air conditioning System.
Refer to "POWER SUPPLY ROUTING" In El sect/on and Wlr.
ing Diagram.

-------------------,

~1~i8

OIVG

lJOR

Auto amp.

connec1or @i)

AUTO AMP. CHECK

Check power supply circuit for auto amp. with ignition switch
ON,
1. Disconnect auto amp. harness connector.
2. Connect voltmeter from harness side,
3. Measure voltage across terminal @ . @ and body ground.
Vollmeler termInal
----e
_ _ _ _t!i=---I_ _,,----""--

ttl).

Body fjrDund

t--_----=-

Vollage

Approx. 12V

ZHA048A

Check body ground circuit for aulo amp. with ignition switch
OFF
1 Disconnect push control unit harness connector
2. Connect ohmmeter from harness side.
3. Check For continuity between terminal @ afld body
ground
Ohmmeter terminal

I
I

HA-ll0

e
Body ground

Continurty

Yes

TROUBLE DIAGNOSES
Diagnostic Procedure 1

C\l)~i5~

SYMPTOM: Ambient sensor circuit Is open or shorted. (21 or

-21 is indicated on display as a result of conducling Sell-diagnosis STEP 2.)

OM! Amb1ent sensor

connector@

"I:
No

CHECK AMBIENT SENSOR CIRCUIT

BETWEEN AMBIENT SENSOR AND
AUTO AMP

~_

00 approx 5 volls exist between ambient sensor harness terminal

Ambienl sensor
conn9clo, @

[ID

r!1~i5 ~~i5
Ambient sensor
conneclor @

db

Note

Check Circuit conlinuity

between ambienl sensor

@])

''''''''

and

body ground?

AulO amp, COrlnector

'*=~
U=w*

CD

r-

ness connector

Disconnect ambient sensor harness connector

ZHAOSOA

Disconnect aulD amp hOI"

Yes

harness terminal

CD

and

auto amp harness terminal @

harness

conne~

I_R_e_p_l_ac_e_au_t_o_a_m_p

------'1

WT

'--------------,,-----

Auto amp connector

@i)

mffiEE,

Lli:J~".~.

NOle

Check circuit continu,ly behNeen ambient sensor harness termInal I?) and
-\'

aulo amp harness terminal f~

OK

CHECK AMBIENT SENSOR.

(Rete' 10 Conlrol System Inpul Compo

NG

Replace ambIent sensor

nents I (HA-129)

[RePlace a_u_t_o_a_m_p_.

Note:
If the result 15 NG aller checking circuli conllnulty, repair harness or con
neelor.

HA-111

Coli"

- c\

---- -l
r

TROUBLE DIAGNOSES
Diagnostic Procedure 2

!ttaJ ~ i5 f!rry,

ORA

In-vehicle sensor

connector ~

_ _ _ _ _ _ _ _ _ _ _ _ _Z_H_AO_53----.JA

~ ~Do<a:HO'

In-vehicle sensor

&lw.

.\

SYMPTOM: In-vehicle sensor circuit is open or shorted. (2('or',

-22 is indicated on di&play as a result of conducting Self-diag. nosis STEP 2.)

EHECK \N-VEHIGlESENSORCIACUIT--~o.1

D1W)-;;-n~~a-:t~~~:Jar-

BETWEEN IN-VEHICLE SENSOR AND

ness connector

rAUTO AMP

Disconneci In vehicle sensor harness

connector
Do approx 5 voils eXist between ,n'veh,
cle sensor harness lermlnal CD ilnd
bedy ground?

Auto amp. connector

(!J

--1---

NOl

Check circuit continuity

between in-vehIcle sensor

con~tI~w,or@
mEm=@yeSharneSS!ermlnal(!)and
mJ

aulo amp "arness terminal %.~,

Nole
Check Clicull contll\l"ty between in-vehicle sensor harness terminal r1) and
aulD amp harness terminal @
OK

CHECK IN-VEHICLE

SENSOR~:::J1GReDiae':! ",-ve~~

(Refer 10 Control System Input Compo[ nents) (HA-',28)

---1'----

I Replace auto amp

so'
~
-- ----

-~

Nole:
\I the result Is NG IIlter checking circuit continuily, repaIr harness or con-

neclo,.

HA-112

TROUBLE DIAGNOSES

Diagnostic Procedure 3
Sunload sen sor
connector

SYMPTOM: Sun load sensor circuit Is open or shorted. (25 or

-25 is indicated on display as a result of conducting Self-diagnosis STEP 2.)

No

CHECK SU"iLOAD SENSOR CIRCUIT

Disconnecl aula amp har-

ness conl)eclor

BETWEEN SUNLOAD SENSOR AND

AUTO AMP,

Disconnect sunload sensor harness con

nector,

FlHA5 14A

~i5~

SunloJld sensor

~i'@

AUlD amp, connactor

Do lIpprox 5 volts eXIst between Sllnload sensor harness terminal

I

CD

Note

and
I Check Circuit

body ground?

conlin~~j

belween sun load sensor

tay-

Yes

harness terminal G) and

C?'f':

auto amp harness termlnal

@
OK

'Cl

ZHA057A

Disconnect auto amp, harness connec-

I_R_e_p_l_ac_e_a'u_t_o_a_m_p'

,,:rf

tOf

Nole
Check clIcud conlHIUlty belween sun-

load sensor harness !erminal and

auto amp harness terminal 1i)
OK
~.: I~.,

ZH A.058 II

CHECK SUNLOAD SENSOR

NG

Replace 5unload

s~

{RIe!er \0 Conlrol Syslem Input Compo-

nenls ) !HA-129)

I'rl
(",-

Nole:
II Ihe ,esull Is NG alter checking circuli conUnulty, repair harness or con-

'F,I[

IIII

neclof,

'-,
""1

HA-113

Diagnostic Procedure 4
SYMPTOM: PBR circuit is open or shorted. (26 or -20 is indl.
cated on display as a result at conducting Self-diagnosis STEP
2.)

Air mix door motor

conneclor@

lHA059A

CHECK PBR CIRCUIT BETWEEN PBR

AND AUTO AMP
D,sconnecl all mix door mOlor harness
connector
00 approx. 5 volts eXist between air mix
door molor harness terminal (1) and
body ground?
--

N~JDisCDnne-;; auto

Note

,.

Check

continUity

CirCUlI

between air mix door

molor harness terminal

Auto amp CQnneclor

CD

,~~

and auto amp. har-

ness terminal @ .

D,sconnect aulD amp harness

lor
ZHA06Q'"

_J

[!J

can"ec~

Replace aulo amp_

Note

rc;,,?Ck CIrculI conllnuity belween air mix

door molor harness terminal and
'1uto amp harness terminal @ _

~.O~

Ai, mIx door molar

~i5fB

Air mix door motol

conneclor@

illTlp har.

l..:~ss connector

Auto amp. conneclor

t~

ZHAOS,,,,

lt

OK~

(!]

CHECK PBA CIRCUIT BETWEEN PBR

AND AUTO AMP

Yes

1 Reconnect aula amp harness conneC-j

__ .

Dlsconnecl auto amp harness connector and air

mix door l1arn"?ss connec-

lor and air n'lx door harness conneclor

2 Set temperalure swdch to full hot 32"C
(90'F) Wllh IgrllllDn SWItch ON
Do apprDx 4" lIolls e~'sl tJelween air
mix door molor hd'fle~s lerml(1al
and body ground?
-

tor

'------1----I

GI

r.v

"

Che'ck Circuit

Note

cont,nu~ty

between air mix door

No

molor harness lermlPlaol

Air mix door 'nolor

(~ and aUla amp har-

connector@

ness terminal

1i-,

--~OK

\ Replace
CHECK PBR lHA06?A

NG

------

(Refer to Control System Output Compo

[ nenls I (HA-132)

a~.(~----'----a-m-p---J

Replace air mix door

mollJr (PBR)_

_. __- JOK __-_-_~D~~au~~rr:D___

NDle

II 'he re!>ull is NG aller checking circuit conllnuity, repair harness Or conneclor.

----

- - - - _ . _ ZHAOGJ';
--

HA-114

m
U8

VoN~ I III
~2'..

LJR

Diagnostic Procedure 5

~ FA ~
l..la1 w;v ~
Aulo amp.
connector@

Self--diagnosis
STEP 4

folloWing flow chart.

m
CHECK MODE 0 00 R MOTOR POSITION
SWITCH.
1. Set up code N o '-/ : if"> Self-diagnosis
STEP 4.
2. Disconnect aul o amp harness connector after lu rni n9 Ignilion sWitch
OFF.
3. Check if conlin uit y e.,sls between Ie',
minal @ or @o f auto amp. harness
connector and bo dy ground
4. Using above p roc edure. check lor ton
tinuity in any olh er mode, 8S inditated
in charI.

ZHA064A

Mode doo, molor ~ ~

connector@!!
~ OSV

~~

':

SYMPTOM: Mode door motor does not operate normally.

Perform Self-diagnosis STEPS 1 to 4 before referring to the

Code No

l{t

lHA065A

Te'''''l1lia.1 No

CMd.

lion

VENT

all

'i'-j

FOOT

0'

'15
'Hi

~ID

i'or

DEf

Note

CHECK BODY GROUND

CIRCUIT FOR MODE
DOOR MOTOR
Does continuity exist
between mode door
molor harness terminal
and body ground?

Contl-

OK

~ully

Reconnect auto amp harness connector

or@

0'

Dlsconnecl mode door

motor harf">ess connector

[;]

to, @

~('0''i3

'ji'

Body
ground

V...

[!J
CHECK POWER SUPPLY
FOR MODE DOOR
MOTOR CONTROL CIR

L - - _____ ,

OK

CUlT
Do appro. 5 volls exist
between mode door
motor harness terminals
and body ground?
I

TermInal No.

INSPECTION END
I

Voltage

Body
ground

Appro.

(B

~
C6'

~
(4)

IHA066A

5v

.~

~
res

No

Reconnect
mode door
molor harness con-

neelor

(Go to next page.)

Note:
II the result h; NG alter checkIng circuit conllnulty, repair harness or con

nector.

HA-115

LG

TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Cont'd)
--------._--------------.

rl.J

~i5~

UB

~2~

l1W~ Aulo amp,

conneclor@

Check clrcuil conllrlurty-----=

SWITCH

Sel up Self-diagnosis STEP 4,

between each terminal 0/1

auto amp and on mode

Measure voltage across auto amp t1ar-

door motor

ness lerminals and body ground_

Terminal No

Condillon

Code No

"'""'""" trrn.

10 ~

,-----.-. lAJ
:, :"Auto
i
amp,

i lJWiJ!~
ftttjjj
:

','

VENT

5V

OV

5V

B/L

5V

5V

OV

ov
ov

OV

5V

ov

5V

5V

5V

OV

511

5V

OV

flO

OV

OEF

ov

OOT

Body
Qround

Appro. 011
Appro, 511

'---~-

!l
a.. __ ..

('l)

,~

III
'-I20r'-l3
,--/y
'--/5
OV
5V

conneclor@

NOe
I

CHECK MODE DOOR MOTOR POSITION

NG

OK

Terminal

N~

__

tt>

(j

Aulo

Mode doo_

amp,

mO'or

nu.ty

I1i

@
@

<!J

(1) Dr

I!)

or ~

--1,

Conti-

Yes

0K

Replace auto amp

-J
~

Replace mode

'

dOOr motor

;.. ---.. _- -.--...-- r--'"

~
:::

I.
I
I

Ii.. _____.

'lJWILJR

Do

L-.~\4!;I'~
con"ooor @W

~ Replace

10 S IIolls exisl between aulo

<1J

and

aulo amp_

-~

IS switched Irom " '--I J

or when code No 1'5 slNltct1ed

When code No

~ I~A
~

appro~

amp harness terminals

LJR

Mode door molar

-_

CHECK FOR OUTPUT OF AUTO AMP

10

"'-fc ..

Irom . '/6" to ,.

ZHA068A
Code No
Sell<hagnosis
STEP 4

';1

~'-IC'

y: ...,

Mode
door
motor
opera
tlon

Term,nal

NO

Voltage
V

(f}

ffi

,-

--

VENT
--. B/L

DEF

-.
'i6 ~1I:
VENT
------- L -_ _ _
Stop

pprol
10 S
1--- --

Yes

d rII]
3~v-~6
_ ~.

RePla:e mode

~o_o_r_m_o_to_r_-

Auto amp, conneclor@

Selfa,a9nosIS

Note:
II the result Is NG alter checking circuli continu4lv. repair harness or con-

n('clDr

~~'--(S--'i;

-. - - HA-116

TROUBLE DIAGNOSES

Diagnostic Procedure 6
SYMPTOM: Intake door motor does not operate normally_
Perform Selfdiagnosls STEPS 1, 2 and 4 before referring
to the flow chart.
@r:
Note
CHFCK BODY GROUND CIRCUIT FOR
INTAKE DOOR MOTOA.
D,sconnect intake door motor harness
conneclor
Does continuity exist between intake
Auto amp.
connector

"19

rnmmt~y

~ C"""lCT

Lm If)

11

Self-diagnosis

GIV

"-----_J.....!o..._----'-_STI0~

door molor harness terminal ~ and

body ground?
Yes

00
CHECK FOR AUTO AMP OUTPUT

Sel up Self-d,agnosis STEP 4

Measure voltage across auto amp har-

NG

NOle

.-

!~?:

Check circuit contlnu'ty

between each lerminal
on auto amp and on
inlake door molar

ness terminalS and body grOllnd

ZHA07'A

Terminal No

Code
No

~i5~
Inlake tloor motor
conneclor

I EI

G"

,,,

VIR

.,'
.
.''

'-II

~)

0'

<!1\

'-12

~1) 0'

~~ 0'

01;)

'--13

IGJ tl
-7'~jJ-_tll

@or@

'--/'--/
'--15

@or @

@)or @

Body
ground

amp.

20%
FRE:

- - _..

5
f-------

-_.-

--

FRE

5
r----0

Inlake

door
motor

Conhnuity

(!)

<!l

Ves

0K

OK

Replace auto amp

Replace intake door motor

Note:
If the result Is NG after checking circuli contlnull~. repair harness or con-

L- __'-----''--

Terminal No.

Auto

OV Approx OV
5V' Appro_ 5V

~~~~6
GIV

!Ion

!'lEG r - - - -

AUlo amp conneclor @

Gondl- lVoltage

c1

<D

---/

~~

nector.

l'-<AD1~'"

HA-117

TROUBLE DIAGNOSES

~i)~

AIr mix door rmlor

connector @

Selldiagnosis
STLP 4

CD

Diagnostic Procedure 7
SYMPTOM; Air mix door molor does not operate normally.
Perform Sen-diagnosis STEPS 1, 2 and 4 beloTe referring
to the following flow charI.
IS PBA OPERA TlNG NOAMAlL y'J

No

1~2-Y3

Go to f)i;tl)noslic Proce-

--~-

dure 4. (HA-114)

--

CHI;CK FOR OUTPUT OF AUTO AMP

5e' \JP SelldiagMsis STEP 4,

00 l;!l-lprox, 10.5 volt exist oetwe en air

Au mx door motor
connector @

CHECK PBR CIRCUIT

Refer to Selldiagnoses STEP 2.

mix door motor ha.rness termma Is

No
L

.....

Disconnect auto amp, and

air mix door molor haness connectors.

.~

and @ when code No. is switch ed from

''-{(? .. to ''13'' or When code No IS
switched from" '-(& " 10 "

y;

IE]

"?

Note

A.1r

Auto amp.

Air mix door moW

opera

'12 -.
'i:r

%~

'lot

[QJ
'----------

Check circuli contlnUl1y

Terminal No

t'on

.,:

Cc;ld
Hot

Cold

q;

CS)

between auto amp harness termlna ('i)

voltage
v

( ) and

air mix door

moter harness lerminal

Approx

(3) , @ ).

10.5

OK

Slop

[R~;~~
RiG

door

Code
No.
ZIiA073A

~i5~

mil(

Yes

\ Replace avlo amp.

RiG

ZHA074A

~pl~ce air

m,,, door mulor.

Note:
If the reSLlU Is NG after checking circuit conllnully. repair hamess or connector,

HA-118

Diagnostic Procedure 8

(1ti)@B

co~nector @

Salt-diaqnosis

Brl~~J S"
"Iv

[j[

'-12 ... '-13

SYMPTOM: Bi-Ievel (B/l) door motor doeg not operate nor-

mally.

Perform Self-dlagnosls STEP 4 belore referring to the fol- ~1(i

lowing flow charI.

.-T-PU-T---- I--Ye-.:.../ R I
8/l
~
~ _ ep ace
door mOIO~ 'f~~

CHECK FOR AU fa A MP . OU
Set up Selt-d1ilgno5is STEP 4
Do approt 12 volls e~isl between B/L

Sell-d'agnQsJS

door motDr harnes5 lerminals <II dod

when code No is switched from

STEP 4

"'iC"

a\

\0 "en" or when code tIlo is

switched from "'i6 " \0 "'-II "?

Code
No

BIL
door
cand,tiurl

'N
-1~3

'l6
-l.{1

~iD~

AUlD amp

81-llJ\Iol door molor

connector@

cDnnedor@

~ g!:~~]
~

~([ rnJ

Terrnl'lal NO

(fl

tl.}

ED

Vollage
V

01>1-1
CLOSE

Apprax

12

CLOSE

EfJ

OPEN

lNO
Di5cOnnect auto amp harness connector

Zf-lA076A

Note

Ch&ck circuit continUIty between auto

amp_ harness terminal CD (~) and
ol-Ievel door motor harness terminal
(i) (@).

1
;:jeplace aulo amp_

Nole:
If Ihe rell"ll 1/1 NO .tler checkln; clrc;vll Gonlltlulty. repair

.,ector.

HA-119

h<lr"e$~ 0'

I;on-

TROUBLE DIAGNOSES
Diagnostic Procedure 9
SYMPTOM: Blower motor operation is malfunctioning under
out ot Starting Fan Speed Control.

Perform Preliminary Check 5 before referring to the follow.

ing flow chart.

(!J

,='-------------------,
CHECK POWER SUPPL Y FOR FAN
~ CHECK POWER SUPPLY
FOR BLOWER MOTOR.
CONTROL AMP
Dlscol'lnec! fal'l control amp harness

SHA~lE

ml

harness connector

Do appro~ 1~ volts e~lsl be!ween

00 approx 12 volls exist

fan conlrol amp harness lermmal

between blower motor har-

CD

ness terminal ~ and body

and body ground?

Fan control amp

r~

Disconnect blower motor

connector

ground?

Yes

~Fr-._-~

Note

Ched lSA fuses

,-------_~_-----.........,

at luse block

CHECK BODY GROUND CIRCUIT

RHA537EA

FOR FAN CONTROL AMP.

fRefer to

Does continuity exisl belweer'l fan

. POWER SUP.

conlrol amp. harness terminal 0)

and body ground?

In El sechen and

PL Y ROUlING
Wiring Diagram)

~Yes

Fan conlrol amp

connecto r @

Note

Reconnect fan control amp. harness

f~~'
Self-diagnosis
l~'"
STEP 4

connector.

lIY

Check circlJll conllnUily

between blower molor harness terminal 'J) and ran

all

CYJ
_

'-I: ..... 'if,

control amp harness lermlnal

G)

Sl-\A521E

--------_._----,

m~_o~

CHECK BLOWER MOTOR

AMP

(Refer 1o EIE'clncal Componenls Inspection,) fHA-68)

Set up Self-diagnosis STEP 4.

Measure voHage across Jan control

Blower mOlor
oonnector@

I.NoI

CHECK FOR OUTPUT OF AUTO

amp harness lerm,nal

!1l

NG

and body

grOlJnd

- - .---- -- ---::----l

Col:le No

'-I: --lfb
ZHAOBOA

DlIlDHCT

fi?n.

lA118~

Fall control amp

Blower malar
connector@

, Replace blower

re,m,nal No

Volta..e

(C,

Il.ppro,
2 . JV

Body

<1;

mDto~

ground

NG

-r--

'A'

iG<:l 10 next page)

----

Replace Ian conl'ol amp

coonec1or~

Ll~

NDle:

II Ihe result I" NG alter

nector.

lHAOBIA

HA120

ch~Ckil'lg

circuil continuity, repair harness or con

TROUBLE DIAGNOSES
Diagnostic Procedure 9 (Cont'd)

Ii

~i5~

-,r:1
Fan co~trol amp,

~r

ALlto amp con~ctor@

m:J

Nole
Does continUI!V e~lst between aulD amp
harness termInal @) .and Ian control
amp harness terminal @?

2r1AO&~A

Yes
I Replace aulD amp

l"

Note:

If the resull Is NG aftar checking circuit conllnully. repair harness or connector.

11]'

i'::'

-,rX'1

HA-121

Diagnostic Procedure 10

UR

Thermal protector
connector@D-1

SYMPTOM: Magnet clutch does not engage after performing,

Preliminary Check 6.

Perform Preliminary Check 6 before referring to the flo"

chart.

Self-diagnosis
STEP 4
(Code No. 41)

CHECK POWER SUPPLY FOR THERMAL

No

PROTECTOR
ZHAOtl3A

Thermal protector
co"nactor@-l

Compressor
connector@.2

1mI

~W
~

ill)

1 Disconnect thermal proteclor harness

connector
2 Set up code No '-I : in Self-diagnosis
STEP 4
3 Do approx. 12 volts exist between thermal protector harness terminal G) and
body ground?

harness connector

Note

Check circuit continuity

between AIC relay har.
ness terminal @ and
thermal protector harness terminal (j).

res

OK

Disconnect compressor harness connector

ZHA084A

~16 ~iO

Ale relay connector

I Disconnecl Ale relay

Note NO

r-------

Check circuit contif1uity betweef1 thermal

CHECK THERMAL
PROTECTOR

Thermal protector

protector harness terminal G) and com-

(Refer to Electri-

connec\or(ffi).l

pressor harness terminal (!)

cal Componenls

~[ I~ r~

Inspection,) (HA-

70)

Check magf1et clulch, coil continuity

-l

~NG
ZHIIOBSA

Replace magnet clutch assembly.

Refer to HA-146,

Ale relay
COM8ctor@

~Oi5'

Turn ignition switch OFF to cancel Selfdiagnosis STEP 4

[YJ

(!]

CHECK POWER SUPPLY FOR Ale

RELAY
Disconnect AIC relay
RHA947DB

Do approx 12 volls eXist between Ale

relay harness terminal

ground?

CD,

~Yes

and body

r--

CHECK POWER SUPPL Y

CIRCUIT AND 7 5A
FUSES AT FUSE BLOCK,
(Refer to "POWER SUPPL Y RO UTiNG"

In

EL

section and Wiring Dia-

9r1l m

(Go to next page)

Note:
II the resull Is NG alter checking cIrculi conllnully, repair harness or conneclor.

HA-122

TROUBLE DIAGNOSES
Diagnostic Procedure 10 (Cont'd)
@

~~io~

Reconnect Ale relay.

Triple-pressure switch
connector@

Note
No

CHECK POWER SUPPLY FOR TRIPLE-

ZHA087A

iii AlC relay

connector

Check Clrcuil continuity

PRESSURE SWITCH

between AlC relay har-

Disconnect Iriple-pressure switch harness connector

ness terminal No @ and

tnple-pressure switch har-

Do approx 12 voils exist between triple-

ness lerminal No. @

pressure switch harness terminal @

Triplepressure
switch connector

CID

W~160li
~

G,W

OK

and body ground?

CHECK AIC RELAY.

OK

(Refer to Electrical Components Inspection.) (HA70)

GIW

1][1

CHECK TRIPLE-PRESSURE SWITCH.

(Refer to Electrical Components InspecRHA396EA

tion.) (HA-69)
OK

[!1

~ ~~

DISCO_Ole'

,.;v

ccea
OfF

Triplepressure
switch connector

r;===EC=M~W'FC=OO=NE=CT=OR=;-11

em

r~1

CI=LJ

Disconnect ECM (ECCS control module)

harn ess connector.

Note
Check circuil continuity between ECM
-.::;,;

(EGGS conlrol module) harness terminal

and triple-pressure switch harness

terminal

CD

ZHA086A

CHECK POWER SUPPLY FOR THERMO

LIOFI

CONTROL AMP
Disconnect thermo control amp harness

Thenno control
amp. connector~

connector.
Do approx. 12 volts eXlst between
thermo control amp harness terminal

No

~-

GHE CK POWER SUPPLY

CIRC un AND 7 SA FUSE
AT FUSE BLOCK.
(Rele r to "POWER SUPPLY ROUTING in EL section and Wiring Diagram.)
L-.

@ and body ground?

ves

ZHA089A

GHECK THERMO CONTROL AMP

(Refer to Electrical Components Inspec-

ace thermo control

~~1R;1
amp

tion I (HA-68)
lOK
')i)

(Go to next page.)

Nole:
If the result Is NO aller checking circuli conllnully, repair harness or connector.

HA-123

i I':"

Diagnostic Procedure 10 (Cont'd)

ID",~_," ~OE,..:"",,()cr~,
amp. conneclo'

CfF'

"~

EeM

Rro~

Check cirelli! conlll)Ully between

{~

l_I1A_O_90_A,

-----l

CV

tor

Auto amp. oonnector@!)

[fEr

and tl1ernlO control amp. harness

Disconnect auto amp harness connec-

~~i5tLea
=
amPr5l3oo~_n~n~
Iii R3Hf8m
-----l1c::::lIL

Note

ECMI
I

(ECCS con~rol module) harness termInal

lermlnal

L-

Thermo oontrol

*____

JI

Nole

-----------------,

Check C"C:Ult continuity between aulo

9.

amp harness terminal @ and thermo

control amp harness terminal @

,.
Roc," ", '"'o=!==~~J
L lBJ
if!J

II

[Q]

fiji~

13

Auto amp connllclor@

~Itor
L______

Ce-icr

~ )

,---------...::-....----._-----,
NG~
CHECK FOR AUTO AMP OU1PUT
'-- ~ aulo amp

L__ ,. ~ 1..,.1 ~:~m:::m~;~;OO~id

:switch ON

12V

~OK
CHECK EeM (EGCS CONTROL MODULE).
(Refer to EC section.)
lIIole;
If the resull Is NG after checking circuit conllnully, repair harness
nectl)f.

HA-124

0'

con-

TROUBLE DIAGNOSES
Control Linkage Adjustment
MODE DOOR
1.
2
3

Install mode door mOlor on heater unit and connect it to

main harness.
Set up code No % in Self-diagnosis STEP 4
Make sure mode door operates properly when changing
from code No. '-i; to Y6 by pushing OEF switch

y:

,I

'-12 I t-l3

VEN~ I

BIL

'-ILl

Y5

Y6

FOOT

F/D

DEF

.H
\'i~,f:-,

AIR MIX DOOR

1 Install air mix door motor on heater unit and connect it 10
2.
3.

4.
S.

main harness.
Set up code No. '-i: in Self-diagnosis STEP 4
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
tram code No. '--/; to YO by pushing OEF switch

WI

I'

'-12

Full cold

HA-125

'-13

: --+-_--='------L.-_ _------'-_
Full hoI

'-16

:Nj'

";:,~,

TROUBLE OIAGNOSES
Control Linkage Adjustment (Cont'd)
INTAKE DOOR
1.

2.
3.

Install intake door motor on intake unit and connect it to

main harness.
Make sure lever of intake door motor is fitted in the slit of
intake door rink.
Set up code No '-/: in Self-diagnosis STEP 4.
Make sure intake door operates properly when changing
from code No. '-I: to '--16 by pushing DEF switch

y:

I Y2

'-13

REC

YY

LIS

Y6

FRF

20% FRE

SI-LEVEL DOOR
1.

2.
3.

Install Bi-Ievel door motor on cooling unit and connect it to

main harness
Make sure lever of bi-Ievel door motor is fitted in the slit
of bi-revel door link.
Set up code No 'J6 ;n self-diagnosis STEP 4.
Make sure Bi-Ieve) door operates property when changing
from code No. <.j: to'-/fi by pushing DEF switch.

y: [Y': oj '-13 I '-I '-I I '-15 1-'-1-6OPEN

HA-126

_.

CLOSE

SYSTEM DESCRIPTION
Overview of Control System
The control system consists of a) inpul sensors and switches
b) the auto amp {microcomputer). and c) outputs. The rela~

tionship of these components is shown in the diagram

--------------

below:i~r

r-l1
lHA IIKJA

HA-127

SYSTEM DESCRIPTION
Control System Input Components
POTENTIO TEMPERATURE CONTROL (PTe)
The PTe is built into the auto amp It can be sel at an Illterval

01 loe (2'F) through both

(H01) and
(COLD) control
switches. Selling temperature is digitally displayed

IN-VEHICLE SENSOR
The in-vehicle sensor is attached to cluster lid A It converts
variations in temperature of compartment air drawn from an
aspirator into a resistance value It is then input into the auto
amp.
After disconnecting in-vehicle sensor harness connector.
measure resistance between terminals (!) and (~) at sensor
harness side, using the table below,
Temperature C CF\

---------

Resistance kn

---

~-------

-15 (5)

12.73

-10 (14)

9.92

-5 (23)

7.80

0(321

6,19

- - - - - - -_..

5 (41)

49S

10 (50)

399

lS {59}

324

20 (6B)

265

2S (77)

219

30 (86)

1,81

35 (95)

1,51

.---------

--,--

-.-----

- - - --f--- - - - - -

40 (104\

1.27

45 (113)

1,07

ASPIRATOR
The aspirator is located on healer unit. It produces vacuum
pressure due 10 air discharged from the heater unit. continuously taking compartment air In the aspirator.

HA-128

SYSTEM DESCRIPTION
I AUTO
Control System Input Components (Cont'd)

AMBIENT SENSOR
The ambient sensor IS aHached 10 the hood rock stay It
detects ambient temperature and converls it into a resistance
value which is then input to the auto amp
Alter disconnecting ambient sensor harness connector, measure resistance between terminals <I> and al sensor har
ness side, uSing the table below.
Temperature 'C ("F)

Resislance kfl

-IS (51

1273

-10 (14)

9.92

',"L

- - - - - - - - - -f - - . - - - - - - - - - - - - - - - -5 123)

180

0(32)

6,19

-----

5 (41)

495

.-----------

399

10 (50)
15 (59)

32"

20 (58)

2 65

25 (77)

2 19

---

---~-----

30 (86)

.-----

1.81

----._-~-

:>5 (95)

151

40 (104)

127

45 (113)

1.07

;'1'r

SUNlOAD SENSOR
The sunload sensor is located on the LH defroster grille It
detects sunload entering through windshield by means of a
photo diode and converts it into a current value which is then
input to the auto amp,
Measure voltage between terminals C:i) and @ at vehicle
harness side, using the table below.
Input currenl

Outpul vollage

rnA

_ _ _ _ _ _ _.

~o

._

----

----II
"I

>----,----:-~--

____.~f;_ ----- -~-.------<~----_ _ _ _ _ _ _ _ _- - - \ - - - .

025

shines directly on it.

.c,

I'

10

When checking sunload sensor, select a place where sun

HA-129

~n

..--JI---_ _ - - - - - - - -

______ 1

~~

! " .

Control System Automatic Amplifier (Auto

amp.)

The auto amplifier has a built-in mIcrocomputer which pro.:

cesses information sen I from various sensors needed for air:
conditioning operation. The air mix door motor, mode doori
motor. intake door motor, bi-Ievel door motor, blower motorl
and compressor are then controlled
'
The auto amp is unitized with control mechanisms. Signals
from various SWitches are directly entered into auto amplifier.,
Self-diagnostic funcUons are al'so built into auto amp. to provide quick check of malfunctions in the auto air conditioning
system.

AMBIENT TEMPERATURE INPUT PROCESS

SUNlOADINPUTPROCESS

The auto amp. includes a "processing circuit" for

the ambient sensor input When the ambient temperature increases quickly, the processing circuIt
controls the input from the ambient sensor It
allows the auto amp to recognize the increase of
temperature only O.2"C (O.4F) per 60 seconds.
As an example, consider stopping for a cup of
coffee after high speed driving. Even though the
ambientlemperature has not changed, the ambient sensor will detect the increase of temperature. The heat radiated from the engIne compartment can radiate to the front grille area. The
ambient sensor is located there

The auto amp. also includes a processing Circuit

which "average" the variations In detected Sunload over a period of lime This prevents drastic
swings in the ATC 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. As a result the effect the
above mentioned does not cause any change in
the ATC system operation On Ihe other hand,
shortly after entering a long tunnel, the system
will recognize the change in sunload, and the
system will react accordingly.

Control System Output Components

AIR MIX DOOR CONTROL (Automatic temperature control)
Component parts
System operation
Air mix door control system components are:
Temperature set by Potentia Temperature Con1)
2)
3)

4)
5)

Auto amp
Air mix door motor (PSR)
In-vehicle sensor
Ambient sensor
Sunload sensor

trol (PTe) is compensated through selting temperature correction circuit to determine target
temperature.
Auto amp. will operate air mix door motor to set
air conditioning system in HOT or COLO position,
depending upon relatIonship between conditions
(target
temperature,
sunload,
in-vehicle
temperature. and ambient temperature) and conditions (air mix door position and compressor
operation).

HA-130

SYSTEM DESCRIPTION
I AUTO
Control System Output Components (Cont'd)

-l

A.ulo amp.

r-------------------------,

r-------------------------i
i

COntrol un,'
AUTO sWitch
II AIC switch
{

L---- In-ve

,----I
F r----

itl" sensor

_______

utPUl
signal

--\
PTe

I
I

'nput

~
--!
I-~

Sunlaad sensor

Control

~:

MlcrocompuTer

----I

signal
I-process

~~

.
~n'l

Air mlI dOOf

molor

\....--..l-

r-A-;;:;-b,ent sensOl

'

:ess

I
I
_ ~~(\Jre sllllingi
J : ~correct ron
I

L,'.~

I
I

I
I
I

I
I

/
I

----------------------~

r:,_
ZHA106A

Air mix door control specification

-4
"'il18 1")/

'e",
'Df,'IJ1V'6

Without sunloaa

._-

With sunload
0768 kW (660 kcal/h. 2.619 BTU/h)/m'
(00113 kW (61 31 kcal/h. 243.3 BTUlhllsq

'" "

'" '"

.ff

(o/,,)

'" '" .....

\:~n

Condition
PTC 25 b C (77 D F)

Itl

F-Ij)

;;:'~\

'F,:.3:..
:

Position

_'--Full hot
posll,on

(~)"""

~~~~_~

c'\......

1(;\

: :

\:.><1___

~-~---

Air mix eloor

Full cold
t)pening poslHon position

15
(59)

20
(68)

25
1m

30
(881

35

to

(9S)
(104)
I/I-vehlcle tamperature C (bFl
CD If temperature selting 15 set at 25C (77 b F) \meler no ,unload condition when ambient and tn-vehicle temperature are :}saC (95 D Fl
air mi. door '5 initial'Y automalically set in lull cold pos't,on
1) WithIn some period, in-veh,cle temperature will I_er towerds the objactive temperature, and th<l eir mix door position will shill
incrementally rowards lhe nol SIde and finally stAy in this poslt,on @.
SHA'>21E
Air mix door opening pOSItion is always red back to auto amplifier by PBA buill-In air mix ooor motor

~I

E.~mple:

~L~

gj 1

AIR MIX DOOR MOTO~

The air mix door motor is attached 10 the bottom of the heater
unit. It rotates so that the air mix door is opened to a position
set by the auto amp. Motor rotation is then conveyed through
a shaft and air mix door position is then fed back to the auto
amp. by PBR built-in air mix door motor.

~Il

SYSTEM DESCRIPTION
I AUT::QJ
Control System Output Components (Cont'd) -

nrr

----l

--t

---

~~u "O:"cO~

L __

Ii

Air mix door operation

--

ill
-

-!-

~l
A rr mix door
opt'ratron

---

Direction of lever
men'

Clockwise (Toward passen-

COLD. HOT

e-.

ger compartmeoq
L---------

HOT. COLO

STOp

STOP

-----'-------1-------

rnov~

Counterclockwise (Toward
engine compartment)

__

~r-=--_Approx4.5

PBR characteristics
Measure voltage between terminals @ and
harness side.

at vehicle

.,

~ 25-

g ~,.,.

CI~Se:
C01d1

L=

5'---l-'-A-,r-rn-,-x-d-oo-r-o-panlng _
degree

Open
(Hot)

-----------

ZHA1Cl!lA

MODe DOOR CONTROL

System operation

Component parts

The auto amp. computes the air discharge conditions according to the ambient temperature and
the In-vehicle temperature. The computed discharge conditions are then corrected for sunload
By this correction, it is determined through which
outlets air will flow into the passenger compartment.

Mode door control system components are:

1) Auto amp.
2) Mode door mOlor
3) PBR
4) In-vehicle sensor
5) Ambient sensor
6) SunJoad sensor
----

- - -- - - - - -

HA-132

I
J

Mode door control specification

----,

.
I

--- With .unload

Cond'lr<:m:

:i[

PTe 2S"C [77FI

WIthout sunload

0769 kW (660 kcal/h, 2,619 IHUIh)/m'

(D 07t3 kW (5131 keal/h, 243:l BTUlh)l'Q If I

I
I

i:,'~:~

01

Ci:

j-,

L'"l.o,

E.ample

J:

~:j~l

...JL ....
III

I
I

I
I

I
I

.-1

Z,
~:

______ 1_
Discharge mode

CL

I
I

I
I

:{~

15

20

315--40-'- - -

(59)

(6&)

(77)

(88)

(95)

l/l-veh>de temperature

Eumple

-:t

L~

- - - - - - - ---I-

De

;~

(' 041

[OF)

II temperature setting '5 set at 25C (nOF) under no sunload condItion when ... ",bient and in,er.icle temperature are 3()"C (!l64Fl.
mode door is set automallcally at IIENT POSltLon
If templ>lalure set ling IS set 8t 25C (nOF) under no ,unload cond't'D~ when ambient temperature ,~ 2QoC [B8 Q f) and In-vehicle
temperature IS 25C (nOF), mode door is set automatically at B/l po5 l tlon.

'~t

5HAS24E

o/!7'7
:~,~';;l

~.~

;t-~

f:'\"!,

MODE DOOR MOTOR

The mode door motor is attached to the heater unit. It rotates
so that air is discharged from the outlet set by the auto amp,
Motor rolation is conveyed to a link which activates the mode
door
8

Mode door operallOIl

VENT - OEF

CounterclockwIse

STOP

STOP

f!l

DEF ". VENT

Clockwise

HA-133

---------

J
~

~or

Direction 01 sIde link rotallon

7
(.)

_ _ _l_H_A~

"gJj))

----

R1~

SYSTEM DESCRIPTION
~'
Control System Output Components (Cont'd) - '
INTAKE DOOR CONTROL

System operation

Components parts

The. i.ntake door control determines Intake door

POSition ba<;ed on tfJe ambient temperature and
the in-vehicle \emperature When the OEF button
is pushed, the auto amp sets the intake door at
the "Fresh" position

Intake door control system components dre.

1) Auto amp.
2) Intake door motor
3) PBR
4) tn-vehicle sensor
5) Ambient sensor
6) Sunload sensor

C'-~

AUloamp,

Oo,,:H~: --~
SJgnal

p,()Ce_::~- ~ _

Microeomo<.lIer

,,,

,,
r

,
,
,

~o~~~ LI"'------I

AUTO

~~i'ch

------'

I'
DEF switch ~

,REC sw'tch

L,

~.

OF:_SW\\Ch_,}!

(__

~o~~~ u=-

:_

-fT-

~~

Intake door mOlor

l_

-J

i
---------,-------

~~:~t~~re--=t:,n~

lHA' 'JA.

Intake door control specification

Cond,r'on

PTe 2S oc \nOF\
- Wirhout sun load

I
I

r
I

I
ill

a: wi
\.L 1:1:1

lU

!il r~

~...

a:l:J

l.i..a:

;j!. lLl

f-r~
I

~:

a:,

CD

Intake doo, mt>d.

'

-----L_-_~
Example

E(ample'

--- ~~~~7~0=~=~r_-_J_
:

'

:ZO

2S

30

35

40

(68)

(71)

(86)

(95)

(104)

---~--.-----l1S
(5~)

----------J...--------l- ._- '~---

In-vehicle temperature "C (OF I

If temnp.r.turp ~ethng I. . .,I a' 250C 177~q ~n<:ler no sLlllo~'" COll"',,(>n wt\en an\Ole n 1 ",r,,;1 \n-verI<Cle lemperalure are 3SoC 195~FI
intake door IS set aulomat,cally al FlEe position to make in-vehicle temperature cool dDwn etl,c,enlly
" In-veh,ele temperalur. will lower Ind when 31J"C {86FI s reached, inrake door w.1I sh,tt 10 20% FRE ~ositlon
,~, In the slale "'-"en ",",ehlele lemperature re~rh~s Ihe ODleC\.vo \~mr"ra'\.lre 25C (77?f\ lr\eke door ,s set at FRE POS/I,on

-----

HA-134

--

-----

--

Control System Output Components (Cont'd)

INTA.KE DOOR MOTOR
the intake door motor is attached to the intake unit. It rotates
so that air is drawn from inlets set by the auto amp. Motor
rotation is conveyed to a lever which activates the Intake door

ir

Intake door motor operation

6

Inte"'~o door operation

E\

REC ---. FRE

STOP
FRE -

REC

Mo~eme[\t of

hnk rotallcl\

COUI1 terclockw isa

STep
Clockwise

Er';
GrouM

REG -

FRE

RHA~71E

FAN SPEED CONTROL

Component parts
Fan speed control system components are:
1) Auto amp.
2) Fan control amplifier
3) PBR

4) In-vehicle sensor
5) Ambient sensor
6) Sunload sensor
7) Thermal transmitter

System operation

."
_I,;

co,trol un,t
AUTO ~wirch
MODE ,wlt~h
FAN .....'tch
OFF 5Wllch

c,

, .

I,::,

HA-135

ad

SYSTEM DESCRIPTION
[AUT"]
Control System Output Components (Cont'd) AUTOMATIC MODE
In the automatic mode, the blower motor speed is
calculated by the auto amp. based on inputs from
the PBR. in-vehicle sensor, sUllload sensor, and
ambient sensor. The blower motor applied voltage ranges from approximately 4 volts (lowest
speed) to 12 volts (h:ghest speed).
To control blower speed
the range of 2V to
3V). the auto amp_ supplies a signal to the fan
control amplifier. Based on this signal, the fan
control amplifier controls the current How from
the blower motor to ground

en

START'NG FAN SPEED CONTROL

Start up from "COLD SOAK" condition

(Automallc mode)

until the engine coolant temperaUre rises above

50'C (122Fl Then the blower speed will increase
to the objective speed

Slarl up from normal or "HOT SOAK"

condition (Automatic mode)
The blower will begin operation momentanly
after the AUTO switch is pushed. The blower
speed will gradually rise to the obje~live speed
over a lime period of 8 seconds or less (actual
time depends on the objective blower speed).
If the in-vehicle temperatu-e is 35'C (9S FI Of
more, the blower will not operate for 3 secunds
after AUTO switch is pushed
0

BLOWER SPEED COMPENSATION

In a cold start up condition where the engine

coolant temperature is below 50'C (122"F) and
mode door position is BI-LEVEL, FlO or FOOT,
the blower will nol operate lor ;I shorl period 01
time (up to 150 seconds). The exact start delay
time varies depending on the ambient and in-vehicle temperature.
In the most extreme case (very low ambient) the
blower starting delay will be 150 seconds. After
this delay. the blower will operate al low speed

Sunload
WhfI the in-vehicle temperature and the set tern
perature are very close. the blower will operate
at low speed. V\'ith Ihe mode door in the VENT
position, the low speed varies depending on the
sun load. During conr1itions of hig" sunlOld, the
blower low speed will rise (approx. 6.QV). During
lesser sun/oad conditions, the low speed will
drop lo "normal" low speed (approx 5.0V).

Fan speed control specificalion

Cond.rlon.
~TC

2S'C [nOr)

W~hoUl

sunload

- - .. Wj~h ~llnl04d

0768 kW (660 kcal/-.. 2.619 BTU/hj/m'

[037 \ 3 ..'II \61.3 \ k~al/h. 243 3 BTU/h\lsq 11\

,
I
I
I

VQI\~ge {VI

Example

---,------,------,---- ~ ~ - - U
20
30
35
40
(591
(6&1
(861
t951
(1041
In-vehicle tenperalUre C [Of)

,n

:emper1.lure setl.g \~ set ~I 2S"C U7FI under f\Q su"load col'\dilior wh.,,, &<r>b,efll ""d
vehcl" l<r,nve'ah,'" .re J5 C
llJsoF J. blower mOlor vollage 15 applOx_ 7 volts
(1:' Whe~ amb'ent lemperalV,e " J5C (95"F) .ani '"-veh,cle lemp~ralure '$ reduced 10 2S"C 177fl under the same co,.,ditlon
ab'Jve. blower molo, voltage,s appro. [) volts

Cf' "

HA-136

r__----------S:..Y.;.S;:..T.:....:E:;.;M~O;.;;E;.:S:;.;C:;.;R.;.:)~P..:.T-10;,::N.;...--------"-~-1 ,.A;.U. .; ;TO; ; ; ; ;I

Control Svstem Output Components (Contd)

FAN CONTROL AMPLIFIER

The fan control amplifier is located on the cooling unit 11
amplifies the b<:lsC curront Howing from the Fluto amp to
change the blower speed within the range of 4V to 12V,

,.
-i,

ZHA'1M

MAGNET CLUTCH CONTROL

l,~

The ECM (EGGS control module) controls compressor operation using inputs from the throttle position sensor and aulo
amplifier.

p(:

'-'::\

Acceleration cut control

The FCM (EeeS control module) will turn the compressor
"ON" or "OFF" based on the signal irom the throWe position
sensor.

HA-137

,;,'1

SERVICE PROCEDURES

I MANUAL AND AUT:]

HFC.134a (R.134a) Service Procedure

SETTING OF SERVICE TOOLS AND EQUIPMENT
DISCHARGING REFRIGERANT

WARNING:
Avoid breaChln" Ale refrigerant and lubricant vapor or mist. Exposure mav IrrJlate eyes, nose and throat.
Remove HFC-1.34a (R-134a) from Ale syslem using cerlltJed service equipment meeting requirements
of HFC-1348 (Fl-134a) recycling equipment or HFC-134a (R-134a) recovery equipment. If accidental .yatern discharge occurs, ventilate work area before resuming service. Additional health and ssfety Informallon may be obtained from refrigerant and lubricant manufacturerA.

~I
I
I~

SHAS190A

EVACUATING SYSTEM AND CHARGING REFRIGERANT

PnleITed (8..t) mett\od

~Item.t.

nlethod
MaFlifold gauge sel

HA-138

SERVICE PROCEDURES
1 MANUAL AND AUTO]
~
HFC-134a (R 134a) ServIce Procedure (Cont'd)
w

Set tM recovery/recyclinll eQlJill'

mer.1.

Recovered luhricant (HA-1401

Discharge ra/rigeranl into recoveryl

rec~c\ing

equipment

Repair or replll.ce parts

E\lacuale lhe unwanted air in chargIng hoses.

Repair

Check air Ughtness

P~f\\al cnarg(ng
(approx. 200 9 (7.0502)).

Repair

~;

"-\

~__C_h_e_C_k_'.o_r_r_e_lrTig_e_r_a_n_t_'6_e_k_'_------'HL

r'
R_e_p_a_ir

'-2

Check lor A.IC operation and Ale

cooling porformance.

Remove service couplers from AlC

s/lJrvice valves.

Recover relllgeraC\t in charging

[

hOseS.

II.

Note ',1 Before cl1argin9 refrigerant. ensure engine i5 oft

'.2 Before c~,ecking tor leaks, starl e"'!;Jine 10 aclivale air COl\dil,cnmQ system then /Urn ,loft
Service val\1e

ClipS

must be attached to val\lCs (to prO',ont loakag e )

HA-139

[MANUAL AND AUT[]

SERVICE PROCEDURES

Maintenance of lubricant Quantity in

Compressor
The 1ubrica nt used to
through the system with
pressor when replacing
leakage occurred. It is

lubricate th e com pressor circulates

the refrigerant Add lubricant to COmany component or alter a large gas
important to maintain the specified

amount

If lubricant quantity is not maintained properly, the follDwing

malfunctions may result:
Lack of lubricant: May lead to a seized compressor
Excessive
lubricant:
Inadequate
cooling
(thermal
exchange interference)

LUBRICANT
NamE!!: Nlssan Ale System Oil Type A
Pari number: KLHOO-PAGRO

CHECKING AND ADJUSTING

Adjust the lubricant quantity according to the flowchart shown
below.
START

Can oil return operation be performed?

system works properly.
fhere is no evidence of a large amount
ot oil leakage.

Ale

Yes

f------- fPerform
--

No

No

:::::J.- .

-----1

~~"" 1M <omp""" be "pl,oed'

oil return operation. proceeding as foil ows'

1. Star! engil"le. and sel the following condition s'

Yes

Test condillon
Engine- speed: Idling 10 1,200 rpm
Ale or AUTO swllch: ON
Slower speed: Mal(. posltlon
Temp. control: Opl/onal (Set so that Intake air temperature Is
25 to 30C (17 10 86F).J
2. Nel(l Item Is lor \1-5 or V-6 compressor. Con neet the manifold
gauge, ilnd check thatlhe IIlgh press\Jre sid e pressure Is 588 kPa
(5:9 bar, 6 kg/cm~, 85 psi) or tllQher.
II less than the reference level, a"ach a cov er 10 the fronl hJce 01
the condenser to raise the pressure.
3 Perform lubricant return operation for about 10 minutes
4. StoOP engine.
CAUTION:
If excessive 011 leakage Is noted, do nOl perlor m Ihe Dfl relurn opera
I/on,

;!J
lGo to

ne~1 page. I

Is there aflY part to be replaced?

(Evaporator, condenser, liqUid tank or in
case there is evidence of a large amount
of lubricant leakage)

Yes

After replacing any 01 the !ollowing malor componenlS, add the car
rect amount 01 lubricant to the system
Amount 01 lubrlcanl to be added
Lubricant Ie be added III

'---------..,.------No

Part replaced

-E-va-p-",..-IO-'
C~nd,,05e,
llDl}JlJ'rln'"

l~~rry out the Ale

I_--,-_s~y--;<l""'

A""0uf\! (if lutlflC;lfll

-+_ _m-'(-:'~~-'m"'=2-=-~c-Q--'l)--T-------+-_.

7:..::5-,,{<:....:6,,-)------t.......,-.,..,....,-----

'5 (02)

Add

I' ~:;:::;~~~ .,

{lOr

- - - - - - --+------:-:c---:::------r--~-_:_:_:_:__30 (1 1)
largo I.a~

performance lest

Small lea,'2

"\

If compressor 'S replaced, addition of lubricant is included in the

flaw chart
'2 II refngeranl leak IS small, nO add ilion of lubricant is needed

HA-140

SERVICE PROCEDURES
[ MANUAL
Maintenance of lubricant Quantity in
Compressor (Cont'd)

AND AUTO

1. Discharge refrigerant inlo the refrigerant recoverylrecycllng equipment Measure oil discharged ,nto the reCOveryi
recycling equlpmenl
Remove the drain plug of the 'old-' (removed) compressor (applicable only to V-5. V6 or DKS-16H compressor)

0"11'1 the

011

into a graduated contalOer and record Ihe amount of drained oil.

Remove Ihe drain pluQ and drain the

011 from

the .new" compressor inlo a separate. clean container

Measure an amount of new oil Installed equal to amount drained from "old" compressor_ Add this oil to

new

com-

pressor through the suction port opening.

5 Measure an amount of new oil equal to Ihe amount recovered during dischargmg Add this oil 10 "new" compressor
through the suction port opening.

6_ Torque the drain plug

V-S or V-6 compressor: 18 19 N'm (1.B - 1.9 kg-m. 13 - 14 fl-tb)
DKS-16H compressor: 1416 N'm (1.4 - 1.6 kg-m. 10 12 Itlb)
If Ihe liquid tank also needs to be replaced, add afl addlt,oflal 5 m

Do not add this 5

mr

r (0-2

Imp tl oz) 01 all al Ih,s lime

(0.2 Imp II oz) 01 011 II only replacll\g Ihe compressor.

,:1,

011 adjusting procedure for compressor replacement

00

00

lfl

(Old

Recoveryl

compressor

Ij

Record amounl

Record amount

-B--,"---- -~- ---- -~m~-

New

cornpre~~or ...I~lJ

Recycling
eQuipmenl

Drain oil
lrom new

compressor
into cleafl

m~

conlainer

[l

--------_.. --- - ------~;I,n~~1

0' new

"y"

m~

011

New

:::~~~_=-=-.=--=-.=-~_: J

'--

.-J

rAdd en additional
15m Q (0.2 Imp II oz)
I 01 new 011 when teo

I
I

~~~~~~~J

__....

-------------

-_._---------

HA-141

-.,N

SERVICE PROCEDURES
Refrigerant Lines
LHD MODEL

Refer to HA-4 regarding

Connection"-

"Precautions

for Refrigerant

SEC. 271272.276

I~

~11G~

(For Ale k" mODe11

~ Nm (kgm. rt-Ibl

I~]

SERVICE PROCEDURES
Refrigerant Lines (Cont'd)

[MANUAL AND AUTO ]

RHO MODEL
SEC. 271-272-276

=c::

'L

(O.J 10

(OJ

- 20 (1.0 - 2.0, 7 - 1-4)

8 mm dla.
is . 25 (1.5 - 2.5, 11 - 18)
12 mm dl.

;"(
Low-pressure (Suctionl servIce valve

Comp'<i!~~O'

CI
[J I

L'

Comlenser

(Tightening torquel
I (Wrench size)

',O-ring size)

!AJ

,20 29 (2.0 - 3.0, 14 . 22)

: 9.3 - 10.1 (0.951.1.6.9 - 8.0)

(Q : 10 20 (1.0 . '2.0. 7 . 14)

[QI : 3.8 - 4.5 (0 39 . 0.46. 2.8 .
~

HA-143

N.m [kgm, tHtll

3.31

SERVICE PROCEDURES

[ MANUAL AND AUTO]

Compressor Mounting

--------

Belt Tension

Refer to MA section ("Checking Drive Belts", "ENGINE

MAINTENANCE").

Fast Idle Control Device (FICO)

Refer 10 EC section ("IACV.FICD SOLENOiD VALVE",

"TROUBLE DIAGNOSES").

HA-144

SERVICE PROCEDURES

Compressor -

Model OKV-14C (ZEXEL make)

SEC. 274

':If

I,'.

Htad boll
~ 20 24 12.0 2.4. 14 - l1) ' \

MBgO&t co"

- ", pulley

\'-snap ring

~
""- Clutch dISC

Nm (kg-m tt-lbl

0181: to

pullo~

c1o.,.nee

0,3 0.6 mm (0.012 0.024 In)

RfIAle:)fJA

HA-145

Compressor (Cont'd)

Model DKV-14C (ZEXEL make)

KV99231162

COMPRESSOR CLUTCH
Removal
When removing cenler bolt, hold clutch disc with clutch
disc wrench,

SHAB21B

Using clutch disc puller clutch disc can be removed easily,

SHA822S

Inspection
Pulley

Clutch disc
If the contact surface shows signs of damage due to excessive
heat, the clutch disc and pulley should be replaced.

Coil

Sl1A703B

Pulley
Check the appearance of the pulley assembly. If the contact
surface of the pulley shows signs of excessive grooving due
to slippage, both the pulley and clutch disc should be
replaced. The contact surfaces of the pulley assembly should
be cleaned with a suitable solvent before reinstallation,

Coil
Check coil for loose connection or cracked insulation,

Installation
Position coil assembly on compressor body. Be sure that
the electrical terminals are reassembled in the original
position, Install and tighten coil mounting screws evenly.

HA-146

SERVICE PROCEDURES

Compressor -

'.,

~
....

',-'''''

I MANUAL AND

AUTO

Model DKV~14C (ZEXEL make)

Press
(Cont'd)

,K,V/,99,/,234330,

pulley assembly onto the neck of coil assembly

using pulley installer.
Wipe oil thoroughly off the clutch surface.

;,)}'~---a

..

C:=ilal
~

,~."

'"

SHAB3JBA

Adjustment

Select adjusting shim(s) which give(s) the correct clearance between pulley and clutch disc,
Using a plastic mallet, tape clutch disc in place on drive
shaft.
Do not use excessive force with a plastic mallet or in a
press, or internal damages may result.
Place spring washer and center bolt onto drive shaft.
Tighten center bolt to drive clutch wheel onto drive shaft.

= c:

SHA051C

Check clearance around the entire periphery of clutch disc,

Dlsc-Io-pulley clearance:
0.3 0.6 mm (0.012 - 0.024 In)
If the specified clearance is not obtained. replace adjust
ing spacer and readjust.

Break-in operation

SHA052G

When replacing compressor clutch assembly, always conduct

the break-in operation. This is done by engaging and disengaging the clutch about thirty times.
Break-in operation raises the level of transmitted torque.

THERMAL PROTECTOR

Inspection

Thl!fmal

prOf2:CrOr

When servicing, do not allow foreign material to get into

compressor.
Check continuity between two terminals,

RHA'13

HA-147

".,.

~',.,

SERVICE PROCEDURES
Overhaul -

Push Control Unit Assembly

Switch knob
RHA5&OE

Disassembly
1. Remove switch knobs.
Be careful not to scratch knobs during removal.

Small flat-bladed

screwdriver

RHA56\E

2.

Remove fan switch knob.

Small flat-blacled

screwdriver

Control un,t

tlHA562E

HA-148

SERVICE DATA AND SPECIFICATIONS (SDS)

I MANUAL AND AUTO I

General Specifications
LUBRICATION OIL

COMPRESSOR

ZEXEL make

DKV-14C

Model

_----.------1----------

Model

DKV-14C

Vane rolary

Type

~cem~~(cu inJ/Rev
DHecllon 01 'olahon

N,ssan Ale System 0,1

Name

1401854)

Clockwise {Viewed !'om drove

end)

D"ve bell

Type fI

Capac1ty

Poly V type

KLHOO-AAGRO

Part No

m[ (Imp II ozi

Tolal In system

200 (7.0)

Compressor (Service parI)

charging amounl

200 (7 01

REFRIGERANT
HFC-134a (Rl3-4a)

Type
Capacity

kg lib)

LHD model

0.70 - 0 80 I' 54 - , 761

RHD model

0,60 - 0.70 (1 32 - 1 54)

Inspection and Adjustment

ENGINE IDLING SPEED
When AIC is ON

Refer to EC section ("Inspection and

AND
"SERVICE
DATA
Adjustments",
SPECIFICATIONS").

BELT TENSION

Refer to MA section ("Checking Drive Belts",

"ENGINE MAINTENANCE").

COMPRESSOR
Model

DKV-,4C

----- ----+------C Iulch d,scpu Iley clearance

mm (in)

03-06

(0012 . 0024)

'rpl

ELECTRICAL SYSTEM

SECTION

E l]::

When you read wiring diagrams:

Read GI section, "HOW TO READ WIRING DIAGRAMS".
When you perform trouble diagnoses, read GI section, "HOW TO FOllOW flOW CHART IN
TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENT".

CONTENTS
4

PRECAUTIONS

.
Supplemental Restraint System "AIR BAG"

and" SEAT BELT PRE-TENSIONER"

5
5
6
6
8

HARNESS CONNECTOR .... , ......

Description
STANDARDIZED RELAV
DescnptlOn ... '.. '.. "
POWER SUPPLV ROUTING ....
Schematic
WIring Diagram -

.8

..
POWER-

Fuse
Fusible Link

....................... 10

Circuit Breaker.
BATTERY.

How to Handle Baltery

Battery Test and Charging Chart

Service Data and Specifications (50S)
STARTING SYSTEM

"
.
System Description
..
Wiring Diagram - 5T ART -

Trouble-shooting
Construction

.. 23

.. ..27
28
28

...................... 32

32

.. 34

38
38
... 39

40
41
41
42

Schematic.
Wiring Diagram - OTAL _.
Trouble Diagnoses

'.':'r

45
.45
.46

.46
.48

?_;)

. 49

20

.35
36
37

Disassembly ..

Check.....
Replacement
HEADlAMP.. .

Brush Check

Construction
Removal and Installaiion

Assembly... .. .
Service Data and Specilications (50S)..
COMBINATION SWITCH

System Description
Schematic
..
Wiring Diagram - H/LAMP Trouble Diagnoses
HEADLAMP - DaytIme Light Syslem -...
System Description
. .
Operation (Daytime light system)

Yoke Check.
Armature Check
Assembly.
Service Data and Specifications (SOS)
Syslem DescriptIOn.
Wiring Diagram - CHARGE - .
Trouble-shooting

43
44

20

.33
33
33

CHARGING SYSTEM.

42

Stalor Check.
Diode Check.

... 29

Removal and Installation

Magnetic Switch Check ..
Pinion/Clutch Check.. ..

.42

Bulb Replacement.. ..
Bulb Specilicalions .. .
HEAD LAMP - Without Daytime Ught

.......... 31

..

..
..

19
19
19

... '"
.. '
..

.
__

Rotor Check..
Brush Check...

..

.49
49

.
Sy~lem

,50
50
. 51
52

. 55
.56
..
56
. .. 57
. 58

..
__

HEADLAMP - Headlamp Aiming Control - .

Description.
Wiring Diagram - AIM Aiming Adlustment
Trouble Diagnoses.....

EXTERIOR LAMP

f ..

59
62
.. .. 64
. . 64
.. 66
70
71
72

Clearance, License and Tail Lamps/System

72
Description
Clearance, License and fail Lampsl
Wiring Diagram - TAILIL _....
.701
Stop Lamp/WIfing Oiagram - STOP/L 80
Back-up Lamp/Wiring O,agram - BACK/L - . . 81

,'"'-r

CONTENTS

(Cont'd.)

Front Fag Lamps/Svstem Description

Front Fog Lamp/Wiring Diagram - ' F/FOG

82

Front Wiper and WasherNVifing Diagram

84

Front Fog Lamp Aiming Adjustment.

Rear Fog Lamp/System Description
Rear Fog Lamp/Wiring Diagram - R/FOG -

89
90
91

Trouble DIagnoses
Front Wiper Amplifier Check

Turn Signal and Hazard Warning

Lamps/System Descriptio'! ..
Turn Signal and Hazard Warning
La mps/Sch e rna ti c ..

93
,,95

Turn Signal and Hazard Warning

Lamps/Wiring Diagram -- TURN " ... _.96
Turn Signal and Hazard Warning
lampsfTrouble Diagnoses .. ,
101
CombInation Flasher Unit CMck ....
... 101
Bulb Specifications .. "
. . 102
INTERIOR LAMP ..
103
103
Illumination/System Description
Illumination/Schematic, "104
Illumination/Wiring Diagri>m - ILL - .
105
Intenor, Spot and Trunk Aoom Lamps/System
Description ..
110
... 110
Bulb Specifications .......
Interior, Spot and Trunk Room Lamps/Wiring
Diagram - INT/L-.

METER AND GAUGES"

System Description
Combination Meter,
Speedometer, Tachometer, Temp. and Fuel
Gauges/Wiring Diagram - METER-,

111
113
.. 113
... 114
115

Inspection/Fuel Gauge end Water

Temperature Gauge
)nspecl io niT ach 0 mete r
Inspe~tionlSpeedometer and Vehicle Speed
Sensor ....
Thermal Transmiller Check ..

Vehicle Speed Sensor Signal Check.

Fuel Tank Gauge Unit Check
Lead Switch"
WARNING LAMPS AND BUZZER .......
Warning Lamps/Schematic.
Warning Lamps/Wiring Diagram - WARNFuel Warning Lamp Sensor Check ..
011 Pressure Switch Check
Diode Check.
Warning Buzzer/System Description,
Warning BUller/Wiring Diagram - CHIME Trouble Diagnoses - WarnirlQ BUlzer,
Warning Buzzer Check,
WIPER AND WASHER
Front Wiper and Was~er/System Description

116
.117

118
,,120
.120
120
121
. \22

12?
123

129
129
129

no
131
133
,137

138
138

WIPER -

Fronl
Front
Fron!
Front

Wiper Instal',alion and Adlustment

Washer Nozzle Adlustment
Washer Tube Layout
Wiper Linkage

Rear Wiper and Washer/System DeSCription.

~car WIper and Washer/WIring Diagram
- WIP/R -..
Rear Wiper Amplifier Check...

.... 149
151

Rear Wiper Installation and Adjustmenl

.151

Rear Washer Nozzle Adjustment...

..151

Rear Washe r Tube Layout ."

Check Valve (For rear washer}

,152
152
Headlamp Washer/System Description
. 153
Headlamp Washer/Wlrlr1g Diagram - HLC 154
Headfamp Washer Amplifier Check .. "
... " 156
Headlal'lp Washer Nozzle Adjustment
156
Headlamp Washer Tubf'. Layout "....
156
Check Valve (For headlamp washer)
.156
POWER WINDOW
.157
System Description
,
\57
Schematic
15e
Winng Diagram - WINDOW 160
Trouble Diagnosis.
" .. 163
POWER DOOR LDCK.
" ... " 169
System Description
169
Wiring Diagram - D/LOCK --,
171
Trouble Diagnoses
POWER DOOR MIRROR
Wiring Diagram - MIRROR ELECTRIC SUN ROOF
Wiring DIagram - SROOF --,
HORN, CIGARETTE LIGHTER AND CLOCK
Wiring Diagram - HORN REAR WINDOW DEFOGGER AND DOOR
MIRROR DEFOGGER
System Description
Wiring Diagram - DEF
Tfouble Diagnoses,
Filament Check

AUDIO AND POWER ANTENNA

Audio/System OescriptlOr\
Audio/Wiring Diagram - AUDIO - ,
Audio

173
. 175
\75

179
.179

... 181
181
. '85
185
186

'88
189
190
.190
,191

,195

Radio Fuse Check

... 195
Power Antenn<1/W',ring Diagram -- P/ANT - , ,196
Location of Antenna
197

CONTENTS
Anlenna Rod Replacement,
Window Antenna Repair .. ,.. ,..

, .197
198

Trouble Diagnoses
LOCATION OF ELECTRICAL UNIT.
Engine Compartment, .,
Passenger Comparlment .....
Trunk Compartment.
HARNESSLAVOUT.
Outline

200

HEATED SEAT.

(Cont'd.)

.,200
Wiring Diagram - H/SEAT - ,
MULTI-REMOTE CONTROL SYSTEM
.. 202
System Description .... ,..... ,..... ,
. . ,.. ?02
component Parts and Harness Connector
Location,.
204
Schematic......
__ " 205
Wiring Diagram - M U L T I - . , 2 0 6
'npullOulput Operation Signal..
.210
...... 2i1
Trouble Diagnoses",.
ReplacIng Remote Controller or Control Unit. 217
THEFT WARNING SySTEM ........ , .
'" .. 218
System Description.
218
Component Parts and Harnes!> Connector
., .. ,221
Location
__
"" .
,... 222
..
Schematic
.223
Wiring Diagram - THEFT ,229
Input/Output Operation Signa!... ...

__

__

,249~f

' __ .... 249

.250
.252
,.~3

,,253

Main Harness .......

. 254
Engine Room Harness"...
,258
...... 264
Engine Con trot Harness .,,__
Engine Harness, ''''
268
Body Harness '"''''
270
Tall Harness.
".274
Room Lamp Harness. ......
" , ... 276
Air Bag and Seat Bell Pre-tensioner Harness ",,277
Door Harness (LHD models).
__ 278
Door Harness (RHO models)
.. ,279
SUPER MULTIPLE JUNCTION (SMJ) ...Foldout page
Disconnecting and Connecting.
Foldout page
Terminal Arrangement
Foldout page

WIRING DIAGRAM REFERENCE CHART

Eees

, ,,230

"

AIT CONTROL
__
,
__
ANTI-LOCK BRAKING SYSTEM
_.................
DIFfERENTIAL OIL COOLER "
__
AIR 8AG AND seAT SEll PRE-TfNSIONER
HEATE" ANO AIR CONOtTIOHER

__

EC SECTION
__ 4T SECTION
BR SECTION

.. __

"

__

"
,

PO SECTION.
PS SECTION
HA SECTION

?~

PRECAUTIONS
Supplemental Restraint System "AIR BAG" and
"SEAT BELT PRE-TENSIONER"
The Supplemental Restraint System "Air Bag" and "Seat Belt
Pre-tensioner", used along with a seat belt, help to reduce the
risk or severity of injury to the driver and front passenger in a
frontal collision. The Supplemental Restraint System consists
of air bag modules (located in the center of the steering wheel
and on the instrument panel on the passenger side), seat belt
pre-tensioners. a diagnostic sensor unit. warning lamp, wiring
harness and spiral cable. Information necessary to service lhe
system salely is included in the RS section of this Service
Manual.
WARNING:
To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or dealh in the evenl
of a collision which would result In air bag inflation. all
maintenance must be performed by an authorized NISSAN
dealer.

Improper maintenance, Including incorrect removal and

Installalion of the SRS, can lead to personal injury caused
by unintentional activation of the syslem.
All SRS electrical WirIng harnesses and connectors are
covered with yellow outer Insulation. 00 not use electrical
test equipment on any circuli related 10 the SRS SYSTEM.

EL-4

HARNESS CONNECTOR
Description
HARNESS CONNECTOR
All harness connectors have been modified to prevent accidental looseness or disconnection.
The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector.
(Examplel

Terminal ,etaine,

LlFT

PUSH
PUSH

L'U:
'./(,

PUSH

~
*

PUSH

P USH

IFor 'el.... )

(Fo, combin.tiofl meled

:-{'~'"

5FI/610

El-S

Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays

NORMAL OPEN RELAY

-I
~
(/)

Flows
~

=
D'~

rio...

it
p

SW 1

BAITERY

.....-..

~~:5 ~~

SW 1

Flows

~~

MIXEO TYP E RELAY

NORMAL CLOSED RELAY

L=~
SW 1

8AneAY

flows

Does

U)

SW 1

flO\

L~
~, ",m"U_~~
nnw

B"ITERY

BAnEFl'Y

SEl6a,fl

TYPE OF STANDARDIZED RELAYS

_.-

I
I

--

------

--

--

---

1M

1 Make

1T

---

2M

2 Make

1M 18

1 Make 1 Break

2M

1M

--

Transl~r

--

[g[~

(-~)

rm'"
,",;-===

HJ

-I - -

~=--~=

1T

~~~'B

_l

L{~~,"

-------.

SEl662H

EL-6

Sf ANDARDIZED RELAY
Description (Cont'd)
Type

Outer view

Circuit

connector symbol
and connection

---+---------

1T

------,
Case color

--------+-----~

[tl1

BLACK
~

\,"

241

I.'
~

.!'

BLUE

or

1M

GREEN

CD

-~

li

2M

BROWN

i-'I;.

7 5

6 J

GRAY

1M1B

1M

~/

~11JK

~~

LL1

ttl
til]

[li=
2 5 1

L __

@_2__3

-J-

J-----

The arrangement 01 termmal numbers on the actual relays may differ from those shown above.

EL-7

BLUE

POWER SUPPLY ROUTING

Schematic
~-----"[HAAG
75A

W
CIRCUIT
BREAKER

~7''''':=--1~-.f).G--------y-

30A

j-P~_~

WINDOW,THEFT.
D/LOCK,
CHIME,
MULSAOQF,
TI

'"------______________ COOL/F,

A/C. M, A/C. A I

IGNITION SWnCH
~F

4ee

ST

L - - - - - - - - 1 START

.---\>---------tNE }--

L.-

------<:>-

LHD models
I:lHD moCle Is

AIT ma<:le 1~

For Europe
E~ceot

for

E:'Jrope

L_-

I---;

TArL/L. F/FOG. ILL

LHD moCl'!ls l;,tMout

7.5A~

dayt 1me llgnt ;ystem

---{2J---i AAC!VJ

E.<cept@

7.5A~

(027 . @2q
(016

14

(029 .

28

CD lOA.

1'iA

EL-8

-1 MAIN, MAFS. CMPS. IGN/SG

POWER SUPPLY ROUTING

Schematic (Cont'd)

TURN. MULTI. THEFT

IGNITION

RELAV-2
15A

DTRL. AIM. TAILIL.

F/FOG. ILL

IDA ~

~--~

~
1511.

ClEAT. A/C. M. 4/c;--AJ

7_5A~

______r-;'L.=:.J

I FICO. COOL/I",
~ 4/C. 1-1, A/C, A

ILL. AUDIO,
I
MULTI. THEFT

[12]
HORN

HEU]

'1] ACCESSORY
1 "ELAY

LIGHTING SWITCH
~ OFF

\11.
5
6

2ND
A

1511.

IGNITION
RELAy-j

~
EU

0 IFF

104 ~

/~

'R
9

15A

-~

10
-II

EL
7 5A@]

~
1011.

[8]

AIM. TAl
~
LlL.1
L
F/FOG. ILL

IDA
L::J
r MUIII. EGRC/y. H02S.]
~WGIVVTC
1011. ~
.-:.::.~-----

-----11 IGN/SG.

rN.JECl ]

5EL667T

EL-9

POWER SUPPLV ROUTING

Wiring Diagram -

POWER -

EL-PDWER-01
~eATTERY

1~
W!R~

<D;
:
:

R>

W/A

W/R W/R

<ID:

LHO models
PJ-IO mOde 15
For Europe
Except foT' Europe
LHD models wi thout
daytime llQht system

@: Except@

* 1 ... <C>

*1

em

CD
G/R

W/R

W/R

1f1

RIL

I
R

+HLC

-~- RIL
R.}ABS

_ _ _~_ _. ._ _. . . .~ G/A

w/L

FUSIBLE LINK AND

FUSE BlOCK-1

25A

W/A .

*1

.1

W/R
...

W/R
W/A

~g3EL-POWEA

-@>

Next page

~} -03
TD EL-POWER
P

W!R

W ~ Next page

~~l
BIR

"t ~~EOE~~~
/G

WIG
W!L

~
~

B/A

l..

..1

AM)

Next page
To EL-POWER-05

CHARGE

:~ ~~: ~@@

I
I

FUSIBLE LINK
ANO FUSE

7.5A

tiL
G/R

GIB

[ill

em

l-

----

BLOCK-3

G/8 . .

~ G/R

CHARGE

~;g~AAIC, M.

HORN. THEFT

POWER SUPPLY ROUTING

Wiring Diagram - POWER -

(Cont'd)

EL-POWER-02
Preceding
page

cQ!

WIG

--1JL.

*1

.'

<b>:

LHD models
RHO models
For Europe

:
:

<@]-

=r

- - - - - - - - - - W/G.e> To EL-POWER

i ... < 0
*2<0
M3"'<O

',,1

-09

W/R ,
LlR ,
27 .

loiI/L

w
29

EU

1f1

wiG

L/R

[I]

ID~~gEK

FUSIBLE

LINK AND
FUSE BLOCK-2

25A

~CHD

ern

eu

112

B/W

L..

~
1f2

lH1Q>

LlR-O

LlR

A/FOG

CIRCUIT
BREAKER

~l1ill>
W/R

..

B/W

w ~

LHO
FRONT.

F1I@])

EL-11

HIA

CHIM" HI"""'. D/lOCK.

SROOF,MULTI. THEFT

+ COOL/F. A/C. M. A/C. A

To EL -PDWER-D4

~
~- ~
~ ~

@)
LHD

,
UP

RHD
UP

Refer to last page

(Foldout page) .

~,OO

'.Tr

POWER SUPPL V ROUTING

Wiring Diagram -

POWER -

(Cont1d)

EL-PDWER-03

G/R

rrnu

t
W!R

W/R

G!A

G/R

FUSIBLE LINK AND

FUSE BlOCK-2

20A

@)

ill]

:
:

<IT>:

LHD models
RHD models
LHD moae Is wi thout

daytime light system

@: Except
114"'(1;) R
RIG
lt5(C>R/W' R
*6"'(0

116
115

...- - - -_ _ G/B
OR

. .- - - - - - - - - - - - B/Y
1f4

Fl/W

H/LAMP. OTRL. A/FOG

HILAMP, DTRL, HLC

HORN. THEFT

TAIlA. F/FOG. ILL

AAC/V

MAIN. MAFS. CMPS, IGN/5G

FRONT.

SEl6111

EL-12

Wiring Diagram -

POWER -

(Conttd)

EL-PDWER-04
<D:
:

LHD mOdels
RHO models
1f7-<b) aiR,

-..

W!L

t/7

---II-"'---~----

..----.1

1
-

----1-

.....

BIA

IGN/SG. INJECT

elY. ST"RT

e/W~

QJ
B/W~
I

BIA

W!L

B/W
7.5A

~
1.....-_-'........

:~~.<O:

'tID:m3:l
I
I

I
I
I

: T5TTI m, :
,~w

IL

.&

I
~ To EL-I'O.......09

OR/L. S/SIG. DTRl

J~

To EL-POWER-07

FUSE BLOC/(

To EL-POWER-06

,I

~~ :
ti

: ffiJ~

UtD
UP

: @8] w

~
~

,
I

I
I
\
I
I
I
I
l

Reter to last page

(Foldout p;,ge) .

@Q),W

,;

III

RHO,
UP

I
I

\
I
I

~------------------------------~
SEL671T

EL-13

:m'T

POWER SUPPlV ROUTING

Wiring Diagram - POWER -

(Cont'd)

EL-PDWER-05
<u.

(fill)

To EL-POWER.....-J'- AIL ~ R/L ~ R/L _ . ~

-03
~

R/L
AIL

ri1l~1DA

~ffi)
R/L

RIL

!' Lt"1L .TAILIL

LHIJ models without

daytime light system

@: Exc:ept@

R/L

AIM. TAILA. F/FOO. ILL

W!L W!L

_ _ _ _ _ --....!I...m-51L...!L!~_l'_----------_,

----

G/R

A/V

FIIB

ORr

Ne)(t page

FUSE

BLOCK

QID
~

151\

em

/"L
" "t:.

"IY

SIR

OA/G.

.OEF/S,OEF
DEF /S. DEF

~f~ ~~~I~~~~~~P~ANT

..................... R/V +A8S. STOP!L

. ._--~-----R/B

+ INT /L, CHIME. MULTI

TURN. ~UL n. THEFT

. ._ _ G/R +OTRL. AIM. TAIL/L. F/FOG. ILL
G

..

..

..

.
I

aID :

I
I
I
I

1
I

23

~~

LHO

UP

Refer' to
{Fo Idout

last page
pagel .

t:,

Z2
21

f:

1[1

18

RHO

uP

I
I

I
I
I

~---------~--------------------~
5EL672T

EL-14

POWER SUPPLY ROUTING

Wiring Diagram - POWER -

(Cont'd)

EL-POWER-06
Preceding

NI-------<r-----~-----__iO

page

TO

Next page

EL-POWEA

-04

C
1

"I] RELAY
ACCESSORY

3"

FUSE BLOCK

CHI)

lOA

[]]

OR

0RI8

LG

:
:

LHO models
RHO mode 19
MB .. (b) 16
M9<b> lOA.

ILL. HOR'l. AlJOIO.

MULTI. THEFT

"\

"'_ _ OR/9. HORN

LG +WIPER

i.

Gill

OR

a=EP

~ ~+
2
3

MIRROR, OEF

sa WIP/R

12
11
10

LHO

,t
UP

RHO
UP

a=EP
El-15

14
l5A

Wiring Diagram -

POWER -

(Cont'd)

EL-POWER-07

- - - - - - - - - - - - - -......~ Next page

FUSE
BLOCK

CHD
..-....--......---+__---_---------10

Next page

lOA

I:EJ
G/OR

G/W

<D:

A./T mode 1s

"'--G/W.T~

G ..

II

G
.G/OR . . AlT

~--

cfu~

@l+
:3

,
~~.

1---.1l..

t--'--1-

qp
qp

~~~~~6~~~A~~jCR.HLC.

OEF IS. MIL, A/T, SRS, OTRL.

OEF. SROOF. WINDOW, THEFT

:!6
25
24

-'--f-r-f---I-

-'--I--

-r--I1--1-1--

1--1----1-

I
I

~' :

LHD I
UP

~
~

t:
I

,;
RHO
UP

I
I

I
I
\
I

SEL67H

El-16

POWER SUPPLY ROUTING

Wiring Diagram - POWER -

(Cont'd)

EL-POWER-08
<0: LHD models
: RHO models

@: For' Europe
*10<0
*11<0

29
R/L .

28
L

I,,'"

ro-~
-IE

W/B

4>

W/B

H/B

FUSE
BLOCK

lOA

Gill

[JJ
*11

SR

B/w

1 GL

l!::
L

~
L

G/V

'BS

PU +H/SEAT

+ OIFF

...- - - - - - - B/W +F/PUMP

BR

...

1f11

+ MAIN.
EGAC/II. H02S.
WG/II. VTC

SRS

r-----------------------------------,
I
.....
/"
I

~
t:
~- ~ ,:
~ ,~
l-

CHD :

IL-

LHO

5
4
3
'\.

1.

LHD
UP

RHO
UP

r ",~,

I
I
I

I
I
I

-----------------------~-----------~

I
S~t675T

EL-17

POWER SUPPLY ROUTING

Wiring Diagram - POWER -

(Cont'd)

EL-POWER-09
~g!L -POOER <&

WIG

I
WIG

~
TO EL-POWER

MI---..----;---~--,

-041

FUSE

BLOCK
@
~

7.5A

rn

LLi=JI
8

L/W

LlW

L/OR

if

...- - - - - - L/W

HEAT, A/C. M, A/C, A

r------------------------------------,
I
I

:: tJ[J
rn~
w
I

:~

:
I
I
I

qp
qp
~+
3

a
7
6

~
~
~

I
I

~I
LHD

,
UP

RHO
UP

SH6T6T

EL-18

POWER SUPPLY ROUTING

Fuse

OK

Blown

If fuse Is blown, be sure to eliminate cause of problem

before Installing new fuse.
Use fuse ot specified rating. Never use fuse of more than
specified rating.
Do nol partially install fuse; always insert it Into fuse
holder properly.
Remove fuse for clock if vehicle Is nol used for a long
period of time.

m
~!I:l:'.

n~

SEl954JA

Fusible Link
A melted fusible link can be detected either by visual inspection or by feeling with finger tip. If its condition is questionable, ~~C
use circuit lester or test lamp.
CAUTION:

If fusible link should mell, it Is possible that critical clrcuil;-~

(power supply or large currenl carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of
problem.
I~l

Never wrap outsIde of fusible link with vinyl tape. Impor.

tant: Never let fusible link louch any other wiring harness,
vinyl or rubber parts.

ime 1.... 1
100

50201--+--1-\.....

Circuit Breaker
For example, when current is 30A, the circuil is broken within
B to 20 seconds.
Circuit breakers are used in the following systems.

Power window

Power door lock

Power sun roof

Multi-remote control

Theil warning
Warning buzzer

Rear window defogger and mirror defogger

EL-19

];)~.:

BATTERY
CAUTION:

If it becomes necessary to start the engine with a boosler

battery and Jumper cables, use a 12-voll booster battery.
After connecting battery cables, ensure that they are

rightly clamped to battery terminals for good contact.

Never add distilled water through the hole used to check

specific gravIty.

Keep clean and dry

How to Handle Battery

METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-discharging a battery.
The battery surface (particularly its top) should always be
kept clean and dry.
The terminal connections should be clean and tight.

At every routine maintenance, check the electrolyte level.

When the vehicle is nol going 10 be used over a long period

of time, disconnect the negative battery terminal. (If the
vehicle has an extended storage switch, turn it off.)

Check the charge condition of the battery.

Periodically check the specific gravity of the electrolyte.
Keep a close check on charge condition to prevent overdischarge.

CHECKING ELECTROLYTE LEVEL

WARNING:
Do not aI/ow battery Ifuid to come in contact wilh 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 the acid contacts the eyes, skin or clothing, immedialely flush with water for 15 minutes and seek medical attention.

El-20

BATTERY
How to Handle Battery (Cant'd)

Remove the cell plug using a suitable tool

Add distilled water up to the MAX level.

SELOOIK

_ _ Normal baltery

Charging voltage

~
k-..

--- Sulphated battery

----

Charging vollage

~L_._'

Charging current
__
'L::current

SUlPHATION
A battery will be completely discharged if il is lell unattended
lor a long time and the specific gravity becomes less than
1,' DO. This may result in sulphation on the eel! plates.
To find if a discharged baltery has been sulphated, pay attenlion to its voltage and current when charging it
As shown in the figure at left, if the battery has been
"SUlphated", less current and higher voltage may be observed
in Ihe initial stage of charging

tt
~~

~~

':~>1,

Duration of charge
SElOO5Z

SPECIFIC GRAVITY CHECK

Read top level

with scale "-

Read hydrometer and thermometer indications at eye

level

When electrolyte level IS too low. tilt battery case to raise

it for easy measurement

ThermomaIer

SEL4420

Thermal .........
gauge
]

$E'lDOtil

EL-21

.'~\1

BATTERY
How to Handle Battery (Cont'd)
2. Convert into specific gravity at 20"C (68"F).
Example;

When electrolyte temperature is 3S"C (95"F) and specific

gravity of electrolyte is 1.230, converted specific gravity al
2{)"C (68"F) is 1.240.
When electrolyte temperature is O'C (32"F) and specific
gravity of electrolyte is 1.210. converted specific gravity at
20"C (68"F) is 1.196
Converted spedflc gravity

.30

I----+-=-od:-----='\---o<~___t.=.._:;:l__-=.,t__..:.::

: : =-.=

::::E!"'O"'1''\
1.10

---

---+---+A~------lIIl~----+-c:=.~

-~.-

-ao
(-22)

~.

--,

-20
(--4)

-10
(14)

(32)

10
(SO)

20
(68)

Electrolyte lemperature C

EL-22

(OF I

30
(8&)

so
(122)
SELOO7Z

BATTERY
Battery Test and Charging Chart

Chart I

VISUAL INSPECTION
Check ballery case lor cracks or bends
Check battery termInals lor damage
II the difference between the max and m,n electrolyle level 'n cells is wllhin 10 mm (0.39 in). il is OK

NG

OK

Replace
battery

CHECKING SPECIFIC GRAVITV

Reier \0 "'SpecIfic Gravity Check"

LF:

'n
SLOW CHARGE
Refer 10 "A" Slow
Charge"'.

QUICK CHARGE
ReIer to '"C' QUIck Charge'".
NG

NG

Ready for
use

Replace
battery

use

Ready lor use

Mount battery agaIn
and check loose lermlnals. Also check othe r
relaled CirCUItS.

CHE~~ING

QUICK CHARGE
SPECIFIZ-J
GRAVITY
Refer 10 ""C' QUIck Charge"
Reier to "Specihc Gravity
Time required' 4S min
Check"
.....
..,----

RECHARGE
Reter 10 "C QU1ck Charge"'
II baltery temperature rises above 6O'C (140F).
SlOp chargIng Always Charge battery when ,ts
lemperature IS betow 60'C (140'F).

OK

Ready lor use

Ready
for use

Replace
baltery

"STANDARD CHARGE" is recommended Illhe vehicle Is In storAge aller charging.

EL-23

-'

NG

Replace
battery

r-r"

BATTERY
Battery Test and Charging Chart (Cont'd)
Check battery type and determine the specified current
CharI II

using the following table

FIg 1 DISCHARGING CURRENT
~-

--

FOllow manufacturer's
instructions 10 check and
determine i1 ballery is serviceahle.

Read load lesler voltage

when specified discharging
current (Aeler to Fig, 1.)
Ilows through battery for 15
seconds

NG

Ready lor use

(load Tester)
Type

Current (A)

28B19A(L)

90

34B19A(LI

99

46B24R(L)

135

55B24R(L)

135

SOD23R(L)

150

55D23R(L)

180

65D26R(L)

t95

80D26R(L)

195

7SD31R(L)

210

95D31R(L)

240

Go 10 next
slep

Ready lor use

115D31A(L)

240

95E4tA(L)

300

t30E41R(L)

330

Go to ne(t
slep,

SElOO8Z

EL-24

r::

BATTERY
BaUery Test and Charging Chart (Cont'd)
SLOW CHARGE

Delermine ,nilial charging current from specilic gravity

relerring \0 Fig. 2,

FIg. 2 INITIAL CHARGING CURRENT SETTING (Slow chargel

Charge battery
Check charg ing voltage 30 minutes alte r starlIng the
battery charge

BATIERY TYPE
CON
VERTe:O
SPECIFIC
GRAVITY

:J

:J

[{ [{

iO

;1,

::; ::I ::; ::; ::I

[ ~ ~

5;:

III

cr

::; ::I :;

re ~
~ ~ ~

~
~

[ ~
~

Below

4.0

5.0

70

8,0

90

1,100

(A)

(A)

(A)

(Al

(AI

:;
~
M

:;

~ ~'"
100
(A)

::I

cr ~

\40
(A)

Check battery type and determine the specltied current using the
table shown above,
Afler starting charg,ng. adjustment oC chargll,g current ;s not neeessary.

~~_i;

Fig 3 AODITIONAl CHARGE (Slow charge)

BeloW 1. ISO

Conduct additIonal charge as per Fig. 3. if necessary

Charge lor 5
hours at
initial chargIng current
selling,

I[

150 \ ,200

Charge for 4
hours 11\
initl al cl\ar9ing current
seiling

I
Charge for 2
hours at
Inil'al charg.
ing current
selling

Go to "CAPACITY TEST".

Go to "CAPACITY TEST"

CAUTION:

Set charging current to value specified In Fig. 2. If charger

Is not capable of producing specified current value, sel Its
charging current as close to that value as possible.

Keep battery away from open flame while It Is being

charged.

When connecting charger, connect leads first, then turn on

charger. Do not turn on charger first, as this may cause a
spark.

If battery temperature rises above 60C (140 F), stop chargIng. Always charge battery when lis temperature is below
60'C (140 F).
D

EL25

:1

BATTERY
Battery Test and Charging Chart (Cont'd)

FIg 4 iNITIAL CHARGING CURRENT SETTING

B: STANDARD CHARGE

(Slanda'd cha'9 c )
r---------,------- -----------------------.,
SA TTEAV

TYPE

CON
Determine inll,al charging current Irom
specific grav'ty, referring to Fig 4

VERTED
SPECIFIC
GRAVITY

1 100 , 130

a [AI

SOIA)

B () (A)

7 D (A)

11301160

30lAl

4DIAj

5_DIA)

B_O(A)

1 160 - 1.190

'- 0 (A)

3,0 (Aj

40 (Aj

5_0 (A)

80
(AI

7C
(A)

60

90 (AI

130
IAI

aD

IA\

70 (A)

Il.a
(Aj

':to

(A)
(A)
r----.-----t-------j----f-----j-----r-----jr---------j-----/
10
SO
1 I~ 1.220
? 0 IA)
20 (A)
30 (Aj
40 (Aj
50 (A)
(A)
(A)

Check ballery type and dete rmme the speciried current usmg the lable shown
above
Alter starting charging, adjustment or charging current <s not necessary
Fig 5 ADDITIONAL CHARGE (Standard charge)
Conduct addlhonal
5. II necessary

Go 10

chil,ge~
_

CAPACITV TEST"

Go 10

CAPACITY TEST"'

CAUTION:
00 not use standard charge method on a battery whose specific gravity is less than 1.100.

Set charging current to value specified in Fig. 4. If charger Is nol capable of producing specified
current value, set its charging current as close to that value as possible.

Keep battery away from open flame while It Is being charged.

When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as
this may cause a spark.

It battery temperature rises above 60"C (140F), stop charging. Always charge battery when its temperature is below 60C (140"F).

EL-26

BATTERY
Battery Test and Charging Chart (Cont'd)

[C.

QUICK CHARGE
Fig 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick

ch"'gel

,-'-0'

,----" -

Determ,ne Inlt,al charging current sellln9 and

charging I,me trom spec"ic gravIty relerrlng tl>
Fig. 6,

BATTER.Y TYPE

CURRENT IA)

':..t

:i

:i

CO

~ [

:i

::r

:;

::; :; ::;

::;

~ ~ ~ ~ ~ ~

III

10 (A)

Cl

rr
;:;

::;

::;

----'

::J

~ ~ g w...

ii

~ ~ ~ ~ ~ ~ "~

15 (A)

20 (A)

40

30 (A)

i:'1i'

(AI

;: ~~:~

--~

~~arge~~-

Go to

>-

r-

f-

'>

1 100 - 1.130

25 hours

1 130 - 1 160

I 160 I \9{)

1 5 hours

1 190 , 220

10

<l:

cr:

Cl
U

u::

U
W

0-

--

1-

. -

a hours
1 ',

U)

CAPACITY TEST"'

ffi

=~

~Ovrs

>

Above 1 220

075 hours (45 min)

Check ballery type and determine the speclired currenl USing the t~ble
shown above,
Aller starting charging. adjuslment or chi rg Ing curr enl is '101 neceSS8 r y

CAUTION:

Do not use quick charge method on a battery whose specific gravity Is less than 1.100.

Set Initial charging currenl to value specified in Fig. 6. If charger Is not capable 01 producrng specified current value, set its charging current as close 10 that value as possible.
Keep battery away from open flame while it is being charged.

When connecting charger, connect leads first, then lurn on charger. Do not turn on charger first. as
this may cause a spark.
Be careful of a rise in battery temperature because a large current flow Is required during quickcharge operation.
If battery temperature rises above 60~C (HO'F), stop charging. Always charge battery when its temperature is below 60'C (140'F).
Do not exceed the charging lime specified In Fig. 6, because charging battery over the charging time
can cause deterioration of the battery.

Service Data and Specifications (50S)

Fa, Europe

Except tar Europe

Optional on LHD
models lor Europe

Type

5502JFl

65026A

BOD26R

CllpaClly

12 .

12 - 65

12 - 65

Applied mod"i

El-27

~C

STARTING SYSTEM
System Description

MIT MODELS
Power is supplied at all times

to ignition switch terminal @

through 30A fusible link (letter Q:1J , located in the fusible link and fuse box).

For models with theft warning system

Power is supplied al all times

through 75A fuse (No ~ . located in the fuse block)

to theft warning relay terminal CD
With the ignition switch in the START position, power IS suppl ied
from \gniliol'\ switch terminal

to theft warning relay terminal @)

If the theft warning system is triggered, terminal of the theft warning relay is grounded and power
to the starter motor is interrupted.
When the theft warning system IS not operating, power is supplied
through thelt warning relay terminal @

to terminal of the starter motor windings.

For models without theft warning system

With the ignition switch in the START position, power is supplied
from ignition switch terminal @
directly 10 terminal of the starter motor windings.
The starler motor plunger closes and provides a closed circuit between the battery and the starter motor.
The starter motor is grounded to the engine block. With power and ground supplied, cranking OCcurs
and the engine starts.

AIT MODELS
Power is supplied at all times

to ignition switch terminal CD

through 30A fusible link (letter ~ , located in the fusible link and fuse box).

For models with theft warning system

Power is supplied at all times
through 7 SA fuse (No ~ , located in the fuse bloCk)
to theft warning relay terminal CD.

With the ignition switch in the START position, power is supplied

trom ignition switch terminal @

to theft warning relay terminal @.

If the theft warning system is triggered, terminal at the theft warning relay is grounded and power
10 the inhibitor switch is interrupted.
When the theft warning system is not operating, power is supplied
through theft warning relay terminal @

to inhibitor switch terminal

hrough inhibitor switch terminal <!l, with the selector lever in the P or N position

to terminal of the starter molor windings.

For models without theft warning system

With the ign ition switch in the START position, power is suppl ied

from ignition switch terminal

to inhibitor switch terminal

through inhibitor switch terminal CD, with the selector lever in the P or N position
lo terminal @ of the starter motor windings
The starter motor plunger closes and provides a closed circuit between the battery and slarter motor.
The starter motor is grounded to the engine block With power and ground supplied, cranking occurs
and the engine starts.

El-28

STARTrNG SYSTEM

Wiring Diagram -

START-

MIT MODELS

~
ATTER""

30A

C5J
G

Iw

m
ON ST

OFF :~.....

~~~~~ON
@

lliJ

II
8/Y

~~

'T'w
OA/13

~ TlFT
Wo\RNING
~LAY

4J

I..---o-u>-

SlY

-O~

~
~

f:
LG

LHO models
RHO models
Models with theft warning system
Models without theft warning system

<r)

<B>

~
~

liI1"'@ SIR.

r-------J,

BIY

STARTER
MOTOR

@Q>
BATTERY

: ~ ~; CD

I
I

t1=tJ

Refel"' to last plIge

(Fe Idout page) .

fTFlffi {W:<D:

tI=IJ

I
I

:~
~@:
[lJ

I
I

I
I

SEL662T

EL-29

STARTING SYSTEM
Wiring Diagram - START -

(Cont'd)

AfT MODELS

to EL-POWEA.

~ 00

Iw
OF

11

S(Y

OR/G

~
3

ST ~~f~AON
@

THEFT

WARNING
RELAY

lLiJ

B~

@Q)

I----o~elY -O~

:2
~

~ <EQD

LJ

LG @Q)

INHIBITOR
LG
SWITCH
32
~
STARTER
CUT
OUTPUT

SMART

ENTRANCE
CONTROL

L__ (ffi])

8/W

<@

I - a/w ~ B/W -

<C>;
:
:

LHO models
RHO models
Models with theft war-ning system
Models ~ithout theft warning system

*2- -@ B/A.

r----j
!

~ ~:(D

SlY

UNIT

BfW

(?

BIR -ill)

- I~
~

STARTER
MOTOR
@Q)

BATTERY

em ~:<Di

~-------------------~---~-~

A
~ep :ffit
I
I
I

~~:

Refer to last Dage

(Foldout llllge) .

SEL66JT

51ARTtNG SYSTEM
Trouble-shooting
If any abnormality is found, Immediately disconnect ballery negative terminal.

~~er does ~l stop.

~_.-r~Place magnelie switch

=:=J

:;[

r;::---i
~ne does not start.
J

=c

~.
t
b
k
7
engine urn If eran In\;)

~oes

__

I~ ~
Yes ~ ~ - - lYes i;;:c
. ,------'J
g l n eturf) normally?~~ekIgnltlonlfue,1 Syst~

--JNO

No

(Turns slowly.)

CheCk baltery as tallows:

OK

Repair

starler malo,

Charging condition
Terminal connections
Terminal corrosior

--~G--

Does starler motor turn?

I Yes

r-;=

hi?

~--""L_:~~rs altum.

~ Y~h k ,.
I I h
I
-------.I
~~_uc.-------.-J

~_

No

Check reduclion gear. armature

and

gear shaft

NG

,-------~-~
Charge battery

El-31

STARTING SYSTEM
Construction

------

~----------.----

----- - - - - ' - - - - - - - - - - - - - ,

S114-705B,
S114-705C

m~

SEL555r:lll
------J

----------------------

-:0

Gp-ar case

,r~

Bearing cover

Adjusting plate
Magnetic switch assembly

I.:\)

Ball beartng

E-ring

(4)

P,nion assemhly

Thrust washer
Center bracket

@
@

Pinion shalt
Planetary gear

@
@
@

Cenler bracket
Yoke assembly
Armature
Brush holver assembly
Rear cover

~j)

Oust cover

.~l

Shifl leller

J)

Oust cover

,7)

Torsion spring

@
@

Internal gear

Removal and Installation

REMOVAL
1.

2_
3,
4.
5-

Remove battery negative cable from battery.

Remove transmission harness bracket
Remove battery cable from starter motor.
Disconnect harness connector from starlAr motor harness
Remove starter motor from under vehicle.

INSTALlATION
Installation procedure
removal.

El-32

IS

basically the reverse order of

STARTING SYSTEM
Magnetic Switch Check

1.

Before starting to check, disconnect battery ground cable.

Disconnect "M" terminal of starter motor.
Continuity test (between "5" terminal and switch body)
No continuity ... Replace.
Continuity test (between "5" terminal and "M" terminal)
No continuity
Replace.

r_,.~

SEL010Z

Pinion/Clutch Check
1.

2.

3.

Type 1

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 warn or damaged.
(Also check condition 01 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 resisReplace.
tance is evident.
Type 3

Type 2

Type 4

"'-r

~ 1':'-

':,.\'

Type S

SELOllZ

Brush Check
,(,

BRUSH
Check wear of brush.
Wear limit length:
ReIer to 50S. (EL-37)
Excessive wear .. Replace.

SEt ~,.z

EL-33

11-'

STARTING SYSTEM
Brush Check (Cont'd)
BRUSH SPRING PRESSURE
Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush);
Refer to 50S. (EL-37)
Not within the specified values ... Replace.
Brush

BRUSH HOLDER

Type 1

1.

2.

Perform insulation test between brush holder (positive

side) and its base (negative side).
Continuity exists .... Replace.
Check brush to see if it moves smoothly.
If brush holder is bent. replace it; if sliding surface is dirty.
clean.

Type 2

T~
SElO'6Z

Type 1

Yoke Check
Magnet is secured to yoke by bonding agent Check magnet 10
see that it is secured to yoke and for any cracks. Replace
malfunctioning parts as an assembly.
Holder may move slightly as it is only inserted and not bonded
CAUTION:
Do not clamp yoke In a vice or strike II with a hammer.

Type 2

STARTING SYSTEM

Armature Check
1. Continuity test (between two segments side by side).
No continuity ... Replace.
2. Insulation test (between each commutator bar and shaft).
Contmuity exists .. ,. Replace.

SEL019Z

3.

Check commutator surface.

Rough ... Sand lightly with No. 500 ~ 600 emery paper.

il~

(;:l

Check diameter of commutator.

Commutator minimum diameter:
Refer to 50S. (El-37)
Less than specified value _.. Replace.

SEL021Z

5.

Check depth of insulating mold from commutator surface

Less than 0.2 mm (0.008 in)
Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)

0.5 - 0.8 mm

R'~""I
Correct

Segmenl

,~\mr1W

"'"

Incorrect
SELonz

EL-35

:ji}i\

STARTING SYSTEM
Assembly
Apply high-temperature grease to lubricate the bearing, gears'
and frictional surface when assembling the starter.
~
Carefully observe the following instructions.

PINION PROTRUSION LENGTH ADJUSTMENT

With pinion driven out by magnetic switch, push pinion back
to remove slack and measure clearance" f" between the front
edge of the pinion and the pinion stopper.
Clearance" Cit:
Refer to 50S. (EL-37)

r~

Clearance .. i' ..
SEl026Z

Not in the specified value", Adjust by adjusting plate.

El-36

STARTING SYSTEM

Service Data and Specifications (SOS)

STARTER

5114.7058
S114705C

Type

HITACHI make
Reduction geer

system voltage
Term'''al voltage
Noload

12

11.0

Current

RevoluliOn

rpm

M,nimum length ot brush

Brush spring tension
(WIth new brush)
Mln,mum diameter or commutator

mm(lr\l

N (kg. IbJ
mm ('n)

Clearance between pinion 'ront

edge and pinion stopper

mm I,n)

Clearance belween bearing metal and armalure shall

mm (Inl

Less [he" 90
More man 2,950
110 (0433)
17 6 21 6 (1

eo . 2.20, 3 96 - 4 86)

320 (1 26Q)
03 I 5 (0 Q12 . 0 (59)
less than 0 2 (0 0081

'~'l
d)l,

;',

EL-37

CHARGING SYSTEM
System Description
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 through

100A fusible link (letter @] , located in the fusible link and fuse box). and

7.5A fuse (No. [ill , located in the fusible fink and fuse box).
Terminal supplies power to charge the battery and operate the vehicle's electrical system, Output
voltage is controlled by the IC regulator at terminal detecting the input voltage. The charging circuit
is protected by the 100A fusible link.
Terminal of the alternator supplies ground through body ground <ill!) ,
With the ignition switch in the ON or START position, power is supplied

through 7.5A fuse (No. @ ,located in the fuse block)

to combination meter terminal @ for the charge warning lamp.

Ground is supplied to terminal @ of the combination meter through terminal CD of the alternator. 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 fault is indicated.

CHARGING SYSTEM
Wiring Diagram -

CHARGE-

EL-CHARGE-01
BATIERY~

IGNITION SWITCH ]
ON or START

W/R
100A

~~
B/R
t

17.5A
~

W/A

rT1

@D

IFtITiI @

lbidJ OO

ts

W/R

M~W/R-I

~OO)B'"

LHO models
RHO mode 15

W/A

I i:

BIR

(DH4 ,

(CHARGE
WARNING
LAMP)

I
Y

*1"

~~~~NATION

~~

Y @

d:

C6

AL TERNATOR

@!)

~
L

,----------------------'

Refer to lost pagE'

(Foldout page) .

<E. <00>
L

,---------------~
I

:
\

IL

~ ~
J

EL-39

-.
I~_

CHARGING SYSTEM
Trouble-shooting
Before conducting an alternator test. make sure that the battery is fully charged, A 30-volt voltmeter and
suitable test probes are necessary for the test The alternator can be checked easily by referring to the
Inspection Table.
Before slartlng trouble-shootlng, Inspect the fusible link.

WITH Ie REGULATOR
WIth allernalor Side L lermlnsl
grounded. ,nlernal SMc,t ot:Cu'S
when + d'ode IS shorld,cuded

Burned-ou!
bulb
Replace and

f---------------......,~,_,_",__--,

L-

proceed 10

'Se<! 4J (or ground,ng F lerm,nal,

f-------j Connect
(HITACHI connector
malle)

DIm light

(5.

L) and
ground F
term,nal

(MITSUBISHI
make)

Ughl (Iickers

8"9hllight
f-------j Lighl"ON'"

Ughl "ON"

LIght "OFF"

l - - - - - j Engrne

Use fUlly charged battery.

lIghl: Charge warning light
ACG : Alternator paris except IC regulator
ICRG ; IC regulator
OK ; Ie-alternator is in good condition.
3) When reaching "Damaged ACG", remove
alternator Irom vehicle and disassembly, inspect
and correct or replace faUlty parts.
4) 'Method 01 grounding F terminal (HITACHI make
only)
Gasoline engine model
Contact tip of wire with brush and aUach
wire to alternator body.
1)
2)

speed

1.500 rpm
(Measure

Make sura

connecto, (S, l)
co"nected
c.orr~cH.,.

SElU301

5)

Terminals "S", "L", "S" and "E" are marked on rear cover 01 alternator.

El40

terminal
voltage)

IS

Construction
SEC. 231
,UT82191

ROlor

Diode assembly

Ie regulator assembly

Removal and Installation

REMOVAL
21.
3'
.

Remove
en glOe
.
R
und
emove stabili
ercover.
Remove p
zer bracke!
wer
4.
Remove
do.
steering
lub
5 . O.Iscanneclrive
i lalternalo
e mou n t"109 bracket
ha b
e from
Re
rness
r.
move coolin
connector
67 Remove
all ernalor
g fan lower sh roud
.

INSTALLATION
To install , r everse Ih e removal procedure.

EL-41

i:Xf

CHARGING SYSTEM

Disassembly
REAR COVER REMOVAL
CAUTION:
Rear cover may be hard to remove because a ring Is used to
lock outer race of rear bearing. To facilItate removal of rear
cover, heat just bearing box section with a 200W soldering
Iron.
Do nol use a heat gun, as It can damage diode assembly.
SEL032Z

REAR BEARING
CAUTION:
Do not reuse rear bearing after removal. Replace with a
newone.
Do not lubricate rear bearing outer race.

Rotor Check
1.

Resistance test
Resistance: Refer to 50S. (EL-4S)
Not within the specified values ... Replace rotor.
2. Insulator test
Continuity exists ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to 50S. (EL-45)
Not within the specified values
Replace rolOf.
SEL033Z

Brush Check
1.
2.

Check smooth movement of brush.

Not smooth ... Check brush holder and clean.
Check brush for wear.
Replace brush if it is worn down to the limit line.

Type 2
8rush wear
I,mit line

EL-42

CHARGING SYSTEM

Stator Check
1.
2.

Continuity test
No continuity. Replace stator.
Ground test
Continuity exists ... Replace stator

SEL0371

EL-43

CHARGING SYSTEM
Diode Check
MAIN DIODES

Use an ohmmeter 10 check condition of diodes as indicated in chart below

If any of the test results is not satisfactory, replace diode assembly.
Ohmmeter probes

- - - - - - - - - - - -f---

Judgement

Positive ED

Negative 8

Positive diode plate

DIode terminals

O,ode terminals

POSIlive dIode plate

direction.

Negalive diode plale

Diode lerminElls

Diode terminals

Negative diode plale

Diode conducts in only one

direction.

Diodes check (Positive side)

Diodes check (Negative side)

Diode conducts in only one

Type 4

Type 1

SUb-diodes

Type 2
~_c:,ode

termInal

N.""::::'.,.

--------

POSitive .-

diode

~ Diode

lermln&'~

plaH~

Type :l
Negative diode piaIe

,"'''

~ ,..,,_L.

~;;012J0~

"

I~/

(Slalor Sldel

LDiode

pialI'

terminals
(Rear cover s'da)

EL-44

CHARGING SYSTEM

Assembly
RING FITTING IN REAR BEARING
Fix ring into groove In rear bearing so that it is as close to @~
the adjacent area as possible.
CAUTION:
Do I\ot reuse rear bearing after removal.
~~

REAR COVER INSTALLATION

).IC

(1) Fit brush assembly, diode assembly, regulator assembly

and stator.
(2) Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.

~t
?~

'Ct
S~l/}'8Z

o/iIj
1~1

'prj)

-~.Jf<~

SEI.049l

Pl"

['J-..\

Service Data and Specifications (50S)

igj~

ALTERNATOR
A21B2191
Type
MITSUBISHI make
V-A

Nominal rating

MInimum revolution under no-load

Iwhen 135 volis

12-90
Negallve

Ground pOlarily

15

applied}

Hoi outpul currenl

rpm

Alrpm

14 1 - 147

M,nlmul'rl tength of brush

More than 5 (0 20)

Slip ring minimum outer dIameter

mm (in)

More (han <2 , (O 870)

EL-45

Less than 1.300

mm (in)

~l~

.--More than 2211,300

Mote than 6712,500
More lha~ \lOl5.000

Regulaled oUlput vOl\3gC

flOlor (held COIl) resistance

~I

25

COMBINATION SWITCH
Check
FOR EUROPE

REAR WIPER

AND WASHER
ON

WASH~INT
"<";OFF
WASH

FRONT WIPER
AND WASHER
~

f)J
VOLUME

TURN

LIGHT

\r

2NO'

WASH

",~,s/
~

INT

LO

HI

OFF

OFF

1111
1 01 14

(Turn s 19na] J

[Fr-ont w1perand wasMer)

[,:lear wlj:>"rana wa.9her-j

LIGHT LNG

OFF 1ST
>liB CII Bc

2ND
~

~
7

Ii')

10

tl
12
~

(og

J3
14

ro
ro-

)omp)

REAR WIPER AND

WASHER SW!l CH

WASHER SWJ TCH

1'..fJl'" INT LO Hl ~
15

e
10

[Rea,..

FRONT WIPER AND

SWITCH

I'i:-..

[HornJ

21

"f--

16
17
B

24

rURN

SIGNAL

swITCH

re

16INTEFlMITTENT

WIPER VOLUf.lE

HORN SWITCH
{Moa" 1S wI thDut

~c

fil"

SEL671T

EL-46

COMBINATION SWITCH
Check (Cont'd)
EXCEPT FOR EUROPE

REAR WIPER
AND WASHER
ON

....0

~~gN~~~~~

TURN

LIGHT

f\J

r---'--------.

A
U

2ND

ON

"""

_----.J.~~ &~ ~

WASHE:'\ INI

, - - - " - - - - - - - -,

O~~

vco

'"

WASH

OFF

... fU
OFF

l,:r;

INT

VOLUME

WASH

LO

It;L

HI

ili
(FrD"t

togl

jI 5 7 5
I

10 9

rn

(T,,"n signa II

(Llghtlng)

[Hornl

[Qear wiper
and washer)

TUr:lN

LIGHTING
SWITCH
~

OFF

1ST

2ND

A8C ABC ABC

5
6
7

6
9
to

11
12

SIGNAL
SWllCH

REAR WIPER AND

koIASHER SWITCH

fRDNT koI1PEA AND

koIASHER 5\o1! 1CI-'

IJT Ion LO HI WA!'}1

r,

.3

140 -0
\5
\6
17

21

-0

16

FRONT fOG
LAMP SWI TCH

IJTlJ'

31
32

INTERMITTENT
WIPER VOLUME

HORN SWITCH
(Mode 1S w 1thout

~ l

SEL676T

EL-47

COMBINATION SWITCH
Replacement

W;per and washer switch

Each switch can be replaced without removing combina_

tion switch base

1/

SWitch base

Lighting sWItch
MEl304D

To remove combination switch base. remove base attachLng screw.

MEl305D

EL-48

HEADLAMP
Bulb Replacement

1..::-:

L-

..

---

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

A'.~I

bod~

f~

Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
; .,'.
2. Disconnect harness connector from rear end of bulb
(Outer).
3. Turn bulb cover counterclockwise, then remove it.
y:L
4. Pull off rubber cap.
5. Push and turn retaining pin to loosen it.
6. Remove headlamp bulb. Do not shake or rotale bulb when ]in,
removing it.
7. Disconnect harness connector (Inner).
_err
8. Instatl in the reverse order of removal.
CAUTION:

Do not leave head lamp reflector without bulb for a long :i.:;"
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 ~;:I
before a replacement bulb Is Installed.
-J1;.

Bulb Specifications
Item
Ouler (High/Low) (H4 type)
Inner (Low) (H3 type)

EL-49

OJ'"~

Wallage (W)

60/55
55

HEADLAMP -

Without Daytime light System System Description

The headJamps are controlled by the lighting switch which is built into the combination switch

MODELS FOR EUROPE

Power is supplied at

to lighting switch

through 20A fuse

to lighting switch

through 20A fuse

all times
terminal
(No [3D . located In Ihe fusible link and fuse box). and
terminal
(No. 1m . located in the fusible link and fuse box).

Low beam operation

When the lighting switch is turned to the 2ND position and placed in LOW ("B") position, power is supplied

from lighting switch terminal @l

to terminal @ of the LH headlamp. and

fr()m lighting switch terminal (J)

to terminal @ of the RH headlamp.
Terminal of each headlamp supplies ground through body ground (ill) or @.
With power and ground supplied, the low beam head/amps will ilruminate.

High beam

operationlflash~to~passoperalion

When the lighting switch is turned 10 the 2ND position and placed in HIGH ("A") position or PASS ("e")
position, power is supplied

from lighting switch terminal @

to terminals G) (Outer) and (Inner) of RH head lamp, and

from lighting switch terminal

to terminals (1) (Outer) and @ (Inner) of LH headlamp, and

to combination meter terminal @ for the high beam indicator.

Ground is supplied to terminal @> of the combination meter through body ground @).
Terminals (Outer) and (Inner) of headlamp supply ground through body ground @ or Cill).
With power and ground supplied. the high beams and the high beam indicator will illuminate

MODELS EXCEPT FOR EUROPE

Power is supplied at

to lighting switch

through 20A fuse

to lighting switch

through 20A fuse

aJl times
terminal
(No. iI~ , located in the fusible link and fuse box). and
terminal
(No. Q71 , located in the fusible link and fuse box).

Low beam operation

When the lighting switch is turned to the 2ND position and placed in LOW ("B") position. power is supplied

from lighting switch terminal ([)

to terminal 01 the LH headlamp. and

from lighting switch terminal @l

to terminal of the RH headlamp.

Terminal of each headlamp supplies ground through body ground @ or @}
With power and ground supplied. the low beam headlamps will illuminate.

High beam operationlflash-to-pass operation

When the lighting switch is turned to the 2ND position and placed in HIGH ("A") position or PASS ("C")
position. power is supplied

from lighting switch terminal

to terminals CD (Outer) and @ (Inner) of each RH headlamp. and

from lighting switch terminal

to terminals 0) (Outer) and (Inner) of each LH headlamp, and

to combination meter terminal @ for the high beam indicator.

Ground is supplied to terminal @ of the combination meter through body ground
Terminals (Ollter) and (Inner) ot each headlamp supply ground through body ground @ or C
With power and ground supplied, the high beams and the high beam indicator will illuminate
EL~50

HEADlAMP -

Without Daytime Ught System Schematic

------------

FUSE

LIGHTING SwITCH

OFF

1ST

2ND

AB CA BC ABC
fc

--

r;o;

": L
>------

:Elr

"0

lJ.lI-

(]b~~

l:lO
>-<Z

"" '"
'" '"

-'

~~

:I:~

EL-51

.t::.

<Jb

,;q
r

a:

----

SEL679T

HEADlAMP -

Without Daytime Light System Wiring Diagram -

H/LAMP -

EL-H/LAMP-Ol

I BATTERY I

~~

...............

Refer to EL-PQWER.

LtJ~

lIJ&zj

-2

wi

-2

Iff

m
LIGHTING

SWITCH

@:@)

l!.iJl ~

IbjdI ~

Ai~Y
~}'
1---------- ~

AL/GA/bLA/B

1------------

(b)

liD models
RHO models

For Europe

576

RIG

AIL
RIB

*1 (b)A (IDR/W
*2 (OR/W, (IDR

8109

RIY

~:@
W

EL-52

.JB>

Next Dage

HEADLAMP -

Without Daytime Light System Wiri~g Diagram - H/LAMP - (Cont1d)

EL-H/LAMP-02

BATTERY

rt-----;t
~~

~~

@: For Europe
@: Except f or Europe R/w

.'

~~~~~w~~

ITtil

R/w

t<-

- c

,-"

2ND
LIGHTING
SWITCH
PASS

... LOW
HIGH- ......

If!:
",1

Preceding { : :
page

:~: ::a::~::_-_-_.II.-_O_-.-.---...--..-.-.-.-.-.-.-.-. :~: :: }'

N ext

~ AIL ~ O - "

RIL

-@>

~ RIB ~

A/B

-s>

age

:ih68"

EL-53

HEADLAMP -

Without Daytime Light System Wiring Diagram - HflAMP - (Cont'd)

EL-H/LAMP-03
Preceding
page

1::<m- :~:

AIL

<8)aR/8

.11...

...._ _. .

..

_g

I-EADLAMP LH

ffi

gR~. =-1_
@

{jt

RIB

OUTER

-r- R;G

=.
-1- -O~O- ~O-

~ R/V . ; ; . . -

HEADLAMP RH

~ -O~

HIGH

RIG

---

B
AIL

~3,

HIGH
LOW

OUTER

RIB <ITQ1)

!W

I~

ICOMBINATION
METER
(HIGH BEAM
INDICATOR)

~@

.-.!
B

t.,

CBD

<D:

LHO models

@: RHO models
1f3-<O D2

E2

~~

,------------------------~~
1

Refer to last page

@
8

;~ @.ffi
1!TI.ill B
B

(F01Clout page) _

~~.~;
GY

I
I

EL-54

GY

I
I
I

HEADlAMP -

Without Daytime Light System

Trouble Diagnoses

Symptom

Possible cause

LH head lamps do not ope' ate

Bulb
2 Ground @

Repair order

or

(ill)

.2 Check groul'ld (ill) or @

.3 Check 20A Ius!! (No !jl . located

3 20A luse

~~adlamps do

~.

not operate

<ii'

\, Check bulb,
In fusible link and
IUSE> bolt), Veflfy ballery positive voltage is present
at term'nal '1 of lighting SWitch.
4 Check lighting swilch

LighlmQ SWitch

Bulb
.2 G,ound@or@

1 Check bulb

.3 20A tuse

or @
2 Check ground @
3 Check 20A luS& (No ~7i . located in fusible link al'ld
fuse bolt). Verily battery positive voltage is present
at terminal '2 of lighting sw,tch

4 Lighting sWitch

p-'O-

d. "01

1 Bulbs
b..m;
""e."e. bOO
LH low beam oper!lles
2. Open in LH

.2 Check R/B wire between lighl,:ng switch and lH

beams circuit

head lamps tor an open cirCUli

.3 Check lighting sWitch

low be.m do.. "" opm'e. 1 Bulb

but lH high beam operates,
2. Open in LH low beam circuit

head lamp tor an open CirCUit,

3, Check lighting switch.

t Bulb

_'0_ be.m ope..'e; ~ e " '" RH low be.m ",,""

'-,1,

~n

--

High

beam

indicator

I'

does not I

2. Check ground
3 Check RIB wire belween lighllng SWitch and combination meter lor an open CirCUit

'1

.~
(~)

'2' ',5)

V"D

.2 Check R/L wire between I,ghl'ng switch and RH

1, Check bulb in combination meter

Bulb

3 Gmood
Open 11"1 high beam circuit

Models lor Europe

Models except for Europe

:::; .'~

,~,I~,

f.]P

Models for Europe

MOdels except tor Europe

~.~ ,lJ

~n

El-55

i
i

~
"

,:~'I

Check bulb,
headlamp (or an open circuit

work,

?"2

3 Check lighltng SWitch,

3 Lighting SWitch

,----.

1:f:

Check bulb

Check bulbs,
RH high beams do nol operate.
Bulbs
12. Open in RH high beams circLll1 2 Check RIG wire between lIghting switch and RH
blJl RH low beam operates,
headlamps lor an open Circuit
3, Check lighting switch
3. Lighting switch

bOO RH

U~:

2 Check R/V wire between lighting SWitch and LH

3. LightLflg switch

RH low beam does not operate.

~w,~

1 Check bulbs
h,!~h

3. Lighting switch

Check lighting switch

'1~,

HEADLAMP -

Daytime Light System -

System Description
The head\amp system on vehicles for Norway and Sweden contains a daytime light unit. The unit activates the following whenever the engine is running with the lighting SWIlch in the OFF position:

Low beam headlamps

Clearance, license, tail and illumination lamps

Power is supplied at ail times

through 20A luse (No

located in the fusible link and fuse box)

to daytime light unit terminal @ and

to lighting switch terminal '

Power is also supplied at all times

through 20A fuse (No lMl , located in ttle fusible link and fuse box)

to daytime light unit terminal @ and

to lighting switch terminal .

Power is also supplied at all times

through 10A luse (No. Ill] , located in lhe fuse block)

to daytime light unit terminal CD and

to lighting switch terminal @_

With the ignition switch in the ON or START position. power is supplied

through 7.5A fuse (No. lZ5l ' located in the fuse block)

to daytime light unit terminal (f).

With the ignition switch in the STAAT position, power is supplied

through 7.5A fuse (No, [lJ . located in the fuse block)

to daytime light unit terminal .

Ground is supplied to daytime light unit terminal through body ground @D.

rm .

HEAOLAMP OPERATION
low beam operation
When the lighting switch is turned to the 2ND position and placed in LOW {"B"} position, power is supplied

from lighting switch terminal (J) or

from daytime light unit terminal @

to RH headlamp terminal .
Ground is supplied to AH headlamp terminal through body ground @.
Also, when the lighting switch is turned to the 2ND position and placed in LOW ("S") position. power is
supplied

from lighting switch terminal @ or

from daytime light unit terminal <:'

to LH head/amp terminal @.
Ground IS supplied to LH head/amp terminal (:?) through body ground (ill)
With power and ground supplied. the low beam headlamps illuminate
High beam operatlonlflash-Io-pass operation
When the lighting switch is turned to the 2ND position and placed in HIGH ("A") position or PASS ("C")
position, power is supplied

from lighting switch terminal @

to terminals (!) (Outer) and @ (Inner) of AH headlamp, and

from lighting switch terminal

to termInals G) (Outer) and @ (Inner) of LH headlamp, and

10 combination meter terminal @ for the high beam indicator.

Ground is supplied to terminal @I of the combination meter through body ground @.
ferminals @ (Outer) and (Inner) of headlamp supply ground through body ground (ill) or @
With power and ground supplied, the high beams and the high beam indicator will illuminate.

EL-56

HEAOLAMP - Daytime Light System System Description (Cont'd)

DA YTIME LIGHT OPERATION
With the engine running and the lighting switch in the OFF position. power is supplied

to daytime light unit terminal '-?)

through daytime light unit terminal (~

to terminal of LH headlamp

to daytime light unit terminal @

through daytime lIght unit terminal @

to terminal @ of RH head lamp

Ground is supplied to terminal of each headlamp through body ground (ill) or @D
Ground is also supplied to terminal rID of daytime light unit through body ground @

l:~~

Operation (Daytime light system)

The headlamps' low beam and clearance, license. tail and
illumination lamps automatically turn on after starting the
engine with lighting swilch in "OFF" position.
Lighting switch operations other than the above are the same
as conventional light systems
Engine

lightmg switch

~r~

Headlamp

Low beam

Clearance and tail lamp

L,cense

~nd

Instrument Illumlna

tion lamp

1ST

-----

OfF

2ND

1ST

2ND
-,------

:.:

)(

)(

)(

)(

)(

0: Lamp "ON"
X Lamp "OFF'
[J

With engine runnIng

Wdh engine stopped

OFF

Added functions

El-57

1--.

t - - - f--

.-

-- - -

~{,

-"t

Schematic

I"

....r
8

..I

~><I

-. -

Q~
I -'

it
~

SFI

EL-58

~6]T

Wiring Diagram -

DTRL -

EL-DTRL-01
!

BATTERY

~;Gr~ ]Aefer to EL-PDWER.

~~~20A
~~l4Jcm~[]ID
G/R

lH!Q)

OAIL

R/W

I]]

I
..-

$1
G/R@D
I

1-

_ : " :}Next page

1
----G/R~

COMBINATION
METER
(CHARGE
WARNING
LAMP)

1
~@
WIR

OR/L~

4JJ
G/W~
G/Fl

TAIL
FUSE

G/W

LH
FUSE

RH

m
IGN

5T

wIR

G~ wIF!

rm

FUSE

.----$
@Q)

I I

R/W

~~

r"/R~"/Rl
W/A

W/A

A~L

MA~RNATOR
DAYTIME

LIGHT

UNIT

r-----------------------~

i mID~]~:
:

:~

:
:

27
368
GY

eI9~j
BY

_______________________

Aefe,.. to last page

(Foldout D<!Ige) .

i"

ii,,:

El-59

HEADLAMP - Daytime Light System Wiring Diagram - DTRL -

Preceding
page

(Cont'd)

EL-DTRL-02

i G~R =1-------- .......,

<Q1

A/W

::

FI

R/W

rn

G/R

rrf1n
2ND

LIGHTING
SWITCH

(@)

~~
RIG AIL

~~

RIB R/Y

R/L

1
::1- - - ::IEjNex.t page

Ll=:-1
It

-t

R/L

R/Y

AlB-@>
AIL

riTru

H/LAW

H/LAMP

TAIL

OUTPUT

OUTPUT

LAMP

RH

LH

SW

DAYTIME

LIGHT
UNIT

11576 ~
1 B 109
W

:4B~

11

GY

:
I

~:

GY

SEL665T

EL-60

HEADLAMP - Daytime Light SystemWiring Diagram - DTRL - (Cont'd)

EL-DTRL-03
DAYTIME

LIGHT
UNIT

AIL

L.....

clea~ance,

To
license. tail
and illumination lamps

R/B@

HEADLAMP RH

l$J

T~

HIGH

I!I
RIB

METER
COMBINATION
(HIGH BEAM
INDICATOR)

36
HIGH

LOW
OUTER

OUTER

~ <HID @1) :

GY'

GY

I
I

=-

!!

~-------------------------~

: [3L@ffi
:[IIill
B' B

I
CHD

ffi
I
I
I

LOW

-! -!

I
I

e-e

HIGH

~rn;

tftf7

Refer- to li!lst page

(Foldout page) .

GY

~-----------~-------------~

~]

~
B

SEL666T

EL-61

'~"

HEADLAMP -

Daytime Light System

Trouble Diagnoses
DAYTIME LIGHT UNIT INSPECTION TABLE
(Dala are reference va ues )
TDrminal

Judgerr~nt

Condition

Ilem

standard

No
1

Power source

(BAT)

Power sourcp.

(BAT)

Power source
(BAT)

~
~
~

te

-~
---

te

When lurning ignition switch to 'ON"

Battery positive vol1age

When lurnil19 l~nition slI/llctl to "OFF

Battery positive voltage

When lur",ng

I~niliull

sw,t<;h to -ON'

When turning ionition switch to "OFF"

Baltery positive volli:lge

When turning Ignition switch to "ON"

Battery pJsitive voltagp.

Wile" turning lQnilion switch \0 "OFF'

Battery positive voltage

RH 10 beam

When turning lighting sw-tch to -'HEAD" and

2ND positions

r--------s- lH (0 beam
~

Satter)' positive vollage

When turning lighting sWitch to "OFF" with

Baltery positive voltage

englf'le rUl'ln ing (dayllme '19M ope-allan)

When turning lighting switch 10 "HEAD" anj

(llghtir.g switch)

_._--1 - - - - - - - - - - - - - - -

~-

(Lighting switch)

ID

Battery positIve voltage

Battery posit.ve voltage

2ND positions
When turning lighting switch to "OFF" w.th

ID
te3 - -

Ballery posilive voltage

engine running (daytime light operation)

Start sigllal

,-

When turning ignition swilch 10 "ST"

1--------

f-

Power source
(IGN)

Alternater

~
~
~
~
~
~

ID
~

Batlery positive voltage

,--~--

When turning ign tioll

~wHch

to "ON' trom "5 1-

Whel'l lurn"'!J H;lnlf,on

swil~h

to "OFF"-

---

_.--_._--- .. - - - 1\i or less

IV Of less

--

--------~-

When turnIng i91'11tiol1 SWitch to "ON"

Ballery positive vollage

- - I---.

When

tur,~Jng

Igni!ion switch to "ST"

Battery positive voltage

When turning igni1io" switch to "OFF"

--- -

When engine

IS

--

--

-----

--~

--,

8allery positive vollage

running

- - - - - - - - -f----

When turning ignit;on switch to "OFF'

EL-62

--

More Ihan 5V

When lur ""'g Igni"on swi\ch to "ON'

- - - - - - - - - -------

--

1V or less

lV ')r less

HEADLAMP - Daytime Light System Trouble Diagnoses (Cont'd)

Ter

Judgement

Condllion

Item

mlra l

standard

No
9

Ground

II)

Small lamps

,,-

Wher turning lighting switch to 1ST 0' 2ND posi- Battery positive voltage
... -.

ID
1t

lion
Wher turning lighting switch to "OFF" with

When turnmg IIgMing sWllcn to 1ST or 2ND pasi-

lighting switch

Ballery positive 'tollage

eng.re running (daytIme Ilghl operation)

Battery positive 'IOttage

lion

-_.-

When turning lighting switch to "OFF"

lVar

I~s

I:rm

El-63

HEADLAMP -

Headlamp Aiming ControlDescription

The vertical direction of the headlamp beam can be adjusted from inside the vehicle, This prevents
the headlamp beam axis from facing upward due to changes in number of oCGupants and vehicle
load conditions
Bl!Ittery

,-----~----------,

1------------------------------,
I
I

Reversing
relay

!
I

1
I
I

: MOTOR

I
I
I

No contInuIty
<Wh I ttJ port lonJ

SENSOR lRotat\ng I

port I on)

I
L

Therm I star

AIMING MOTOR UNlT

lR. H.)

r------------------------------i
I
I
I
I

ReversIng
relay

I
I
I \

-L

-----t---

I
I MOTOR M
I
r

No cont Inu I ty
lWhlte portion}

I
I
I
I
I

SENSOR (Rotat r n9
port I on)

I
I

I
L

Thermistor
AIMJt-.lG MOTOR UNIT

Enll!lrged view o(
portion A

CL. H.)

-----

El-64

SEL464M

......J

HEADLAMP -

Headlamp Aiming ControlDescription (Cont'd)

SELlI7T

CIRCUIT OPERATION
[Example]
Aiming switch "0"

MOTOR

When the aiming switch is set to "0", the motor will nol
star!. This is because the power terminals are positioned
at the nonconductive section of the sensor's rotary unit

-:;[g

Thermistor
SEL06SM

--------------

Aiming switch "0"

It\efmistor

-4

"1"

When the aiming switch is moved from "0" to "1 ", the
sensor's conductive section activates the relay. Power is
supplied through the relay to the motor. The head lamps
will then move in the "DOWN" direction.
The motor continues to rotate while the rotary unit of the
sensor moves from point A to POint B.
The power terminals wiU then be positioned at the nonconductive section. disconnecting the power to the motor The
motor will then stop.

::'/}.,

SEL364P

Aiming switch "1"

--+

"0"

When the aiming switch is moved from "1" to "0", the

sensor's conductive section activates the relay Power is
supplied through the relay to the motor. The motor will
rotale to move the headlamps in the "UP" direction
When the rotary unit of the sensor moves from point B to
point A, the motor will stop.

ThermIstor
SEL365P

El-65

~~n

HEADlAMP -

Headlamp Aiming Control Wiring Diagram -

AIM -

LHD MODELS

EL-AIM-01
] Re f er to EL-POWER.

BATTERY

7.5A

[@

OR1/G

L/W

LIB ~ LIB ~

~~

-=
LIB .... LIB

~~@]>
L/W

. . . L/Y

L!Y

L!W

L/W

ID L/Y

. . . . L!Y

~
~

Next page

!@>

T;~i=i=~I-HEAOLA-MP -,-II II
M~~~ LH

..------:a...-"-~~t-J!--'~'__'1...:i'_"____,~

HEAOLAMP
AIMING

OR/G LIlt! LIB L/R L!Y MOTOR RH

~
~ 3 ~ ~

,----------'L..'i'-"--"-T-"----"'-';'-'"-"-~....:L...T:...&:.......,

------------i
!

~
Refer to last page
(Foldout pagel.

~ ~ <rn>

GY

G'f'

El-66

HEAOLAMP -

Headlamp Aiming ControlWiring Diagram - AIM - (Cont'd)

EL-AIM-02

~
ATTEFlY

]
Flefer

45A

til

EL-POWEFI

...--.
I
I

1ST

2ND SWITCH

~:@
~

OFF-1ST

~
I

FUSE

s.

~:>

IVl

LIGHTING

TAIllL

~~~t~NG

IFITi1

TAIL

daytime lIght system

2ND

OFjO>-

G/R

R/L

@: MOdels without

rrt'ru

(;/R~

FIlL

@: Models wlth
daytime light system

G/A

G/R (ffig)

RIL
AIL
~1lH@
I

AIL

~
I
El-DTRl )
:
,.-!1lr....!11....l!....-1I_~ff11i1~1~1' ;:-_ _--, ~ @ I I

~
Preceding
page

~l>Ci.gjo AIL

L/W

L/W

~@
till:fj GY

L/R

9
~

O
AIL

-oc-o- AIL @

AIL ]

HEADLAMP

~~~f~~
@

~l/B
~

AIL

mlliJ
OA

~rfI~~e~~~io

RIL

~ R/L

l/Y - - - - - - -

last page
(Foldout page)

Refer to

~~
~w

SEL688f

EL-67

HEADlAMP -

Headlamp Aiming ControlWiring Diagram - AIM - (Cont'd)

RHO MODELS

EL-AIM-03
SATTERY
] Re f er to EL -POWER.
7.5A

[@
~

DR/G

Llw

r-=
I J=

<HW @])
L/w

LIB

LIB

~ IlliJ)

L/A

L/Y

@
~ LIY @
L/A

HEADLAMP

LlW LIB L/A L/Y

~6~6~LH

Il1l ~

-=-

LIB -

fiE
T.I'~'=I=I~I---I
OR/GQ)

-=_

L/w

L/A

L!V -

-I

L/W

LIB

~
~

L/R

L/V

o;p.

Next page

HEADLAMP

~6~~~ RH

r-----tL';!-J!.....!L~.!L4_.l!.......!L.:;!_J!.......!1...+...lL_,rn

~
B

,------------i!
@

Refer to last page

(Foldout page) .

~@<

GY

BY

SEl~8qT

EL-68

HEADLAMP -

Headlamp Aiming ControlWiring Diagram - AIM - (Cont'd)

EL-AIM-04

1.:(;

LIGHTING

SWITCH
~

([f@0i@@([D
~ AIL ~ RIL - -..

. . ._ _ R/L

I-EADLM4P

;1

AIMING

SWITCH
@)

Preced ing (
page

::

~~:

~4JJ 14Jl~

---

L/W

LIB

L/A L/V

L/Fl

L/V - - - - - - - - - - - - - - -

----~----

~~, r '

ri

B
~

B
~

\ill>
Refer to last page
(Foldout page) .

SEl690T

EL-69

HEADLAMP -

Head'amp Aiming Control Aiming Adjustment

When performing headlamp aiming adjustment, use an aiming
machine, aimIng wall screen OT heacllamp ~ester A1mers
should be in good repair, calibrated and operated according
to their operation manuals
Ii any aimer is not available, aiming adjustment can be done
as follows'
For details, refer to lhe regulatlons In your own country.

CAUTION:
Keep all tires inflated to correct pressures.
Place vehicle and tester on one and same flat sUrface.

See that there Is no-load in vehicle (coolant, engine 011

filled up to correct level and full fuel lank) other than the
driver (or laqu!valent weIght placed In driver's poslllon).
CAUTION:
Be sure aiming switch is sef to "0" when performing aiming
adjustment on vehicles equipped with headlamp aiming Con.
1rol.

LOW BEAM
1.
2

, H'

Honzontal
center Ime
01 /1eadlamps

Turn headlamp low beam on.

Use adjusting screws to perform aiming adjustment
Flrsl tighten the adjusting screw all the way and then make
adjustment by loosening the screw.

Adjust headlamps so Ihat main axis of light is parallel to

center line of body and Is aligned with point P shown In
iIIustrati on.

Figure to the left shows headlamp aiming paltern for drivIng on right side of road; for driving on Ie" side of road,
aiming pallern is reversed.
Dofled lines In illustration show center of headlnmp.
"H";
Horizontal center line of headlamps
"W L ": Distance between each headlamp center
"L":
5,000 mm (196.85 in)
"e":
65 mm (2.56 in)

EL-70

HEADLAMP ------------------------.,

Trouble Diagnoses
SYMPTOM: Headlamp aIming does not operate,

EILJ

g
I

RIL

Headlamp Aiming Control -

(J...Y-'

Ughtinq switch "Bf'

'POWER SUPPL Y CI'lCUIT CHECK (For

aiming SWilch)
Check " 12 volts exisl between terminals

1,

NO

Check lOA fuse at fuse

block. (ReIer to "POWER
SUPPLY ROUTING")

ancl~;;

[Y]

Voltmeter lerminals

.. -

I')

Q)

SE1714T

Vcltaaa [VI

H
Appro, 12

OK
AIMING SWITCH CHECK
Check continUity oetweel'\ term,nals at
each sw,tch posilion

pos,tlon

~j I~

',:r----r--<:'

TCf'mll,a'
SWitch

SELJ67P

l!J

C+-

NG

Replace aiming sw teh,

-{)
")

2
J

()

~J

l!1
GROUND CIRCUIT CHECK FOR AIMING
MOTOR
Check contonuily belw99n t&rminals
and bocly ground.
Cont,nUlty exists ". OK

OK
SEl22lP

POWER SUPPLY CIRCUIT CHECK (For

aiming motor unit)
Check ,f 12 vol1s exist between terminals
(1), (~, @.
@J and '

Check harness between

a,ming SWitch and aiming
motor unit

c!>.

Vullrllt:'ter

lermnals

(t)

.,11

~,

A,mon!! ~w'lch
posilion

API3'Olt 12

"0 '

E.cnpl '"0'

Appro~,

,~\

Voltage
[VI

12

"1"

E'cep' '1'

tID

Appro" 12

"2'

I:,cegl

2'

-,-

Approx 12

'4'

~,

'"3 '

E,cept
"l'PfO~

I-RePI'lCC aIming motor,_u_n_It

EL-71

'"3"'

\2

' g1,"T

EXTERIOR LAMP
Clearance, License and Tail Lamps/System
Description
LHD MODELS WITH DAYTIME LIGHT SYSTEM

The clearance. license and tail lamps on vehicles tor Norway and Sweden contain a daytime right unit
The unit activates the small lamps whenever the engine and lighting swilch are under the fOllowing:
conditions.

Engine running
Lighting switch in the OFF position
(For daytime light system. refer to "HEADLAMP - Daytime Light System -".)
Operation (when daytime light system is triggered.)
Power is supplied at all times

through 10A fuse (No, Inl , located in the fuse block)

to daytime light unit terminal CD.

With the engine running and the lighting switch in the OFF position, power is supplied

through daytime light unit terminal @>

to terminal (!) of each lamp.

Ground is supplied to terminal of clearance lamps through body ground @ or @.
Ground is a Iso suppl ied to terminal @ of I icense Iamp and to terminal @ of tail Iamps through body
ground@.
With power and ground supplied, the (;Iearance, license and tail lamps illuminate.
Operation (when daylime light system Is nol triggered.)
Power is supplied at all times

through 10A fuse (No. ~ . located in the luse block)

to lighting switch terminal @,

With the lighting switch in the 1ST or 2ND position, power is supplied

through lighting switch terminal @

to daytime light unit terminal ~

through daytime light unit terminal @)

to terminal CD of each lamp.

Ground is supplied to terminal @ 01 clearance lamps through body ground @ or @
Ground is also supplied 10 terminal of license lamp and to terminal @ of tail lamps through body
ground@.
With power and ground supplied, the clearance, license and tail lamps illuminale.

LHD MODELS WITHOUT DAYTIME LIGHT SYSTEM

Power is suppJred at all times

through 45A fusible link (letter

to lighting switch terminal @.

W.

located in the fusible link and fuse box)

Operation
With the lighting switch in the 1ST or 2ND position. power is supplied

from lighting switch terminal @

through 10A fuse (No iL4] , located in the fuse brock)

to terminal CD of clearance, license and RH tail lamps.

With the lighting sWitch in the 1ST or 2ND position, power is also supplied
from lighting switch terminal @

through 7 SA fuse (No. @ , located ill the fuse block)

to LH tail lamp lerminal (!).

Ground is supplied 10 terminal of clearance lamps through body ground @ or @,
Ground is also supplied to terminal of license lamp and to terminal o( tall lamps Ihrough body
ground @.
With power and ground supplied, the clearance. license and tail iamps illuminate

El-72

EXTERIOR LAMP
Clearance, License and Tail Lamps/System
Description (Cont'd)

RHD MODELS FOR EUROPE

power is supplied at all times
through lOA fuse (No ~I , located in the fuse block)
to lighting switch terminal I!l)

operation
With the lighting switch in the 1ST or 2ND position. power is supplied
through the lighting switch terminal @
to terminal (D of each lamp.
Ground is supplied to terminal @ of clearance lamps through body ground @ or <TID
Ground is also supplied to terminal of license lamp and to terminal @ of tail lamps through body
ground @D
With power and ground supplied, the clearance, license and tail lamps illuminate.

t~~

RHO MODELS EXCEPT FOR EUROPE

Power is supplied at all times
through lOA 1use (No. ff3] , located in the fuse block)
to fighting switch terminal @, and
to front fog lamp relay terminal '
Operation (when front tog lamp system is not triggered.)
With the lighting switch in lhe 1ST or 2ND posilion, power is supplied
Ihrough lighting switch terminal @

10 terminal (}) of each lamp.

Ground is supplied to terminal of clearance lamps through body ground or @D.
Ground is also supplied to terminal of license lamp and to terminal @ of tail lamps through body
ground @.
Operation (when front fog lamp system is triggered.)
With the front fog lamp switch in the ON position.
ground is supplied to front fog lamp relay terminal @ through the front fog lamp switch and body
ground @.
The front fog lamp relay is energized and power is supplied
through front fog lamp relay terminal (j)
to terminal G) of each lamp.
Ground is supplied to terminal of clearance lamps through body ground @ or (ill)
Ground is also supplied to terminal of license lamp and to lerminal @ 01 lail lamps through body
ground (ill)
With power and ground supplied, the clearance, license and tail lamps illuminate.

.'~"T

~,}~

_orr

EL-73

EXTERIOR LAMP

Clearance, License and Tail Lampsl

Wiring Diagram - TAILlLLHD MODELS WITH DAYTIME LIGHT SYSTEM

EL-TAIL/L-Ol

G/A

G/R~

rff)

.---.

GIl=!

@)

G/R

/f1iil
~
~ 1ST
-

Od.. . _

2ND

LIGHTING
SWITCH

lfi9l) QiIQ)

. .- - - - - . - AIL

R/L

TAIL

TAIL/L

FUSE

rFffil
SW

R/L -

R/L

~ ~~~~

l-c-- R~ ~ I~R~E

R/L

G/R

AIL

Ir~~liAR~~E

rmru

TAIL/L DAYTIME
OUTPUT LIGHT

.-.

UNIT

~----------------'~

1 1
@~
~ltW
0Ctlj
w

Refel' to last page

KL1 @

<I@

GY

(Fa 1dDut page) .

GY

SH69,T

EL-74

EXTERIOR LAMP
Clearance t License and Tail lampsl
Wiring Diagram - TAILIL - (Cont'd)

EL-TAIL/L-02

~~~~edlng ---t:L-e~

4ill)(]D
AIL

R/L

R/L - . -

RILE
<J

LICENSE
PLATE

t~

LAMP
I

2:C

tm)

TAIL

REAR
COMBI-

NATION

LAMP RH

STOP

lHID(ID
~
R/l~R/L~RIL_-

-RIL

e--

TAIL

._R/G ~

o::::IQO]@
[I]l]]II] w

~@

CITJ::lli]

<rn>

w w

<!lID

EL-75

@
SR

RIG

<:IT!>

REAR
COMBI-

NATION
LAMP LH

STOP

TOL--E-L--S-T-O-PI-L.......

Re fer to last page

(Foldout plIge) .

gn

EXTERIOR LAMP
Clearance, license and Tail Lampsl
Wiring Diagram - TAILIL - (Cont'd)
LHD MODELS WITHOUT DAYTIME LIGHT SYSTEM

EL-TAIL/L-03

:J

Refer to EL-POWEA.

G/R

O/F!

rrTIiJ
2ND

LIGHTING

SWITCH
(fl@

R/L~

r---=

l$J
R/L Q)

mAil

RIL

AIL

(!r@i

J .-.

@])~

r-

RH

CLEARANCE

~~LH

tIl

ill

RIL

..

~w

CLEARANCE

_ _ AIL

.-AIL~RIL

~~

'~'- ~ ITb

RIL

R/L

RIL

~}Next
~

Page

lD I itsl page
[FoldDut DfllO'e) .

~8fer

f.;Ll~~

C!..@ GY

GY

5EI69JT

EL-76

EXTERIOR LAMP
Clearance, License and Tall Lampsl
Wiring Diagram - TAILIL - (Cont'd)

EL-TAIL/L-04

6~~~edlng ~

~CID

RIL

RIL -

~ill)

R/L

ID RIL - e - R.[J
/L]]
LICENSE
PLATE
LAMP
@l)

TAIL

COMBINATION
LAMP RH

REAR

;~

STOP

l.ID>

~~il

t~~

Pl"ecedlng
page

lffi)) CID
R/L

AIL -

@
AIL

em
W R/L -

__

RIL-(Q
B

TAIL

~\1

NATION

e- R/G-fQ

REAR
COMBI-

LAMP LH

STOP

p;ij

RIG

'il

TL...O-E-L-_S-T-QP-I-L---l
~:'~l

[I]Q[I]~

ITJ1NLlJ

~lITJ)

CIIJ.lli w

~
W

~@

Wg SR

({/~\

5EL69 4T

EL-11

EXTERIOR LAMP
Clearance, License and Tail Lampsl
Wiring Diagram - TAILll - (Cont'd)
RHO MODELS

EL-TAIL/L-05

BATTERY

~'-WJ-15-A------~&;
DR

tIT

G/A@

-.
$

G/A@

~~:a..--c;

OR

G/R

o
o

~nJ FOG
FRONT
n
LAMP
U U RELAY
1!4JI~:

,=

TT

I~ I
OFF--

rr*n

G/R

112 II

ON

Refer to EL-POWER.

2ND LIGHTING
SWITCH

OFl~" ....lST

<IT>

.~

Ri~._ R~Q~/L
~:~:
!
~
~@

Lr:;

FRONT

~ST~~MP
@:@)

~
B

@: For Europe

<IT>;

E><cept for Europe

11

lIf1"'
lf2"'@ 12

~
(W
tj]j 8R

g.,..Q

WID
B

:
KLl

12
11

RIL

RIL

R/L~
<!

o@>

CLEARANCE

r-B~

1-,.-.I
i

RH

CLEARANCE

LAMP LH

1 @Z>
1

GY

Refer to last page

(Foldout page) .

GY

,----------------~---------~

i~~:~~:i
IDfj
Iffi:tj

I
,L

I
I

SEl695T

El-78

EXTERIOR LAMP
Clearance, License and Tail Lampsl
Wiring Diagram - TAILIL - (Cont'd)

EL-TAIL/L-06

6~~~eding<Q}

lHTI> CID
R/L

AIL

CID

FlIL-.

RIL

r=

.-

RlL

LICENSE

PLATE
LAMP

@l)

~.------~

TA IL

REAR

COMBI-

NATION

LAMP RH

STOP

TAIL

REAR
COMBI-

STOP

@g)

~I(

R/L-(Q

_ _ a'[;4

. - RIG

RIG

~(ill> ~

~w

EL-79

~~

W5JBR

NATION

LAMP LH

T'---O-a--S-T-O-Pl-L---'

EXTERIOR LAMP
Stop Lamp/Wiring Diagram -

STOP/L-

EL-STOP/L-01

R/Y

ml

STOP

n SWITCH
u~

~
R/G

@~

RIG

RIG

To EL-TAIL!L. R/L

RIG

-e---

~
e-I-

-e- - e--

~ ~~~Tfl)

BW
RIL

RIG

R/L

-((1

1= R~G

e
<I>:

HIGH-

RIG

'

~
TAIL

REAR

COMBl-

NATION

.----_ _
ST_O_P-,

TAIL

REAR

COMBrNATION

ST_OP----'@LH

L-.._ _

LHD models

@: RHO models
IH

<D

B
~

Refer- to last cage

(Foldout pagel

SEL8J6T

EL-80

EXTERIOR LAMP
Back-up Lamp/Wiring Diagram -

BACK/L-

EL-BACK/L-01

I
<i>-aJ

.~
G

G @

1$
G

r;:::::
I I
--1-

~~~-~
em

a
G/W

~BACK-UP

I ~_I- ~
B

LH

lfl

G/w

G/.

INHIBITOR
SWITCH

~:@

~:~-UP

wl

G/W

R~A~O

--

oo:~
I
G/H ~ G/H ~

(J;): All mode 1s

:
(1):

MIT mode 1s
LHD mode Is
RHD models

*1 - .. (J;) R
*2(1) R
113"' 4

G/W
G!W
7

Refer" to llllst pelge

(Foldout Delgel .

~@D

ti:tt:t:7

*2 (]I)

~~:

$M2 ~

t$ tHW
It

I. ] SWITa-t

~@
G/W ~ G/W

(ill)

CTID

GY

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l.!..[g]

SFIM1T

EL-81

EXTERIOR LAMP
Front Fog Lamps/System Description
LHD MODELS WITH DAYTIME LIGHT SYSTEM
Power is supplied at all times

through 15A fuse (No [~il , located in the fusible link and fuse box)

tD front fog lamp relay terminal @.

Power is also supplied at all times

through 10A fuse (No. 1?3] , located in the fuse block)

to lighting switch terminal @. and

to daytime light unit terminal CD.

When the daytime light system is triggered, power is supplied

through daytime light unit terminal @

to front fog lamp relay terminal d), or

With the lighting switch in the 1ST or 2ND posHion, power is supplied

through lighting switch terminal @

to daytime light unit terminal @

through daytime light unit terminal @)

to front fog lamp relay terminal d).

Front fog lamp operation

If the rear fog lamp system is triggered, terminal @ of rear fog lamp relay is grounded and power to
the front fog lamp switch is interrupted.
When the rear fog lamp system is not operating, ground is supplied
With the front fog lamp switch in the ON position:

ground is supplied to front fog lamp relay terminal

from rear fog lamp relay terminal @

to rear fog lamp relay terminal @

through front fog (amp switch and body ground or @.

The front tog lamp relay is energized and power is suppl ied

Irom front fog lamp relay terminal

to terminal CD of each fronl fog lamp.

Ground is supplied to terminal of each fog lamp through body ground @ or @.
With power and ground supplied, the front fog lamps illuminate

LHD MODELS WITHOUT DAYTIME LIGHT SYSTEM

Power is supplied at all times

through 15A fuse (No.

located in the fusible link and fuse box)

to front fog lamp relay terminal @.

With the lighting switch in the 1ST or 2ND position, power is supplied

through 45A fusible link (letter fi:"J. located in the fusible link and fuse box)

to lighting switch terminal @

from lighting switch terminal @

through 10A fuse (No. LM1 . located in the fuse block)

to front fog lamp relay terminal G).

rm ,

Front fog lamp operation

The lighting switch must be in the 1ST or 2ND position for front fog lamp operation.
With the front fog lamp switch in the ON position:
ground is supplied to front log lamp relay terminal through the front log lamp switch and body
ground or@
The front fog lamp relay is energized and power is supplied

from front fog lamp relay terminal

to terminal CD DI each log lamp.

Ground is supplied to terminal of each fog lamp through body ground @ or @
With power and ground supplied, the front fog lamps illuminate

EL-82

EXTERIOR LAMP
Front Fog lamps/System Description (Con"d)

RHO MODELS FOR EUROPE

power is supplied at all times

through 15A fuse (No i3\l , located in the fusible link and fuse block)

to front tog lamp relay terminal @

With the lighting switch in the 1ST or 2ND position. power is supplied

through 10A fuse (No. [23) , located in the luse block}

to lighting switch terminal @

through terminal @ of lighting switch

to front fog lamp relay terminal @-

Front fog lamp operation

The Iighting switch must be in the 18T or 2ND position for front fog lam p operation_
With the front fog lamp switch in the ON position.

ground is supplied to front fog lamp relay terminal CD through the front fog lamp switch and body
ground (ill or @D.
The front fog lamp relay is energized and power is supplied

from front fog lamp relay terminal rID

to terminal ill of each front fog lampGround is supplied to terminal 01 each front log lamp through body ground (ill) or
With power and ground supplied, the front fog lamps illuminate.

RHO MODELS EXCEPT FOR EUROPE

Power is supplied at all times

through 15A fuse (No, @] ,located in the lusible link and fuse box.}

to front log lamp relay terminals CD and .

Front fog lamp operation

The front fog lamp switch is built into the combination switch.
With the front fog lamp switch in the ON position:

ground is supplied to Iront fog lamp relay terminal through front log I am p switch and body ground

The front tog lamp relay is energized and power is supplied

from Iront fog lamp relay terminal

to terminal G) 01 each front fog lamp.

Ground is supplied to terminal of each Iront fog lamp through body ground @
With power and ground supplied, the front log lamps illuminate

El-83

or (ill)

~ I~

EXTERIOR LAMP
Front Fog Lamp/Wiring Diagram -

F/FOG -

LHD MODELS WITH DAYTIME LIGHT SYSTEM

EL-F/FOG-01

I BATTERY
I
I

.--------~

illJ
m
!m

G/A ~

Refei' to EL-POWER.

liJEm
OR

aiR

AIL

~ ]~T
U
~FOG

II

. ._ _

U:;JI

G/QR

OR/8

G/R

LIGHTING

SWITCH
(@)

LAMP

RELAY

ern

]D lli@
- G/OR ~ G/OR - - G/DR ~ Next page

.L -

. . . ._ _. . - .

G/R

R/L

lA1LIL

TAlLIL
OUTPUT

rn

FUSE

OA/B~r~TRH
~~
B

rIToi1
DAYTIME

r-

LIGHT

DRIB

UNIT

(J~ ~~NT
..lR

LAMP LH

1
ffi

e-e

1
@
~oo tiB
~~
GY

~w

ft

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(Foldout page) .

ffi)@
GY' GY

Front Fog Lamp/Wiring Diagram -

F/FOG _

(Cont'd)

EL-F/FOG-02

Pl"eceding
page

r---

....--AI-......::r G/OR -----~I

G/OR

11

R/Y
FOG LAMP
RELAY

\bj:JJ

RIG

I.e

~REAR

no

U0

To EL-ILL. B/L

R/Y ~To EL-R/FOG

B .To EL-B/FOG

RIG @]>

G/OR

AIL

rn

G/OR

rm

FRONT
FOG
LAMP
SWITCH

OFF-L.-..-,.----r-----='-'--'~.-.!2:-r;-----'

@)

r----'
B

......

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t11]

f@
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(Foldout page) .

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SEL699T

EL-85

EXTERIOR LAMP
Front Fog Lamp/Wiring Diagram (Cont'd)

F/FOG -

LHD MODELS WITHOUT DAYTIME LIGHT SYSTEM

EL-F/FOG-03
I

OJ
rn

BAT;ERY

G/A

m:TiI

l!H
R/L

~
R/L l&W

~~~~~NG
2ND

lr

~~

L{Jilll
AIL
,

em

OR

~(_T
-I
I_

<t!W

Refer to EL-POWER_

OR

R/L @Q)

1ST

OFF-

FOG LAMP
AELAY

;~T

,----- OR/B~
-(C
~~NT
~-~-.
W)G/OA
m m

.-__

...IF-

LAMP RH

R/L

'--;r---,r:---.".-,!,-.,.,...--J

FRONT

OR/B~
JF.
FRONT
~
FOG

FOG
LAMP
@)

SWITCH

...JF-

IB~
B

LAMP LH

e-e

ffi

ill

~~
W

0C:fjj

f2lITlcw

!Jill

A
T
L

~<ru).~
~
GY

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SEllOUT

EL-86

EXTERIOR LAMP
Front Fog Lamp/Wiring Diagram (Cont'd)

F/FOG -

RHO MODELS FOR EUROPE

EL-F/FOG-04

rwr
L4JEm

~~..........~

G/R@

OFF

RIL

LIGHTING

RIL

~C~

OR

F.r.

FOG LAMP

U RELAY
(IT)

O"I/B

L-

lflQD G/OR

.,__-.-----O"/B~~T

~~.

$~;

R/L G/OR

rm

~ffiJ
I

n
~
:nr~
~
~

T~ r=LJ"

,_iST

Refer to EL-POWER.

OR

rip
G/R~
@

ffi

RH

,',
FRONT
FOG
LAMP

OR/B~..JPjFRONT
-n=

SWITCH
'--ri:-..----,.--.."....---'

@)

.. B
B

FOG
LAMP LH

- e
e
1
1
ffi
~
~oo

llitl

ffifI(@
~

~@ ~GyGy
~ru>
TL

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(Fo Idout page) .

SEI TOH

EL-81

EXTERIOR LAMP

EL-F/FOG-05

~
m

~
t5A

mJ

mJ

OR

I
I
Df1

Refer to EL-POWER.

iOA

G/R

I
~
G/R@l

...,

G/RlMiQ)

OR

[ ] ~J~AMP
~

liB

' ~~NT'
cZJ
G/lloORR

OR

~<W

Lr-;-

R/L. To .L-TATL. a-ILL

ON

OFF--

LAMP

SWITCH

....

L:I

OO/B~ FRONT
B

-G

E~

RH

OR/B~~~NT
B

-c

LAMP LH

e-e

1-

m
~(il)
t:':l2.EI B

V
2

57
3 6

@
8R

~~,~

ld.lS' GY

@L>
Refer tD l"gt page
(Foldout pagel.

GY

SH702T

EL-88

EXTERIOR LAMP

Front Fog Lamp Aiming Adjustment

Before performing aiming adjustment, make sure of the following.
a Keep all tires inflated to correct pressure.
b. Place vehicle on level ground.
c. See that vehicle is unloaded (except lor full levels of
coolanl, engine oil and fuel, and spare tire, jack, and 1001S)
Have the driver or equivalent weight placed in driver's
SLS38T

seat
Adjusl aiming in the verlical direction by lurning the adjusting
screw.
Check the distance between Ihe vehicle and the ground point
where Ihe main axis of light of fog lamp reaches. Keep the
distance Within 40,000 mm (1,574.8 in)

Main axis
of light

[
~---

':;,/.\\

-----~-

Leu than
40,000 rnm (f ,514.8 11\)
SEL539T

EL-89

L.~::

EXTERIOR LAMP
Rear Fog lamp/System Description
Power is supplied at all times

through 7.5A fuse (No. r~I for LHD models, No 29 for RHO models, located in the fuse block)

to rear fog lamp relay terminal lD (with daytime light system) or @ (without daytime light system)
With the lighting switch in the 2ND position, power is supplied

through 20A ruse (No.

located in the fusible link and fuse box)

to lighting switch terminal @

through lighting switch terminal @

to rear fog lamp relay terminal CD.

JZJ ,

Rear log lamp operation

The lighting switch must be in the 2ND position for rear fog lamp operation.
Ground is supplied to rear fog lamp relay terminal through body ground @
With the lighting switch in the 2nd position, the rear fog lamp relay is energized and power is supplied

through rear fog lamp relay terminal @ (with daytime light system) or (without daytime light
system)

to rear fog lamp switch terminal

With the rear fog lamp switch in the ON position, power IS supplied

through rear fog lamp switch terminal CD

to terminal
of rear fog lamp.
Ground is supplied to terminal (~ of rear fog lamp through body ground @
With power and ground supplied. the rear fog lamp illuminates

cD

EL-90

EXTERIOR LAMP
Rear Fog lamp/Wiring Diagram -

R/FOG -

WITH DAYTIME LIGHT SYSTEM

EL-R/FOG-01
I

BATiERV

m~
7.5A

[gZ]

'I'

Refer to EL-PDWER.
20A

To EL-[LL. RIL

LIGHTING
2ND

~
~
R/V

G/OR

-.
GI

t_

-I~

La

DRIB

IND

EL-F/FDG

ILL FOG
LAMP
SWITCH

..JFii
B

~----------------~---~

2@@Q)

3 7 6

LAMP

@Q)

I i-J
.-e
1 1

~~

IOJ]I em
-

@:
W

OR/B

DRIB

:-----------ffiE--~------:

, I

REAR

~~
DRIB
r--

ON

~l!4=!f~

L...-OR/B~REAR
fOG

: ~<E@
,
~

R/L

OFF r
.,.,....-...."..--':-.-~...........-----l
1

CHID

~ ~lTO

OR/S

REAR FOG
LAMP
RELAY

RIG
_ _ _ _ G/OR+

rnmm

$R/V @Q)
I
R/v

~
~
RIG G/ Y

(ill)

@QD

SWITCH
~

.... 1ST

OFF-.......

[]I]

GY

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~e' er

to last page
(Foldout Page) ,

SfLlOH

EL-91

':'I'r
'[

EXTERIOR LAMP
Rear Fog Lamp/Wiring Diagram -

R/FOG -

(Conl'd)
WITHOUT DAYTIME LIGHT SYSTEM

EL-R/FOG-02

I
]
i~
Refer7.5A
20A

I BATTERY

[ill

to EL-POWEFl.

[ill

111

m
LIGHTING
2ND

..... 1ST
DFF-........

~
A/Y

_
SWITCH
_
~

T_lJ_EL.-I_LL_+
. .fl/l

00

G/Y

rn

R/Y @Q)

l
OA/B

AIL

a
G

LAMP
SWITCH

R/Y
1

L-~~....."....J,-."----,,,.-,i.--.,..--J

~l1i1'

REAR FOG

LAMP
RELA't'
2
@el

IJ
I1iJJ

REAR

ILL FOG

t_

..

..----1 _I.--------__...

6/Y

DR/8

~@])

'~CID

:
:

OA/e~

$dn

LHO mode Is

RHO lIIode Is
Ill1(b)R, A/W
29
*2<0 27.
*3 , . <0 55,
57

1f4

<D

13,

OA/S

L-OA/B~REAA
FOG
-

,.....

LAMP

B
~

(ffi)

r---

iI WTI~
I

@)

I i.....l
e-.
1 1

~@> i A []JQlg]~
~@Q)
tftjj WIT
~
I

BA

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(Foldout Daoe) .

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~----------------~---~

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SfllOdT

EL-92

EXTERIOR LAMP
Turn Signal and Hazard Warning
Lamps/System Description
TURN SIGNAL OPERATION
With thEl h,qzArd switch in the OFF position and the ignition swi:ch in the ON or START position. power
is supplied

through lOA fuse (No .

,located in the fuse block)

to hazard switch terminal

through terminal (1) of the hazard switch

to combination flasher unIt terminal

through terminal @ of the combination flasher unit

to turn signal switch terminal (1)

Ground is supplled to combination flasher unit terrninal (,!J through body ground @ or @).

.w

L;'_

LH turn
When the turn signal switch !s moved to the lH position, power is supplied from turn signal switch terminal 'J) to
front turn signal lamp LH terminClI W

side tum signal lamp LH terminal ill

rear combination lamp LH terminal @

combination meter terminal @

Ground is supnli~d to the (ront turn signal lamp LH terminal through body ground aID.
Ground is supplied to the side turn signal lamp LH terminal @ through body ground @) (LHO mOdelS)
or @ (RHO modelsl.
Ground is supplied to the rear combination lamp LH terminal @ through body ground <TID.
Ground is supplied to combination meter terminal @ through body ground .
With power and ground supplied. the combination flasher unit controls the flaShing 01 the LH turn sig- ,,'I
nal lamps.

RH turn
When the turn signal switch it; movp.d to the RH position. power is supplied from turn signal SWitch terminal ~ to
-~'"
front turn signal lamp RH terminal d)

side turn signal lamp RH terminal c:D

rear combinR.tion l;:Imp AH terminal (2;1

combination meter terminal @.

Ground is supplied \0 the front turn signal lamp RH terminal through body ground @).
Ground is supplied to the side turn signal lamp RH terminal through body ground @ (LHO models)
or @
(RHr1 models)
g.; ~
Ground is supplied to the rear combination lamp RH terminal @ through body ground (!!D.
Ground is supplied 10 combination meter terminal @ through body ground
~~.r
With power and ground supplied. the combination flasher unit controls the flashing oi the RH turn sIgnal lamps

HAZARD LAMP OPERATION

Power is supphed at all times to hazard switch terminal @ through:

10/\ fuse (No. ~2J . located in the fusp. block)

With the hazard switch in the ON position. power is supplied

through terminal '1) 01 the hazard SWitch

to combination flasher unit ~erminal @

through terminal '~) of tho combination flasher unil

to hazard switch 'ermlrlal (iJ

Ground is supplied to combination flasher unit terminal Cj) through body ground
Dower is supplied through terminal ') of the haz.ard switch to
(ronl turn signal lamp LH terminal (D

side turn Signal lamp l H terminal (1)

rear combination lamp LH terminal (~

combination meter terminal t!J

Power IS supplied throuqh terminal ("6~) ot the hazard switch to

or @.

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/System
Description (Cont'd)

front lurn signal lamp RH terminal (!j

side turn signal lamp RH terminal 1;

rear combination lamp RH terminal @

combination meter terminal @).

Ground is supplied to terminal @ of each fronl turn signal lamp through body ground @D or @D.
Ground is supplied to terminal of driver's side turn signal lamp through body ground or @D.
Ground is supplied to terminal @ of passenger side turn signal lamp through body ground @ or @.
Ground is supplied to terminal of the rear combination lamps through body ground @
Ground is supplied to combination meter terminal @ through body ground @).
With power and ground supplied, the combination flasher unit controls the flashing of the hazard warning lamps.

WITH MULTI-REMOTE CONTROL SYSTEM

Power is supplied at all times
through 1QA fuse (No. [llJ located in the fuse block)

to mult,remote control relay-1 lerminals G), and @.

Ground is supplied to mufti-remote control relay-1 terminal . when the multi-remote control system
or theft warning system is triggered through the smart entrance control unit.
Refer to "MULTI-REMOTE CONTROL SYSTEM" or "THEFT WARNING SYSTEM".
The multi-remote control relay-1 is energized
Power is supplied through terminal CD of the multi-remote control relay-1

to front turn signal lamp lH terminal 0)

10 side turn signal lamp LH terminal <.D

10 rear combination lamp LH terminal

to combination meter terminal @

Power is supplied through terminal ' ID 01 the multi-remote control relay-1

to front turn signal tamp RH terminal CD

to side turn signal lamp RH terminal CD

to rear combination lamp RH terminal 1>

to combination meter terminal @>.

Ground is supplied to terminal of each front turn signal lamp through body ground @ or @D.
Ground is supplied 10 terminal of driver's side turn signal lamp through body ground @ or @.
Ground is supplied to terminal 01 passenger side turn signal lamp through body ground @ or @
Ground is supplied to terminal @ of the rear combination lamps through body ground @,
Ground is supplied to combination meter terminal @ through body ground (!D.
With power and ground supplied, the smart entrance conlrol unit controls the flashing of the hazard
warning lamps

EL-94

MULTlREMOTE
CONTROL
RELt. Y-1

To thef

-----.<.>-t-I-t--- system
remote

TUR
SW

m
r-

_ _ To lllumlnat lon
system

eO

U'I

COMBINA TION
FLASHER UN] 1

REAR
LH

tttt

REAi=l
RH

PILOT
Lfo1

PILOT
I'IH

SIDE
lH

SlOe

RH

FRONT
LH

FRONT

@>

RH

/
lUI'IN SIGNAL
LAMPS

'PIa
~~

l~>

:~gj

2,.C)

-{]

(?0J

10;'
~1

I:l.~

;.mI

~qJ

t"'1

1111

i:::--,

"~J

~;:I

~'

gJ

......:!,

<IV

I_II
;ri'll

Mooel
contr

MOOe

contr

For E

Excep

nru
(,'{)

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring
Diagram - TURNlHD MODELS

EL-TURN-01
to EL-PQWER,
.,

...

.. RIL

+ To

EL-ILl

AIL

~
HAZARD

SWITCH

1- T

!14JI I!4Jl I!:ill

"1;

GI/R

It

G/R LG/B

IWwdiJ I
8

COMBINATION

FLASHER UNIT

@3>

@)

_LG~~G/B~

I'= .C-

.----.- -

.I
._

11 111

=r

G/8

.::: _

~ G/Y -@>

GIB

~
~ GIB 0\9
-f>

~:Q[I)

G/Y

G/Y

@]):
G/8

G/8

@@
G/Y

fiT7iI rrf9i1
LH

G/Y

G/Y

G/Y

Next page

-(t>
~

COMBINA nON
RH METER (TURN)

...-_..-_----------.
1ID}r B -

CED

<8@

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(Foldout page) .

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SEL mGT

EL-96

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring
Diagram - TURN - (Cont'd)

Preceding
~
LG/B
page
~

EL-TURN-02

------1
LG/B

S;J
1

L....

G/V

----11--- -

G/Y

G/S ....

GIY

G/Y - - - - -. . .

G/Y ,

-- e---,
-e---..

G/V

SIDE

~~~AL

LAMP RH

~ ffi

G/S

~~~AL

mI~~AL 1
1

rn

LAMP LH

<rn>
SA'

Cill)

GV'

<ill>
GV

~Cilll

rnr:::nJ w

G/V
~REAR

COMBINATION

LAMP RH
(TURN)

~cm>
B

...---e
I

e
-!
m

SR

~~

1i~:L B
G/V

LAMP RH

-!

~5~~INATION

l~~~NfH
~ <.!W

LAMP LH

G/S

cflID

FRONT

~ffi)

IT::QI](lliQ)

GIS

1
1

~w

---1---

<el- G/Y
<U- GIS

<a-

GIS

Preceding
page

TURN

SIGNAL
SWITCH

-:!@

~~

CIIJ!QlI!IIIJIJ

SEL70n

EL-97

EXTERIOR LAMP

Turn Signal and Hazard Warning lampsJWiringDiagram - TURN - (Cont'd)

RHO MODELS

EL-TURN-03
BATT"":OA ] Aefer

to EL-POWER.

em

~--E-I-----G

RIL

tEID CID
G

~Ne)(t

page

R/L

@: For- EUf'ope

HAZARD

II j ...

SWITCH
>:~
:~

lI4=ll lbiJl

To EL-ILL

Exc~pt for Europe

LG/B .

I!:iJl

i'l T.----I It - -.I- - f

I
I::
~A5IR
i- --L:::- ::;:: :;: ~}~g5EL-TUAN
1

O/R

G/tY

*1

~l

.,y.-

~ GIS -Q>
:~
e - - G/Y ~ G/Y -B>
G/B

G/R
2

*1

0I

Next oage

-.

COMBINATION

GIB

G/Y

Ifffl I@J

LH

GIB

-B>

Next page

METER (TUFN)

CBD

I
I

RH COleINATION

------------_._---

Refer to last page

(Foldout pagel.

~~: 4856 @ : @ : ~~

;lMZ:ItlillJ

@:~

GIB

7213

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~--~------------------------~

~~
~

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rn

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@,

EL-98

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring
Diagram - TURN - (Cont'd)

precedin g {
page

<81'
<!1

1(1

-::---w
-I------------....
t-T-T~
G

n n
I~
~
U

ILQJI 1l1.J1

XI

IL~II

"T" "T" "T"

o/Y

0/8

REMOTE

~MULTJ-

~ LG~B ~

*1 ' ..

~E/B~_

,I

6~ ~t=~~c~I T

O. LGIB - " ' , " ' -

Except tor Europe

<U> LG/B

v-2

~CID

@: For' EUr'ope

~~~~

<ffil

Qg

Q~

G
r=!::,

O.LG/A

~
<tP@:D

KLTlCONTROL
RELAY-1

EL-TURN-04

<IT>

LG/BID

LG/Bm

W
L

6/8

<@r G/Y
~~~~edino <@- G/Y

<@-

@):@

~@:~

GIS

G/y

!-I- Jt>}
-----1-1--------------.~
----0- _
G/6

G/Y

G/Y
G/Y _ _- , , -_ _ G/Y

~:CID

G/B - - - - -... 0 - GIG

: ITQIJ @ID:@) D[L <illD::

: rn::TI..Il] w
calli] w
:
t

~------------~----~-----~

G/a - - - - - - - G/D

~~~~

Re fer to last page

r-----------------------~

~~:AL

SWITCH

V
57

:3 6

EL-99

(Foldout p"ge) .

@
FIR

f "

EXTERIOR LAMP
Turn Signal and Hazard Warning LampslWiring
Diagram -

TURN -

(Cont'd)

EL-TURN-05

~glL-ruAN <Q- GIB

PI"'eced1ng
pag.

---1
I

- - - - - - - -. . . .- -. .- - - -. .

~
{~
GIV - j -__
GIB

G/Y

G/Y

11

SIDE
TURN
SIGNAL
II 2 II LA.'4P RH
"'T-' ~
8

Gis

FRONT
TURN
SIGNAL
LAMP RH

f
8

GIS

11

FRONT@sroE
TURN
TURN
SIGIIIAl
SIGNAL
\I 2 \I LAMP lH
LAMP LH

=t= @
8

r--'--t

Pf'eCeding{~ GIB
G/Y

page

G/~

r,

m~

1
G/Y

REAA

COMBINATION

LAMP LH (TlSW)

~@

REAR COMBINATION

LAW AH (TURN)

~(@>

1....__---.--1
I

B
~

<!lID

~rnrum
BR'

BR'

GY'

GY

SEl110T

EL-100

EXTERIOR LAMP
Turn Signal and Hazard Warning

Lamps/Trouble Diagnoses
Symptom

PosSible cause

Turn Signal and hazard warning

lamps do not operate

Hazard SWitch
2. Combination flasher unit
1

3 Open
UrllI

In

combination !lasher

r.ireuit

--

HeIer ,0~omblnallon f1a,her UJlII t:l,,~ck (EL- \D 1\

J. Check wiring 10 combinalior'l flasher unil for open

circuit
--

4 Ope' in turn signal sWitch Clrcult

1, IDA fuse

t. Chl!ck lOA fuse (No

huf hazard warning lamps cperate

2 H"zard SWitch

3 Turn s,gnal switch

lnl

, located in fuse block).

Vertfy battery posit've voltage is presert at ler",,-

operate.

:'lal @ or hazard switch

2 Check h'llard swtlch

2 Hazard swi\:h

t. Check 1CA fuse iNo i2~J , localed in fuse block).

Tu,n Ig(l,tlon switch ON and ver-fy battery POSitive
voltage '5 preSe'll al ler'lImal @ u! halQ,d
swireh,
2 Check hazard switch
3. Check turn signal switch
4 Check wire between combmallOll Hasher unil and
turn signal switch for opnn circuit.

Turn signal lamps do not operate 1 lOA luse

Hazard warning lamps do nat

operi:lle but lum signal lamps

Repair order
1 Check hazard slIiltch

3 Ope" '11

h"~ard

","wilCh cirCUIt

3. Check ""rS b .. t",ee" ("cmbiniltion flasher unit a.,d

hazard sWitch lor Dpen Circuit

fronl turn ':llgnal la,np LH or IlH

does 1101 operate,

2 GroJnd@or@

2 Check ground @

Bulb
2 Ground@or@

1 Check bulb,

Side 'url1 ~i{JI1;'l1 lame on

Side does

1"101

drivers

operate.

Side turn signal lamp on passenger side does noloperale.

1 Check bulb,

Bulb

@D.

2 Check ground @) or @D.

Bulb
Grounu@or@

I Check bulb,
::l ChBCk ~round @

Buib

1 Check bulb

or

Rear lurn signal lamp LH or RH

does nol operate

2, G'Otll1<1@

2. Check ground @

LH and RH turn indicators do not

1 Ground

1 Check ground

or

(i1)

orerRle.
L!; or

AI-! lurn Ind cator does not

1 Check bulb '1"1 comblnal,on meter.

Bulb
It

operat~

Te51 lamp (27W1

~(~,

~~/j

r~rT

Combination Flasher Unit Check

Before checking. ensure Ihat bulbs meet specifications

10 th~ combination flasher
unit. as shown Combination flasher unit is properly functioning if il blinks when power is supplied to the CircUit.

Connect a battery and test lamp

--~--Batlel)/

EL-101

e.
L'.A

EXTERIOR LAMP
Bulb Specifications
It"lm

Watl<lge (W)

Fronl log lamp

55

Fro"l turn s19"a1 lamp

21

Clearance lamp

Side lurn signal lamp

Rear combination lamp

Turn signal lamp

Stop/Tail lamp
Back-up lamp

21
21/5

21

license plate lamp

Rear fog iamp
Hlgll-mounled stop lamp

El-102

21

INTERIOR LAMP
lilumi nation/System Descri plion
power supply routing for illumination lamps are the same as that of clearance, license and LH lail lamp_
rrr
Refer to "Clearance, License and Tail Lamps"
On vehicles fa r Europe and Austral ia, ilIumi na tion of combi nation meter and clock is contro II ed by ill umination control switch
The illumination control switch that conlrols the amount 01 current to the illumination system As the V'I:'
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.
'~~~'l
Component

Connector No,

Power terminal

M40

Ground terminal

f----

Audro

(Unit ground)

Ground

--

Push control unit

M32

15

16

@or@

Aulo Ale Unil

M31

13

14

@or@

88

09

15

16

@or

Cigarelle lighter

M42

@or

Combination meier

M20

33

('1)

Clock

M20

33

('1)

M.14

@or@

All indicator
--

-~-

--

power window maIn switch

_.

1---

Hazard swilGh

(For Europe)

bo~

lamp (switch)

Rear fog lamp SWitch

' -

@or@

@or@

67

@or@

@or

----

M3B

--- t - - - - - - - - . -.-

M36

Rear window defogger swach

M37

{)

Illumination control SWitch

M21

Headlamp washer sWItch

-"'-

M35

- -- -

Fronl tog lamp switch

L-..-._ _ _ _ _ _ _ _ _ _

- - - - - - 1--

Ml03

Hazard Swllch {E xcepl for Europe)

Glove

---

@or@
_.- t-------:::---------

'1: For Europe and Australia models _ Illumination control SWitch

E(cept lor Europe and Australia models
or @

EL-103

,._-

@or@
@ar@!)
@or

INTERIOR LAMP

Illumination/Schematic
.----~
AIT [NOICAroR

-------------11.
[LI.UM[NATION

"-------f'T+-----------------JI.
FRONT FOG LAMP SWrTCH
[LLUMINA r ION
b----am---~+-------

--------1I.

HEAOLAMP WASHER SWfTCH

[LUMINA r [ON

'O'-------f'T'+---------

---I~h

AUDIO ILLUM[NAHON

+--------f'T+-----------------1I'
CIGARET TE LIGHTER rLLUMINA T raN

-------11,
[LlUMINA T ION

-111'

'-...A,A,Vv---f'T'l-----

----,II.

>---frl"l------

----jII,

L------f'P}------

AUTO

Ale

UNIT ILLUMINATION

REAR WINDOW DEFOGGER SWI TCH

ILLUM[NA nON

I
U

w
Ul
::>

t:;
):

+-------f'>''l-----------------1II'

u..

(J)

REAR FOG LAMP SWITCH

ILLUMINATION

20

HI..

0+--------111'

~O
ZU

GLOVE BOX LAMP

~U

GLOvE BOX

LAMP SwI reH

+---------f"I'l--------

H<t

Zirl'7==-=<r-T=

~~Z~<lm~~~~

COMBINATION HETER
L-

[')

----jI',

POWER WINDOW f.1AIN Si'III TCH

It.LUMINA T TON

~ r..~:l"<I"t-+--+-~+-+O~
I~I';::P'f~I"'+"'!-I--+--l

8 1n1"3--+-+-f-++4-+--l
--.J

>-

cr

~
<t

1-+--......-------111
ILLUMINATION
SOIl TCH

cm~THDI

~ ----lHJ---1)'
=o

-~----

>-

:.-

Z Q<%
O<!l:t..-J

aO<tll.J
Lt.LL..JC!

<;ElIllT

El-104

INTERIOR LAMP
Illumination/Wiring Diagram -

ILL-

EL-ILL-01
I

BATTERY

1--10A.....-.~~~cm

liJ@]
G/R

OR

G/R
$fiM\
I
I&!Qy

.iiii~~DiiiiO-@;

I
~

G/R

LIGHTING
_1ST 21'> SWITCH

Tr
OR

G/R

SWITCH

~: @

i [~

I!4Jl
RilL

'-=-'-:...,....J.=r---'

~~

~~EA~AMP
<E@:

Gr

i~1nU

m
~USEAIL TA~IL

<t
...--0---:

m
it

12

~;

lOA

ffi]

R/L

~~

rn@ID
~ R/L ~

0-

:
I
I

RHO moctels
U..() models without
daytlme llght system
@: Except@
@: Models loIitl\ daytime
light system
: For- Eur-ope
Except for- Eur-ope
II'"
@ l l 12
12' @12:ll

<IT>:

R/L

~ ~:
<ID
!ITt::t:tj
W

~,

:
:

RI L

~----------------------~-----~
1

JEW'

FOG
FRONT
LAMP
SWITCH

TAIL/L
UNIT
:
LIGHT
L...---=OU.,;-T.,:.."P..,;.U,--,-T-----l@.

! ;;
I

~ <mID

DAYTIME

RIL
R/L

G/OR

G/R

~:

OFF

NT

LIGHTING

45'

[}Jm

@ID

Refer to EL-POWER.

car
2

00
SR

RIL

-B> Next

page

Refer to last pilge

(Fa ldout oage) .

~----------------------------~

~~
till:::t::f7
GY

S!"l112T

EL-105

INTERIOR LAMP
Illumination/Wiring Diagram

ILL

(Cont'd)- .

EL-ILL-02
IGNITION
ACC
or ONSWITCH]

~~~~eding eQ}-

RIL

1-

---+'------i
R/L

R/L

m
I

QDILL

~
8

RIL

Ne,' page

.----m"-'METER
j<S"""------------"-'m'f-"-_

ILLUMI-

ILLUMI-

NATION
CONTROL
SWITCH

NATION

CLOCK

COMBINATION

NATION

I LLt..JMI - METER

<BW:@

~~
B

R/v

*1

L-l~!

t8

: For Europe and Australia

@: Except
M1.@ R/Y ,@ 8

:-,
I

CHD

i---------------------------j
c:I::QTI]~

lill.!J]]

r~

1
1

[EEmIj]@!
W

--------------------_1

Sfl.71JT

EL-106

INTERIOR LAMP
U1umlnaUon/Wiring Diagram -

ILL -

(Cont'd)

EL-ILL-03

~~~eding ~

R/L

-to

R/L

~
6

HEADLAMP
WASHER

SWITCH

~;

Rl-~L 00>
J

R/L

~5 DEFOGGER
REAR WINDOW ~6 REAR
LAMP FOG
SWITCH

(ILLUMINATION)

lbiJl

Ne"

p,ge

RiL@

R/L

(ILLUMI~ NATION)
B

to

l.liJI
B

"

$
R/L

GLOVE

SWITCH
BOX LAMP
(ILLUMI-~: 4ill>
NATION}

~:A/W

;,wr

R/W

GLOVE
BOX LAMP
SWITCH

'----~4=Jlrl1......,...-- ~: 4ill>
B

+1
B

~~

T~
B

I L-t---- ..---Q-L-,1
11

[I]gJZ]@

rnI..I.IlJ

SR

!-

-!

CHI)

C8L>

<BY>:

LHD model'
RHO models

Except for Australia

@: For Europe

[]Q[]~
BA

II..rnJ.ID

[Q]~

[.I[g] BR

SEL11dT

EL-107

.\;

INTERIOR LAMP
Illumination/Wiring Diagram -

ILL -

(Cont'd)-

EL-ILL-OLl
Preceding
page

~
~

RIL

-e-----e------------eI
I

r f fr
RIL

R/L

IMI AUTO Iii PUSH

UNIT

CONTROL

Ale

(ILLUMINATION)

IL1AII~.~
"'T'~.~

UNIT
(ILLUMI-

I~ HAZAAD

SWITCH
(ILLUMINATION)
~:

LIGHTER
ltGAAETTE
ILLUMINATION

4=Jl~
B

I
B

1.....--1------1
I

@: Models with auto Ale

<IT>:

NATION)

!~

;
:

SWITCH
lrAZAAD
ULLUMI-

Mode 15

WI ttlout

auto Ale

For Europe
Except for Europe

t-,

<8@

QID

r-$l-n~
w:m
w

[I]Q[]
[[[2[I]]

EL-108

JQ--.~

RIL

RIL

111611 NATION) IWI ~:

""i""~:@ ~

AIL

AIL

<EB>
w

Next page

INTERIOR LAMP
Illumination/Wiring Diagram -

ILL -

(Cont'd)

EL-ILL-05

~~~e.,"o <Qlo

R:- -i------i

~.
<t>

R/L @

t~

I~I

t8B>

R/L

<,=CQD

AIL

AIL <HID

AUDIO

(ILLUMI-

NATION)
@:@

AUDIO

(ILLUMI-

NATION)
@:@

i~~~W

SWITCH

(ILLUMI-

NATION)
~@)

Ii

R/Y CQD

1,~

1---+
R/L

R/L

w]

~
R/L@

AIT
INDICATOR
~ii~~;
t16J1 @
<,=

; 5 FRONT FOG

Q~~CH

(ILLUMI-

11611
<,=

NATON)

CID:

em:)

reP ]) rep lE@

B

Lt

<0:

LHD models
@: RHO models
@>: For' Europe
@: For Central and South America
@: Except @
<D RIY, @ B
1t3

IB

JL
_=-'1=
1.

rLI:QI]@)
ITJJ2lJ W

f
.
a

~
~
@~

FTll
@]ill

Refer to last page

(Foldout page) .
,I'

~----------------------------------------------~

: WI I 1r 0[

IC:

1I I I
<D
161151
r I I
w
,--------------------------~-------------------~

SE1716T

EL-109

INTERIOR LAMP
Interior, Spot and Trunk Room Lamps/System
Description
Power is supplied at all limes

through 10A fuse (No I f1 1 located in the fuse block)

to interior lamp terminal CD.
to spot lamp terminal CD and
to trunk room lamp terminal CD,

INTERIOR LAMP
Switch operation
With interior lamp switch in the ON position, ground is supplied to turn interior lamp on
When a door switch is set to OPEN with interior lamp switch in the DOOR position. ground is supplied
to interior lamp terminal
through diode @ terminal CD (Except for Europe models)

to diode @ill terminal (Except for Europe models)

through diode terminal CD (Except for Europe models}
to diode @ill terminal (Except for Europe models)
through door switch passenger side terminal ill or
through door SWitch driver's side terminal ,
through door switch unit ground.

Interior lamp control by multi-remote control system

When the smart entrance control unit receives a signal from multi-remote controller to unlock the door
with interior lamp switch sel in DOOR position, ground is supplied
to interior lamp terminal

through smart entrance control unit terminal ,

through smart entrance control unit terminal @l and

through body ground _

With power and ground supplied, the interior lamp illuminates.
For smart entrance control unit, refer 10 "MULTI-REMOTE CONTROL SYSTEM".

TRUNK ROOM LAMP

When the trunk room lamp switch is set to OPEN, ground is supplied

to trunk room lamp terminal

through trunk room switch terminal CD,

through trunk room lamp switch terminal and

through body ground (ill)
With power and ground supplied, the trunk room lamp illuminates.

SPOT LAMP
With the spot lamp switch in the ON position, ground is supplied
to spot lamp terminal
through body ground or @.
With power and ground supplied, the spot lamp IIJuminates_

Bulb Specifications
Item

Interior lamp

Wallage (W)

10

Spot lamp

10

Trunk room lamp

3_4

EL-110

INTERIOR LAMP
Interior, Spot and Trunk Room Lamps/Wiring
Diagram - INT/LLHD MODELS

8ATTEA:

EL-INT/L-01
] Refer

OA

Models with sun roof

Models wIthout sun roof

to EL-POWER.

lie

RIB

'------1
I

RIB ~

R/B@1)

4J CBD

$R/B CID

RIB

A/B

. - - - - - -....- - - - - -. . .

I
TRUNK
ROOM

LAMP

RIB

1 SPOT LAMP (@
.------'J4-''------......;;;;;;;

l!:iJI @D

----~

CID

"--I-~!------------.J

~
TRUt-I<

ROOM
LAMP
SWITCH
ill)

I
B

B
~

ern>

CBD

reP ~

~
R/W

rep

CRD

R/W~
I

:~1

..... :
DOOR @: @

I
CLOSED

INTERIOR
OFF LAMP

ON

I~--~t
R/W~

*m

A/W

t-,

R/W~

DOOR
SWITCH

SIDE
~

OOOA

SWITCH

OPEN

OPEN DAIVER' S

CLOSED

ffi

CLOSED

PASSENGER

SIDE
~

CHI)

[Q]102@)@)
[TIgJ w' W' W

Refer to last page

(Fa ldout page) .

SEL815T

EL-111

INTERIOR LAMP
Interior, Spot and Trunk Room Lamps/Wiring
Diagram - tNT/L - (Cont'd)
RHO MODELS

EL-INT/L-02
~

RIB

'---

cHID

RIB

~
AlB
I

~
AlB CRD

TRUNK
ROOM
LAMP
~~

R~B

r.=Ib,

II 1 II SPOT LAMP

ICBD

<BID

O~.- R/W ~ L/R

':4:

aD

*2@

OPEN LAMP

SWITCH

~
B

B
~

rep lMiID

r.,
I

IHZ>

R/W

ROOM
LAMP

OPEN

OUTPUT

SMART ENTRANCE
CONTROL UNIT
(Refer to
EL -MlA...TI ) iHIID

CLOSED
DOOR

SWITCH
PASSENGER

SIDE

DIOOE~

~L/;-_.
--.J

L /R @>

I
<ED

~R/W.O~

L/R(@

I CBD

CLOSED

OroOE ~

o~-I

TRl..N<
ROOM

qJ) L/R

R/W

R ~

rm

R/W~

ON

111-

QJ

~------,

sun roof
~ R!W
-2 , .
R/W :

QH): @
@:@
DOOR

~
-=-

. - - _..

LAMP

.....

AlB <H:@

R/B

OFF

ON

liliiii

$A

sun roof
@. MOdels Wltr10Ut

INfERroR

For Europe
Except for Europe
Models Witt!

111

lffi})

R/W

CID

OPEN

CLOSED
DOOR
SWITCH
DRIVER'S
SIDE ~

Re f e .... to lest oage

[Fo 1Clout pltge)

El-112

METER AND GAUGES

System Description
With the ignition switch in the ON or START position. power is supplied
through 7 SA fuse (No ~~ . located in the fuse block)

to combination meter terminal @.

Ground is supplied
to combination meter terminal @

through body ground @.

'~r

WATER TEMPERATURE GAUGE

The water temperature gauge indicates the engine coolant temperature. The reading on the gauge is
based on the resistance of the thermal transmitter.
As the temperature of the coolant increases, the resistance of the thermal transmitter decreases A
variable ground is supplied to terminal @ of the combination meter for the water temperature gauge
The needle on the gauge moves from "C" to "H",

tot:
~'t;;

TACHOMETER
The tachometer indicates engine speed in revolutions per minute (rpm).
The tachometer is regulated by a signal
from terminal ('J) of the EGM (EGGS control module)

to combination meter terminal @ for the tachometer.

FUEL GAUGE
The fuel gauge indicates the approximate fuel level in the fuel tank.
The fuel gauge is regulated by a variab~e ground signal supplied

to combination meter terminal @l for the fuel gauge

from terminal ill of the fuel tank gauge unit

through terminal @ of the fuel lank gauge unit and

through body grounds @, aD and @D.

SPEEDOMETER
The vehicle speed sensor provides a voltage signal to the combination meter for the speedometer.
The voltage is supplied
10 combination meter terminals @ and liS) for the speedometer

from terminals ill and of the vehicle speed sensor.

The speedometer converts the voltage into the vehicle speed displayed.

EL-113

rf.

METER AND GAUGES

Inspection/Fuel Gauge and Water Temperature
Gauge

1-

INSPECTION START

~_J

HECK POWER soUL-- - - - - - - - . , NG

RC E
1) "Turn .gn,tlon sw'tch "ON'

Combinahl>n meter
connector
@

~ ~ is ~ffi+E]

[J

2) Cheek voltage between terminal ~~

and grOl1nd

---------

OK

00
CHECK GAUGE OPERATION.
I) Turn ignition switch "ON".
SE1121T

between battery terminal and combination

meter
2) Ignition relay
3) Fusible link and fuse
4) Ignition switch

Battery I/oltage should ells!.

Check the following

items.
1) Harness continuity

H r;::---

Repair or replae

(Fuel),
(Temp.) and ground with wire lor
less Ihan 10 seconds.
3) Check operation of gauge.
Gauge should move smoothly 10 full
2) Connect terminals

scale.
OK

: W.aI41r temperature gauge

' Fuel gauge
SEL7?2T

~
I

Check harness continuity between com

bination meter harness terminal @
and thermal transmitter harness termi-

~l

Repair or replae e

nal CD.
Check harness continuity between com
bination meter harness terminal @
and fuel tank gauge unit harness terminal CD.
Conllnuity should exlsl.

K
]
---

----

CHECK COMPONENT

Check gauge un<ts and harness

ReIer 10 "Fuel Tenk Gauge Unit Checll"
(El12D) or "Thermal Transmitter
Check (El-120).

(Go to ''X) 0(1 ne~t pagel

El-116

NG

Repair or replace
Refer 10 FE sectIon. (Fuel
gauge)

METER AND GAUGES

Inspection/Fuel Gauge and Water Temperature
Gauge (Cont'd)
Fuel lank gauge
unst connector

,~~

:i}1

ID~

fl--aJ'i8

NG

Check harness continuily between fuel

lank gauge u(ld harness terminal @

Repair

harnes~ ~.:1.('.

nector

_~

and body ground

.2..J.~

Conllnullv shauld exist.

OK

SEL12H

Reinstall any parI removed

[---

INSPECTION END

Inspection/Tachometer
Combination meIer
connec1or @

INSPECTION START

~iS[tBml]

[LiJ.~

NO 1 , - - - - - - - - - - .. Check the follow,ng

CHECK POWER SOURCE.

1) Turn ignition switch "ON"

items.

2} Check voltage between !erm'nal @

') Harness continuity

SEU;J5T

and ground

between ballery termi-

Battery voltage should elist.

nal anel com!:lrnal,on

meier

OK

2) Ign'tlon relay
3) Fusible link and luse

Combination meter connectors @

m+FFHII ffiEmll

~
~?
"
~---- ~ ~'"

4) Ign'\Iol'\ sw'tch

NG
Check hamess aM con--+neCID! bel ween ECM and

CHECK ECM OUTPUT

1) Start engine.
2} Check voltage between terminals

(l!J

and @ at idle and 2.000 rpm

check ground.

HICjlher rpm = Higher voltllge

Lo~er

rpm - Lower voltage

-'--r=-

Voltage should change with rpm.

~;;~t~;,~~t~;
-

L~

---

---

[-----

EL-117

--~

- - - - . .-

INSPECTION END

combination meter, Dr

METER AND GAUGES

Inspection/Speedometer and Vehicle Speed
Sensor

Combination meter
conneclor@

Hma~IO

CBJl

SYMPTOM: Speedometer stays at 0 km/h (O MPH).

INSPECTION START

CHECK GROUND CIRCUIT OF SPEEDOMETER

SEL 727T

Repair harness or con.

nectar

Check continuity between terminal @

and body ground

Combination meter
connector ~

Continuity should edsl.

OK

~i)SEm

~'~

and body ground,

Battery voltage should exist.

HElaCJIHEl
A~

i5

OK

CHECK VEHICLE SPEED SENSOR OUT

PUT

Combination meter connectors ~

CY:

nector

2) Check voltage between terminal ~

SEU28T

Repair harness or con-

CHECK SPEEDOMETER CIRCUIT

1) Turn ignition switch "ON"

vehiCVle
speed sensor

@J

transa){le,

sensor pinion,
Vollage: Approx. O.5V
--

-----

and @

NG

---------

-r=..'OK

~,._----

speedometer and vehicle speed senSor.

INSPECTION

~ I~

18 ~GJ1~
DEtDOEa

[ill
.-,---'---"-- -

---'--.

Repair harness or connector between

VehiCle speed
sensor connector @D

--~

SEL 130T \

---

Replace speedometer,

2) ChecK voltage between lermmal

and ~~ while quickly turnIng speed

Resistance: Approx. 250fl,

Vehicle speed -.-/

sensor pinion

1) Remove vehicle speed sensor from

CHECK VEHICLE SPEED SENSOR

Check resislance belween lerminals (1)

This connector should ~

remain connected.

OK

EL-118

E~ _ _~

NG

Replace vehicle speed

sensor,

METER AND GAUGES

Inspection/Speedometer and Vehicle Speed
Sensor (Cont'd)

Vehicle speed sensor

SYMPTOM: Speedometer indication flutters.

-~~

INSPECTION START

Is vehicle speed sensor installed prop-

NG

Speed sensor pinion

OK

AEL061

Combinalion meter connectors @

Install vehicle speed sensor properly.

erly? Check looseness and so on.

No

Do you lee I resistance when turning

Replace vehicle speed

sensor.

vehicle speed sensor pinion?

Yes

Check continuity between speedometer

terminal @ and vehicle speed sensor
terminal

CD.

and between @ and (j)

Continuity should ellisi.

~----r=-[-RePlace speedometer.

Vehicle speed sensor

connector ~
SEL731T

El-119

NG

Repair harness and conneclor

METER AND GAUGES

Thermal Transmitter Check
Check the resistance between the terminals of thermal transmitter and body ground
Water temperature

Resistance

M'e (140'Fj

Appro)(. 70 - 900

100'C (2 T2'F)

Approx. 21 240

SEL698F

Vehicle Speed Sensor Signal Check

to
~s.enSOJ
~
Jl""'<
.
em.
'&

Vehicle speed

Voltmeter

1.
2.

Remove vehicle speed sensor from transmission.

Turn vehicle speed sensor pinion quickly and measure
voltage acrDSS G) and .

~(fI

[Y]
Appro~. O.5V
[Alternating
current {AClJ

SEL640T

Fuel Tank Gauge Unit Check

Sending unit

For removal, reler 10 FE section,

Check the resistance between terminals
(+)

CD
MEL3\3D

CD

Float position

Ohmmeter

Resistance value
(n)

mm (in)
'1

Full

358 (1409)

'2

1/2

245 (9.65)

..

'3

i
I

Empty

42 (1 65)

1 and 3. When float JS In contact With stopper

EL-120

and @,

Appro~.

4 -6

30 - 3S
85 - 93

METER AND GAUGES

Lead Switch
Lead switch
side connector

Sending unit
side connector

00 ffi
@-------

(11).. - - - ---2

.. _ - - - - - - - - - -

Lead switch is buill into the fuel tank.

Check the continuity between terminals (~ and

or @ and

lead SWllch

Terminals

(4)

'--

cond,tlon

)---

r--. "

'.)---

f-\:)

lIne

SWl

SW?

ON

ON

Fuel level

OFF

ON

OFF

OFF

Abov~

~i) -

Fuel capacIty
{Approximate valuesl
f (Imp qt)

ll;'

Below (~

More than 6 B (61

25-68{2-1/4-6}
Less than 2.5 (2-1/41

:-,1

EL-121

WARNING LAMPS AND BUZZER

Warning Lamps/Schematic
w

~
~

ii:

~
q

SECUfOllTY

INDICATOR

------&--------4

f-----------fl,

en

w
OJ

n
0

S ..W 0-

SWITCH

"'

0
L
:::J

OIFF OIL

----&~--------~+---------------II'
DIFF OIL WARNING LAMP

00

:J
<l

~
L
0

ASS

-&----

ASS
C~~+ROL

I1 - - - - - - - - - - - - 1 r '

..-

e ~
w
<-

" lL
0
W

@@@@

OIL

.----&---------~
OIL PRE55l.JF1E

SWI TCH

----11'

FUEL

~--------~
~

II'
FUEL TANK GAUGE UNI T

WA5HER
WASHER FLUID LEVEL SWITCH

0001'! SWITCH
(P1l5Sengel'" 5 Hle)

8AAKE

- - -..--&--.---o------+c

8r:lAKE FLUID LEVEL SWITCH

PARKING

8RAKE

..---&---+--

I-------------fl'

CHARGE

--&--

-----------11

MALFUNCT ION

INDICATOR

,,- ---&------AIR 8AG

- "NIr--

-----Jr'

------------jl.

5EL 7)2T

EL-122

Warning Lamps/Wiring Diagram -

WARN-

LHD MODELS

~~

EL -WARN-O 1

Refer to EL-POWER,
~

,]

r---

@@

RIG

RIG .... RIG

~ AL~~G

mt
RIG

MALFUNCTION
INDICATOR

lHW

CHARGE

OIL
AlA

'~J_

BAG

4Jl
V/L

4Jl
OR

~~

.:

~~

@~

LJ

W/R

V/L

(ECes
CONTROL

MODl.A...E)
(Refer to

W/R

~
__

EC-MIL. )

(ill

i!

OIL

~CH

W/R

FUEL
TANK

~~~E

~@
I

.1-

~--------------------------~------------~

rLIQIII]@

[LffiIIllJ

~@ ~~ ~ C I D

~
r----------I
10
I

: [g]

W-J B

GY

<ill ~\
~
J

p\---

i~~]_iEB~-~l dfu~

Refer to last page

(Foldout pagel.

4ill>

<fl

em

lfi@

(ill

SElln T

EL-123

,;~,

@)

-:...

R/B

I4 JL 3 AL TERNATOR

R/B

PRESSURE

'~",,'r

AlB

~@
~

ECM

Ale

$~------.
Y/L

OR

W/A

V/L ~

OR

32
LED-R

DIAGNOSIS
SENSOR
UNIT
(Refer to
AS-SRS .)
(II)
COMBINATION
METER

~"

WARNING LAMPS AND BUZZER

Warning Lamps/Wiring Diagram (Cont'd)

WARN-

EL-WARN-02

COMBINATION
METER
@
.----=---....,...---------------------~-----::------..

WASHER

~
RIL

~
R/L 00

R /L

WASHER

FLUID
n LEVEL

IJ

L/R

R /L@

DOOR

ASS

SWITCH

~@
B

i-,

R/W

LlR ~

R!W

l$~
L/R

r$
R/W

L/R

I
m

*~
ASS

W!L

R/W ~

ASS

CL~

82~+ROL

$
L

R/W

I~I

lHW

~~~~CH

OPEN DRIVER'S
SIDE

~~

(Refer to
SR-ABS .)

gS~~CH

OPEN PASSENGER
SIDE
CLOSEO@

~~

~~

Refer to last page

(Foldout page) .

~w

3EI7J4T

EL-124

WARNING LAMPS AND BUZZER

Warning lamps/Wiring Diagram (Cont'd)

WARN-

EL-WARN-03

~~iNG

BR....KE

-~~COMBINATION
METER

Y /R Q11)

'i

1"

V/PU4iID

LlA

:t

~--------------~

Y/PUm

Y/IPU)

rep m

Lr

Y/PU

rnI]
2

BRAKE
FLUID

LEVEL

Y/pu

SWITCH

PLLLED

RELEASED

i-,

lUJJJ

Y/R

giEF

L/R

PARKING

~:~~~H
eM)

ON

DIFF

OIL

(HiQh
~:~ING
temp.l SWITCH

OFF ... _/Lolll

temp.)

ill

Ell @
w w CD B

R(@

Aefel' to last page

(Foldout page) .

@Jl

,CID

f-f}.,

~rn

tgj

GY

SEL1J5T

EL-125

WARNING LAMPS AND BUZZER

Warning Lamps/Wiring Diagram --- WARN (Cont'd)
RHO MODELS

EL-WARN-04
@: For Austra Ita
Refer to EL-POWER,

.-----------,~J~~~gSIS

aID

UNIT

,... RIG ~ RIG .... RIG ~ A~~~G

I
G

RIG

rr*il

(Refer to

RS-SRS.1
ezI)
COMBINATION
METER

MALFUNCTION
INDICATOR

FUEL

CHARGE

OIL
ALA BAG

l~lcEW
OR

OR

LJ
32

ECM
(ECCS
CONTROL

l-r.n--I

MODULE.)

Ee-MIL.)

em

t-,

CHD

RIB

O
I~ -

~---------@
1{!QD
T

rOO
T

Y/L

W/R

RIB

~i:

~:

~~

OIL 3
W/R

PRESSURE

SWITCH

ALTERNATOR
~

12

FUEL
TANK
GAUGE
UNIT

~CID
B

~ \IlARN-Q6

RIB

-J?..... To EL-

W/R @

W/R

<ill>

i~] [tmE] WHE] ~ Q@! dill>eJP

,W

W/R

\ilIA <&Q)

Y/L

(Refer to

W/R

""T' (IT)

LED-R

Y/L

OR

~------------~-------------------------~~

ReteI' to last page

(Foldout gage) ,

iHIQ)

<flQD

@)

l8W

<TI)

em

SEl736T

El-126

WARNING LAMPS AND BUZZER

Warning Lamps/Wiring Diagram (Cont'd)

WARN -

EL-WARN-05
~:

Except for Australia

For Europe
Except for Europe

:
~:

*1' -<ill>
~2 - , .

R!W

R/W,

L/R

1--------.-------lIl------------.l~-------@>

Next

I"':

page
COMBINATION
METER

0000

ABS

-lLiJJ

R/L

Ir

JH

I l
~
I
I
RlL

..g:.O

*1 ~

*2

~------------------------~

$L!R~

r$ m
1

L!R~

R/L~

DlC:'~

O~ L/A~

R/W

'J FLUID
WASt-R

OPEN

LEVEL

~ ~~H@)

CLOSED -

L/R

DOOR
SWITCH
DRIVER'S
SIDE

I~

L/R

J67':1I
~

L/R

rrh

L /R

L!J
12

i-'m

ffi

CONTROL

W/L

UNIT

CLOsEO-

(Refer to
BR-ABS .1

DOOR SWITCH
PASSNGER

SIDE@

Re fer to last page

(Foldout page) .

\[OOffiJ [EHIffi] @! um ~ tH5fiE ~

I
I

<H!ID , WD

I
I

@1)

~-----------------------~

EEffiEtID
12

f"

OPEN

ASS

ABS

r-----------------------

-.a

rIm ~

@
B

ill)

dJ ~
SA

~FI ""

EL-127

I~:,

WARNING LAMPS AND BUZZER

Warning Lamps/Wiring Diagram (Cont'd)

WARN -

EL-WARN-06
@: For Europe
: Except for Europe
@: For AustralIa

PARKING
BRAKE

V/pu

To ELWARN-{)4

*~

W/R -

W/R

Jt>
~

Y/PU~

OR/G

VI"

LIA
~

L/R

Y/pu C1)

L/R

I
Y/pu

I
LJR

V/B

G/OR

~----------~

$Y/R~

V/R

ml~~~
I]

PARKING

BRAKE

LEVEL

PULLED SWITCH

SWITCH

IhjJJUID

RELEAsED

I
LJ
G/OR

~
LlR em

L/R

SECURITY
INOICATOR
@: @

33

SMART

ENTRANCE
CONTROL

UNIT
(Refer to

EL-THEFT .l
~

ON

(High
DIFF OIL
temp.) ~~~ING
OFF "'-SWITCH
(Low
~: /ED'
temp.)
~

i-'

@~

i~mw]@)i Il\um
tgj
GY

r
B
W
I
~~------------~-------~

fVl(ffi)
CD B

Refel" to last DOlle

(Foldout pagel"

lE@

U@

l8ID

CID

Q@)

3EIJJ6T

EL-128

WARNING LAMPS AND BUZZER

Fuel Warning Lamp Sensor Check

It will take a short time for the bulb to light.

Oil Pressure Switch Check

Ohmmeter

_ _ _ _ _ _ _ _- \ -

Engine start

Engine stop

Oil pressure
kPa (bar, kg/em', pSI)
More than 10 . 20
(0,10 - 0.20, 0 , 0 2. 1 3)
Less Ihan 10 . 20
(O.10 020. 0 , - 02, 1 . J)

r-

CcnlinUily

NO

YES

Check the continuity between the terminals of oil pressure

switch and body ground,

Diode Check
Check continuity using an ohmmeter,
Diode is functioning properly if test results are as shown
in the figure at lett.
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.

_-:-1

(_.'

r~

r"

SEL901F

Diodes for warning lamps are built into the combination

meter printed circuit.

MFlJI60
~---

-------

EL-129

Ie L

WARNING LAMPS AND BUZZER

Warning Buzzer/System Description
The warning buzzer is controlled by the smart entrance control unit
Power is supplied at all times

through 10A fuse (No [211 , located in the fuse block)

to warning buzzer terminal @l

to key switch terminal CD

Power is supplied at all times
(LHD models without daytime light system)

through 45A fusible link (letter :11, located In the fusible link and fuse box),

to lighting sWItch terminal @

(LHD models with daytime light system and RHD models)
through 10A luse (No, rnJ . located in the fuse block)

to lighting switch terminal @ (For Europe) or @ (Except for Europe)

Power is supplied at all times

through 2SA fusible link (Ieller [I} located in the fusible link and fuse box)
to circuit breaker terminal CD

through circuit breaker terminal

to smart entrance control unit terminal <DWith the ignition switch in the ON or START position, power is supplied

through 7.5A fuse (No. ~ , located in the fuse block)

to smart entrance control unit terminal @,

Ground is supplied to smart entrance control unit terminal @ through body ground @.
When a signal. or combination of signals. is received by the smart entrance control unit, ground is supplied

through smart entrance control unit terminal @

to warning buzzer terminal (!).

With power and ground supplied, the warning buzzer will sound.
Ignition key warning buzzer (Except tor Europe models)
With the key in the ignition switch in the OFF position, and the driver's door open, the warning buzzer
will sound. A battery positive voltage is supplied

from key switch terminal

to smart entrance control unit terminal @.

Ground is supplied

from driver side door switch terminal <D

to smart entrance control unit terminal @.

Driver side door switch terminal is grounded through body grounds and @.
light warning buzzer
With ignition switch OFF, driver's door open, and lighting switch in 1ST or 2ND position, warning buzzer
will sound. A battery positive voltage is supplied
(LHD models without daytime light system)

from lighting switch terminal @

through 10A fuse (No. lliJ , located in the luse block)

to smart entrance control unit terminal t~

(LHD models with daytime light system)

from lighting switch terminal @

to daytime light unit terminal @

through daytime light unit terminal @)

to smart entrance control unit terminal f~

(RHO models)

from lighting switch terminal @ (For Europe) or @ (Except for Europe)

to smarl entrance control unit terminal @

Ground is supplied

from driver side door switch terminal CD

to smarl entrance control unit terminal @_

Driver side door switch terminal @ is grounded through body grounds and @,

EL-130

WARNING LAMPS AND BUZZER

Warning Buzzer/Wiring Diagram -

CHIME -

EL-CHIME-01

(Sf

] R,f,r to EL-POWER.

111

R/B

I~_~

~~
lffiID
l/R

l/R

1 ~~~~~~~

'~

Ll4dJ
\Il/R

R/B

;3

A/B

=~~~~~G
~

G/Y

I @Q)

-I

G/Y

W/R

,--------'-'Iffru~l1u:......-~
_ _----:.L:-m.Lll-'-------_ _ ~
IGN
BAT
WARN BUZZER
OUTPUT

GNO

<I): LHD models

<IT>:

-1 ... <b) L/R

RIL

B/.P ~

~
alP @

rrtru

KEY SW
OOOA
SW OR

GY/R@

*m

--=t

~\'T

~~~lNCE

CONTROL

UNIT
~

G Y/R@

DOOR

SWITCH
OPEN ~MER'S

ClOSEO-

~
B

J::Ql~

ITI..TIJ

@i['I ~~1
TCH
~:

_ _ _ _ _ _-:r~,-----------~r=>':----

RHO mode Is
E)(cept for Europe

~~

[ill]

i-,

B
~
C@

B
~

tIDID

Re fer' to h,st page

(Fo ~dout. page) .

S~L1J9T

WARNINGIILIIA~
Warning Buzzer/Wiring Diagram (Coot'd)

I BAT'ERY I
.-.-...~

rfl~
~
G/R

Refer to EL-PDWfR.

<B>:

~:
:

G/R

~~
~
G/A <EiQD
I

G/R

?il

[OFF-/1ST;2ND

*3

~
AIL

LIGHTING
1ST 2ND SWITCH

~:

Ir

(@):

R/L

R/L

TAIL
LIGHT UNIT
LAMP
(Refer to
SW
EL-DTRL.l
~---------' @: <ID

1m

RIL

,.......:>....
i=l------_ _L<..:::""--,DAYTIME

12
11

AIL

AIL

lOA

<IT>

[J [IT]

RIL

Except

R/L

-f'-f-----

1 ight system
LHO models Without
daytime light system

11
M.04 _@ 12 :

II

RIL

Except for Europe

*3 ...

(fiQj), @Q)

AIL

:IEE

@:

LIGHTING

SWITCH

I-.. AIL

<HD

RHO mOdels
For Europe

@: Models with daytime

G/R
r=Ib
11

~F~

EL-CHIME-02

J
Q

CHIME _ -

R/L
r@TISMART

LIGHT SWJENTRANCE
CONTROL
UNIT

lH

'------------~---~---------~

I
I

11

12

(@):
W

11

~:IIII
W

~--------------------------~

I
I

~~
t1tf7
GY

fl@fer- to la~t page

(Foldout pagel.

SE1I40r

EL-132

WARNING LAMPS AND BUZZER

Trouble Diagnoses -

Warning Buzzer

SYMPTOM CHART
MaIn Power Supply
and Ground CircUli
Check

PROCEDURE

REFERENCE PAGE
SYMPTOM

[) iagnostlC P raced u re

EL-13J

EL'~.J

f:L134

EL-135

EL-136

Prel,mll)ary

Preliminary

ehee. I

chHk 2

MaIn pOlNer supply

and Ground Clrcu"

Dlagnost,c
Procedure 1

DIagnostic
Procedure 2

Light war" I ng buzzer

does nol acllvale
191'II,on key warnIng
buzzer does not activate {E.cept for

(]

Europe mode')

PRELIMINARY CHECK
Preliminary check 1

I,'.L,

light warning buzzer does not activate.

Does ignition key warning buzzer acti-

Go to "DIAGNOSTIC

vale?

PROCEDURE 1 1"

No
Yes

Does interior lamp come on when door

is open'

Go 10 "D'AGNoSTIC
PROCEDU,RE 1 2' (EL-135)

No

Slep

{EL -135)

-J

nj

-Go 10 "DIAGNOSTIC PROCEDU~l

~

Step 3" (EL-135)

1-

------

Preliminary check 2

Ignition key warning buzzer does nol activate.

-r
i:__

[DO~s Ilghl warning

Dm
IS

'AI""~. com. 00 WheA '00'

open'

"DIAGNO~TIC

PROCEDURE 2 -

c-G-O-I-o-'-'O-I-A-G-N-O-S-r-,--'cLp-R-O-CEDUAE , -

Step

1' (EL-136).

V",

~G-o-t-o-'-'D-I-A-G-N-O-S-T-I-C--~
PROCEDURE 2 -

IN o - -

Step 3" (EL-136)

Go 10

buzzer .acl,v"lIe'

Step

2" (EL-136)

--- ..

"'I

Step

_----~

WARNING LAMPS AND BUZZER

Trouble Diagnoses Smart I/lltranee control unit conneclor @

lli

CONNECTOR

loCl1

Main power supply

," .,,!" is
1---------

Warning Buzzer (ConI1d)

MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK

Ballery voltage e.,stence condHion

'ermlnals

Ignition sWltd'l posilion

. - - - - - - r - - - - - - - . - - - . . - - - ____
OFF
ACe
ON

@-6JJ

No

No

(II-@)

Yes

Yes

t
I

Yes

Yes

SEL40JTA

Ground circuit
Smart entrance control unit conneclor @

I[CIU CONNECToBl=ll ~
(I

_ _

Terminals

Continuity

@ - Ground

Yes

fes

! LflJ iCr8
....

SEL3S3TA

I
El-134

WARNING LAMPS AND BUZZER

Trouble Diagnoses - Warning Buzzer (Cont'd)
~---------------'-

DIAGNOST1C PROCEDURE 1
SYMPTOM: light warning buzzer does not activate.

Perform "Preliminary check , .. before referring to the following flow chart.

Smar19nt,allCe control unit COMector@

es
"t-aJ
1'1

CIU CONNECTOElQ]

11

fa

,---_.

L-------------~- """",,I

._s::::-t=-=e~p3 NG

'

OK

I ~UZZER

r----------------~

[!l
Smart entrance@
control un!f connector

Waming buuer
connector @

IlcNCON~:J OO]~

~~l~es
~

~L.~7TAI

Smart entrance control unit connector @

loCll ~

1 V L 2 W,"
'

=-N~:-.. _ _

I __'t..;e..;..

- Orl"~' side door IS op8_n_ ......

iJ

[Y]
-

POWE-R-SU-IP-P-l-Y-C-H-E-C-K- Ste

\, ,~.

l_

nar-

Measure lIollage between warning

bUller harness term,nal @ and body
ground
8allery vollllge should exist.

J"t

-----r<*

[!] - -

BUZZER OUTPUT SIGNAL CHECK

Check CO~IH1Ulty between warning
buzzer harness terminal III and control un,t harness lermmal @)
~nlinuilY shDuld ulsl.
_

---r=

~AN~~8UZZERC~~ ---

.-O~,

Repair harness
neCiors

-=-J:_-

t!
-

-;;ep\;ce-warnlng

NG

Sle

NG

CHECK
Measure voltage belween conlrol unit
harness lelmlnals @ and @,
v~ll~g"

IVI

APEro x 12

..

..

_---=--j

---1-

'c;~~-;-;-~I'--

Ii

bUZ~:J

~-----------

Check Ilghllng switch

Check harness continuity between conlrol unit
h~rness terminal 15:'
and lighting sWitch-i'3r.
neSS termmal ~.i)
Conlinulty should e.ist.
Me~sure voltage
between IIghling SWItch
h~mess terminal ,-n\
ilnd body ground
Baltery vollage should

e.lsl.

L __ --- -,

[RePlace control \Jnit

-,: ~',

I~},

11

UGHTING SWITCH INPUT SIGNAL

l'qtlllng switch IS ON

:: i'

._--.J

L~~er to El-137

COod,lIon

SEl40BTA

sWItch

!Refer 10 EL-246 )
Check harness continuIty between conlrol unit
ha"'ess terminal ri~
and dllller side door
switch harness term,
nal C!).
Contlnully should exist.
Check harness continuity between driller side
door switch harness
lerminal @ and body
ground
Conlinulty should exllli.

CondiliOIl ul driver S dO,-O_'+1

_ _C
__o_n._"_"U_ily'----_

DJi-wer slae- dllOr lOS Cl05-=-,ed=-+--I

Warning buzzer

[I CIU CONNECTOR

- - - - - - -...- . - - - - -

~I. Check door

DODA SWITCH INPUT SIGNAL CHECK

Check continuity between control unll
harness lermlnals @ lind

~,I

/'

II

Ii

Re(

WARNING LAMPS AND BUZZER

Trouble Diagnoses - Warning Buzzer (Cont'd)
~

DIAGNOSTIC PROCEDURE 2
Smalt entrance control unit connector @

II CiU CONNECTOR 10

G'fIRW"
."

IJTI

~
SEl40BTA

SYMPTOM: Ignition key warning buzzer does not activate.

(Except Europe model)
Perform "Preliminary check 2" before referring to the fol~
lowing flow chart.
Step 3

DOOR SWITCH INPUT SIGNAL CHECK

Check continuity between control unit
harness terminals @ and @>.
Conditioll or driver'! door I

Gonltr'Luily
~o

Duer side door i9 closed. ,

Driver side

door

is open

Waming buzzer
connector@

r:n~

NG

I-----

Ves

OK

[Y]
~

SEl~2TA

l!J
Smart entrance@
controt un;1 connector

Waming buzzer
connector @

0] OCZ&~

Step 2

BUZZER POWER SUPPLY CHECK

Measure voltage between warning
buzzer harness terminal @ and body
ground.
Baltery voltage should exist.

SEl407TA

Smarl entrance control unit connector @

I CiU

CONNECTOR

100] ~

BfP2~4J "~
[YI
...

-'

SEl411TA

FiE

Check lOA/use ~1.1 . har

ness and connector

- -----

II CIU CONNECTOR 10

~~I~Ii5
iD~

Check door switch

(ReIer to El-246.)
Check harness continu.
ity belween control unit
harness terminal @
and driver Side door
switch harness terminal CD.
Conllnully should ellli!.
Check harness contil1uity betweel1 driver side
door switch harness
terminal @ and body
ground
Continuity should exist.

OK

SUZZER OUTPUT SIGNAL CHECK

Check continuity between warning
buzzer harness termmal CD and conlrol unit harness terminal @_
Conllnully should exlsl.

NG

Repair harness or connectors

,--------,-------OK

WARNING BUZZER CHECK

Refer to EL-137
OK
Step 1
IGNITION KEY SWITCH INPUT SIGNAL
CHECK
Measure voltage between control unit
harness terminals @ and @)
Condition

Key Is pulled

Vollag~

IVI

r-

Key is Inserted

I-A-e-p-la-c-e-c-O~lrol unit

EL-136

Appro. 12

-_.

__ .~

NG

Check ignition key

switch
Check harness continuIty between control unit
harness terminal @
and key switch harness
terminal ~_
Conllnully should eJrtsl.
Measure voltage
between key switch
harness terminal CD
and body ground
Ballery voltage should
exist.

WARNING LAMPS AND BUZZER

Warning Buzzer Check
Supply battery voltage to warning buzzer as shown in the
ill uslrationWarning buzzer should operate.

'-,1.

'i
'2r,

"I

EL-137

.'

WIPER AND WASHER

Front Wiper and Washer/System Description
WIPER OPERATION
The wiper switch is controlled by a lever bUilt into the combination switch
There are three wiper 5witr.h positions'

LO speed

HI speed

tNT (Intermittent)
With 'he ignition switch in the ACe or ON ",oSItion, power is supplied

through 20A fuse (No. [1I] , located in the fuse block)

to front wiper motor terminal @

Low and high speed wiper operation
Ground is supplied to wiper switch terminal @ through body ground @ or (ill)
When the wiper switch is placed in the LO position, ground is supplied

through terminal of the wiper switch

to wiper motor termmal @).

With power and ground supplied, the wiper motor operates at low speed
Wherl the wiper switch is placed In lhe HI position, ground is supplied

tl'1rough terminal @ of the wiDer switch

to wiper motor terminal (~).

With power and ground supplied, the wiper motor operates at high speed

Auto stop operation

With wiper switch turned OFF, wiper motor will continue to operate until wiper arms reach windshield
base.
When wiper arms are not located at base of windshield with wiper switch OFF, ground is provided

from termir.al @ of the wiper switch

to wiper motor terminal @, in order to continue wiper mDlor operation at low sre ed .
Ground Is also supplied

through terminal @ of the wiper switch

to wiper amplifier terminal @

through terminal (JJ of the wiper amplifier

to wiper motor terminal (fJ

through terminal of the wiper motor, and

through body glOund @,

When wiper arms reach base of windshield, wiper motor terminals r'iJ and are connected Instei.HJ uf
terminals G) and . Wiper motor will then stop wiper arms at the PARK position.
Intermillent operation
The wiper motor operates the wiper arms one time at low speed at a set Interval of approximately 3 to
13 seconds This feature \s controlled by the wiper amplifier
When the wiper switch is placed in the INT position, ground is supplied

to wiper amplifier terminal <D

from wiper switch terminal @

through wiper switch terminal Wand body ground @

or @D,
to wiper molor terminal @

through the wiper switch terminal @

to wiper switch terminal @

through wiper amplifier terminal

to wiper amplifier terminal @

through body ground @D

The desired interval time is inplll

to wiper amplifier terminal @

from w'lper switch terminal @

The wiper motor operates at low speed al the desired time interval

WIPER AND WASHER

Front Wiper and Washer/System Description
(Confd)
lASHER OPERATION
lith the igniti~n switch in the ACe or ON positIOn, power IS supplied
tnrough 20A fuse (No [11 ' located in the fuse block)
10 washer molor lermlnal d)
Vhen the lever is pulled to tne WASH pOSition, ground is supplied
~ to wastier motor terminal , and
\0 wiper amplifier terminal
trom terminal @ of the wiper switch
through terminal ~} of the wiper switch, and
~ through body ground @ or (ill)
Nlth powp.r and ground supplied. the washer motor operates.
) .l,
fhe wiper motor operates when the lever is pUlled to the WA.SH position for aile second or more and
lor appro)(imately 3 seconds after the lever is released. This feature is controlled by the wiper amplifier :O:i~;

"I"'

\'~:\

in the same manner as the intermittent operation.

~-

,;],

-'.'~.',

?-", -~'

EL-139

WIPER AND WASHER

Front Wiper and Washer/Wiring Diagram
- WIPER-

EL-WIPER-01
to EL-POWEA

(b) : LHO models

(8): RHO models

LG

-------I
I

<rnD

LG ~ LG

LG

LG <MQ)

LG

i-----='--=--=--1t-I
~

I~

I
_.,
1

~~

m@

OR

~
p

Next

page

r--,-,-rm-=.3-,,------,-,-ffi=-5~_,
GND

ACC

WIP
MOTOR

FRONT
WIPER
AMPLIFIER

~
OR

L:LG/B~LG/B
:

LG~~LG~

LG/B~}

LG/R~LG/R

LG/R~ ./

I
I

<ffiQ) ~

...-----LG/R~LG/R

Next
page

Re fel" to last pagE'

(Fo lClDUl page) .

: ~<D:<UQ)
'~GY

Fi3ITlm

c::r:z:om

FRONT

WASHER
MOTOR
~

LG/B

~
t

<D

GY

FOO:~:
~W

,
I

~Ei idl1

EL-140

WIPER AND WASHER

Front Wiper and Washer/Wiring Diagram
- WIPER - (Cont'd)

EL-WIPER-02
Preceding
page

{~L:IB

@: For Europe
: Except for Europe

-'

<tJ- LG/A - - - - - - -

FRONT
WIPER
AND

WASl-ER
SWITCH
~

1!JJ=!l
B

----.
11>

I

.-.
1 1
8

~
BR

!fer

BRltW

BR~

$t--------$

SR @

~--------$
SR

BR

rn

Iftil

OFF AND

WASH

INT SW

FRONT
WIPER

SW

AtoIPLIFIER

FTl2IT1ru
tID:JIJ

<D

GY

i~:~
I~
L

117:@~

1
11114

tITD

Re'ef" ta lagt pSl:le

(Fa ldaut p.IIQe) .

~-------~-------------------~

SEL142T

EL-141

,j

Trouble Diagnoses

-----p

Wiper amp. connector

~i5~Hf8

DIAGNOSTIC PROCEDURE 1
SYMPTOM: Intermittent wiper does not operate.

~tJ!:l' ~
~r
@)

tl

1LaJ

COI"\,~htlol" oj

Wiper amp. connec1or

n;J

OFF
1:t

\~

II em C to

e-v~,v )'~ 1)

L-

.---

sec._

NG

"G>

Measure voltage between wiper amp

harness terminal (t) and body ground
Battery voltage shoutd exIst.
'----

SE:LB201

,-

----'

OK
WIper amp connector

--- - -----

onds

BR

[]]

Appro.
~Doln1~' ~WI"O~

IUT

I~-

_ .. ~heck wiper motor

Voll1lge IVI

wiper $wilch

~ iOlEiB1

OK

WIPER AMP OUTPUT SIGNAL CHECK

1) Turn Ignition SWitch to' ACe"
2) Turn wiper sw,lch 10 "INT' or OFF"
)) Measure I./ollage belween wiper
amp. har"es~ ler mloal (J) and body
ground

<TID

G~i5
[1[]

~ Check Wiper sWllch

Check wiper molor

Check harness contlnUIty between wiper amp

h~rnes5 lermlnal ClJ

and w'per SWllch har.
ness lermlnal @
Conlinully shOUld exist
Check harness continuity between w'per
SWitch harness terminal @ Bnd wiper
motor harness terminal
'~

Conllnully shOUld ew.l!OI.

SEL82\TI

INTERMITTENT SWITCH INPUT SIGNAL

NG

Wiper aomp conn9Cl.or @

~.---

Check harness cont,nuIly between w'per amp

harness terminal
alld wiper switch har-

CD

Condlloon 01
_ _. w,pe~_ 5w'lC'.'_

OFF
L.--

Conltnully

---1>/-0-

~_

--

__~_~

I
SEU221

-----

L-.... Check wiper SWitch

CHECK
Check h a mess conti n Ully between
wiper amp. harness terminal (1) and
body ground

L-.

~OO-W-I-P-E-R-A-M-P-G-F\OUN~

-C-IA-C-U-IT-C-H--C-K----,

Check har ness c;ant,nUlty between

wiper amp harness terml,\;\l .j\ arId

.----=c

ness terminal @
Continuity should exist.
Check harness continuIly between wiper
switch harness term,nal ~!l and body
ground
Continuity shQuid exis\.

~~~-~=p-a-l-rharn~ss-o-r

__

con-

neelor
------------'

bOl1y gloulld

COl\llnuily should ellist.

~~'3Ce_W_IP_~_r

_3_ffi P_ _ .

EL-142

1
I

-._-_-~
__ .

WIPER AND WASHER

Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 2
Wiper amp. 0011119clor @

SYMPTOM: Intermittent time of wiper cannot be adjusted.

Ill,
NTEAMITTENT

@~

----.

WIPER VOLUME INPUT

SIGNAL CHECK
Measure resistance between wiper
amp harness lerminals and @
while tvrnlM;! Intermittent wiper volume
P.><'I'M 0' w'~M

Replace wiper amp.

'---------______

~~

Resl.lance (Ill

I~ .n~b

il~

Appro . t k

l=----~:-N_G

____;

Check InlermlHent wiper volume.

Check harness continuity between
wiper amp. harness terminal and
wiper switch harness terminal .
Check harness continuity between
wiper switch harness terminal @ and
body ground.

Wiper amp. connector

DIAGNOSTIC PROCEDURE 3

SYMPTOM: Wiper and washer acllvate indlvlduallv but not In

combination.

J~i3~

WASHER SWITCH INPUT SIGNAL

IYJ
+

SEL824T

Chp.ck narness COrlllnUily

between wiper amp harness lermlnal and

CHECK
1) Turn Ignition switch to "ACC"
2) Measure voltage between wiper
amp. harness terminals @ and @

wiper sWItch harness termonal @

Condition 01
washer switch

Wiper amp_ connector

1

NG

fA?

8m

~ ~

la'EJ

ON

MI~ ~

,lpp,o. 12

Off

OK

WIPER AMP OUTPUT SIGNAL CHECK

Measure voltage between wiper amp
SELe25T

harness lermr"als (~ and @ aUer

operating washer switch

OV lor appro . 3 seconds aller washer

has operaled.

EL-143

~eplace wiper amp

--J

r~~

WIPER AND WASHER

~ Wiper amplifier

Front Wiper Amplifier Check

1,
2.

~EElJ
~

Connect as shown in the figure at left.

If test lamp comes on when connected to terminal
and battery ground. wiper amplifier is normal.

CD

Or

T~eSllamp
1 2 3
5 6 7 ,1

+ - SElBd2T

Front Wiper Installation and Adjustment

1.

3.
4.
SELBd3T

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 "L 1 " & "L 2 " 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 "L 1 " &
"L 2 " .
Clearance lilt": 18 - 33 mm (0.71 - 1.30 In)
Cle3rance "l2": 17 - 32 mm (0.67 1.26 In)
Tighten wiper arm nuts to specified torque
Front wtper:
16.7 - 22.6 N'm (1.70 - 2.31 kg-m, 12.32 - 16.67 fl-Ib)

Before reinstalling wiper arm, clean up the pivot area as

Illustrated. This will reduce possibility of wiper arm looseness.

SEL024J

\.

Front Washer Nozzle Adjustment

Using a suitable tool, adjust windshield

~ ~'"' ~ "-

',,~,
Max. 10

~
..:::::::::

':' ',~,

<:~ /5.
~.~~/-~

-~

0-

Das (D.033S)

"-.

_- - ~-]~D~-8_S~I~O ~3 _-S-)_-~- lJ-"~'t-_mS_m-_L-~_'-dn5_I- 'T

_ _..

__

washer nozzle to
correct its spray pattern .
Adjustable range: 10" (In any direction)
Before atlempllng to turn the nozzle, gently tap the end of the
tool to free the nozzle.
This will prevent "rounding out" the small female square in
the center of the nozzle.

E_L_-_1_4_4

I
1

WIPER AND WASHER

Front Washer Nozzle Adjustment (Cont'd)
Unit'm m (')
In

LHD models
"1

358 (14 09)

'5

70 (276)

"2

245 (965)

'6

245 (9 65)

"3

300 (1'81)

'7

378 (1488)

'4

203 (799)

'8

503 (19,80)

The diameters of these Circles are less than 80 mm (3.15 m)

I:~:

Front Washer Tube Layout

EL-145

WIPER AND WASHER

Front Wiper linkage

~----------------------------------

{'PJ

----------.

'.1' S.1 "''' . ''',2.1 ' .

(/
~

"

\ : '.1 .

S' ('" . '.52. , . . "I

~: N'm (kg-m, ft-Ib)

Th is ill uslralion is for lHO models. For RHO models. these

units are installed on the opposite side.

REMOVAL
,.
2

Remove 4 bolts that secure wiper motor.

Detach wiper motor from wiper linkage at ball joint.
3 Remove wiper linkage
Be careful not to break ball joint rubber boot.

INSTALlATION

1.

Grease ball joint portion before installation

Installation is the reverse order of removal.

EL-146

WIPER AND WASHER

Rear Wiper and WasherfSystem Description

WIPER OPERAnON
The rear wiper switch is controlled by a rmg built into the combination switch.
There are two wiper switch positions.

ON (LO speed)

INT (Intermittent)
With the ignition switch in the ACe or ON position, power is supplied

through 10A (LHD models) or 15A (RHO models) fuse (No. [:@ (LHO models) or
located in the fuse block)

to rear wiper motor terminal @, and

to rear wiper relay terminal (1).

Low speed wiper operation

lm

(RHO models)

, 't:~':~

Ground is supplied to rear wiper switch terminal @ through body ground @ or @.

When the rear wiper is placed in the ON position, ground is supplied

through rear wiper switch terminal @

to rear wiper relay terminaf .

The rear wiper relay is energized and ground is supplied

to rear wiper motor terminal G)

through rear wiper relay terminal @

to rear wiper relay terminal @

through body ground @.

Auto stop operation
Wilh the rear wiper switch turned OFF, rear wIper motor will continue to operate until wiper arm reaches
rear window base,
When wiper arm is not located at base of rear window with rear wiper switch OFF. rear wiper relay is I~:I
no! energized and ground is supplied

to rear wiper molor lerminal C!>

through rear wiper relay terminal ~)

to rear wiper relay terminal @

through rear wiper motor terminal . in order to continue rear wiper motor operation at low speed, 'Pi},\
Ground is also supplied

to rear wiper motor terminal @

through body ground or (ill)

When wiper arm reaches base of rear windoW, rear wiper motor terminals CD and @ are connected
instead of terminals G) and . Rear wiper motor will then stop wiper arm at the PARK position.
Intermittent operation
The rear wiper motor operates the wiper arm one time at low speed at an inlerval of approximately 7
seconds. This feature is controlled by rear wiper amplifier
With the ignition switch in the Ace or ON position, power is supplied

through 10A (LHO models) or 15A (RHO models) fuse (No.[!] (LHD models) or Ir4) (RHO models),
located in the fuse block)

to rear wiper relay terminal CD,

When the rear wiper switch is placed in the INT pos ition, 9 round is suppl ied

to rear wiper amplifier terminal @

trom rear wiper SWitch terminal fi)

through body ground @) or @D.

Ground is also supplied

to rear wiper relay terminal :J.)

through rear wiper amplifier terminal ~)

to rear wiper ampllHer terminal '5;

through body ground @

Then the rear wiper re,lay IS energized and ground is supplied

to rear wiper motor termInal 'T

lhrough rear wIper relay terminal '3)

10 rear wiper relay terminal ~

through body ground Gill

EL-147

WIPER AND WASHER

Rear Wiper and Washer/System Description
(Cant'd)
With power and ground supplied, the rear wipr motor operates intermitlcnlly.

WASHER OPERATION
With the ignition switch in the ACe or ON posilion. power is supplied

through 10A (LHO models) or 15A (RHD models) 'use (No [lID (LHD models) or till (RHO models),
located in the fuse block)

to rear washer motor terminal CDWhen the ring is turned WASH position. ground is supplied

to rear washer motor terminal . and

to rear wiper amplifier terminal Ij)

from terminal @ of rear wiper switch

through terminal @ of rear wiper switch, and

through body ground (ill) or Gill

With power and ground is supplied, the rear washer molar operates.
The rear wiper molar operates when the ring is turned to WASH position for one second or more and
for approximately 3 seconds after the ring is released. This feature is controlled by the rear wiper
amplifier in the same manner as the intermittent operation.

EL-148

WIPER AND WASHER

Rear Wiper and Washer/Wiring Diagram
- WIP/R-

EL -WIP/R-O 1

~r

REAR

~_1_~_I

INT

INT

Ace

Sill

SW

OUTPUT

GNO

I_t__L.GI/~/:"':I/Wt_

O~SBQSB~

*1(b) lOA

15A
1.4

*2"'(D 16:

~
~

LG/8

oB>}

NepagXet

~:L,

REAR

WASHER LG/B ~ LIB

M MOTOR

RHO models

sa

.-_L/W~

SB

B_

@)

I
~m
I
~ SB ~ SB <E-<jl

(b): LHD models

WIPER
AMPLIFIER

WASHER

L 'II

$---$J--$
<E!QD
L/w
I

LG/B

II

LIB

LG/B

LIB

L/W

rrfrn

~41---------J.-----_----l

REAR WIPER
AND WASHER
SWITCH @l

i,
GfD

Refel' to last page

(Foldout page) .

SEl7431

WIPER AND WASHER

Rear Wiper and Washer/Wiring Diagram
- WfP/R - (Cont'd)

lHID CID
-AI-......::r

Pl'ecet:l1ng
page

58

~
~

58

EL --WIP /R-02

-e-----..._...
~

LG/R

(b):

LHO
: RHO
W3"'(b)
*4(b)
.5 .. (b)
*6(D

models
models
Q4
Q3'
9
3 :

PH
R4
10
4

58

..-J

~ LG/R

~----$
sa CID

OR~

m
"T'cm

LG/R

OR

[ JiJ~
sa

LG/R

$CID
_
Preceding
page

-Bl~

@@)

WIPER
RELAY
<IT)

QLA

L/W~

LIlli ~ L/W .......

~

...-.,

----~

~@)

Refer to lost Dllge

(Foldout page) .

~
~w

CJ:JQill4l

LU.IJIDIQI

SFl744T

EL-1S0

WIPER AND WASHER

Rear Wiper Amplifier Check

~~~"""

1
2.

Connect as shown in the figure at left.

If test lamp comes on when connected to terminal (!J or
@ and battery ground. wiper amplifier is normal,

~I

Balte"i
SEll>46T

r:='

Rear Wiper Installation and Adjustment

/
;.

l
[

1,

.----;:--=:---=.:.-","

\\

2.

\.

: ~

.__
~ E

~.-s::::s

L"--~"

Clearance

3.

"u"

4.

Molding end

Black printed end

sELB47T

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 sel the blade center to clearance "L)" 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 "L J ".
Clearance "L J ": 26 - 42 mm (1.02 - 1.65 In)
Tighten wiper arm nuts to specified torque,
Rear wiper:
12.7 - 17.7 N'm (1.30 1.81 kg-m, 9.37 - 13.06 ftlb)

"Cl,

,:<,,1

-----------------~

Before reinstalling wiper arm, clean up the pivot area as

illustrated. This will reduce possibillly of wiper arm loose
ness.

~JJ~;I

,""r

Rear Washer Nozzle Adjustment

~ultable 1001

._

',>.,:::>::;;;:fMe . 15

~<;;:::/

USI ng a suitabl e 1001, adj ust rear wi ndow washer nozzle \0

correel Its spray pattern .

Adjustable range: 15" (in any direction)
0

I)~:----;~~~~,,~"I"b"'&J'

i/I
~~

1.5 mm CO 059 In)

sEL8-lBI

-- -------

-----

EL-151

WIPER AND WASHER

Rear Washer Nozzle Adjustment (Cont'd)

Uni!. mm (iri)
"1

219 18.62)

'12

45 (177)

The diameters of these circles are less than 90 mm (3.54 in)

SEL849T

Rear Washer Tube Layout

SEl850T

Check Valve (For rear washer)

From

reservoir
tank

Check ~ah(e

To
n02lle

A check valve is provided in the rear washer fluid line. Be

careful not to connect check valve to washer tube in the
wrong direction.

"CJ~D"
SEL411H

EL-152

Headlamp Washer/System Description

ower is supplied at all times
through 25A fusible \ink (letterLJ, located in the fusible link and luse box)
to headlamp washer motor terminal 1)
ower is also supplied at all times
through 20A fuse (No. ~ . located in the fusible link and fuse box)
to lighting switch terminal @.

leadlamp washer operation

he headlamp washer operates for apprOXimately 1 second at one time. This feature is controlled by
eadlamp washer amplifier.
or headlamp washer operation, the lighting switch must be in the 2ND position and Ignition switch in

l~

,e ON or 5TART position
Vith the head lamp washer switch in the ON position. ground is supplied
to headlamp washer amplifier terminal
through head lamp washer switch terminal CD
to headlamp washer switch terminal
, through body ground or (!ill.
~round is also supplied
I
to headlamp washer motor terminal
through headlamp washer amplifier terminal @
to head lamp washer amplifier terminal
, through body ground @.
lIJith power and ground supplied. head lamp washer will operate.
.~,1

F,),

WIPER AND WASHER

Headlamp Washer/Wiring Diagram -

HLC-

EL-HLC-01

Refer to EL-PQWER.
20A

[][I
G

I~
G

~
~~

G ~

rm!

~HEAOLAMP
WASHER
M

*3

G
m
m
.------'-IL.::~"-"----H/-L:.J...4...:..W.l.!...AS-H-L/R

MTR

LISGWHT~

HIL

Fr.ilm~

rn:r:m:n

page

MOTOR

GND
~

~ Next

WASH
SW

RIL _ - -

(flQD @

~ L ~ L

.....,
L

rm

HEADLAMP WASHER

AMPLIFIER ~

Film
[gJ

BA

--

UIJP[7] @

<D:

LHO models

RHO models
_. <b> I i

"1 A7
*2<b> H7 ' C7
*3 . - <b> R/W:
R
RIL

~Next

r - AIL.

page

To EL-ILL

AIL

Refer to last page

(Foldout pagel.

~BR

~EI 11~1

EL-154

Headlamp Washer/Wiring Diagram (Cont'd)

HLC -

EL-HLC-02
PrecedH\Q ~
D"ge
~

M3

LIGHTING
SWITCH
PASS

l&W

~~
AlB

A/Y

Ii-1_......__..._--I
-~

RIB

~4J

DIODE
~

RIL R/L

~
Bt 9

+}

To EL-H/LAMP

R/B

R/Y

~~
Preceding./6\" AIL _
page
~

R/Y

-----!J

....

~
W

EL-155

;
:

LHO models
RI-() models
M3 ... (D R/W.@

WIPER AND WASHER

Headlamp Washer Amplifier Check
I
2

Connect as shown in the figure at left.

If test lamp comes on when connected to the !erminal ~)
and battery ground, headlamp washer amplifier is normal.

SEL8SIT

Headlamp Washer Nozzle Adjustment

Using a suitable tool. adjust headlamp washer nozzle to

correct its spray pattern.

Adjustable range: 3" (Up and down)

Headlamp Washer Tube Layout

SEL853T

Check Valve (For headtamp washer)

Check val\le
To
nozzle

From

;eservOlr
lank

SE:L854T

EG1~

POWER WINDOW
System Description
Power is supplied at all times

from 25A lus'lble fink (Letter [] located in the !use and fusible link box)

to Circuit breaker terminal (i)

through circuit breaker terminal '!I

to power window relay terminal @

With ignition switch In ON or START position, power is supplied

through 7 SA fuse (No. ~ located in the fuse block)

to power window relay terminal CD

Ground is supplied to power window relay terminal ~)

through body ground Cill.

The power window relay is energized and power is supplied

through power window relay terminal r.il

to power window main switch terminal ,

to power window sub-switch terminal ,

to power window amplifier term ina! @ and

to power wmdow amplifier terminal @.

@v

'1i'1L1.1

~M1

.1,{:

tC
;;;-e

MANUAL OPERATION
~~:1,

Driver side door

Ground is supplied
to power window main switch terminal

to power window amplifier terminal 11'

through body ground (ill,

and

~rr
l~\j

WINDOW UP
When the driver side switch in the power window main switch is pressed in the up position, ground sig~Ti;
nal is supplied

to power window amplifier terminal (1)

from power window main switch terminal ~.
F.~
Power is supplied

to driver side power window regulator terminal (j:J

through power window amplifier terminal
l!Ii~
Ground is supplied
'

to driver side power window regulator terminal

through power window amplifier terminal @

~'W
Then, the motor raises the window until the switch is released.

:gy
WINDOW DOWN
When the driver side switch in the power window main switch is pressed in the down position. ground
signal is supplied
p\~.

to power window amplifier terminal

from power window main switch terminal @.

Power is supplied
~r

to driver side power window regulator terminal

through power window amplifier terminal @.

Ground ;s supplied
f4ll\

to driver side power window regulator terminal CD

through power window amplifier terminal ~~\

Then, the motor lowers the window untd the switch is released.
Passenger side door
Ground is supplied

to power window main switch terminal /.~)

through body ground

El-157

It:
I

POWER WINDOW
System Description (Cont'd)
NOTE:
Numbers in parentheses are lermlflal numbers. when power window switch is pressed in the UP and
DOWN positions respectively

MAIN SWITCH OPERATION

Power is supplied
through power window main switch (:ID, (f))

to power window sub-switch (G), lID},

The subsequent operation is the same as the sub-switch operation.
SUB-SWITCH OPERATION
Power is supplied

through power window sub-switch (@, ~))

to passenger side power window regulator (<1), ).

Ground is supplied

to passenger side power window regulator (, CD)

through power window sub-switch (@, @)

to power window sub-switch (' ill)

through power window main SWItch ((J), )

Then, the motor raises or lowers the window until the switch is released.

AUTO OPERATION
The power window AUTO feature enables the driver to raise or lower the driver's Window without holding the window switch.
The AUTO feature only operates on the driver's window.
When a power window main switch is pressed and released the AUTO position, ground signal is supplied

to power window amplifier terminal

from power window main switch terminal CD

The subsequent operation is the same as the manual operation of driver side door,
Then, the driver side door window will fully close or fully open.

POWER WINDOW LOCK

The power window lock is designed 10 lock-out window operation to passenger side door window,
When the lock switch is pressed to lock position, ground of the passenger side switch in the power window main switch is disconnected. ThiS prevents the power window motors from operating.

EL-158

[BATTERY

fusltJle

(i~~k.)

'

~
" FUSI8LE LINK

POwER

WINDO~

L_

MAIN SWITCH

CIRCuIT
BREAKER

POwER

(Dr 1" er . s S 1 Cle)

CRIVEfl'S SIDE, LDCK

ONE-TOUCH
(Auto)
~ \ ~J

I~I

I~

MANUAL

I u I

SWITCH

WINDDw

I PASSENGER

I D I ON 101=1"1

RELAY

SIDE

U I, N

I 0

~11

I
I. . . . .

U'l
fD

:~s:~:".,n."a,(:-

:JI

POWER wINDDw
Sus-sl-a TCH
(Passenger Sloe!

ru1NT5

II

II

Auto-",p moce 15 mountel

except lor Flnla"a

l-~L~:

II~

1%

'Ii/V

--'iJ

gel
:ic~

2t>J
i~~'

POWER wnroow
AMPLIFIER

r---~

1
\r:::-)

-IIU
l~J

-1

'l')

<t;?J

.....1

ll'"'iI
J

oil
rir1I

n;j

ih>

Wiring Diagram -

WINDOW-

EL-WINDOW-01
] Refer to EL -POWER

(b): LHO models

III

I
1f1

RHO mode Is

*1<0 L/R.

lUQD

$L/R @:ID
I

L/R

1,

CIRCUIT
BREAKER

'~

~@)

e- W/S

W/R

..f';:-....... To

W/S

~ w/a

-e-e- W/S -@>Next

IT ]r

G!OR

G/OR

POWER POWER

OWER

n WINDOW

I ~@ J ~

1!4Jl~@

page

rmm

W/R

IJ RELAY

~EL-WINDOW-03

GNO

AUTO
SW

UP
SW

DOWN
SW

POWER

WINDOW

AMPLIFIER

@)

~4=U4Jl~
8

W/R

L/B

L/W

LL/W~}

WI.

~L/8~

.-

Next page

W/R ~

t-,

CHD

<E!)

Refer to last page

(Fa Idout page) .

SEL 74ST

El-160

Wiring Diagram

WINDOW -

(Cont'd)

EL-WINDOW-02
r~"/8
Preceding
page

I ~ L!W ~

1<Q}- LIB :::--1

41 W/R..,

W!A

LIB

r-

RIL . . To EL-ILL

W/B

L/W

AIL

mrmm

rri5il
POWER
WINOOW
MAIN

DRIVER'S SIDE

.-

SWITCH

PASSENGER
SIDE

ILL.

@)

LOCK
LOCK
SWITCH

~
RIB

~~
R/W

112

'2

R/w

To EL-ILL

~}

RIB ~

Ne)(t

Page

CD: LHD models

: RHO models
W2(1) R/V <B> B
_3 .. Auto-up ~ode is
mounted el(cept
for Finland.

~--------------------~------------------------'
I

r2n

111 , I
1 I I I 1(1)' @) IT I I I n21 I r::::m: @) : m:::IQIT] C@
: 161151 3 J I 6 f 5 17 I 4

W
6 I 5 I 7 L l 3 If5II6]
W
I
ITrD-lJ "
I
I

-----------------~

rr:;:::'

SEL 749T

POWER WINDOW
Wiring Diagram -

WINDOW -

(Cont'd)

EL-WINDOW-03
To EL-WlNOOW-01~ "'/8 -

Preceding

Page

<& R/'" {

W/B ~ W/8 _ _~

~ R/W
'D2' 1JG"i'2'

R/W

~:~
_

R/lol

~,'CllSSl'

~ RIB -

RIB

@Jo

RIB -

RIB

R/W _

~ RIB

RIB

lollS

R/W

mrnlFTil
POWER
WINDOW
SUB-

POWER

WINDOW
UPH

DOliiN{+)

UP (+)
OOWN(-j

AMPLIFIER

4Jl
L

L.,t I t
t

OOWN~

~@)~
~W'W

~t
L

POWER WINDOW
REGULATOR

DRIVER'S SIDE
@)

~
G

It
mm

tlI]
UP

@}Q)

CQID

SWITCH

POWER WINDOW
REGULATQA
PASSENGEFl

UPt

SIDE

DOWN.

~~

,..R,@)~

~w

Lll~

B.

SEL750T

EL-162

POWER WINDOW

Trouble Diagnosis

~16~

t:t:tfj

DIAGNOSTIC PROCEDURE 1
SYMPTOM: Driver and passenger power window cannot be
operated .

Power window amp

connect!)r @

~Cas1
SEl826T

CHECK MAIN POWER SUPPLY AND

GROUND CIRCUIT.
'1 Disconnect power window amp. conneClor.
2) Check volta.ge while igr,ition switch is
"ON".
Termi'1als
~.

GND

I
I

NG

'::{

Check the following

Fuse
Power window relay
Power supply harness
- '

l.:
Vollage [V}

Approx. 12

0K

iii

No

Check continuity between power window amp. terminal (J) and GND.

Repair harness.

'-----=:J

-=

Does conllnully exlsl?

C.I~

S8F366HA

~o

10 DIAGNOSTIC PROCEDURE 2 and

EL-163

POWER WINDOW
Trouble Diagnosis (Cont'd)
DIAGNOSTIC PROCEDURE 2

~i5tca
r-.-,

SVMPTOM: Driver's power window cannot be operated but

passenger power window can be operated.

Power window amp_

Etrn oonnector

GIO~

CHECK POWER SUPPLY FOR POWER

WINDOW AMP.
1) Disconnect connector from power
window amp_

!aJ~

SBFJ65HA

,-----Repair
- -harn
-,,,

Bollery voltage
e .. slence

Terminals

(l) . GND

connector ~

Yes

- GND
OK

m
CHECK POWER WINDOW MAIN
SWITCH CIRCUIT.

~,"".;main switch.

1) Disconnect connector lrom power

window main switch_

2} Check continUity

Power window mall'

switch operation
Aulo (Down)

Termmals

(!).@)
@-@
.(!J

Up

Down
Does contlnuJly elfisl?
Yes

SEl&27T

[!]

connecto;"'~~m ;;;:;;;;-- N~ajr ham

1) Disconnect
window amp_ conneclor

:--'---

2} Check continuity
Terminals

(D.t!)
@J-t!)

Aulo

Up
Down

(~

Does continuity exist?

res
WIR

RHO model

I
I

(Go 10 next page)

lJW

PEh VW;Q
2

SEL828T

EL-164

- I-!J

bel.:," ]

power wind ow relay and

power wind ow amp

2) Check voltage across power Window

amp terminal @ and GNO. @ and
GND while ignrtion sWitch is "ON".

Power window
main switch

LHO model

NG

f----

POWER WINDOW
Trouble Diagnosis (Cont'd)

O
-

Ct,

~ 'S...J
~

Powel window amp.

oonnector @

!Z~:~ -_OJ @l
~'~'"

rolo,

CHECK POWER WINDOW MOTOR CIR

CUlT.

amp.

2) Check vollage for power window

motor.
Terminals

ffi
@

~=~~IO
1
0Cffi]

Power window
amp connector'

------

tor,

SEL829T

I!I

~"po.", . , : ]

1) Connect power window amp_ connec-

[Y]

I!l

~ [ill

'------=-....

lID

lID

\.t

Power window main

switch operation
Up
Down

,,!\

Does ballery voltage edst?

Dnver's side
power window
regulator

connector@)

lj G

Yes

I!I
1) Disconnect driver side power window
regu la tor con nector,

SBF370HA

Repair harness.
I

2} Check continuity_
Terminals

(ID-(!)
l!l-~

Does continuity exist?

Yes

Check driver side power window motor

Refer to "ELECTRICAL COMPONENTS
INSPECTION" (EL-168)
'--

EL165

';,:i"

POWER WINDOW
Trouble Diagnosis (Cont'd)

m ~~ ~r:!\
-~"

t..m -.;c:;,.J

LHD model

DIAGNOSTIC PROCEDURE 3-1

Pc>wtlr wmdow maln

sWitch connector @
RHD model

SYMPTOM: Passenger power window (main switch and SUb.

switch) cannot be operated. But driver side power
window can be operated.

'Eirt
II

swdch connector
2} Check contlnu'ty between power w,n-

dow main switch terminal ',~ and

GND.

SELBJOT

[Lin

LHD model

L~'

Does conlJnully elllst?

Power window main

switch connector ~

RHO model

II

I: 'ciilJ

r.I I I I I

'-'-1-'--'1Iro:lllln-""""'Uo--lJ

rT

Repair harness

1) D,sconnect power w,ndow ma,n

rnJ

m~IO

CHECK GROUND CJRCUIT.

Ii]

rcRePlnce

CHECK POWER WINDOW MAIN

SWITCH.

Check continUity when power window

lock switch is in "UNLOCK" posit,on,
Terminals

SEL631T

t!l-@
@-@
Does continuity elllsl?
lYes
,-

Check passenger side power window

motor Refer to "ELECTRICAL COMPONENTS INSPECTiON" (EL-168)
'---------- . - - - - - - - - , -

El-166

pow., window

main switch

POWER WINDOW
Trouble Diagnosis (Cont'd)

'JtSGo:tH'I?JCI

Power window main

switch connector @
RHO model

I1III n
I I I i

LHD model

DIAGNOSTIC PROCEDURE 3~2

SYMPTOM: Passenger power window cannot be operated
using maIn swllch. But driver side and passenger
side (using SUb-switch) can be operated.
@f

B55f+55Y1

~---~

CHECK MAIN POWER SUPPLY.

1} Disconnect power window main

WIB

switch connector.
2) Check voltage across power wondow
main SWitch terminal

r!:

and GND.

Does battery Yo\lage eltlst?

Power window main
switch connector

It

Yes

CHECK POWER WINDOW MAIN

SWITCH.

No

Replace power
main SWitch

WlrldoJ

~~

'---------------

Check continUity,

,~. I

Power Window main

Terminals

SWitch operallon

_ _ _ _u_p__
Down

~i5
re;]
\=

Yes

Power window Power window

sub-switch
main switch

--,
RiW

Does conllnulty eds!?

i5

connector
Rill

connector

1) Connect power window main switch

connector
2) Check voltage

!'ower wtndOw main

swilc~

5EL834T

opcratia"

Up

(~)

- GND

Down

Ooes bllllery yollage e_lsl?

,- -

=c_-----

'I

Replace power Window sUO-switch

~;. -)

"

POWER WINDOW
Trouble Diagnosis (Cont'd)

DIAGNOSTIC PROCEDURE

[EE53! ~IO
-

Power window
sub-switch
connector

1'118

3~3

SYMPTOM: Passenger power window cannot be Operated

using sub-switch. But driver side and passenger
side (using main switch) can be operated.

~i-Il

N~

CHECK MAIN POWER SUPPLY.

Repair harness.

1} Disconnect power window sUbsw,tctl

saB35T

connector
2} Check voltage across power window
sub-switch termInal c..~, and GND.
Does ba1tery Yollage eJd~17

Yes
Replace power window

SUb.sw,t~

Nole: 11 passenger power window does not h>ck using tock bullon 01 main
&wlt~h, replace mllln swllch.

~i5

-f

'----:

~
..

,,

ELECTRICAL COMPONENTS INSPECTION

{',

FUSE

BAJ-

Power window
regulator connector

.,~':

.... ~

,~

'

Ori~r side

POWER WINDOW MOTOR

(f\

Terminals

Operation

GJ

Upward

CD

Downward

I)o,om

SBFJ76HA

EL-168

----

POWER DOOR LOCK

System Description
ower IS supplied at all times
through 25A luslble link (No, CD located in the fuse and fusible link box)
to circuit breaker terminal CD
through circuit breaker terminal @
to smart entrance control unit terminal CD,
iround is supplied to smart entrance control unit terminal @J through body ground (]D,

OWER DOOR LOCK OPERATION

then one 01 the following Input signals IS supplied:
driver side door is locked/unlocked using key or lock knob.
passenger side door is locked/unlocked using key or lock knob (Only for models with multi-remote
control system):
mart entrance control unit locks/unlocks driver side door (Only lor models with multi-remote control
ystem) and passenger side door.
or operation by the remote controller, refer to "MULTI-RE MOTE CONl ROL SYSTEM".

l,I~;

~:r;,

'put (Unlock signal)

'odels with multi-remote control system

~hen the driver side door is unlocked using key or lock knob, ground is supplied
to smart entrance control unit terminal @
through driver side door lock actuator (door unlock sensor) terminal
to driver side door lock actuator (door unlock sensor) terminal
through body ground
Vhen the passenger side door is unlocked using key or lock knob, ground is supplied
to smart entrance control unit terminal @
through passenger side door lock actuator (door unlock sensor) terminal @
\0 passenger side door lock actuator (door unlock sensor) terminal
through body ground @D.
"odels without multi-remote control system
\lhen the driver side door is unlocked using key or lock knob, ground is supplied
I
to smart entrance control unit terminal @
through lock knob switch terminal ~
to lock knob switch terminal (j)
through body ground (]D.

nput (Lock signal)

ihe smart entrance control unit terminal

f!'

Dr

611

~';f,

recei\les lock signal when the unlock signal is shut

)ff.

:n

)utput (Unlock)

lriver side door (Models with multi-remote control system)

)ower is supplied
to driver side door lock
t
through smart entrance
rhen, the door is unlocked
3round is supplied
to driver side door lock
through smart entrance

actuator terminal CD
control unit terminal @,

actuator terminal @
control unit terminal @,

)assenger side door

Jower is supplied
~ to passenger side door lock actuator terminal (!)
~ through smart entrance control unit terminal (~,
Ground IS supplied
to passenger Side door lock actuator terminal @
through smart entrance control unit terminal r<V
Then. the door IS unlocked.

EL-169
_ _ _ _ _ _ _ _ _ _ _ _ _11""',

"l_'

POWER DOOR LOCK

System Description (Cont'd)
Output (Lock)
Driver side door (Models with multi-remote control system)
Power is supplied
to driver side door lock actuator terminal @

through sma rt entrance control unit term inal :)

Then, the door is locked.
Ground is supplied
to driver side door lock actuator terminal (1)
through smart entrance control unit terminal @
Passenger side door
Power is supplied

to passenger side door lock actuator terminal @

through smart entrance control unit terminal @.
Ground is supplied
to passenger side door lock actuator terminal (j)
through smart entrance control unit terminal
Then. the door is locked.

EL-170

POWER DOOR LOCK

Wiring Diagram -

D/LOCK-

EL-O/LOCK-01
<b>:
:

Refer to EL-POWER.

]
1f1

@: Models with multi-remote

control system

CIRCUIT
BREAKER

~ IHIQ)
111

LHD models
RHO models

111 ..

<I>

L/R

~L/R-L/R~W/R-'

I'

W/R

SMART

BAT

ENTRANCE
CONTROL
UNIT

DOOR
UNLOCK
SENSOA

LOCK

OUTPUT
(PASS)

(PASS)

lI4Jl
L

Y!L

'.'1'(

... __ ~~KED

DOOR LOCK

ACTUATOR
PASSENGER
UNLOCK

SIDE
~

LOCI<

~@
8

.....

-:'T

i-i
-! -!
<E@

CHD
Refer to last page
(Foldout page) .

~~
t!tl7
GY

SEllSlf

EL-171

POWER DOOR LOCK

Wiring Diagram - D/LOCK -

(Cont'd)

EL-D/LOCK-02
SMART

ODOR
LOCK
DUTPUT
(DR)

DOOR
UNLOCK
OUTPUT
(DR)

UNLOCK
SENSOR
(DR)

4JJ
L

W/PU

L (ffig) W/PU

4&---$

ENTRANCE
CONHIOL
UNIT
~

Y/G

~odels with multI-remote

control system

I 1MBl

~odels

without multi-remote

control system

Y/G

~~:-_------1

rnv :!"":__yO.....

L/W

W/PU

rrTil

UNLOCK LOCK

Y/G

Y/G

,. . . . . .!Lm..;:-:~
! __

__ ~~CKED DOOR LOCK

ACTUATOR
UNLOCKED
DRIVER'S
SIDE
ODOR
~:@
UNLOCK
SENSOR

.""..---LOCKED
......

LOCK
KNOB
SWITCH
~:@

4Jl
B

I......__-J
I

C
m
T
B

(ffig)

:-,
I

CHD
~ (ill)
rnrrrrr:::o w

ITIJE5Iill (]V

IT:IZIIIJ w

~ tili:7
~
GY

GY

~
Refer to last page
(Foldout page) .

POWER DOOR LOCK

Trouble Diagnoses

~""o..".

18

DIAGNOSTIC PROCEDURE

Smarl enlrance

[i-'=iu=_=c=oN=N=E=c=T=o=A~ID ~~~~~~~'t
CD
@

SYMPTOM: Power door lock cannot be operated.

lwl
SBF177H

CHECK MAIN POWER SUPPl V

GROUND CIRCUIT.

~i5

uM

connector

'~
L-

Ched" the follOWing

"'use
CirCUIt breaker
Power supply harness

-----.J

'(es

r;=======rOI Smarl
enlrance
II CN CONNECTOR I~
control
-

A.UNN~

II Dlsconnec.t conneclor from control

unit
2) Check voltage across control unit
terminal I:t) and GND
Does battery voltage edit?

SBFJT8H

..

---------!

.--------------------,

Smart entrance
~
control uml conn~tor ~

Check continuity between terminal ~i

and GND
Does conllnully exlsl?

11

I--

Connect control un,l connector.

2) Check voltage across control unit

terminal @ and GND

Orover side door
knob condi [,on

Terminals

Locked -. Unlocked
-. Locked

@-GNO

loc~

'~~

NG

CHECK UNLOCK SENSOR CIRCUIT.

Cl

[!]

.E~k GND hMne~

Yes

'-.J

~CONNECmmr=JI

No

Voltage
(V)
12

0
12

11

Disconnect connector
from control unit
2) Check continuity
between @ and GND.
Driver side
door lock
knob cond,loon

Termmals

Unlocked

@) - GNO

Does conllnully elllsl1

OK

No
SH6J6r

.------_._------

Smart ltntrancfI
control unit connector

@!l

Ilcl\.J

0""""'.'"
10

CONNC"TOU1

--_.-----'

(j

'GLa-n
@

L.

-~.'f

~-

CI-iECK DOOR LOCK ACTUATOR CIRCUlT.

Check voltage for door lock motor.

-~

Driver Side door I-- - - lock knob con(j,lion

(p

SEL6J7T

-------

Locked

Smar1 entrance

II C/U CONNECTOR

co,.w

L"\

~I

.:__ :~

--

~.

--

~:'

Unlocked

'--------

Q
t~

----

Does baflery voltage ul~l?

10
'

--------------i~

Repair door knob switch

harness or replace lock
knob switch

Terminals
----

conlrol unit connector

lves
Replace
smart
enlrance
control
unit.

~NO

A
(Go 10 nexl page)

WI\.

:_)

SB,40THA

EL-113

lb'

----~4)

--

Replace sma,t enlr<lnce

control unll

Troub\e Diagnoses (Cont'd)

[i

- Ir:!"\
V
~
======;=;0'
------1]
I
IO~

~ Smal1 !lnlrance ~
~onlrol un,l
COI'lr'lBctor@

lrel

CJ\J CONNECTOR

Door lock actuator

conneclor
@

(~

iii

1) Disconnect control unit connector

~)

-IO'et

Repair harness

and door lock actuator connector

2) Check continuity
Terminals

......----<..:_--'
SEl6J6T

Conlinuity

@-@
Yes

~.<D

Does continuity

e~lsl?

Yes
Check power door lock molar.
ReIer to "ELECTRICAL COMPONENTS
INSPECTION"

ELECTRICAL COMPONENTS INSPECTION

~O<$'O,.'"

~ &)

r---_..~

Door lock
actuator connector

tz!----,'-

Power door lock molor

Driver

side:~

:'

Passenger

:.----------1

side:~

Terminals
Door lock condition

Locked

CD

Locked - Unlocked

(i)

Unlocked

-~

5 BI'398H A

EL-174

- f------

----l

For removal of door mirror, refer to "DOOR MIRROR" in BT section.

Wiring Diagram -

MIRROR-

lHD MODELS

EL-MIRROR-01

OR

OR@

~
OR <ID)

OR

m
CHANGEOVER SWITCH
N ... R

DOOR

N ... R

MIRFlOR

SWITCH
(])

~ ~~~

v!L

Ii-,
B

-:!:-

-:!:-

ViR

L/R

L/Y

L!~~
--.....

LlR~

VIR ~
V!L

Next
page

PU/W~

Refer to last page

(Foldout page) .

SEL7!>JT

EL-175

r~,~"

POWER DOOR MIRROR

Wiring Diagram - MIRROR -

(Cont'd)

EL-MIRROR-02
~

--:f-,-=-

Preceding

page

<-

L/Y - - - - - - - - - - - - - - - - - -. . .

~L/R-...VIR

~ Y!L
<& PUfw

Y/L

..-

..

L/R

PU/w

Y/A

L!Y

~---~-------------~----~--~
Y/L <HID L/A
PU/W
Y/R
L/Y

,I-I

PU/W ~

Y!L

PU/w CQD

YIL

til

L/A

$----1biJt---$

PU!W ~

YIR

l!Y

4ll

YIR

L!Y

4Jt----$--~

L/R

PU/W

DOOR

LEFT:- AIGHT-

WARD

WARD

omm:- UpWARD

WARD

DOOR

~~~~~~OR

LH

M
LEFT:- RIGHT-

DOWN:--

WARD

WARD

WARD

Up-

~~!itl~OR
RH

WARD ~

Ae fer to l~sl page

{Foldout pagel.

~@)@

w w

~)@QD
~w'w

SEL )'>41

EL-176

POWER DOOR MIRROR

Wiring Diagram - MIRROR -

(Cont'd)

RHO MODELS

EL-MIRROR-03

OR

OR

".:l-

18ID

~
OR

I
m
OR

CHANGEOVER
N _R

S~ITCH

DOOR
MIRROR

N ... R

SWITCH

~ ~~~

V/L

i-'
~

L/R

L!Y

ll~:
-

I
B

V/R

--

VIR

.e>

Y/L

!{!>

Next
page

pu/w-Q>
Refer to last page
(Foldout page) .

EL-177

Wiring Diagram -

MIRROR -

EL-MIRROR-04

--

<& L/Y

(Cont'd)

..

j'

~L/R---..
Preceding

page

<@-

<!1-

VIR
Y/L

PU W
/ -

1=-

Y/L

CD L/R

PU/W

YfR

L/Y

~---~-------------~----~--~

Trr

~I~r

PU/W ~

Y/L

L/R

PU/W ~

Y/R

L!v

Y/L

L/R

PU/W CQD

Y/R

L!Y

4It----$ ---4JJ

PU/W

$ ----$t--t@

__M__

OOWN-

UP-

WARD

WARD

DOOR
MIRROR

ACTUATOR
RH

CQD

Re fer to las t page

(Foldout page) .

(I 111213)

@) @[D
W

~@)@@
~

w. w

EL-178

For removal and adlustment

or

sunroof, refer to "SUNROOF' in BT section.

Wiring Diagram -

SROOF -

~~

EL -SROOF -0 1

JR'f'"

<l-PDWER

to

<D:
:

v;

LHO models
RHO

mode ls

111 .. <D LlR , W

-2, '<D:~, :lHJ9)

1f1~

L/R lHIQ)

(';L,

L~R

CIACUIT

BREAKER

I!4JlI@>
W/R

...-_1

IT ~IPDWER
G

W/R

I]

~~~

W[NOOW

RELAY

@)

W/B

IL

@)
W/B

... /8

@
H/8

~~-------[3:> Next

page

. j

il

@>@
Refe!'" to la5t page
(FDldout pagel,

R
LiJ W

SEl755T

EL-179

Wiring Diagram -

SROOF -

(Cont'd)

il

EL-SROOF-02
Pf'eced ing
page

SUN ROOF MOTOR ASSEMBLY

DOWN/OPEN --

I~

- UP/CLOSE

tv1

I
\

I:,3 \ IDOWN/OPEN

lUP/CLOSE

RELAY

RELAY

I
SLIDE SW

TILT SW

SLIDE SW
LIMIT
SWITCH
-1

OTHER -O-THEol_
4 ___ .e

___ ....

FULL

CLOSED

TILT SW

LIMIT

\ OTHER -OTHER
..... __..u
___

SWITCH

-2

~~

FULL
OPEN

FULL
TILT-UP

FULL

TILT-DOWN

-=2-

-~~ ...~-------~------N

.r-~~-

CLOSED OPEN

~i~~H ~.

... ~~-l
UP
DOWN

SUN ROOF
SWITCH

~~iicH

SEt

EL-180

7~6T

HORN, CIGARETTE LIGHTER AND CLOCK

Wiring Diagram -

HORN-

LHD MODELS

~I

EL-HORN-01
EL-POWER.

ORIB

G/8

GIS

d)

To
ILL EL-

I]

HORN

I. . . . ,

R/L

m rn

CIGARETTE DRIB

RELAY

LIGHTER

lbiJl4dl(@
G

1:(

rc

l.!:::d

G/W

O~:---....- - - - -..

RIL

CIGARETTE
LIGHTER

ILLUMI-

SOCKET

NAnON

~
B

@: Models with
air bag system
@: Models without
air bag system
;/A\
G/W~

lillv

~,,'l:,

i,

'---I
G

QJ
t

HORN

01

HORN
SWITCH

PUSHED
HORN

~I ~ J~I

RE- ---""
LEASED

CHD

'f),'i

Refel"' to lest page

(Foldout page) .

m CID

[ill]

ro

F.l~~
~

B'

: [gl

1m
:
...

'1

'
I

~~:
8

_------~--~

SElIS7T

EL-181

HORN -

Wiring Diagram -

(Cont'd)

EL-HORN-02

Refer to
EL-POWER.
7.5A

OR/G

Im

OR/G

If23TI
COMBINATION
METER
@

CLOCK

ILLUMINATION

~
A/Y

To illumlnatlon
control sWitch
~
(Aefer' to EL-ILL.1

Aly

DRIB

~~
Sly

YIG

YIG

II PW

DRIB (HIQ) S/y

~---$

OR/B@ B/Y

~ SENSOR
AMBIENT

ri

CHD

U
~

OAIB

r------------------------------------------,

i
I

~ ~J [ffiHjj] ~
W

Aetel' to last page

(Foldout pagel.

f
I

~--------------~---------------------------~

KLl~
@
a

I
EL-182

J'

- - - -_ _.SEL.
J58T .

..

RHD MODELS

EL-HORN-03

Jl"7",5-A---:E

LlJ@]

,.,

G/R

" I

V/G

~~E~~-

1-"
B

PUSHED HORN
SWITCH
RE- --_....
-=

LEASED

=
~ <]I)

@: Except fo~ EU~Dpe

@: Models with al~ bag system
s~stem
@: Models without air-bag
---------_._------Refel' to last page
(Foldout page) ,

W
2
57
36

"I

@
SR
'"----------~

2
*8

ffi

I~@:
8
~

..

j:',,,

EL-183

Wiring Diagram -

HORN -

(Cont'd)
EL-HORN-O~

Aefer- to
EL-POWER.

7 SA

lli]
L

Im
L

DR/G

OA/G

CCJo4B1NAHDN

METER
@

CLOCK

ILLUMI-

NATION

*3

~~B

To illumination
control switct'l

(Refer to EL-ILL.)

R/Y

~
OR

OR ~

1
rt lJ
$_:~$l
QR@Y

~ SENSOR
AMBIENT

~
OR

~)

V/G

P ItW

I:l

i ~ rmtmJ

~I

Y/G

: For EUl"'ope and Austral1a

@: Exceot
*3,@R/V,@

[EHmj] ~]
W

Refer to last page

(Foldout page) ,

~------------------------------------------~

~~
@) B

~EL760T

EL-184

System Descriplion

The rear window and door mi'ror defogger system is controlled by the smart entrance control unll.
POwer is S'Jpplied at all times

to rear window defogger relay termina' @

th rough 15A fuse (No ~~I located in th e fuse block} and

to rear window defogger relay terminal @

through 15A fuse (No, !17] located ill ltfe fuse block) and
10 mirrar defogger relay terminal IlY

thrnugh 10A fuse (No, 1121 . located in the fuse block).

Witf1 the ignition switch in the ON or START positron. power is supplIed

to each defogger relay terminal CD and

to smart entrance control unit lerminal @

Ground is supplied

to rear window defogger switch terminal @ and

to smart entrance control unit terminal @l
through body ground or @.
::>P() ratio n
fhe ignition switch must be irl the ON or START position for defogger operation,
Nith the rear window defogger SWitch 11'I the ON position and for approximately 15 minules alter the rear
,vindow defogger switch has lurn~d to OFF from ON. ground is sup[)lied
through terminal G) of the rear window defogger switch
10 smart entrance control unit terminal @,
rerminal @ of the smart entrance control unll then supplies yround to each defogger relay terminal

I,r,

,(~,\.

'Wi

~)

Nilh power arid ground supplied. ear:h defogger relay is energized

:or rear window defogger syslem, power is supplied
through terminals :ID and ill of the rear window defogger relay
to condenser terminal CD
through terminal @ of the condenser
to the rear window defogger terminal G),
=or mirror defogger system. power is supplied
through mirror defogger relay terminal
I
to each door mirror defoggp.r terminai (1).
~round is supplied
I
to rear window defogger terminal i.!J
I
through body gruund ~. and
10 each doo~ mirror defogger terminal
I
through body ground or @D,
Vith power and ground supplled. each defogger filament heats and defogs the rear window and door

~.'r

njrror,

Vhen the system is activ;:tterl, the rear window defogger indicator Lluminates in the rear window de/ogrer switch
lower is supplied
to termlnal @ of (he rear window defogger switch
I
from terminal of the rear window defogger relay
'erminal @ of the rear window defogger switch is grounded through body ground @ or <!ill

-~ ~'I'.,

~,

11

-,r,'

___________
EL.-.18.5

.J

Wiring Diagram -

OEF-

EL-OEF-01
] Refee to 'L-POOER
D~

<b) :

<B> :

.r;;-....

Next

~ page

LHO models
AHO models

lf1<b>7,2
*2" <b> 3
9
*3
ii I
5

r216m@
~

~CQD @QD
~w'w

Refe'" to las t page

(Fo Idout page) .

\II

C.@@

QIIDL

S,L76"

EL-186

Wiring Diagram -

DEF -

(Cont'd)

EL-OEF-02

eil ]

~~

rn

Preceding ~
page
~

Refer to EL-POWER,

i5A

i5A

ern

[lID

T~'

-I
G

BIR

H'til

B/Y

rrn ~
U

<-

L/Y

<B> :

,AELAY

!.--2:-.:--:r~-=-5"""""'r"""!7""

{4l-

~~w

1"1] DEFOGGER

11

Preced ing
page

1.0

CHID

LHD models
RHO models

*4""

TL.I." Lf

P2

1>112
(:-,1 r

-:
. ....

LlR _ _- _ _

LlR~L/R

~-=-~
~
L....-&- L/R~
(J
L/ALlR

;,,~~.,

CONDENSER

I
1

rn

~\, ~\

REAR
WINDOW
DEFOGGER

~~
8

!
r---------------'

"

r-----------~--I
I

UJ~~~::
B
B
I
I

ED@~@@~
B
B,

__ ~

...

f I

IL

2
57
36

eml

Re fer to last page

(Foldout pagel -

@
SR

.J

'1,",

~[\

EL-187

Ib2T

Trouble Diagnoses

mSmart enlrance contrDI unit CDnJ'l&c1Dr

DIAGNOSTIC PROCEDURE 1

~I]~

~f

f is

~~

SYMPTOM: Rear defogger does not activate. or does not go

off after activating.
REAR WINDOW DEFOGGER OUTPUT
SIGNAL CHECK
Measure voltage between control unit
harness terminals @ and @.

SEL422TA

Condition

VOllage IVI

'iwltc~

is

Rear defogger switch

IS

Rear defogger

(;J

Appro> 12

"OFF'

Smart entrance control Unit connector

II CJU CON;ECTOR 10I::J

~I ~ 3 5

LElJ

NG

(;J
REAR WINDOW DEFOGGER SWITCH
INPUT SIGNAL CHECK
Check continuity between control unit
harness terminal @ and body ground.
CondWon

0'

~CI1JCONNECTORloI::J ~

'~i5
SEL424TA

Rear defogger switch is

pushed
Rear delogger sWItch

NG

r----

Continuity

de'OQger sWllch

Smart llnlr~f1 ronlrol unit connector

Check rear window

defogger relay
(Refer to EL189)
Check rear window
defogger cirCUIt
Check rear window
defogger filament.
(ReIer to EL-189.l

"ON"

SEl423TA

[!J

OK

r-

Yes

IS

No

released.

OK

l!l
IGNITION INPUT SIGNAL CHECK
Check voltage between conlrol unit harness terminal @ and body ground.
Condition

Voltage IVI

Ignrlion swlloh is "ON".

Appro. 12

IQIH!ion 510Nllch IS 'OFF"

Check rear window

defogger switch,
(Refer 10 EL-189)
Check con1inuity
between conlrol unil
harness terminal @l
and rear window defogger switch harness terminal G).
Conllnulty should exlsl.
Check continuity
between rear window
defogger switch harness terminal @ and
body ground.
Continuity should exist

Repair harness or connectars

OK

l!]
CONTAOL UNIT GROUND CIRCUIT
CHECK
Check conllnulty belween control unit
harness termInal Jill and body ground
CDnllnulty shoutd ellist
DK

l~ Repair
. harness or connectars.

Trouble Diagnoses (Cont'd)

ELECTRICAL COMPONENTS INSPECTION
Rear window defogger relay
Check continuity between terminals @ and

and rJ).

Conlinuily

Condition
12V dlfecl current supply between
terminals (D and @

No

No current supply
SEC202B

Rear window defogger switch

Check continuity between terminals when rear window
ger switch is pushed and released.
Terminals

CD-~

Condition

Continuity

Rear window defogger

switch is pushed

Yes

Rear window defogger

switch is relp.ased

No

defog~

SEL430TA

Filament Check
1.

Attach probe circuit tester (in volt range) to middle portion

of each filament

' Air

When measuring voltage, wrap tin fall around the top of

the negative probe. Then press the foil against Ihe wire
with your finger.

~~

6 voln (normal fjlam~~ll

SEL:reJ

SE1I22R

El-189

Audio/System Description
Refer to Owner's Manual for audio system operating instructions
Power is supplied at all times

through 7.5A fuse (No. lm , located in the fuse hlock)

to radio terminal .
With the ignition switch in the ACe or ON position, power is supplied

through 10A fuse (No [~J , located in the fuse block)

to radio terminal @>

Ground IS supplied through the case of the radio.
When the radio power knob is pushed to the ON position. audio signals are supplied

through radio terminals 1, 2, 3, 4, B, 14, 15 and 16

to the door, pi liar ilnd rear speakers.

EL-190

,i
!

I
I

I
i

AUDIO AND POWER ANTENNA

Audio/Wiring Diagram -

AUDIO -

EXCEPT CENTRAL AND SOUTH AMERICA

EL-AUDIO-01

~~I~~O~~SWITCH

NOT USED

r]t

Re fer to EL-POWR .

@])
L.-i-J I--i-J--:-L:J~ I

I r

RIL

(For deck)
7.5A

iOA

[J]]

[]:::I

i_---1

l~t

R/L

To EL-ILL

G/R

To EL-PIANT

G/R
-5
LIGHTING
ANT
SW
SIGNAL

ROO

ANTENNA

OR/G

~
RADIO Ar-D

ACC

BAT
(BACI< UP)

RASP

ANTENNA

-,

RHf+1

WINDOW

RHH

RRSP

RASP
LH (+)

PlAYER
@

I. It

CASSETTE

I It

~---~-----------~---~

I I2_
L

I I

M~~
SPEAI<ER

SPEAKER

RH

[II@~
[I[gJ SR . BR

~@
tfujw

I.H

~--------------~--~

:~114 @:
I

l~
I

1513
W

Refel"' to llist oege

(Foldout pagel _

,
I

~-----------~-----~

SE1.753T

EL-191

Audio/Wiring Diagram -

AUDIO -

(Cont'd)

EL-AUDIO-02
FRSP

RH

FRSP
LH (+)

I It

BR

SA

If

BR/W

L/W

L/Y

't

It

:
;

L/Y
~

~:
--------=~ 'T'

LHD mode is
RHD mode Is

@: Models with
6-speal<er

~
L/W

~JOINT

IL2 " O:;OTO.

=r
L/Y

I' It

tHl

tHl

Ltc 11

f~i"~Jj~

BR ~ BR ~BR/W BR/W~

L/W ~ L/W ~ L/Y

$@)t@$ $@

SR

L/Y

L/W
~

'T' 1 ~
~
~---"..,!,-rn:L""'-------:l'"""a; il1
BR/W

IbjJ

If i t

BR/W

BR
BIVW
~!

SR

lH

I~
LlPl

RADIO AND
CASSETTE
PLAYER

FRSP

PILLAR
BR/W SPEAKER

)t;;-rv"

8R

B!=l/W OOOR

L W

PILLAR

L/Y SPEAKER

L/Y ~

$---$ $

II

L W

1/

L Y DOOR

(jJ:@@J~~
(jJ:@
(jJ:<m)
M~EAKE.
@
J~~AK"
:
@:@3)
@:@@

<D:~
@

:mz>

[Q]@)~@)@
~@)~ t::::t:::TI:TI
~~
BR BR ' 8A 8R
u.JTIJ1Q] W 'w
w

IT:IID

~l@

U-llillligJl.LLLLL{j

I
SEL/641

EL-192

Audio/Wiring Diagram -

AUDIO -

(Cont'd)

FOR CENTRAL AND SOUTH AMERICA

EL-AUDIO-03
I

!1f

INOT USED

~'-~""""'t;--;--~~r;--

P It

l=I/L

I.

FIll

M'~

(For deck)

OR/B

--

G/R

'I'~ ~
>

DRIB

E-:',1

!---~

AIL. To EL-ILL
G/R To EL-P/ANT

OR/G

WINDOW
ANTENNA

F:

ROD

ANTENNA
E~.~

~~~--------------~--------~
W

LIGHTING
SW

ILL

ITtiJ

ANT

BAT

ACe

SIGNAL

(BACK UP)

"7"7'

-e-

EL.
RADIO AND

CASSETTE

RRSP
RH (+)

RASP
AHH

LH(+)

RPSP
LHH

lYJ1l

GND

GNO

~
G

9
G

LG/R

L-J

LG/R

RASP

A/v

R/B

PLAYER

RIB

B/R

IP

IR

)~FaR

SPEAKER

RH

[Q]~~
[Ilg] BR . BR

: ~

y, '

)LJ~REA"

SPEAKER

LH
~

Refe,.. to last pllge

~@)
tfujw

IlliQIJ @

l~~

:
I

~----~--------~-------~

(Foldout page) .

6
:~dB
5
I 13

108

161<1

:
I

~---~------~------~

SEU65T

EL-193

:1

~r

~---~-----------~---~

IL

';~ ~I

SIR

\\~I' .-

(ill

.t I t
I J It
$- --$- ----- --- --$---~
R/Y

1
1

AUDIO AND POWER ANTENNA

AUdio/Wiring Diagram -

AUDIO -

(Cont'd)

EL-AUDIO-04
RADIO AND

FRSP

FRSP
RH(-)

LG/R

~
IVY

SR

BR/W

~~

_T

l$~
BR

BR

IJ

TU J
R/B

~
S/R

L/W

L/Y

~m

BR/W

L/w

L/Y

It

tMl
I

BA/W DOOR

~JOINT
c;CTOO

11~
L/W

IJ

L/Y

It
L/Y ~

$-0--$ $

L~J
SR

~ ~ ~~~ ~~~:~:

L/W ~ L/W ~ L/V

$e$-t--$ $cgn

BR/W PILLAR

tMt
an

SR (ffig) SR ~ BR/W BR/W ~

BR

BR/W

(ill

LHH

-- -------- -----$------ -~

$~- ~ ~

FRSP

LH(+l

CASSETTE
PLAYER

r.Rj~

L/W

L/Y PILLAR

L/W

L!Y DOOR

II 1 II
If 211 SPEAKER
RH
II 1 II
1r2l1 RH
II 1 II
11211
II nl
II~
211 LH
J~
~~~AK~
~r.=I""
~ LH
SPEAKER ~~
SPEAKER

:~

:lID@
:@

:@

:<ffiL)

CD:@)

:~

:~

1
[Q]@J>~@)<Oi@

[IIg]

SR

SA

. SR

. BR

~]18
~

IT:JQIlli] @) @Qg)

IT.I..II:J!QI

~@
t::ttTIf!j

\oj

~Cill

o::II::illIJ

SEI756T

EL-194

1
.'

AUDIO AND POWER ANTENNA

r--------------------;

Audio
ANTI-THEFT SYSTEM

By using a personal 4-digit code known only to the vehicle ,:;-r

SEL40SP

[8BBBB~]
[8BBBB~]
SEUSIP

owner, the possibility of the audio unit being stolen is effectively reduced, because without the code the unit can not be
activated. When in normal use, the unit is unlocked and accessible in the usual way.
II however, someone attempts to remove the unit or the
ground cable is disconnected from the battery, the Anti-theft
system activates and the unit "locks". The only way it can be
unlocked is by entering a personal code number known only
by the owner

UNLOCKING THE UNIT (How to enter a personal code

number)
Use the following procedures to enter a personal code num
ber into the radio
1, Turn ignition SWitch to "ACe" or "ON".
2, Turn SW VOL knob to "ON" and "COdE" will appear on the
display.
3. Press any bullon (except "eject") and "~coO" will appear
on the display

~--?

',-

4.

lIl1mple
Code number is SS23

[BBSSBs]
[BB888S]
SELJ,~P

Enter a personal code number by pressing station select

buttons 1, 2, 3, 4 the requ ired number of ti mes to displ ay
the code,
S Press G
to enter the code.
Unit is unlocked and the radio/cassette will operate.
If the wrong code number is entered, the display shows
"----" Wait ten seconds then enter the correct code
CAUTION;
There ~s a theft prevention mechanism restricting the number
of times a wrong code number can be entered into the radio
unit. If a wrong code number is entered 1 to 2 times, you will
have 10 wait for 10 seconds before the radio will receJve further input. II a wrong code number Is entered 3 10 20 limes,
you will have to wait a duration of 15 minutes. The radio unil
will lock permanently If any further atlempts are made,

l,r:

Radio Fuse Check

EL-195

~ (.,

-=}

n",
l"P

AUDIO AND POWER ANTENNA

Power Antenna/Wiring Diagram -

P/ANT-

EL-P/ANT-01
ANT
SIGNAL

RADIO AND

RADIO AND
CASSETTE
PLAYER
@

CASSETTE
PLAYER
-1

O~---_

DRIB

lHID

G/R

OR/G

G/R

..

~----------------------~

DRIB ~

G/R

aD

G/W

~----------------------~

DR/G

DRIB

G/W

rn
BAT

ANT
SIGNAL

@: For Central and South America

@: Except @

rr--fQh-, ~
t:=M::jj w

[I"QI]

llliL.IID

<ID
w

Refer to lest pege

(Foldout page) .

~
i
!

!
J

II
El-196

AUDIO AND POWER ANTENNA

Location of Antenna

~----------~

Loosen

Window Inlonl'O lllrminal

_----...L
Antonno

Antenna Rod Replacement

REMOVAL
1.

Remove antenna nut and antenna base.

2.

Withdraw antenna rod while raising

antenna motor.

t b
I

operating

I~~:

I
l

:: i

..

AUDIO AND POWER ANTENNA

Antenna Rod Replacement (Cont'd)
INSTALLATION
1.
2.

4.
5.

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

Window Antenna Repair

ELEMENT CHECK
1

Attach probe circuit tester (in ohm range) to antenna terminal on each side.

2.

If an element is broken. no continuity will exist

Cont<nUlly e~isl
SFL.2S21

EL-198

AUDIO AND POWER ANTENNA

Window Antenna Repair (Cont'd)
3.

To locate broken point. move probe 10 lell and right along

element. Tester needle will swing abruptly when probe
passes the point

Refer to REAR WINDOW DEFOGGER "Filament Repair" lor

Element Repair.

:,'1

SEL2531
,

~'

'\:.1

'.L

~'...~.':

G.. -r;

EL-199

HEATED SEAT

For location of heating unit, refer to "SEAT" in BT section.

Wiring Diagram -

H/SEAT -

EL-H/SEAT-Ol
to EL-POWER.

PU (ffi])

~
PU (]D
I

r---------I
PU

PU

r---",-mi=::=========::;--i
HEATED
SEAT

HI
OFF

~
R/W

OFF

~~

PU/W

II

HEATED
SEAT
RH

SWITCH

SWITCH

<IDID

@)

LH

~
A/Ilil

~~

PU/W

1::!::1=p:;:t}

_ __________________1

.J;:-......

Next page

-PU/W~
R/W

-@>

____________________1_

f.
B

@)

to last
(Folaout oagel

~efe~

p~g8

,
SELI68T

l
1

El-200

HEATED SEAT
Wiring Diagram -

H/SEAT -

(Cont'd)

EL-H/SEAT-02

fl./A.

~PU/W

Jreceding

lage

~ R/W

~PU/W'

<]a A!W

R/W

(fill) PUlW

~-----tiJ------R/W

A/W

(@

PU/W

R/W

rn ----- ffl-- -----ffl

I

CUSHION

SUB-HEATER
SEAT
CUSHION

MAIN HEATER

- - - ;,- --- Ej
SEAT BACK
HEATER

PU/W

PU/W

rrTI -- --- ffl-- -----ffl

~~---,"~-----+-::l
SEAT

~------.----____.......::l I

II
II
Ij Ii
I

I
I

I
I

I
I

,
I

L:

I
I

SEAT BACK
HEATER

FRONT SEAT RH

FRONT SEA T LH

f
.
e

@@

:;
:

1~
2
w I W

JQL
~

Nt
L

I
I

, *2 I
L:
I
I

, ;

-, -

,[

EL-201

"

System Description
Power is supplied at all limes

through 25A fusible link (Ielter OJ, located In the fusible link and luse box)

10 circuit breaker terminal CD

through circuit breaker terminal

10 smart entrance control unit terminal CD.

Power is supplied al all times

to interior lamp terminal CD and

to key switch terminal <D

through 10A fuse (No 0J. located in the fuse block).

Power is supplied at all times

to multi-remote control relay-1 terminal ill

through 10A fuse (No, lllJ, located in the fuse block).

Terminal rf~ of the smart entrance control unit is grounded through body ground @,

INPUTS
When the key switch is ON (ignition key is inserted in key cylinder}, power is suppl ied
through key switch terminal

to smart entrance control unit terminal @ .

When the driver side door switch is OPEN, ground is supplied

to smart entrance control unit terminal @

through driver side door switch terminal CD

to driver side door switch terminal

through body ground or (!!D.

When the passenger side door switch is OPEN, ground is supplied

to smart entrance control unit terminal @

through passenger side door switch body ground.

When the driver side door lock actuator (door unlock sensor) is UNLOCKED. ground is supplied

to smart entrance control unit terminal @

through driver side door lock actuator (door unlock sensor) terminal @

to driver side door lock actuator (door unlock sensor) terminal

through body ground @.

When the passenger side door lock actuator (door unlock sensor) is UNLOCKED, ground is supplied

to smart entrance control unit terminal @

through passenger side door lock actuator (door unlock sensor) terminal @

to passenger side door lock actuator (door unlock sensor) terminal

through body ground @.

Remote controller signal input

through window antenna

to smart entrance control unit terminal @_

The multi-remote control system controls operation of the
power door lock

interior lamp

panic al ar m
hazard warning lamp

10 code entry

OPERATED PROCEDURE
Power door lock operation
When the following input signals are both supplied:

key switch OFF (when ignition key is not inserted in key cylinder);

door SWitch CLOSED (when all the doors are closed):

smart entrance control unit locks all the doors with input of LOCK signal from remote controller.
When key switch is OFF (when ignition key is not inserted in key cylinder), smart entrance control unit
unlocks the doo,s wi ttl input or UNLOCK signa I from remote control Ie r.
For details 01 cunent flow, refer to "POWER DOOR LOCK"

EL-202

I
I-

I
j

I'

l~UL TI-REMOTE

CONTROL SYSTEM
System Description (Cont'd)

Interior lamp operation

When lhe following input signals are both supplied.

key SWitch OFF (when ignition key is not Inserted ,n hey cylinder):

door switch CLOSED (when all the doors are closed).

multi-remote control system turns on interior lamp (for 30 seconds) with input of UNLOCK signal from
remole controller.
For delatled description, refer to "Interior. Spot and Trunk Room Lamps"

Panic alarm operation

When key switch is OFF (when ignition key is not inserted in key cylinder), multi-remote control system
turns on and olf horn and hazard warning lamp intermittently With input of PANIC ALARM signal from
remote controller,
For detailed description. refer to "THEfT WARNING SYSTEM"
. l-.

Hazard warning lamp operation

When the following input signals are all supplied

key switch OFF (when ignition key is not inserted In key cylinder).

door switch CLOSED (when al/ the doors are closed):

door lock actuator (door unlock sensor) LOCKED (when all the d()ors are I()cked).
mult.-remote control system outputs two times the following ground signals with input of LOCK signal
from remote controller:

to multi-remote control relay-1 terminal (?J.

through smart entrance control unit terminal 1)

As a result, mu Iii-remote control relay-l is energized, and ha2ard wa rning lamps II ash on and off.
For detailed description. refer to "Turn Signal and Hazard Warning Lamps" and "THEFT WARNING
SYSTEM"

;:L

,,or

i':"'-

_ _ _ _ _ _ _ _ _ _ _ _.E.L.-2.03

.J

MULll-REMOTE CONTROL SYSTEM

Componen t Parts and Harness Connector
Location

I!J Smart entrance

control unit
circuit breaker
Key switctl

II

"."'" 0,""""", ~

I
j

SEL859T

EL-204

REMOTE
CONTROLLER

~CIRcun

~KE'

~;

MULTIREMOTE
CONTROL
RELAY-l

SWITCH

BREAKER

yWINOOW

ANTENNA

m
rI
I\)

(J'l

I"

24

17

SMART ENTRANCE CONTROL UNIT

:6

15

10

DOOR
SWITCH

DOOR
SWITCH
PASSENGER

SIDE

SIDE

DRIVER'S

13

UNLOCK LOCK

DOOR UNLOCK

DOOR UNLOCK
SENSOR

SENSOR

ACTuATOR

DOOR LOCK
ACTuATOR

DRIVER S
SIDE

PASSENGER
SIDE

ODOR LOCK

1.9..J

;;,,)

=4

(Wi)

eJiV
~

2QI

?8J

"~

;:>

UNLOCK LOCK

1
A

12

""121

c={]

~
~

-uU

(f

Wiring Diagram -

MUL11 -

EL-MULTI-01
IGNITION SWITCH
Ace or ON
Refer to

EL-POWER,

RIB

w lfiW

RIB

iDA.

iDA

[]I]

[]:::I
L

lHIID

RIB ~

~
A/S CED

$L/R~

$1
R/L <ffiD
I

RIL

RIB

INTERIOR

rn"]@CH

em

m
LAMP

ON

OFF

...

LlR

R/W

CIRCUIT
BREAKER

R/lil

WIIIOOW ~@
ANTENNA WjR

m
BAT

C8D

B/P

<lliD

rrb
RIW~

$SIP @

I=ljW

B/P

rFf7i1

WIA

Models wIth

sun roof
@: Models without
sun root
j f 1 " ' "@Cfl!). @ @

S/P

DOOR

REMOTE
CONTROLLER

@:

KEY

ACC

KEY SW

AQOtoI LAMP
OUTPUT

37 ANT

SMART
ENTRANCE
CONTROL
UNIT

(B1)

~@)

IT]]II]

[Q]@J@)

[I[g]

EL-206

~(fi

UEJ

Refe" to last page

(Foloout page) "

MULTI-REMOTE CONTROL SYSTEM

Wiring Diagram - MULTI -

(Cont'd)

EL-MULTI-02
SMART
ENTRANCE:
CONTROL
GND

DOOR 51'1
(OR)

DOOR SW
(PASS)

GV/R

UNIT

GY/R @1)

CID

L/R

To EL-INT/L

1,I;_~

L . . . 4t
L

~----------------~

GY/R

o.

L/R~

$L/R~

LlR

rm
DOOR SWITCH
PASSENGER

DOOR
SWITCH

OPEN

DRrVEA"S
SIDE
~

---"

CLOSED

OPEN

SIDE

,...,
B

@)@

Refe,.. to last pClge

(Foldout /loge) .

A~

L.1J

SR

SEL 771T

EL-207

MULTI-REMOTE CONTROL SYSTEM

Wiring Diagram - MULTI -

(Cont'd)

EL-MULTI-03
DOOR
LOCK
OUTPUT

OOOA
UNLOCK
OUTPUT

(OR)

(DR)

UNLOCK
SENSOFI
(DR)

!!4Jl

l!4Jl

Lf

L!W

~W!PU

WIU

ODOR
LOCI<
OUTPUT
(PASS)

DOOR
UNLOCK
OUTPUT

l!4=Jl

lt4=!lL

t I

t---
L!W @W!PU
I W!PlJ
I
L!W

Y!G

It

rn rm m

~
v!L

t I
L
W!L
Y/L
4JtL @-10- 4Jt---$
W!L
Y!L
IL
I Y!LI
w/L
Wi

V!G @3>

$Y!G CQI)
I
Y!G

(PASS)

SMART
ENTRANCE
CONTROL
UNIT
Q@

UNLOCK
SENSOR
(PASS)

m m

LOCKED

,--DOOR

LtlLOCK

LOCK

UNLOCK
SENSOR

l.N...OCK

LOCK

~
B

rep8~

Jrumw
ITJJ

I
B

B @

B@

!-

-!-

<ED

~CQI)

CJ:IIIIJI[J w.

@QD

ACTUATOR
PASSENGER
SIDE
@g)

DOOR
UNLOCK
SENSDfI

DOOR LOCK

ITI::JQIlliJ em @

~W.w

~@g)
tIi:V
GY GY

Refer- to last page

(Fol(jout page) .

SELl72T

EL-208

MULTI-REMOTE CONTROL SYSTEM

Wiring Diagram - MUl11 -

(Cont'd)

EL-MULTI-04
]

R.f., to EL-POWER.

I
G

(fIT!)

$G

r-

I
_-_-e'---I
I I I

To EL-TURN

lJKUI@V-t 4J
:II ':'/I:':I/Y
- i T- LG/S.}
G

ffi

mI] ffl[ ~TI~

~~~~6L

~,...."....~~,......,!,-..,..JI

~ ~ ~

REMOTE
CONTROL
RELAV-2

Ie.

@>

-,ff

G/V.

,n
To EL-TURN

_ _ _ _ _ _ _- - - - - - - G/8

OOcm

QJ

OR@

OR

FLASHER
OUTPUT

V/G

To EL-THEFT

V/G

PANIC
OUTPUT

SMART
ENTRANCE
CONTROL

UNIT

W
2
57
36

Refer to last page

(Foldout page) .

WT

SA

S[I n)l

El-209

,~

Input/Output Operation Signal

SMART ENTRANCE CONTROL UNIT

Term'nal
No

Operated cOrld,l,on

Connections

Power source (CIS)

Passenger door lock

motor

Driver door lock motor

Passenger door lock

motor

Drivers door lock mOlar

12V

..

12V

Free
-

--~

When door lock srgnal is received from remole controller or unlock sensor

Locked

The1l warning horn relay

When panic alarm is operaled using remote controller

Interior lan1p

When doors are unlocked uSing remote controller. (Lamp SWitch in

"DOOR" position)

10

Ground

11

Ignition switch (ON)

"ON" or "START" POSItion

12V

------

12

Driver door unlOCk sensor

Dr Iver door. Locked

13

Passenger door unlock

sensor

Passenger door Locked

15

Driver door switch

OFF (Closed)

IV or less

12V

12V

l;>V

-0

12V

ON (Open)

17

19n'llon SWitch (ACe)

"ACC" or 'ON" pOSition

37

45Vor
less

45Vor
less

12V

1 5Vor
less

12V
--

Multl-remole antenna

12V

IGN key Inserled ... ION key removed from IGN key cylinder

.... 1V or
less

12V
-,

OFF (Closed) ... ON (Open)

.... 1V or
less

12V -.4SVor
less

Unlocked

Passenger door switch

-~

12V

Unlocked

16

1V or
less

---->

lV or less

Free

Ignition key switch (Insert)

--~

When doors are locked using remote conlroller or panic alarm IS

operated using rem-ote controller

24

i
i

When doo, unlock sIgnal IS received trom remote

coni roller or unlock sensor

Unlocked

Muill-remote control relay

Vollage (V)
(Approximate
values)

.4 5V or
less

----

i
j
EL-210

MULTIREMOTE CONTROL SYSTEM

Trouble Diagnoses
TROUBLE SYMPTOM

All functions of remote control system do not oper ate

CHECK REMOTE CONTROLLER BATTERY
Refer to DIAGNOSTIC PROCEDURE 1
OK

Some functions of multi-remote controller do not operate.

i}) DOOR LOCK OR UNLOCK DOES NOT FUNCTION
(Pressing lock or unlock bullon of remote controller normally
locks or unlocks all doors

- - - - - - - - OR - - - - - r]) HAZARD WARNING LAMPS 00 NOT FLASH TWICE WHEN

PRESSING LOCK BUTTON OF REMOTE CONTROLLER
Check il hazard warning lamps flash with hazard sWItch

II check is OK. [ Go 10 DIAGNOSTIC PAOCEO""DAf:~

f - - - - - - - - - - - - - - - OR -----------~
'1l INTERIOR LAMP DOES NOT TURN ON FOR 3D SECONDS WHEN
PRESSING UNLOCK BUTTON OF REMOTE CONTROLLER.
Check i' the interior lamp sWll<:h is
illuminates when a door LS open
If check

IS

In

~---------

Ihe "door" position. the lamp

"Interior lamp" circuit. __

=-----.=J

OK. , Go to DIAGNOSTIC PROCEDUREo:]

f - - - - - - - - - - - - - - - OR -----------~
'1J PANIC ALARM (HORN AND HAZARD WARNING LAMP) DOES
NOT ACTIVATE WHEN PANIC I\LARM BUTTON IS CONTINU
OUSLY PRESSED FOR MORE THAN 1 5 Sl:CONDS_
Check if horn and hazard warning lamp actlvale when test ,s con-

ducled as follows
Open the drivers window
Close all doors_ Wait for aboul 30 seconds \0 make sure that the

___J

lighted "SECURITY' warning lamp begIns to blink

Lock doors wLth door key Inserted ,nlo key cylinder.

4 Manually unlock with dflver's door lock kflOb, tnen panic alarm
should activate (1he alarm will slop when door is locked and
unl6cked Wlt/1 the key}

-1

r:-

--~

0K

Enter the Identity (10) code of another remote control leI and recheck

!- - - - - - -

1 0K

operallon to see d the same Irouble as indicated above /)CCurs

Replace the

- - - - ----

~----

Check multl-remole controller operation again

If necessary. replace Smart Entrance

Control Unit.

mUlli.remo~ controll~_-==-==----=----J

Note: The multiremote control system does not activate with the ignition key inserted in the Ignition key
cylinder.

Trouble Diagnoses (Cont'd)

DIAGNOSTIC PROCEDURE 1
Check remote controller battery.

CHECK REMOTE CONTROLLER BATTERV.

Remove battery and measure voltage
across battery positive and negative
terminals

EEl

and

e,

Measuring terminal

SBF203G

Standard
value

ffi

Baltery posilive terminal

BatterV"89at;ve terminal

tIl

3V Dr more

Note:
Remote controller does not funcl10n II battery Is not set correctly.

DIAGNOSTIC PROCEDURE 2

~""""""w

18

C=fU=CO=N=N=EC=T=O=R"r.U

1"1

CD

SYMPTOM: All remote controls do not function even if remote

controller Is operated properly.

Smart entrance

:~~~~~it

lwl

-No

CHECK MAIN POWER SUPPLY AND

GROUND CIRCUIT.
1) Remove key from ignition

2) Disconnect connector from control

Check the following.

Fuse
Circuit breaker
Power supply harness

unit, Check voltage across control

unit terminal

SBF377HA

CD

and GND

Does ballery voltage exist?

~i5

r[CfU=======F.DI

@lID

CHECK ANTENNA CIRCUIT.

Disconnect 1-pin conneclor from control

Smart entrance

II/Rear
~

Check continuity between

a terminal

and filament on the rear window

I-e

Does continuity exist?

~Yes

filament
(inside)

LT
_____--.S.E6.29
1

lI
i

No

f--......

!j
Check antenna circuit
(Refer 10 REAR WINDOW
DEFOGGER "Filamenl

unit

.;000-

rV

Check GND harness

Does conllilulty ellsl?

connector

and GND

SBF378HA

L!.lJ control unit

---

Check continuity between terminal @)

.~

~i5
rm

f"

Ii)

Smart entrance
CONNECTOR!L control unit
connector

E.~ .: .o2o.ex.1

_ _

p a.ge.l

Repair"' )

I
I
1

i_...:.IL TI-REMOTE CONTROL SYSTEM

Trouble Diagnoses (Cant'd)

IICIU CONNECTORIU Smart

entrance
control unit
connector

GYrRlLm
l

CHECK DOOR SWITCH CIRCUIT.

.@

[Y]
+

No

Replace smart enlrance

control unit

No

Check door switch cir-

1) Close all doors

2) Connecl control unit connector
3) Check voltage across conlrol unit
terminal @ and GND. @ and GND.

Does battery voltage er.lsl?

SBF412HA

Yes

II CN CONNECTOR@
@

Smart entrance
control unit
connector

'larl

1) Open all doors.

2) Check voltage across control unit
terminal @ and GND. and GND.

cuit

Is voltage appror.. OV7

Yes

C:..
SBF413HA

CHECK IGNITION SWITCH "ACC" CIR-

No

Check ignition switch

"ACC" circuit.

CUIT.
Disconnect connector from control uni!.

Check voltage across control unil lerminal @ and GND while ignition switch is
"ACC"
Does baltery voltage exlsl7
Yes

Ch"k-';.e"liOO .,,1,

'0 m"1h ,;mole

control syslem for function

:', ~ ~

'f- .

EL-213

MULTI-REMOTE CONTROL SYSTEM

Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 3

'<, ..'"

~E)
ItELi>NNEC r1iliJi:Jj
Smart entrance
conlrol unit CDnl'lector

.....

SYMPTOM; Door lock or unlock on remote control does not

function.

"'Lw

enec'" ~'Jlta9~ acrQ~; conlIo\ unl' 'erm,na l

conudlorl

[fCIUJONNECT~

GND

VOI\1l9
(V)

SBF40~HAI

~n()b

12

conclltton

'13)

1;>

U"locl<.ed

GNO

I)

Does continUlly

OK

'~ilEm

Door lock

D""O'cr

ector

2) Check cont, nu'ly between

'~i) and GNO, @ and

l"erm,lM.ls

Door lock knob

c~nn

\'C'm control un.\

:~ and m'O. @ and GND

~I

Smart entrance
conlrol unit ~onn~dor

rEl
"lNG
___ ~.
11 D'scannect

CHECK UNLOCK SE.... SOR CIRCUIT

L~

-GND
-GNO

e~lst?

-.-_ _--J

No

[iJ
CHECK DOOR LOCK ACTUATOR CIRCUIT,
Check \foliage lor ,100' lock molor
000' loci< aclualor dllver s,de,

entrance

cOrllrol unit
Termin.als

Door lock knob

Dr;ver side door lock aclualor

@)

II CIU CCNNECEO
-~-~.~--_

""'_

'!l

U"locked

lID

Repair unlock sensor ha'nC3~ Of

Duo, lock actuator passengor side

Terminals

Door lock knob

conciUon

w,"

.----.-::J"

Lot.ed

.... -... _-_ ...--.. _-- .. _--'

I

N~

to!

Unlocked

Passenger SldB door Ioclc. actualor

Smar1 enlrance
~
control un;l oonnector

()

00e9 ballel)' voltage el<i517

ClNlEC'

.L"l

Yes

![CIUQONNECfOFD
@ - - - - .. --------"

L~vi
r.. _-.- -.... _-- ...

,.

.E~
,.;V

illf

-- ---_ ....

'---1
\0
1

~=_====~~l__

:,

'" _.''

'. ;

conl.01 ul'Ht co",nel;loJ ctnO

Terminals

(1)

11.

r=---[;:;: ." ,,::'",',,;:.; : ; ;

Does eo,lI'nully ellst.,

cannec\ol

Driver s I d e , @ i ! ) Y e s

~~ ~
~":_j"OO@
[ill

Ca!C;;C()f'npf'1

door loc;I< actuatDr con ner.lor

2) Check CQ~tl nU'ly

c.,nlrpl UJlIt
connector ~
Door loclo{ actuator

i@NcONNECTOR

I] ; i
\ ::

CD

'e'eo

'0

ELECTRICAL COMPONENTS INSPECTION

J,'

POWER COOR LOCK' ll-174)

I -_.

~6J~

----

EL-214

fepldce u<Jor fock

aclualor

G)

lJWl-alJv!
I

H:l

locked

con;lhor)

~ )COO<K1

Smarl enlra()t;&
control unit connec1or

A.ePlace smarl entrance conU['\~1

MULTIREMOTE CONTROL SYSTEM

Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 4
SYMPTOM: Hazard warning lamps do not flash twice when
pressing lock button of remote controller. Everything else functions.

II C,U CONNECT~
~ Smart e'ltranCll
conlrol UM
""

tl

connector

"~

WARNI~G L A M j p e s

CHECK HAZARD
FLASHING CIRCUIT.
Che~l<

(Go 10 next page)

V(11!age across <:o"\\rol unl\ te'""

nal IJ) and GND.

Does battery voltage e.lsl?

--

----

No

~i5

m
I

Munl-remote
control

Check I/oltage across multi-remote con

reillY 1

Yes

Does baUery voltage eldal?

Of!

1. Disconnect connectors
hum cQnhol Ofl'\ ~,\(J

\rol rel<lY t terminal @ and GND

multi-remote conhol
relay 1

No

Check conl"wrly
between terminal (])

at
SBF)B~HA

contra I unit connec-

tor and

(1)

of mull<-

remote con!rol relay 1.

Does contlnully

~1l151?

No

bctVolee~l "'1,

Rup"," harness
conlrol unll conneGlor

and multi-remole corlrol

SBnS4HA

PI)..

relay t connector

,,_.

Discorloect connector trom multi-remote

Repair power supply harne:\s tor mulli rernvlt:

conhul ,el"y I

Check voltage across multi-remole conIrol relay 1 te/minal

No

-._-----

III

conlrol relay 1

and GND

Does b8tte~ voltage e"&\1

Yes
SBFl85HA

Replace multHemole control relay 1

----

.,.

" I I ._ _. . .

--------~----

. .

Trouble Diagnoses (Cont'd)

~i)

10
CD

IICN CONNECTOR ~

Smart e"trance

cantro/uM
cOllnec\i),

oo~

"USh lock outt:ln 01 remote controller

~nd

check voJJage across COltro/ unii

- G----~.

Replace smarl
("onlrol Urllt

enlran~e

-------------

terminal (1\ and GNO

is voltage approll. OV?
Yas

S6F3l12HA

~i3
!FiJ
1;rr'

Yes

"ush lock bulton of remote c:lll!roliel

and check vollage- aCfOSS mulh-remole

Muhi'r.."..,~

P.epair tazard SWitch cir-

curl harness.

control relay 1 terminal @ and GND.

control

reillY'()

(j) and GNO.

Does battery voll8ge ell1511

----,------_
.. - ---'No

SBF3EW:f.iA

Disconrect connector Irom !TUlll-remote

No

contlol relay 1
Check

Repa', power supply Mr

neS5_

"oHaoe across

multi-remote con-

lrol relay term'nat @ and GND.

and GNO_

Doe-s battery voltage exlsJ?

Yes
Q

Replace mUI\I-remole control relay

j_

snr.'l8"''''

DIAGNOSTIC PROCEDURE 5

~i5
1

II C/U CO"'NECTORI~

SYMPTOM: Interior lamp does not turn on for 30 seconds

when pressing unlock button of remote controller.

Smart ell!TanCll
coruml unlr

Everything else functions.

connector

"wlw!
@

No

CHECK INTERIOR LAMP CIRCUIT,

When inle-rior lamp 51/J'1":;h

IS

"DOOR"

r----

position, check vollage across control

i:l'ld interior Jamp con-

llni! terminal ~ and GND

neclor

Does

ball~ry

vollage nist?

SBf38BHA

Push unlock bulleD 0/ rem ole conlroller

and check voltage aeros~ coMrol Unt\

terminal
I~

(9)

Repair harness belwee

conlrol enit connector

r~,m,,' '"',,~

ard GNO

conhol unit
----,._-- ...

_----

voltage apprOll. 0....,

~eck system

t
3gain

El~16

es

.~

...

-----.....--..----...--

ML'l<;,rJ-REMOTE CONTROL SYSTEM

Replacing Remote Controller or Control Unit

If the remote conlroller or the control unit needs to be replaced or if an additional remote controller
needs to be sct, enter the identity (10) code manually.
ID Code Entrv Procedure
To enter the II) c:ode. follow this procedure.
"Selling mode":
Three steps must be followed to establish the "setting mode "
(1) Close and lock all doors.
(2) Insert and remove the key from the Ignition more than six times within 10 seconds, (The hazard

~'~:'

warning lamp will thell f)<t::,h twice)

At this time. the original 10 codes are eliminated.

10 code entry;
(3) Turn ignition key 10 "ACe" position,
{4j Push lock button on the new remote controller once (for example. if door is locked using the remote
conlroller during this 10 code entry enable slate. a new 10 code can be entered)

At lhis time. fhe new 10 code is entered. (The hazard warning lamp wlll then flash twIce.)
(5) If you need to enter additiol"lal remote controllers !including tile original). release the driver's door
lock, then lock again with door lock knob,
(6) Push lock button on Ihe new additional remote controller once_
(7) This ID code entry enable state and setting mode remain until the driver's door is opened,

NOTE

If the same JD code that existing in the memory Is input the entry Is canceled, and no 10 code wUI
be entered.
Entry of maximum four (0 codes is allowed and allY attempt to enter more will be ignored.
Any ID codes entered after termination of the "selting" mode will not be accepted. Addllionally
remote control signals will be inhibited when an 10 code has not been entered during the "selting"
mode.
1

~'t

~],

i\'~\1
,"'-"1

'.r.'

J"

,-".',

THEFT WARNING SYSTEM

System Description
Refer to Owner's Manual lor theft warning system operating Instructions,
Power is supplied at all times

through 30A fusible link (letter I'; I , located in the Iuslble ,'ink and fuse box)

to ignition switch terminal C"0.

With the ignition switch in the START position, power IS supplied

lrom terminal of the ignition switch

to theft warning relay terminal (3)

Power is supplied at all times

through 7.SA fuse (No [Ig'! , located In the fuse block)

to security indicator lamp terminal .

Power is supplied at all times

through 25A fusible link (letter f j, located in the fusible link and luse bOlt)

to CIrcuit breaker terminal (1)

through circuit breaker terminal

to smart entrance control unit terminal CD

With the ignition sWltch in the ACe or ON poslhon, power is supplied

through lOA fuse (No, ~ . located in the fuse block)

to smart entrance control unit terminal @

With the ignition switch in the ON or START pnsition, power IS supplied

through 7.5A luse (No. @] , located in the fuse block)

to smart entrance control unit terminal @ and

to theft warning relay terminal CD.

Ground is supplied

to smart entrance control unit terminal @J

through body ground

THEFT WARNING SYSTEM ACTIVATION (Without key or remote controller used to lock doors)
The operation of the theft warning system is controlled by the doors, hood and trunk lid,
To activate the theft warning system, the ignition switch must be in the OFF position and the smart
entrance control unit must receive signals indicating the doors, hood and trunk are closed and the doors
are locked
When a door is open, smart entrance control unit terminal t~ or 1..61 receives a ground signal from driver
side or passenger side door switch.
When a door is unlocked, smarl entrance control unit terminal @ or @ receives a ground signal

from terminal @ of the driver side door unlDck sensor

from terminal @ of the passenger side door unlock sensor

through body ground or for the doors.

When the hood is open, smart entrance control unit terminal @) receives a ground signal

from terminal of the hood switch

through body ground @D.

When the trunk lid is open, smart entrance control unit terminal ~l receives a ground signal

from terminal 'J) of the trunk room lamp switch

through body ground @.

If none of the described conditions exist, the thett warning system will activate automatically

THEFT WARNING SYSTEM ACTIVATION (With key or remote controller used to lock doors)
II the key or remote controller is used to lock doors, terminal ~lt receives a ground signal

from terminal of the driver side key cylinder SWitch and

from terminal CD 01 the passenger side door key cylinder switch

through body grounds and @!D.

If this signal is received by the smart entrance control unit. the theft warning system will activate aulomatically.
Once the theft warning system has been activated, smart entrance control unit terminal ,~} supplies
ground to terminal (1) 01 the security Indicator lamp
ThQ security lamp will Illuminate fur approximately 30 seconds and then go on and ott

al
I

_ _ _ _ _ _ _ _ _ _ _ _ _.E.L-.2.18

System Description (Cont'd)

THEFT WARNING SYSTEM OPERATION
The theft warnmg system is triggered by

opening a door or the trunk lid without using the key

opening the hood

tampering with the key cylinder ;n the door

Once the theft warning system has been activated, jf the smart entrance control unil receives a ground
signal at terminal r, ,'~), tGl or @J (as described under THEFT WARNING SYSTEM ACTIVATION) the
theft warning system will be triggered Also, when a door key tamper signal is received al the smart
entrance control unit. the system will be triggered. The hazard warning lamps flash and the horns sound f'v'l
intermittently, and the starting system is interrupted.
When a door key cylinder SWitch has been tampered with, smart entrance control unit termInal ~.!I)
receives a ground signal

from terminal ':3) at each door's key cylinder switch

through body ground or @)

If the theft warning system is triggered. ground is supplied

from terminal @ of the smart entrance control unit

to theft warning ref ay terminal .

,= ,_.
With power and ground supplied, power to the inhibitor switch (A/T models) or starter motor (MIT mod- - "els) is interrupted The starter motor will nol crank and the engine Will not starl.
Power is supplied at all times

through 7 5A fuse (No. ~ , located in the fUSible link and fuse box)

to theft warning horn relay terminals r:D and

Power is supplied at all times

through 10A fuse (No. ~l , located in the fUSible link and fuse box)

to theft warning horn relay terminal @

Power is supplied al all times

through 10A fuse (No '12J . located in the fuse block)

to multi-remole control relay-1 terminals ill, (3) and @

When the theft warning system is triggered, ground is supplied intermittently

from terminal 'gl at the smart entrance control unit

to theft warning horn relay terminal and

to multi-remote control re\ay-1 terminal '

The hazard warning lamps flash and the horns sound intermittently
The alarm automatically turns off after approximately 30 seconds but will reactivate if the vehicle is
tampered with again.
f .5

THEFT WARNING SYSTEM DEACTIVATION

To deactivate the theft warning system, a door or the trunk lid must be unlocked with the key or remote
controller.
.rr
When the key or remote controller is used to unlock a door, smart entrance control unit term mal ~f\
receives a ground signal
from term mal ;'f) ot the driver side door key cylinder switch

from terminal !tJ of the passenger side door key cylinder switch
When the key is used to unlock the trunk lid, smart entrance Gontrol unit terminal ~~ receives a ground
signal tram terminal CD of the trunk key cylinder s W i t c h , ~ ' T
When the smart entrance control unit receives either one of these signals, the theft warning system is
deactivated

PANIC ALARM OPERATION

Multi-remole conlrol system mayor may not operate theft warning system (horns and hazard warning
lamps) as required
When the multi-remole conlrol system is triggered, ground is supplied intermittently

trom smart entrance control unit terminal (~)

to theft warning horn relay terminal and

from smart entrance control unit terminal :7)

10 multiremole control relay-t terminal (,2)

I' 0;':':

THEFT WARNING SYSTEM

System Description (Cont'd)
ne hazard warning lamps flash and the horns sound mtermittently.
he alarm automatically turns off after 30 seconds or when smart entrance control unit receives any
Ignaf from mufti-remote controller

El-220

--..l

--THEFT WARNING SYSTEM

Component Parts and Harness Connector
Location

(tr

Trunk lid

k~y cyl.od p ,

\'11.0,

~wltch

Trunk room la'T1p

MlIlh,emnl"
crmiiDI
relay I. 2

~w'tcn

~ooor key cyl,odet

sWitch

Door unloCk sensa'

7'i'F

s;

~1~

~!~~

" ..' C\

-~ "~~

~::,=';."'O, >i""'.~/\~.'~~ ~

[!JOoo, key

I~,l.

OOO'''''~~:::::~:::':"W~/~'((l~-\'~ld~:-=;~r~
~:~~.

clfcuit breaker.

Ii The'l war",o~ hom-..J

"

'

'"

i~r~

M1
~1

--_

~---~------

~o:

iii Theft warnmg r"lay)

Theil warning norn re,ay
Hood sWitch

"25.\

~~!~\

~~{

~1

El-221

,
I

:~

;;-

~,,~"P

T""""
I

t+
I

i"

I\,)
I\,)

'""' """' '''''''

(HIGH)

iL.O"1

"M.N!NG
HORN

SMART ENTRANCE CONTROl liN] T

'~ L
I
I

1']

I;

r " ,

.~~
~
III~ ~E,; ~oo ~
~

]8j:"

L ,,"'; f1i'"'" I

-------------,....

*
_---~.

_.

__ ..

~,

LOO<Ell

~I--

TRUNK
ROOM
LAMP

DOOR LOCI<.
ACTUATOR
DRIVEl<' 5
SIDE
IDODFl UNLOCK

S~ITCH

5fNSO~1

~~I~=,J1l~ N~

"n,"

.,

I
I

.-':::_---....,._L_----_:"-_--------~------L-

1]

10

IL

.,.

.. _ _ ,...-._~_~..

I---

ODOR LOCK
ACTUATOR
PASSENGER

.,.

DOOR I'EY ('LIN

SIOE::

(DODP U~'LOCK
SENSDP.I

lOO<ED

~~r~~ ~ ~

:
'--t-'------

,~_~.__...".""""'._
. .. ' _ " " " ' . _ ..... _ _

rc:=::l.",DOOR

KEY [;rLINo

.... :c'>..':'. ~l'._~,.,...~4"'~

....

THEFT WARNING SYSTEM

Wiring Diagram -

THEFT-

EL-THEFT-01
','1,

to EL-PQWER.

LA

F1 (ill1)

<8!Q)

i-

CIRCUIT

BREAKER

~~
W/R

BAT

rrilll
ACC

m
B

GV/R

HOOD

h:l

L/R

OPEN

CLOSEO-----

OOOA
SWITCH

~~5~ER'S

,..,
B

B
~

~:

fffiW

Y/e

SMART
ENTRANCE
CONTROL
UNIT

L/R

HOOD

OPEN

Y/B

$----------------$

GY/R (@

EL-THEFT-06

----_....-=.:S...;.,.,...._~

-G> To

IGN

ODOR SW
DODA SW
-......";G;..,.,N""'D:--_ _.;:(DR~)---------~(P,,..:.A.,:;:S~S.:-)

~E~~~~CH
OPEN

CLOSEO---'

SWITCH

CLOSEO---

SIDE

8
~

@) :l
Refer to last page
(Foldout pagel.

EL-223

,<

THEFT WARNING SYSTEM

Wiring Diagram - THEFT -

(Cont'd)

EL-THEFT-02
St-lART

ENTRANCE

TRUNK KEY

POSITION

CYL . ..;:.S~W._ _"...:S~Wo-.-:-

I~

G/B

--;(c=.:0R~)r.--

GIB

y/G

Y/L~

V/L

_-----'.l./I....::r44'--1.'II_-,OOOA LOCK
ACTUATOR
DRII/ER'S
SIDE
UNLOCKED (DOOR

GIB
R
~ ~ ~
lCiJ~
i(jjll
GIB
R

fI

-----

.....

4
r--_.:t--T...L-_ _ , DOOR LOCK

ACTUATOR
PASSENGER
SlOE
(DOOR

UNLOCK

~-

CID

UNLOCK

SENSOR)

SENSOA)

~4lli)

CONTROL

POSITION
UNIT
_~(Pr.A~SSt:-=J _ _~ <t@l

Y!G CQI)

~~_:_-*
GIS (]D

DOOR LOCK

OOOR LOCK

TRUNK

lI[g)

C@

rep ~
8

GIB

liJ

rRUNK KEY

CYLINDER

TRUNK

SWITCH

(UNLOCK
SWITCH)

GID

CLos4
OPEN

ROOt-!
LAMP
SWITCH

(@

..._--------.II

.-.
!- !-

~
@

CBD

<E@

~
CQI) @QD ~ @) ~
~ <ill> @}?)
~ W ' w D..lI.ITJ W' W
ttgj GY GY

Refer tQ last page

(Foldout (lllge) .

~,GID
~

Sf' 7,'fiT

EL-224

THEFT WARNING SYSTEM

Wiring Diagram - THEFT -

(Cont'd)

EL-THEFT-03
TAMPER
SW

-I- - --- I
Y

LG/R

G/V

LG/R

G/V

Iv

~-l:-----$-- ----$

BETWEEN

BETWEEN

.'

AND N

BETWEEN
FULL

FULL

FULL

STROKE

~~~

FULL
STROKE

STROI<E
FULL

KEY
CYLINDER
WITHDRAWN

STROKE

UNLOCK SW '--

,,'

AND N

......
FULL

STROKE

....

NORMAL

--- ......

FULL

STROKE

----; TAMPER Slot

DOOR KEY CYLINDER

SWITCH DRIVER'S SIDE
lID])

DOOR KEY CYLINDER

SWITCH PASSENGER SIoe

,L@)
1m,

,L@QD

Imr

IUi?\

'"r'Ciliv

T~

.....------------.

(@

~CQD@W~@)
~

w w

u.::I...IJITJ

rfF2\@@ll)
~GY'GV

Refer to lollst page

(Foldout Dace)

(J

"

1"'\ '; ~\

SH /TIT

EL-225

THEFT WARNING SYSTEM

Wiring Diagram - THEFT -

BATTERY

~j

~-=-~7.5A
LtJ~ Q-Jffi]
GIS

Refer- to

10A

em

G/R

$'

----~I
I I I

GIS G/R G/R

1[~!Infl
I] I]
~~~Y

If 3 II II 6 II Iff J! WARNING

EL-PO~ER

(fill)

Irl

~ ~

EL-THEFT-OL1

...,

l4J1 ern

rm~4 REMOTE
MULTI-

~ ~ ~

I!.iJl

ll-I-I OR

G/B G/Y

OR

$IG iffiQ>

HOl=lN
(LOW)

V/G

G/W

HORN

(HIGH)

-=-

THEFT

WARNING

PANIC

OUTPUT

To EL-TUAN

GIY~} Next

G/8

page

OR @D

~
OR lHID
I

OA

SMART

FLASHER
OUTPUT

ENTRANCE
CONTROL

HOAN

UNIT

u::D

lE
FIe fer to last page
(Foldout Doge) _

5 7
35

1l

1 1----..

~--

ii
QJ QJ &

2~~1~~

LG/B

Y/G ~

To EL-TUJ:lN

MULTIREMOTE

. . ._ _

,m m IT1il

~~ ~] ~~~x~~

G/w Y/G

(Cont'd)

CIT> <IllfD
SR'SR

@,lillD

lHW,J
~

Sfll7BT

EL-226

THEFT WARNING SYSTEM

Wiring Diagram - THEFT -

(Cont'd)

EL-THEFT-05

-i--r --1--i-i1
TO EL- TURN {

PrecedIllg
{ ; GIV
page

G/Y

G/Y

aD

G/Y

GIB

GIB

GIB -

G/Y @

GIS

I._--.,1

GIB

G/Y

FRONT
TI..JAt,I
SIGNAL
LAMP Rli

~ rn

~1
~

rm
G/S

AEAR

lillD

G/8

~9

COMBI-

~7 E'i~AL ~:r
~

GIB lHID

GIS G/8 @

L ~I
-,

Ii I 1
G/v

1
1

G/v

RH

GIV
: cl.Y

G/'i

rn

TURN
SIGNAL

~~y

,<80 :: ~

G/8

GiS

SIDE
TURN
SrGNAL
LAMP AH

lffi)

t,

@) QID)

FRONT
TURN
SIGNAL
LAMP LH

~m
B

SIDE
TURN
SIGNAL
LAMP LH

ill)

REAR

~~~~6N
~ ~~~6N
LAMP RH
LA!4=' lH
(TURN
SIGNAL) J!4!l SIGNAL)
(T~N

1
B

B
~
~

y..

. ---.
B

...

!-

!-

ern>
V.r:'
Refer to last page
/Foldout pagel.

@Q),OO
~~~ffi

~ BR SA ' GY G'i

@.@

@,

SR179T

EL-227

r.
I"~

THEFT WARNING SYSTEM

Wiring Diagram - THEFT -

(Cont'd)

EL-THEFT-06
30A ] Refer tD

EL-PDWER

[6]
DR/G

i~~i=Ol ~

rm

-.-----1

ST

OFF IGNITION

....

"ON

*
G

Ace /
-~/

SWITCH
~

~IIR:G~ ~
~6~Y

(];):
A/T mode1s
:
MIT models

THEFT
WAANING
o~ RELAY
I
~"""!2,..,.,...-----;r~-7"l4 (ill

LG

-.N

INHIBITOA
SWITCH

~:

0 .. 1
R
.... 2
L.....--l.------1[D1 B/W

R4Jl@

B/W m
~
B/W <@

B/R

SECLJnTV

It-IJ]CATOR
LAMP

G/OR

...

8/'101

rn

G/OR

LG

rrTI=il

INDICATOR
OUTPUT

B/W

4>~A~----OA:--'

DR/G

lH

LG lflQl)

$LG

I f ! " ' @ B/R.

STARTER
CUT
OUTPUT

SMART

ENTRANCE
CONTROL
UNIT

<fill)

BATTERY

Refe,... to lost page

(Foldout page) .

:@B@):

: ill

SEliBOT

EL-228

THEFT WARNING SYSTEM

Input/Output Operation Signal
SMART ENTRANCE CONTROL UNIT
Terminal
No

--I-

Power source (CIB)

Multi-remote conlrol
relays 1 and 2

Thell warnIng horn relay

When panic alarm

IS

._ ... _- -

IS

Ground

11

Ignition sWitch (ON)

Driver door unlock sensor

le-:;5
-_.~-,

--

Unlocked

13

Passenger door unlock

sensor

Passenger door' Locked .... Unlocked

15

Driver door SWitch

OFF (Closed) . ON (Open)

OFF (Closed)

Passel'lger door switch

19l"lilion swilch (ACe)

"Ace"

26

Trunk room lamp switch

ON (Open)

---+

4 5V or
less

-----12V

..

- - - - - ---

..

-------------

...
12V

ON (Open)
.-------

or "ON"" position
-0

OFF (Neulral)

28

Door key cylinders lamper OFF

switch

29

Hood switch

30

Door key cylinder lock

switch

OFF (Neulra l ) -. ON (Locked)

31

Door key cylinder unlock

switch

OFF (NeUlral) _. ON (Unlocked)

32

Theft warning relay

(Slarter cut)

OFF --. ON

33

Security indicator

Goes ofl

15Vor
less
-_.

12V
12V

OV

4.SV or more
.OV

ON (Unlocked)

Trunk key cylinder swilch

.45Vor
less

- -

OFF (Closed)

27

4 SV or
less

-<

12V
~~

-----

16

I,

._-

12V
,2V
.-

--

IV or
less

12V

operated.

.--+

IV or

12V

operaled

"ON" or "STARr' posilion

Driver door: Locked

\,,;~

12V

- --

When panic alarm

- - -- - -

10

12

Voltage (VI
(Approximate
valuesl

Opera\ed condition

Connecl,ons

-_.~--

4.5V or more
- OV

ON

ON (Open)

OFF (Closed)
-- --

-.

OV . 45V or
more
-----

4.5V or more
OV
45V or more
OV
12V

OV

12V

.OV

----+

IIlumlnales

{J

I: ~'.

III
:'. I
~

El-229

THEFT WARNJNG SYSTEM

Trouble Diagnoses
SYSTEM OPERATION CHECK
1he system operation is canceled by turning ignition switch to "Ace" at any step in the following:

A step between START and ARMED, or

In the ARMED phase

In

the followirlg flow charI,

r_

s_r_ArR_T

\ CIDse all doors, hood and trunk lid.

Turn IgnitJon switch "OFF" and pull oul key from
\ cylinder

~ey

INDICA TOR LAMP CIRCUIT CHECK

Go to Diagnoslic Procedure;> (EL-238),

ON"

Does "SECURITY' indicator lamp remain "01=1="?

No

Does "SECURITY" 'ndicator lamp remain "ON" or

blinking?

Yes

Blmking

DOOR SWITCH INPUT SIG~AL CHECK

Go 10 DiaQnoslic Procedun: 1-( 1) (EL23~)
HOOD SWITCH INPUT SIGI\:Al CHECK
Go \0 Oiagnosllc Procedure 1-(2) (EL235),
TRUNK ROOM LAMP SWITCH INPUT SIGNAL CHECK
Go 10 Diagnostic Pmcedurp. 1-/3l In -236J
KEY CYLINDER TAMPER SWITCH INPUT SIGNAL
CHECK
Go to D'agnost'c Procedure '-(4) (El-237j

Does "SECURITY" indicalor lamp blink every second

when
DOOR SWITCH INPUT SIGNAL CHECK
30 to Diagnostic Procedure 1-(1) (EL-234),

each door,s opened?

hood

IS

\-lOaD SWITCH INPUT SIGNAL CHECK

Go 10 D,agnostlc Procedure '-(2/ (El._-2_J_5_
J.

opened?

TRUNK AOOM LAMP SWITCH INPUT SIGNAL CHECI<

Go \0 Diagnostic Prccedure 1-(3) (EL-236).

Irunk lid is opened?

SIG~';l~

-~-------------

~YLlNDER

key l.ylifH.J'" Is wltharawn';

No ._-[KEY
TAMPER SWITCH INPUT
CHECK
Go to D,agnosllc Procedure 1-(4) (El-ni),
-

,,-

-- --

._"

."

all doors, hood and trunk I,d are opened, and key cyl'nder '5 withdrawn?
No

POWER SUPPL Y AND GROUND CIRCUIT CHECK (EL233}

INDICA 1OH LAM!' (,;JfiCUII CHECK

Go to Diagnostic P'oc~dure 2 (El-238)

Yes
}.,

(Go to rle'xl page)

El-230

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

T===
~:

~ .,'Mo'k""

L---~--l

CIJse all doals, hood Jnd trunk lid Inslalll<ey c : J I ' "
dcr,; properly

._-_.

-----

1...,
No

Does "SECURITY" IndIcator lamp turn on}

DOOR UNLOCK SENSOR INPUT SIGN.AL

=-:JHECK
co,-.

Go to DiagnostiC Procedure 3 (EL-239).

Yes

------------

Unlock and open a door wiln'n 30 seconds while Ind,-

cator lamp is on

Close all doors and lock uSII"g key or

controller

mUI11~1~1

---.-J

':Ii

Does indicator lamp 'urn on'>

_D_O_O_Fl
LO_C_K_S_W_IT_C_H_'N_P_U_T_S_'G_N_A_L_C.H
E_C_K
Go to __
Diagnostic
Procedure 4 (EL240), _ _
Yes

]_

After about 30 seconds. does indicator lamp starl 10

t/ll1k ellery 2 -4 second?

Does alarm (horn and ha2.ard warning lamp) operate?

Nc

rom '9 0 ; " , "

ALARM OUTPUT :SIGNAL CHECK

Go 10 Diagnostic Procedure 5 (E~~.

Yes

,.,te'" .STAAT .,(h k., o~~ y" ~ STARTER aUPUT "GN" CHECK
~-

engine star\'>

No

,~,

(Go to

ne~t

page)

EL-231

------J

Go 10 Diagnosllc Procedure 6 (EL243)

-----. ----_.-. - - -

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)
'1)

_ _L_ _
LO. ck and unlock door(s) and/or trunk lid uSing key or
multi-remote conlroller
_

I'

DOOR/TRUNK LID UNLOCK SWITCH INPUT SIGNAL

No

Does alarm slop?

CHECK
Go to DiagnostiC Procedure 7 (EL-244) and 8 (EL-245)

Yes

Turn 'gnltion switch to "START', Does the engine

STARTER OUTPUT SIGNAL CHECK
Go to Diagnostic Procedure 6 (EL-243)

start'

~--

Yes
Close all doors, hood and trunk. lid, Lock doors witt1
~ey

Or mulli-remote controller,

_ _ _ _ _ _ _ _ . _ _ ----,

----.J

every~~-;;~~~~~-.J

After indicator lamp slarts to blink

unlock a door without key or multi-remote conlroller

-----~---

Does alarm stop automatically after approx. 2.5 mm-

No

utes?

Replace control urHt

Yes
Turn Ignillon sWllch to "START" Does the engine
start?
L . . . . . - - - - - - - - - r - - --

No

STARTER OUTPUT SIGNAL CHECK

Go to Diagnostic Procedure 6 (EL-243)

~---

....L

-----,

Lock. and unlock door(s) and/or trunk lid using key or

ITlulll-remote contrOller

Turn IgnitIon SWItch 10 "START" Does Ihe engine

slart?

STARTER OUTPUT SIGNAL CHECK

Go 10 Diagnostic Procedure 6 (EL-24J)

Yes

SyslerTI IS OK

EL-232

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)
POWER SUPPlV AND GROUND CIRCUIT CHECK
Smart enlrance control unll connector

Main power supply circuit check

II CIU CONNECTOR 10

Ignition switch position

~i5~-b

Terminals

OFF

ON

Battery voltage

Battery vDltage

",1"

SEL36tTA

Power supply circuit check for system cancel

Smart entrance control unit connector @D

II CIU CONNECTOR 100 ~

L'LaJ1'OB is

Ignition switch posilion

Terminals

OFF
@.,fil)

ov

ACe
Ballery voltage

.1

ON
Battery \lol/age

[Y]
+

SEL362TA

Ground circLli. check

Smarl entrance conlrol unit connector @D

l~NNECT~~r::::] ~

___

~minaI5 _ _~I--<@ . Ground

ruJ~

=::=J

c_o_n_ti_n_ui_tY

Yes

sEL36HA

r l .-'

(~

'"

EL-233

i,

,.

THEFT WARNING SYSTEM

Trouble DIagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 1
Smart entrance control Llnll connector

SYMPTOM: Indicator lamp does not blink or

Indicator lamp remains blinking every second.

lieN CONNECTORJD] ~

Diagnostic procedure 1-(1)

.;' ~

""H""

ll19-

.. _ - - - -

DOOR SWITCH INPUT SIGNAL CHECK

Check cOrltinuity between control unit
harness terminals ,,-,\ or "1) and @

SEU64r~

C"nl,nu'l, belween

Condilion

1m

SmA" anlrance control unit connec1or

II CiU CONNECTOR
1516

10[:] l..m
~ ~A
W;;v

.;f~'a~

Driver side door is

closed

No

O"ve. Side door

opened,

Ya"

lI~

GY/FI

IS

Continuity belween
'.'~ and 1\1)

CDndll,on

Pass~nQ~(

side
doo' switch
connector

-.-

Passenger side door

IS

No

<:lased

Passenger Side door

Yes

IS (lpe~ed

r[][I

Orlver side
door switch
connector @
aVJA

NG

~c'

NG I~':;---

~ .~ace door SWitch

DODO SWITCH CHECK

~~IO

naJ'

OK

,---IE'I

SEU551P<1

~_. Smart entrance conlrol unit conne=.~

~~-JI8

_=r_

DOOR SWITCH CIRCUIT CHECK

Check harness continuity between
control unit harness terminal !11' or
f!! and door SWitch harness 1~"11lnai
Check harness continuity between
driver Side door SWitch harness ter
manal ,11 and body ground.
Conlinullv should exist.

NG

nepair harness or connectors

OK

Door SWitch

Oriver Side ~. Pa!lsef1ger side:@D

~~

i5

S"1:l944T

Refer to "Electrical CC'mponenls

Inspection" IL245)

Check harness contlnully belwc~n door

switch harness terminal and t.Ddy
ground,
(Before checking harness COrltmulty,
control unil harness connector should
be dl'iconne<:ted )
ConUnolly should nol exist

,------E--CON~iECTIONS

'---C-H-E-C-K-THE
CONNECTOR

__

EL-234

NG

Repair harness
(Short CI rcuit exists
between control urlit ha. r
ness lermillal @ or @
anli door switch harness
letnllnals)

-- -

--- - - - - - - _ . _ -

AT EACH]
0_-

__

J.

----------l

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

mSma"

entrance conlrolun't conneclor

[I eM C~9NNECTOR IOJ ~

LtJ

'C

Y18

rQJ

Diagnostic procedure 1-(2)

t~~~~~~~tiC pr~;e-J-

tI'WDOo""

HOOD SWITCH INPUT SIGNAL CHECK

Go

dure 2 (EL-23B)

C!',eck continuity between control unil

harness termmals @ and @

10
~

Cond,non

Cont"'u,ty

op~n

Ye,

HOOd IS

Hooo ,s closed

--

,--

---- -

No

SEL366TA

NG
,----

Smart entrance control

un,t connector @

.L-

Check hood SWitch and hoed IItlll1g con-

NO

dition

11..'=:~~~u=C=ON=N=EC=T=oR~IO~Ib---_111 ~

Adjust Irlstallalion of
I hood SWitch or hood

OK

18

HOOD SWITCH CHECK

Refer 10 'Eler.lncal Components

Inspection' (E L-246)

OK
\'1

NG

HOOD SWITCH CIRCUIT CHECK

(I'

con-

neclo'~

Check Ilarness continuity between

conlrol Unit harness terminal

Repair harness

@ and

hood switch harness terminal '~iJ

Check harness cont'nUlty between

hood switch terminal

CD

and body

ground
Continuity should e.I!!.I.

-1K"--

I!I

Smart entrance conlrol unit connector @

01 1"'0

dIb

i5

~_

[!J__ ,

II CIU CONNECTOR 10

Chec~ harness continuity between hood

Hood switch
connector @

Y,'ll

between conlro! un,t

(Betore check,ng harness continUity,

ness terminal @' and

control unit harness connector should

hood SWitch harness

be disconnected_l

minal

-- -

SELJ73T4

e~lsts

ground

------J~-

Repair harness
{Short clrcu,1

Contlnuily should not eJlst.

L-

NG

sWitch harness terminal @ and body

CHECK THE CONNECTIONS A::JEACH

CONNECTOR

._------_.---

EL-235

----

(~_~

~'ar

IN'

_~ ;,,:.~

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

I ~CTO~I~
1

Diagnostic procedure 1-(3)

Sman entrance control unll conneclor

,I

., is

26

'0

LB-J

""~",,I

.-

------

TRUNK ROOM LAMP SWITCH INPUTjOK

SIGNAL CHECK
Check voltage between control unl! har-

..,----

-_.-

Go to O'agnostic Proce(jure

2_(_E_L-~_3~~_

ness term in a Is -~ and @),

Condition

Trunk lid 's open_

Voltage
ApprOt OV

Trunk lid is closed,

Appro, '2V

NG
Smal'1 entrance l;'Onlrol
unll conneclor

I!C~CONNECTOPJO ~

TRUNK ROOM LAMP SWITCH CHECKJNG

ReIer to "Elec/rical Componenls

Inspect,of'1' (EL-246)

_JOK

~Cr

18
Trunk room lamp
sWllch connecior

QD

TRUNK ROOM LA M p:....S-W-'T-C-H-C-I-R-C-U-IT-------,' NG

Repair harness or con-

CHECK

neClors

Check harness conllf'1uily belween

conlrol unit harness terminal

,f!:-

and

lrunk room lamp SWitch harness terminal

rD-

Check harness continuity belween

trunk room lamp switch harness terminal @ and body ground

~SELJ69ll..

C!I

Smart entrance CDllliO! unit connector

II CIU CONNECTOR IO[

~

La

I,I

10

~ Trunk room lamp

switchQD

llIS(()IOj(c!

18

ConUl'luUy should exist.

OK

I_

,-C!l

Check harness continuily between lrunk

Repair harness
(Shorl circuit exists

and body ground

between control unit har-

(Before checking harness conllnuity.

ness terminal @ and

control unit harness connector should

trunk (Dom lamp 5Wltch

be disconnected)

harness lermm~1

e: ---

Continuity st\ou/d not exist.

~SE1374T A

NG

room lamp Switch harness terminal ,j)

1Z~-E-c-K-TH-E-C-O-N-N-ECTIONs

~ONNECTOR

EL-236

AT

E~

_~

(i) )

J
_

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)
Diagnostic procedure 1-(4)

'
W
Smart entrance control
unit connector @

II CI\J CONNECTOR
y2

lonl ~
."~

INPUT SIGNAL CHECK

Check continuity between control urnl
harness terminals @ and

'!
Conli~u,ty

Condition
Tamper switch is

[ID

OK

I KEY CYLINDER TAMPER SWITCH-

Normal

Na

Removed

Yes

[Example)

NG

~Key cylinder
KEY CYLINDER TAMPER SWITCH

Tamper switch

y~

NG

Replace door key cylinder switch

CHECK

ReIer to "Electrical Components

Inspection" {EL-247)

No continuity.

OK

OK

[Example]
,---

...J

KEY CYLINDER TAMPER SWITCH CIR-

,---------

NG

I:ontrol unit harness terminal @ and

door key cylinder switch harness terminal @_
Check harness continuity between

door key cylinder SWItch terminal @

and body ground

OK

Continuityexisls

Conllnulty should extsi.

SEL37QTA

II ~ CONNECTOR

OK

Smart entrance control

unit connector ~

(Ne~1

'CII [iI

iO

Door key cylinder

switch connectors
Driver side,

~".~
II

'.~~

Check harness GonlinUlty between

Aeact switch tums on when

'0' oooJ

nectors

CUlT CHECK

key cylinder is removed.

---

Rep", h,mm

SF'37HA

EL-237

page)

[!J

Smart enlr9nce control unl' connector @

i5

[W?ONNECTDA:rr~1
I'F\
\ID

O<I/DHO

&)

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

Door key cylinder

F'--------------'-------------,

switch conneclors
Onver s,,~e, ()
Passenger s,de @lD

~OK
SELJ75fA

[J ~NNECTOR 101

'0 I]

G~AI

B'!

ULJ~

SYMPTOM: Indicator lamp does not blink or

Indicator lamp remains "ON".

Smart entrance control unit connector @

~ [I CIU CONNECTOR
33

GIOR

roD
GiOA

frj

~io

NG

INDICATOR LAMP CIRC.UIT CHECK

Check harness continuity between control un,! harness term,n.. 1 @ and indicalor tamp harness terminal ,j)
Conllnulty should nisI.

rn

Smart entrance conlrol unit conneclor @

It&CONNECTORIO[:J]

16

Secuflty Indicator

l,m~M:('l~'~~

Ll1_LEU

Repair harness or connectors.

!OK

[!1

----_.-

NG

Chack voltage between indicator lamp

harness terminal al and body ground
Ballery voltage should elels!.

EU

Replace indicator lamp

0K

SEL37TTA

Security indicator
lamp connector @

Replace control unit

!NG
CHECK INDiCATOR LAMP.

Security indicator
lamp connector

INDICATOR LAMP OUTPUT SIGNAL

CHECK
Check voltage between control unit har
ness terminals ~ and @
Battery voltage 'Should exist.

SELJ75fA

II

DIAGNOSTIC PROCEDURE 2

18

Repair harness.
(Shorl circuit exists
between control unit har
ness terminal @ and
door key cylinder switch
lerminal @).)

-_.-

IGHECK THE CONNECTIONS AT EACH

I CONNECTOR

Smal1 enlran~ control unit connoc1or @

NG

f--------+

Check harness continuity between door

kl";y cylinder switch harness terminal riJ
and body ground.
(Before checking harness contrnulty,
control un it harness connector should
be disconnected)
Continuity should nol ells\.

'lectors

!OK

Ii]

-NG

Check harness continully belween indicator lamp harness terminal CD and

body ground
(Before checking harness continuity.
control unit harness connector should
be disconnected.)
Continuity should nol exist.
!OK
CHECK THE CONNECTIONS AT EACH
CONNECTOR

~
Replace (;onlrol unil

i5
SEl119TA

El-238

r -~epa-'~~ness o;~

_J

RepaIr harness.
(Short cllcull e~ists
between control unil har
ness lermlnal @ and
InOlcator lamp harness
lermlnad W)

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

'W

DIAGNOSTIC PROCEDURE 3
SYMPTOM: Indicator lamp does nol come on.

Smart enlrance oomfol unit connector @

I~~
Z
'

V.Q

''(I\.

[ill

10"~,
~
~

It
'(0(;

Condition
Driver sIde door IS loCked
Driver s'de door '5 unlocked

\",'1,'

Cont,nu".,.
bet",eell
@ and ,.iii)
No

t:M=--_.

I,

~"

Condlt,Dn

l Err\l
J : j 1 \ . Door lock actuator
'(I\.

;';;''''-J

OK

harness termInals @ or 6Jj all(] ~m..

1 0 t..m
~~
W;;v

LRJ

dure 2 (EL238)

Check conlinuity between control urlll

Smart entrance control unit conneclor @

'2 \3

Go 10 Oi.goo,li,

NAL CHECK

SEL'18QTA

CJU CONNECTOR

DOOR UNLOCK SENSOR INPUT SIG,

'

I!I

passenger side
connector @E)

Passenger SlelB dOOl IS locked,

Passenger s.oe door is
unlocked,

1Foll' ~i5
1nLElJB

Contlnultv
between
and
No

II

Yes

lNG

DOOR UNLOCK SENSOR CHECK

R,pl."

Refer to "Electrical Components

Door lock actuator

driver sIde
connector @D

Replace control unit

tor.

d". lock

":=

'/,'1:

Inspection" (EL-247).

iii

~"0:::J

DOOR UNLOCK SENSOR CIRCUIT

IJ~'

nectors

CHECK
Check harness continuity belween
control unit harness terminal ~~ or

SElla,fA.

f~ and door actuator terminal I}lJ

[!]

Check harness continuity between

Smarl entrance control un,t connector @

II CJU CONNECTOR 10=

~ffiJes1
",'" "Oo'W

passeng~'

sIde

connactor

@ and body ground.

Conllnully shoutd exIst.
--

Door lock actualor

driller side
connector @D

~,

door lock actuator harness terminal

10

[Q]

,--[!J

l_OK

_
NG

Check harness continuity between door

(Short circuit eXists

body ground.
(Before checking harness continuity,

ness terminal @ or r!J)

be\ween control unit tlar-

control unit harness connector should

and door lock actuator

be disconnected)

harness terminal @ )

Conllnultv should '101 exist.

']OK -----.- .

-C-H-E-C-K-T-H-E CONNECTIONS ~

"'-1

Repair harness

lock actuator harness terminal C~ and

CONNECTOR

SEI J8H4

EL-239

~I

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 4
Smart entrance control un" connector

G/Y

101 ~

JOW'O

/1 CIU CONNECTOR

SYMPTOM: Indicator lamp does not come on.

[ill

DOOR LOCK SWITCH INPUT SIGNAL

CHECK (LOCK SIGNAL)
Check continui ty between control unit
harness terminals @l and @.

<DH:cr

OK

j----_ _~

_ _ _I;;ey POslt'o_n
Neutral/lock

Continuity e)(iSIS~N~utral

Replace control unit,

Between neulfal and lock

Lock,""-:

~
~

NG

LH side

Neut,rai/Continully eXiJSS
~,Lock

DOOR LOCK SWITCH CHECK

Refer to "Electrical Components
InspectIOn" (EL247).

.------_TK.-. -~_I
Ii]

AH side
SELJ8JTA

____
-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-

DOOR LOCK SWITCH CIRCUIT CHECK

@]

Check harness continUity between

control unil harness terminal @ and
door key cylinder switch terminal
Check harness continuity between

Sma" entrance control unit connector @

11~i5
Door key cylinder
SWItch connector

OlY

i5 Gj tTh ~:~er

passenger'

lllY

side

()

eY cylinder SWitch terminal and body

NG

Repair harness
(Short circuit ex,sls
between control unit har-

(Belore ched I ng harness conti nuily.

ness terminal @) and

conlrol uno! harness connector should

door key cylinder switch

be d,sconnecled )

terminal)

Continuity shOUld nol exist.

1:_

,----------CHECK THE CONNECTIONS AT EACH

SELJil4TA

CN CONNECTOR

CONNECTOR

10 ,6

Smart entrance control unit connec,or

11

OK

ground

I.Q

\JY \:::IV

[!)

ConlLnully sl\ould exIst.

I Check harness continuity between door

Drover ~ ~ Passenger ~
Side
sode

1
81 8

Door key cylinder

sw,'ch connaclor

Repa,r harness or connectors.

body ground,

'OrY

~"4 j

[ill

do,,, k,y ,yhod" 'wit,h ",moo.' .ed

NG

Door key cylinder sWltch COMaClor

~~

(ifj

MJ
r;;;\] Of'(

LJL

ETh~,~~e<~
1C

pilssenger
Side

____ .

~-

'0ISC0IH<:r
r;;/v
~
1
-':0
__ .'
SEL3B5TA

EL-240

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

DIAGNOSTIC PROCEDURE 5
SYMPTOM: Alarm does not operate.

Smar1 entrance control uni! connector @

II ClU CONNECT~

~C'

ALARM SIGNAL OUTPUT CHECK

Check voltage between control unit harness terminals and @

10

~~~

l~

""""

Condllion
E~cept alarm phlne
I

Alarm P_h_3_se

NG

,~~~

f-------

Voltage
ApprQ" 12V
Voltage II uctua le~
..L...
between 12V anI:! rN _

CHECK THE FOLLOWING

.. Harness continuity
between control unit
harness lerminal
and thefl warning horn
relay harness terminal

lelWl

.. Harness continully
between fuse and lhell
warning horn relay harness terminal CD
Harness continuity
between conlrol unit
harness lermlnal @
and horn relay harness
termillal G)
Harness contmuity
between 'use and horn
relay harness terminal

OK

:\IjJ~

Lt
~~
I~[~

@.

~iD

Then warning
hom relay connector

1llif

~i5

(El2481,

Theft Waffling
hom connector

~@)

'~~

Hom connector
G

.. Theft warning horn

relay,
Refer to "Electrical
Components Inspection"

~@)
l~J@!)

SEL900T

!Cll

~n

!Ol<
HORN CIRCUIT CHECK
Check vollage between (hell warning
horn relay harness terminal @ and
body ground, terminal and body
ground
Battery Yoltage lIIt10uld ellist.
Check harness continuity between
theft warning hor(l relay harness terminals @, (~ and horn harness terminals.
Conllnu/l)' &t\ould &1l1'1.

OK

+NG
Repair harnes~
connectors ~

HORN CHECK
Refer to "Electrical Components
[ Inspection" (El-247)
.

- , -_ _--l

.t

NG

0K

Replace

horn~

GHEFT WARNING HORN RELAY CHECK I

Refer to "Electrical Components
Inspection" (EL-246)
~

~K

(Next page)

EL-241

+NG
E e r e l ay

ALARM SIGNAL INPUT

CHECK
Door switch circuit
Refer to Diagnostic Procedure 1-(1) (EL-234)
Hood switch circuit
Refer to Diagnostic Procedure 1-(2) (EL-235).
.. Trunk room lamp switch
cirCUit
Refer to DLagnosllc Procedure 1-(3) (El-2J6)
.. Key cylinder tamper
switch cirCUit
Refer to Diagnostic Procedure 1-(4) (EL-237).
Door unlock sensor cirCUit
Rpler to Diagnos1ic Procedure 3 (El-239),

\1
'~}Dl

~/!:"

f,il&
~~

:~

~~

0K
1

~~~~~nlt

-J

'~\r

1M

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

r!1

FLASHER OUTPUT CHECK

Check vollage between control unit harneS5 terminals (J) and @
Condition
alarm phase

Voltage
Appro~

E~l:ept

Alarm phase

SV relay-1

connector <E>

00

o!.~
~i5

Multirernole conlt<ll
relay-l connecto r @

Bff

~i5

Rear combination
lamp LH connector@)

~iO

diBJ

FrCllt Mn signal lamp

LH cDMector@

GIB

~~~~~:~~~(@)pcfD

~i5

~ir5

Multi-remote control
Rear combination
relay-1 connector@]) lamp RH connector

1[f

,?V

Voltage tluctuales
belween I?V and OV

OK

Ol5.~O'l"EC'

~ ~ Mum-remote control

l..Im

NG

~-

~i5
Front turn sIgna/lamp
RH connector@

HAZARD WARNING LAMP CIRCUIT

CHECK
Check voltage between multi-remole
control relay-1 harness terminalS .
@ and body ground.
8aUery voltage should exIst
Check harness continuity between
multi-remote control relay-1 harness
terminal (J) and rear combination
lamp LH harness terminal @.
Check ha.rness continuity between
multi-remole control relay-' harness
terminal (J) and rrontlslde turn signal lamp LH harness terminal CD
Check harness contmlJlty between
multi-remote contrDI relay-' harness
terminal @ and rear combinatIon
lamp RH harness terminal @.
Check harness continuity between
mu lIi-remOle control rei ay-1 harness
lerminal and rront/side lurn signal lamp AH harness terminal CD
Continuity should ellist.

Does hazard warning lamp come on

when pushing hazard warning lamp
switch?
Yes

_____________

SEUI04T I

--

MuJli-'emote control
relay-1
Reter tD "Electrlcal
Components
Inspection" (EL-248).
I

:~ Repal( harness or connectors

OK

Gf'(

~I~ecb~~e~~~~mpdD

CHECK THE FOLlOWING.

Harness contil"lulty
between control unll
harness terminal (j)
and multi-remole control relay-1 harness
terminal @
Harness continuity
belwe':!" fuse and
mull;-remote control
relay-' harness terminal CD
Harness cont,nuity
between conlrol unit
harness terminal (J)
and multi-remote control relay-l harness
terminal CD
Harness continuity
between fuse and
multi-remole control
re\ay-1 harness lerminal iJ)

No

f-------...

Check turn signal lamp

system
Refer to TURN SIGNAL
LAMP" (EL-93)

l. CHECK THE CONNECTIONS AT EACH

CONNECTOR.

~.-

E.L.-2.4_2. .

l.

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

lW

DIAGNOSTIC PROCEDURE 6

Smart enlranca control unit connector @

~ECroAJ1
2

Lll

II

IO~
E)
~

SYMPTOM; _ STARTER MOTOR can be operated. (Starter

killed phase) or
- STARTER MOTOR cannot be operated after the
theft warning system is deaclivated.

NG

STARTER MOTOR KILL OUTPUT 51G-

CHECK THE FOLLOw-

f--

NAL CHECK

ING.

Check voltage between control unit har-

Harness conlinuity
between control unit

ness terminals @ and @

LL.

harness terminal @

Co~dlhon

Voltage

Slaner kIlled
phase
Starter k,lled phase

E~cept

and theft warning relay

Approx. 12V

harness termlllal @

OV

Harness continuity
between theft warning
relay

OK

CD

~arr.ess

terminal

and fuse

Theil warning relay

ReIer to "Electncal
Components
~
Inspection" (EL-248)

OK

--~

~,

THEFT WARNING RELAY CHECK

II

Refer to "Elect"c<l1 Components

Inspecllon' (EL-248)

OK

Replace relay

CHECK 'HE CONNECTIONS AT

EAC~

CONNECTOR.
----.J

EL-243

Replace cOl1trol unit.

_I

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

'
LJ

DIAGNOSTIC PROCEDURE 7
SYMPTOM: Alarm does not stop even if slop signal Is given.

Smart entrance control unit connector @

1100 CONNECTOR
LOlA

lei ~

10

CHECK (UNLOCK SIGNAL)

Check continuity between control unit
harness terminals @ and @.

rnJ

Neut,'al/ ContinUity

DOOR UNLOCK SWITCH CHECK

~
AH side

Ii)
SEL390TA

[g

Smar1 entrance control unit connector@

II 00 ~,NNECTOR

lor::::::J ~ i5
Door key cylinder
switch connector

L<lIA

10 Eb

Effj ~i::r

Passenger

'LU/A

LG/R

side

@ill)

--

DOOR UNLOCK SWITCH CIRCUIT

CHECK

Repair harness or connectars,

Check harness continuity between

control unit harness terminal @ and
door key cylinder switch terminal.
Check harness continuity between
door key cylinder switch terminal and
body ground.
Continuity should ellist.

[!]

Door key cylinder

switch connector

Go to Diagnostic Procedure 5, (EL-241).

Replace key cylinder

switch.

Refer to "Electrical Components

Inspection"' (EL-247).

Unlock ' 0

ALARM OUTPUT SIGNAL

CHECK

lNG
LH side
~ N~utral

~-

I Cont,nuoty
Key position
Neutral/Unlock
No
I
Yes
Between neutral and unlock I

e~is!s

~U"'OC"

Continuity exists

OK
~

DOOR UNLOCK SWITCH INPUT SIGNAL

Check harness conlinuity between door

key cylinder switch terminal and body

NG

'-----

ground.
(Before checking harness continuity,
control unit harness connector should
be disconnected.)

Repair harness.
(Short circuit exists
between control unit harness terminal @ and
door key cylinder switch
terminal)

Conllnultv should nol elllst.

0K

SEL391TA

l!J

Smart entrance control unit connector

II CIU CONNECTOR IOJ::]

CHECK THE CONNECTIONS AT EACH

CONNECTOR.

iO

Door key cylinder switch connector

i5 ElJ
Passenger
SIde

[ill

@D

Effj~~~er~

LG/A' LGIA
I

'"
O

t:OCSlXH<E

SELJ92TA

EL-244

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)

Smar1 entrance oontrol unit conneclor @

II C!U C;>,NNECTOR

10]::;11 ~

M~i5
NeU/ravContinuilyexists

~'Unl~k

DIAGNOSTIC PROCEDURE 8
SYMPTOM: Alarm does not stop even If stop signal Is gIven.

m
TRUNK KEY CYLINDER SWITCH INPUT
SIGNAL CHECK (UNLOCK SIGNAL)
Check continuity between control unit
harness terminals @ and @.
Key position
Neutral/Unlock
Between neulral and unlock

SEl393TA

iii

Smart entrance control

un~ connector ~

II C~~ONNECTOACII

eJ

No

Yes

lNG
TRUNK KEY CYLINDER SWITCH CHECK
Refer to "Electrical Components
Inspection" (El-247).

~'i8

SEl905T

TRUNK KEY CYLINDER SWITCH CIR-

liJ

Smart entrance control unit connector @ij)

IlcN CONNECTORr~ ~

i5

Trunk key cylinder switch connector

~CID

ALARM OUTPUT SIGNAL

CHECK
Go 10 Diagnostic Proce
dure 5. (EL-241)

1 Continuity

Trunk key cytlndlll swilch connector

rmJ ~@

OK

f----

CUlT CHECK
Check harness continuity between
control unit harness terminal @ and
trunk key cylinder switch terminal

Replace trunk key cylinder switch.

Repair harness or connectors.

CD
Check harness continuily between
trunk key cylinder switch terminal @
and body ground.

18",_,

@]

Check harness continuity between trunk

key cylinder switch harness terminal

NG

\---+

CD and body ground.

(Before checking harness continuity,
control unit harness connector should
be disconnected.)
Conllnulty should nol exist

Repair harness.
(Short circuit exists
between control unit har
ness terminal @ and
trunk key cylinder SWItch
harness terminal CD )

0K

CHECK THE CONNECTIONS AT EACH

CONNECTOR.

II
EL-245

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)
ELECTRICAL COMPONENTS INSPECTION

!lIS<XNI<C'I

Door switcI\ driver

T~''''''''~

LaJ

Door switches
Check continuity between terminals when door switch is
pushed and released,
Terminal No,
Driver side:

Condition
Door switch is pushed

Continuity
No

(D-@
Passenger side:
(D . body ground

Door switch is

Yes

released.

~ ~ Door switch p9ssenger

llIIIIIIIIID,.;v

sid\! connector ~

SELJ96TA

Hood switch
Hood switch connector

Check continuity between terminals when hood switch is

pushed and released.

G1D~i5

Q)-@

Continuity

Hood switch is pUshed

No

Hood sWllch is
released

Yes

SELJ97TA

Trunk room lamp switch connec1or

~~i5

CCl'dltlon

Terminal No.

Trunk room lamp swilch

Check continuity between terminals when trunk lid is closed
and opened.
Terminal No.

(D-(?\

- __- - -

El-246

Condition

Continuity

Trunk lid is closed.

No

Trunk lid is opened.

Yes

..d.

Trouble Diagnoses (Conttd)

Key cylinder tamper switch, door lock switch and door
unlock switch

Door key cylinder switch

connector
Driver side

Passenger side

Terminal No,

r----------'!

Tamper
SlNllch

~ ~---i

iD

<V

Condition

@.@

Con\,m)'tv

Key cylmder is If\~talle6

No

KllY cylin6e' is removed

Yos

Key position i~ neutr al Dr

Door lock
switch

ooJ

<D'

Door key cylinder switch

Df/ver side' ~ -
Passenger side', (f) .

-,

Key posit,on .~ between

neulral end lOCk,

Key
Door
u-nlock
switch

No

lock,

C!>

(lOS Ilion

Yes

is neulrol Or

No

unlock

Driver s.de (D-@

Passenger aide (J}.(!)

K",y posH Ian is belwllen

neutral and unloc~,

Yes

Door lo"k switch terminal (Passengor side)

Door unlock switch terminal lOriver Side)
Door unlock switch terminal (Pussenger

side)

<D

Door lock switch terminal (Driver side)

Key cylinder tamper switch terminal
Ground 'llrminal
SE.U99TA

Trunk key cylinder

Switch~

Trunk key cylinder switch (unlock SWitch)

Terminal No.

~iD

Condition

ContinUIty

Key position is neutral

No

Key position is un\oc~

Yes

LaJ
SELOOTT

----------

Door lock acluato' connectors

Driver side'S. Passenger side

1~[jIes

LaJ

Door lock actuator (Door unlock sensor)

Terminal No,

(!j, @

Condition

Conlinuity

Door is locked

No

Door is unlocked.

Yes

SEL~C ITA

Horns
Supply horn terminal with battery 'Joftage and check horn r~&.
operation.

THEFT WARNING SYSTEM

Trouble Diagnoses (Cont'd)
Theft warning horn relay and multi-remote control
relay-1
Check continuity between terminals @ and . and (J).
Condllion
12V direcl currenl supply between
terminals

CD

and ~

Yes

--------------+-------- ---No current supply

No

SEC202B1

Theft warning relay

Check continuity between terminals @ and @
Condition
12V direct current supply between
terminals Qj and @
No current supply

SEL360T

EL-248

Continuity

No
Yes

LOCATION OF ELECTRICAL UNIT

Engine Compartment

'~'f

S~L66IT

EL-249

LOCATION OF ELECTRICAL UNIT

Passenger Compartment
LHD MODELS

K'Ckdow~

Ig~i',OtI

sWitch (A/T moclels)

Stop lamo sWitch

call relay IBlue)

Eees relay IBlue)

Mirto< defoggBf ,elay [Blue)

ECM (ECes mntrol module)

ROlli w,pet' ampHfier

Fuel pump relay (Bluel

Power

WlrldOW relay (Blue)-

Rear 'OIl lamp relay(Blue WitMut daytIme hght system)

(Grav With dayt,,,,,, light system)
Rear WIndOW defoggef relay IBrown)

-,.. ...

Ignition relay-2 (Blue)

~~'~

Ignition lelay t (Blue)

5EL852T

EL-250

LECTRICAL UNIT

__
'~)

LOCATION OF E
Compartment (Cont d
----~~---CP~assenger
RHD MODELS

01 a<J 110 Sl $ ~eflSOl unit

f-

19n ,t'QO ca,II"lay (Blue)

ECes rel.. ~ (81U61

defogger ,el... ~ (alue]

~xeept lor AuslralliJl

;ITOI

ECM (ECes canirol module)

AIT elmtral unll

1-

Comb,natloo flasher un,l

SI

lamp sw,lch

OP K,ckdown SWItch (AIT models)

Smart e-ntranee control un,1

- CIrcuit bleaker

:~\1

~
Fucl

"um~ /ela~

IBlue)

SELSS3T

LOCATION OF ELECTRICAL UNIT

Trunk Compartment

Speed control amplif'er

(For Europe)

Multi-'llITIOte control
,elay-2 (Black)
(E_cepl for Europe)
Multi-l'emoIe COf"Ilrol'elay-. (Brown)
IE_cepl for Eu,ope)

Differential oil
cooler relay. (Bluel
(Fa ElXODe)

Dilfe<entilll

oil

cooler relay-2 (Slackl

(For Europe]

ASS control unit

""'per

Rea,
relay 18lack)
(E-cept for Australial
!Ii

Ins ide of s,de panel RH

Rear wiper motor
IE I cept for Australi a)

SEl 864 T

EL-252
d

.HD MODELS

Outline

Eogi ne control harness

Door ha,ness LH

SEUl65T

Room lamp harness

Door harness RH

Eng, ne room hatness

El-253

:?lJi'

Main Harness
LHD MODELS

-t--I
I

,I

-~

/'

II

~I

t
I

- - - --

-..... ----- - . ---,I

EL-254

B5
85
AS
AS

'B
@
@:

1ody ground
Rea, wiper amplifier

E4

Power window relay

Rear fOg IEimp relay (Model", w,thoul CSBYl,me Jighl system\

F3

o1

Prlla, speaker I'l'i

Rear fOil lamp relay (Models with (jayllme IHlhl sysh,m)

~1

G2

@),
@>.

To@

Fuse bloc,",

02

C,D

To I"~

Real wrndOw [j"'ogge r relay

F3

@.}

JOin! conrleClor

To ~ ,SMJ)

04

~. TO@

(iilr rSMJI

B4

B4

,~: Data link con"eCIOr !DI CONSULT

84

@,
@:
@,
@V:

A3
B3

Blower motor

Ttl

(.D

F4

@,

F4

@f~: To

F4

@:

F3

~: Mirror defogger rlll,,~

G3

@El:

Body ground

TO@

To

BJ

8,

CllcUlt breaker

43

():

To

AJ
8<

~:To

tE'

To C!.~ (AiT modelsl

To

(MIT mDdelsl

P,llar speaker LH

BJ

:
:

C3

@:

Kickdown switch

CJ
83

~: Combination meter

F3

,@).

G3

~: Glove bOK lamp

@' 0101'11 00' lamp sw,lcn

Smart entrance control uM

IA/T mOllelsl

B3

C3

~~' CombinatIon flasher unIt

CJ'I
CJ'I

C4

~,

C3

SlOP lamp swrtch

03

,:

All mI' door motor

04

~"

MOde door motor

E3

~!

B,-Ievel door motor

I'-)

Fen resistOr

TO@

@: Illumination control SWltC"

@' AfT control Unit (A/T mC>clels!

,...m

To~

Fuel pump relay

A5

A3

~: Thermo control amphtier

F2

@:
@:
@!,

@:
@:

AS

E2

E3
02

02
E3
3
03

@9)
@'
@:
@:
@:
@:

Buzcer

TO

Push control unit

Fan sWItch
Hazard sWllch
Headlamp ""asher switch
Rear window [jetog~er sWitch

03

~: Rear fog lamp S,yriCh

E4

~: RadIO
@, Not used

E4
E4
02
1
E2

@,
@,

G3

Cigarette Irghlel
JOint COnf\eCIOr

~'Not use"
,y:;._.:~'

II

Intake door mtltor

~L
~:'".I

'~~"~

:-.;,

-:r;'
~~

",

'j~~.1

...

1'<,'

.<;:J.

~r

:-~

'I','
~

lIL'

0-_

e"
,-,

HARNESS LAYOUr
Main Harness (Cont'd)
RHO MODELS

LL

'-/J
)/j

==~::::::~::/
_._l:J__

'

I'~ilo

EL-256

________------ztL

<EG:

Body grouru:l

Cd

Diode (Except for e"ropel

G5

Rear Wiper amplifier (Except fOf Australlal

C3

Diode (Except for Europe)

G5

@:

Fuel pump relay

C2

. Joint connector
<) - Sunload sensor (Aula A/Cl
: Not used (For Europe)
: Intake door motol
l: Thermo control amplifier

F5

G5
FS
F4
F4
F4

:
@:
@):

:
:

Power window relay

8\

Rear fog lamp relay (For EurOpel

8t

Fuse block

C2

Oats link connector for CONSULT

C2
C2

Rear window defogger relay

B (SMJ)

Fan control amplifier (AuIO A

G3
G3

@:TO@

~: To @ IE~cepl for Australia

B3 ~~: Fan resistor (Except auto A/G
C3 @. Blower malar
A I @ ) , Pillar speaker LH
A2 @.1 To @B

G2
F2

@:

@:To@
Pillar speaker AH

A3
84

F3
F3

To

B2

To @(SMJI
C"CUlt breaker
To

@)

A2

F4

~: Sman entrance control unit

F3

@:

E3

~: Combination meter

B4

E3

@:
@,
@,

A3
A4

E3

I"""

E4
E4

'~: Bu~zer
@: Stop lamp sWitch

"

02

In-vehicle sensor (AUIO AfC,

B2

Ail miX dOOf mota,

1'.3
A3

B4

@:
@:
@:
@ill:
@Q):

02

@>:

Auto

C3

@:

Push conllol unit (Except auto

C2

~: Fan switch (Except auto Ale)

@El: Hazard swrtch (For Europe)
@: Hazard sWitch (Except 'or Europe)
@: Headlamp washer switch (For Europe)
,~: Rear window defogger sWitch
~Miil: Rear fog lamp sWitch (For Europe)
SecuIJIy Indicator (Except for Europel

E3

m
N
U1

i:

@]):
@:
@"
@B)'

F3

03
03
C3

04
C3
04

CJ
CJ
04

Kickdown switch (A/T models)

84

Illuminat<on control switch

A/T control unit (A/T models)

To~
(~, Jo,nl connector (For Eu,opel
J. To@'
@, To
(AiT mOdels)

@)

@:
@).

To

' (Models w,th ABS)

M",o< OIl'o911e, relay IE_cep

~,. Body grouM

COmbination flaSher Unit

Mode door motor

1j.<jQ!;'
@:
@:

To

@?

G.love DO' lamo

GlovEl Ix>. lamo sw,lch

I'

IE.

Bi-Ievel door motor

To@

Ale unit

(A "to

Ale)

AIel
Diode

C4
CoJ

~: Rad,o

NOI used

Cd

C'garet1e I,ghler

Smar1 entrance
canuol un,1

tnfellOl lamp

1 c;H

Dear warning

..

lamp

'"'"'"
::5

~~

-:&

i?.. . .

o~

-J

=?~

~:".Jo

SQ,

J..g;

~,

~)

?~

'J!.

-,9

~;.

<9

-ljP

:..,~

~1

...:.!'

.=

Ifl'

nru

oOJ

.('p

HARNESS LAYOUT
.
R 0 om Harness
Engine

u..

u..

/
/

/ //
i

UJ

/
/

,Iii

V
\

)
.A:\

(J

- - - I

--- ---C\I

-1--- -- 'M- - --

-J


@
@

Cool,ng fan ,elay-;>

Fusible hnk and fuse block2

<ill

Fus,ble hnl<. and fuse blOck-3

F2

C:

Brake Ilurd level switch

G3

@' Side turn s'gnal lamp I-H

: Power Iransistor unll
@J - Wastegate valve c:omrol 5Oleno,O
:f"ii'.

,~

F4

CIT!) ,

F,ool wt>eel sensor LH (For ABS)

C2

(ill> ,

D2

C2

@,
@l.

C2

g"

Boos' p,ess ...,,, ~ensor

If'\hlbltor s,""rtcn IAIT modeisl
~evolut,on sensol tAIT modelS)

04
04

<'

'.:lli>:

Bane')'

82

@:

Washer fluid level switcn

Ambient sensor (For outs,de

I~@l@@!
~[;JLJ~!

F ronl

Oropp,ng res,sto' I!~

82

@:

Daytime light un,t

AIT contrOl

B2

'nD:

Headlamp washe' amph/ier

unH

Headlamp washer moior

Front washer motor

Rea' was1'1er motor

A3

@:
@
@,

A3

l1eadlarrp RH ,nner

A4

@:

F'on1 fog lamo RH

A4

@:

FIt>n11u,n s'gn,,' lamp RH

A2

(@) - Body

A2

LH

@):
@:
@:

A3

Headlamp Lf-l outt"

'II

C3

83

f-1\Jadlamp LI< rnner

f-leedlamp a,m'''Q motor Lli

To@,

82

C3

tIom II-Owl

,
~1E7 Hr-

valve

To terminal code assembly ',AIT mOdels)

~: To (@})

':ill>:

FlOi'll 10<;, lamp LH

Fus,ble link and fuse bo.

,~, O'OI'll,ng res,slor (A/T models)

~'Check cOnnector

@:To@

FlOi'll turn s,gnal lamp LH

@,
@
(liD:

84

Power ,teaflng a,l pressure SWitch

C3

@,

C5

@i: Clearance lamp

82 @:To@
04 @: Body ground

Comoressor

C3
CJ

(@'

C5

E4

E3

E3

(D

Fu"oI8 I,nk and luse OoA

Boll

Coil

(ill

E2

U1

HOrn relay
Front log lamp relay

03
03

I
I\)

Coohng Ian ,alay-l

Air conCl,t,oner relay

E2

m
r-

Fusible link and fuse block',

~ Lin

50

Clearance lamp RH
Heaclamp RH outer
Hl/e;llamp alm,ng motor RH

9' ounO

B3

,0,

COOling fan mOIOI

84

@:

HOI n 1f-1,~hl

on

In

'"'"
'"

:-11.::'

':'!.

!k

.~

;;..

.~~

"l..~J

,-:-.j

ii~"")

-1

~
,

'~i'

~~
fll't

n-J

,-',

--

... ---T-

----

-- -

EL-260

--~

@
(ill
@
@

: Cooling fan relfly-2 ,EAcepl lor Europe)

: FusIble h~ ... anCl luse tlIOCk-\
: Coohng fan relay-I
: Theft warnIng relay (E~cept for Europe)

@
02

IFuSlble link and fuse bo.)

FusIDla hnk and luw boo

I@!
~~1~m~'I'd!

@:
@:

Boost pressure sensor

InhibItor SWitch IAIT moClels)

@.ToS

@:To@

C2

@:
@
@'

Banery

82
B3

Heacllamp washer motor IFor Europe}

C3

Front

C3

@:
@

R&ar washer mo'c>, IE.cept to, Austraha)

82

Headlamp washer .. mpl~,el IFQ! Eu,opel

A3

@).
@,

Clearance lamp RH

A3
A3

@:

Headlamp a,min\l malor RH {For Europe}

'"

"'i~,.

Revolution sensor (A/T moClels}

To terminal code assembly (A/T mooels)
Toiffij)

(For outside

I@

Hood switch (Except for Euwpe)

Wash." f1u,d level switCh

Front

W39ne, motD!

HeaCllarnp RH ou'e'

A3

~. Clear::llamp RCl lOner

A4

@,
@:

Fron' tog lamp Rli

A2

@:

Body ground

B3

B4

@: Coohng fan motot (E.cepl lor Ellropel

@
COOlIng fan mOlOr (For Europe)
@ _ Amo,,,nt sensor (For euto Ale)
i ' Horn (Cllgh)

84

@:

84

Headlamp LH outer

Side turn signal lamp RI-I

03

83

@:TO@
@. BoCIy g,ound
@: Ambienl senSO'

Heacllamp LH Inner

Front wheel sensor RI'! IFor ABSI

D3

A4

~: Tnple-pressure switCh

B4

m
j"

82

Clearance lamp LH

03

Fusible link and fuse block-2

03

en
.....

(]B):

Front turn signal lamp LH

: FUSIble link anCl fuse block-3

C: Brake fluid level switch

(lli>:
(ill) ,
@:

OJ

E4

D4

~: TheM werning horn (&cept for Europe)

C2

@:
@l:
@:

Headlamp aIming motor LH

C4

E4

@:
@:

D2

C4

Theft warning horn relay (Except lor Europe)

02
C2

~: Front f~ lamp LH

Front log lamp relay (For Europel

oI
01

@:

C5
04

Air condItioner relay

tEl . Horn reley
CIT) :

C5

Fron' lum 510nal lamp RCl

Horn (Low)

."
~

"'~

,.

.,
~

.2J1J
5.9

;:ii1
;\~:>

"I

;~...

"181

g;

=<:

!r'

"1I1J

iNiJ

.niJI

<OJ

HARNESS LAYOUT
Engine Room Harness (Cant'd)
PASSENGER COMPARTMENT (lHO models)

-- -- . - ,

(~H~OO@

~~
.. c:

.co
Ou

EL-262

Engine Room Harness (Cont'd)

PASSENGER COMPARTMENT (RHO models)

______-------E.L-.26.3-------------.j

HARNESS LAYOUT
Engine Control Harness
LHO MODELS

UJ

I ..

C\l

EL-264

E2
01

Igmlion co,l relay

1'3

01

To@E)

E3

E1

@:TO@

E::l

~: Ignition Call NO.3

01

EJ

~: Ignrtion Call NO.2

03

>:

Ignition coil No.1

@j):

To@

@l IAIT mD<leIS)
@ (MIT mOaelS)

~: Front w,per mota,

E2

62

@:
@:

Front wiper amplifier

03

~: Injeclor No 4

C1

Side turn s,onel lamp RH

C3

ct):

B1

ASS actuator

C3

~. Injector NO.2

TO@

CJ

@:

Injector No,1

M<I~s air flow sensor

C4

::

Eng,ne Cool<lnt temper<lture sensor

To@})
!-1eatecl oKygen sensor

C4
02

EngIne ground

03

E3

@
@,
@

F.3

OJ

!@
@
,.
@:
@,
@:

D4

@;

Camshaft positIon sensor

B3

Throt1le position sensor (Brawn)

C2

@:
@:
@:
@:

E2

~:: Engine ground

E2
02

83
BJ

--- -

D:

(@)
,@'

Injector No.3

Thermal transmitter
To @,
Knock. senSOr

TO@
To@'
IACV-FICD solenoid valve
IACV-Me valve
VTC solenoid valve

Throltle poSItion switch (Gray) (A/T models)

Front wheel sensor RH (For ASS)
Triple-pressure swilch

- II,~"'"~
~
,'~'

ffi:

Cl

E2
02

c.n

To

1'3

em: To

ECCS relay

01

S:>

(3)

SutM'lamess

ECM (ECCS control module)

~: To@)
Engine ground
@: Ignition coil No,4

D4

m
rI

:
@:
@.

01

2!J}
(':.lit)

-0lJ
~1

.S\!'

29)

2-9)

Jl'.>

~~

\.~

-='I

--<I

:0
'r-"

~'iJ

nrJ

(~

HARNESS L A Y O U T " ' "

Engine Control Harness (Cont'd)
RHO MODELS

J
J

EL-266

F3

G4
G3
G3
G3
G4
1'4

.~

..

.~~

@:

D2

Ign't,on co,l relay

TO~

D'2

Tt:l

C3

IModel Wllh ASSI

C3

To
IAIT moatlisl
ReSistor

C3
C3

D:

To

I'les,s!or

ffi:

Ignition COil 11I0.3

@:

Ignilion Call No,2

Ignltoon
coil NO

~. l'1nlllon COli NO,l

02

82

'n,eclor No 4

F4

Side lurn s'gn"J lamp LH

82

In,eClor No 3

ASS actualO( (For A8S1

82

In,eclor No.2

E4

@);
@J
@:

Front wheel sensor LH (For ABS)

A2

@:

I!wetor No,l

D3

Power Iraos,stor un,t

'

AJ

~. Engine COOlant lemperatwre senSOr

03
04

@:

Wasl811&le valve control soleno,d valve

Ch8t:k connector

D4

C4

~,OroPPlng res'slor (A/T mOllelsl

:~
TO@

C3

C"mpressor

C3

'~:;'I

Mass arr !low sensor

~1lt

,,

TO@

OroPp,,," res,

AlT

B3

@:

Thermal Iransm,n,,'

B2

B'

To

BJ

Knock S6"50r

conlfO

wnit

(ill)

PO... er sleenng 0,1 oressure sw'tch

To~)

CI

@,
@.
@.D:

82

'fill: T00

C2

IACV-FICD solenoid valve

82

IACVAAC valve

83

(IE;

vrc SOlenOla valve

C4

I,~

CamShaft pas, lion sensor

Heated o'yQe<'l sensor

Eng,ne ground

To ~

A2

I~

T"rOOI9 POS'I'OI"\ senSOr tBrown)

A3

C:

Thron'e pos,t,on sw,tcn (Gray) (A/T moaBlsl

CI

,~,

Engine ground

II

Power
Irans,slo,
unit

~: Enlline groul'''
~: Ign,"on Co,l NO 4

~: Front wiper mOlor

CI

-...

'
':E',.

SYb-hill rn8&8

~). Front wiper ampillter

03

0)

@,

ECM (ECes conUal maOule/

Eees relay

FJ

D3
D3

'

1'2

E3

CD).

~~
~:

JI:

l-':~

~.

"".r::)

=!2-.
;:?,:

!.-:':.

2~

:~

~:'

~I

,-)'

Iii

1M

I \,~

\j~-)

~(-

Em

G ____
V"" '~~.

" ,__

"'"

--

(lJJ
m
r~

In

co

E2~

iJ, To @
@:rO@
: To (ill)
$~, Bat1ery

: Fusil>le
@

Im"- bloc",

Body ground

~ : Alternator

~ : EGR and camster CDnlml SOleno'd valve

OIl pressure sWItch

(@ : Slaner
@li1J :
@ :
@ ,

motor

Ve h IC Ie s peed sense"

Back-up lamp SWItCh IM/T m!>daIS)

Neutral posll,on switCh (MIT ",OdflIS)

BOdy g

i ~\\

HARNESS LAYOUT
NOTE

EL-269

HARNESS LAYOUT
Body Harness
lHD MODELS

[
o

EL-270

A3

Body !)fauna

02

@j):

CondE!nser (For rear WindOW detoQQerl

B3

(ill:

Healed Sllfl\ LH

02

@:

Rear winao.. dl'logger (+1

~: Fie'" Window delolJger (-I

~: BOdy IJround

63

Parl<ing brfllle switch

F2

C2

@.

HaMlamll aiming sw'.lch

E2

B2
82
83

:
:

.....
......

@:

Door mlrrar control Switch

Front log lamp gw,lch
Overdrive SwllCtl AlT illumlnat,on

C2

'~eate[j seal sWitch RI-\

C4

@).

Heated wal SWItCh LH

C2

~. To@

C3

@:

8.a

l~: Doc>, SWitCh (Driver's s,081

84

@) - Seat

C4

F3

~. Body ground
@l: ConOensar (For rea, "",ndow delogger~
~: Rear speake, RH
@'. TrunK room Iilme

E3

@:

Raa' w'per motor

E" Cilil'

Rea, spea"-er LH

F2

r-

Subh&rne6S

To@)

C2

A3

To@
bell D1fI-tensiorl8r (Dllvel

D4

@:ro@
@:TQ@

C2

@:

D2

@): TO@)
@
ro@

D3

(:3

E3
E.3

E3
G3
G3

F2

sloe)

To':@)

Hell/ed see I RH

Door 9wllCh (Passenller side)

C~: Seal bell pJlHenSioner WilIssenger 5,del

@: TO@)
@l Tr>@
@. Nor usea

_,II

~~
J~'

?~

010'

~!;I

III.

'~'

J,C.I

!_~:s....

-:::J

-:i

r-

"

Jt"J

.J

HARNESS LAYOUT
Body Harness (Cont'd)
lHO MODELS

u..

G3
G3

Raa, w,ndow defogger

Door mirr01' control switch

C2

~,BOdY ground

Front fog lamp swilch (For Eur"pel

E2

<'ED.

To

@)

To

(IT)
(ill)

F<1

I.E'

Door switch IDriver's s,de)

F:I

Seat belt pre-tensloner (Driver'S ~;de) (For Europel

F3

Mu',tHemole control relay' (E.cept for Europei

E2

MUltI-remote control re1ay2 IE,cepl lor Europe)

~: Body grouno
([: Condenser (F", roor windOw C1erO'dgen

B2

@:
@):
@TI):
@:

D3
04

@:To@
@:To@

83
83

C2

E<1

C2

Real w,ndow defogger

Headlamp aiming SWltCt'l (For EurOPel

Overdrive sWItch AfT illuminati""

E3

@.

Rear speake' RH

Trunk room lamp

Rear wiper

moto'

IElc:ltpt lor AuSlralia)

Rear speaker U1

E2

@;

TO

(Models WIth A6S)

02

~: To

(Models w,th ASS)

D3

@:J

E3

:ill"

TO

C3

Door s.."lcn (Passenger SIde)

C3

@ _Seat

82

@
BOOy grounD (Models with ABS)
C - To (Models w.th ABS)

83

Conoenser (For rear w"

D2

FJ

E4

@)

pll'k,ng brake SWllch

F2
F2

F2

r-

E2

:
:
:
.

F3

Sub-h"fnesa

@- TO@!
(]I)' e,,(;ly 9'00n[1

Body grouno

@
be',', pre-tenSlone, (Passenger s,del (For europe)

B3

ABS conlrOI unll (For ABS)

82

@>:

NOI used (For Europe)

V>

'"

fl

110 ~

,;,12

--:-!

f-i

,1.E 1
:-~

~.r;J)

'-~-

.;2J

-=J

~--;I

r"

nru

'n>

@.To@

@:To@
@ : H,gh-mounteo

(IV .
slop lamp

: Back-up lamp RH

. Trunk room lamp sw,tch

Back-up lamp LH

.~

OJlfe,ential 0,1 pump

------------------!'" \ ~-------~
\
----------.

r~

~\

Fuel tank

~: Fuel pump

@
@
@
@l

: Rear skid
: DifferentIa
, Dlfferenllal
: D,fferent,al

: Dll1e'entlBI

SD,,"1l COn

: Rcar comb

.~ - Rear wiper

C
@ .

Body groun

Rear fog la

,~ . LIcense pla

@i : Rear Comb,
@ : POWllI ante
@ : ABS ContrO

(): TO@
@:'o

......

F--i
/'

~~

<to - lCi @;

'21) - TCi@

. H,gh-rnounllJl1 SlOP ramp

. Back-up lamp AH

(~ : Trunk room lamp switch

GEl . Trunk key cylmder sw,tch (E~cep, fo,

Europe}

Back-up lamp LH

,~ , D.tTerenl,sl 0,1 pump {FCir Europe}

. Fuel 181'lO ~auge

Cf:i2) .

Unit

Fuel pump

:Til', : Rear sk,d senSQr (Fo'

ASS}

@ . D,ffe,enllal oil .,.,e,nong lamp 8wilch (For Eu,alle)

-i~

D,ffe'ential oil lemperalure SWllch IFor ELlropel

'S'

Oifferenlial 011 coole' relay'

(~or

c,tlerent,al 0,1 cooler relay-2 (Fo. u'01l9}

@l :

Rear cQmll,n,sllon lamp RH

Rear W'Ile' relay (Except for Australia)

< :

,/"

Eu,opel

( :
@) :

Spee~ contrOl amplifier IFor EUlopCI

Body ground

~ . Rear fog lamp IFa, El.I'''pe)

@; . license plale
@

Rear comb,natlon I"mp LH

(i?li

PI)>Her anlenna t,mer

I'
~

U'\

lamp

~, . To ~~, IModels with ABS)

'l:11

....;:

~J

,:..r..J

~eJ

""fl;J

3.r;;
)~~-,

'11

-q)

~1

'_n~~

(~~

HARNESS LAYOUT
Room Lamp Harness

-~---

-.

@ @@@@

~--~

~~~

SEL880T

EL-276

HARNESS LAYOUT
Air Bag and Seat Belt Pre-tensloner Harness

LHD MODELS

r--\~D

~$\

~IMJ

1.

1
;'.:

~rr"

""

f~
~il

. Diagnosis sensor Un,! (Models WllM all bag system)

@.
@ -

To spiral cable

A" bag mtKlu!e (Passenger side)

ClI'

To

~n

To@})

.:il r

@)

DiagnOSIS senso< unit

IMOdels w'lnout air bag with p<e-tensioner system)

SEL88TT

rm

RHO MODELS

---~
-~-'-----

: Diagnosis sensa,

0'"6)

un,t (MOdels w,th air bag system)

@: To(illl)
(13) . To spu"l cable
@ _ All bail module (Passenger
(ill - To (~l

s,de)

mn

[)l.1~"OSLS sen~ar unit

(Models wlthOu! a" ba

EL-277

wllh pre-Iens,one, s~s,em)

seUl1l2T

HARNESS LAYOUT

Door Harness (lHD models)

FRONT LH
To ~1

(DiJ

(oD

TO@

'D3l

"~-)

Door soeak",f
. Power w'ndow regulato,

:.ID

Door

'~

Door mlrrar

~)

Powe' w,ndow anlplifier

:~l

m",'j,

defogger

Power window main sw,tch

Lock I<nob sWitch

-':...-_-

--

- -~~-----

SELB83T

FRONT RH
'~:To@
~:To@

:@ :

Door speaker

~~[d--

'P~

Power w",dow regulalor

~~,
61~
g~'i)

Power "''''dow SUb-SWllch

.8)

---

-------

~ ~

--------.--=-----=--

"Z

Door mirror defogger

Door minor
000' lock actuator

___________________.

'_,~_Ie_e4---.J'

HARNESS LAYOU_T

Door Harness (RHO models)

ROtH LH
@: To@
~. To C)
Door speaker

@ :

Power ",,,"dow regulator

m.rro, defogger
@:Ooo<

. Door mirror

-sw,fch

~
SUb (Excepf 101 EUlope)
~ : Power window
- del sw,tc h

@
@0 :

Key
Doorcyhn
loc~ a cluator

_
_
--_=:==_
_______

5l6ssr

FRONT RH

@:TO
@:To@

: 000, spea~: regulator

@) .

powe~:::r defogger

. 000; mirror

: 000

r w,ndow amplifier
maIn SWlfCh

~ . Power window
.

'08' .

~
~

Powe

I tor EuroOe)
sWitch (Excep
)
E ept for Europe
acluator ( xC
t h (For Europe)

Key cylinder

ro.v
Door loc~
~ .- loc
k "'nob SWIC
@J
-

--

EL-279

f:ij

To install SMJ. lighten bolts until orange "full~light" mark

appears and then retighten to specified torque as required.
~: 35 N'm
(0.3 0.5 kg-m. 2.2 3.6 ft-Ib)
CAUTION:
Do not overtighten bolts, otherwise. they may be damaged.

Terminal Arrangement

LHD MODELS

MAIN HARNESS

/,-----------------------..,

,'-

-J

ENGINE ROOM HARNESS

,'-

. J1

BODY HARNESS

RHO MODELS

MAIN HARNESS

,,'-------------'

ENGINE ROOM HARNESS

\.'-------------'

BODY HARNESS

SH65/T

Terminal Arrangement (Cont'd)

ENGINE CONTROL HARNESS

/r--------------~-------______"

,'--

-...J

MAIN HARNESS

ECM(ECCSCONTROLMODUL~

View from harness side

AfT CONTROL UNIT

@
View from harness side

SMART ENTRANCE CONTROL UNIT

,:]~

@@i]

View 'rom harness side

SEt B~

IDX-1

ALPHABETICAL INDEX
A

BA-24
L\SS (anti-lock brake system) ..
BR-28
,\BS actuator
.
BA-46
.
J\BS circuit diagram
ASS component parts and connector
locations................................
... SA-43
ASS control unit...
....... BR-28
'\8S hydraulic circuit..
BR-24
C\BS self-diagnosis..........
.. BR-40
I\BS symptom chart.................
.. BR-42
'\ BS system components...
BR-25
\8S trouble diagnoses.....
... BR-39
..
BR-27
.'\BS wheel sensors......
'\8S wiring diagram
BR-29
'\/C HFC134a (R134a) system
precaution
HA-3
'\/C HFC 134a (A 134a) system service
procedure
HA-138
'\/C HFC134a (R 134a) system service
tools
HA-6
'\/C HFC134a system service equipment precaution......
HA-B
!\IC air flow...
HA-12
::"'IC circuit diagram (auto A/C)
HA-103
.\/C circuit diagram (manual A/C)
HA-43
:J,./C component layout.
HA-11
:>../C compressor clutch removal and
installation.
.
HA-146
-\/C compressor mounting........
.
HA-144
-\/C compressor precaution
HA-5
\IC compressor special service tool.
. HA-5
\IC control linkage adjustment (auto
A/C)
.
.. HA-125
\ IC control linkage adjustment (manHA-70
ual A/C)
\iC control operation (auto A/C)
HA-73
\IC control operation (manual A/C)..
. HA-13
'\IC diagnostic work flow (auto A/C) ....... HA-78
\IC diagnostic work flow {manual
A/C)....................
.. HA-1S
\IC harness layout (auto A/C) .. ,..
. HA-101
\/C harness layout (manual A/C) ..
..
HA-33
\/C lubricant (R 134a)
HA-140
\/C operational check (auto AlC)
HA-79
\IC operational check (manual A/e)
HA-16
\iC performance chart..
HA-28
\IC performance test diagnoses....
HA-26
\/C push control
HA-148
\IC relay......
HA-70
\iC self-dfiagnoses (auto A/C)
HA-84
\/C symptom chart (auto A/C)... ..
HA-82
\/C symptom chart (manual A/C)...
.. HA-18
\/C system description (auto A/C)...
HA-127
\/C trouble diagnoses (auto A/C)......
HA-76
\;'C trouble diagnoses (manual A/C)..
HA-14
\/C wiring diagram (auto A/C)....
HA-104

A/C wiring diagram (manual A/C). .

HA-45
Accel erator control system
FE-2
Accelerator wire adjustment..
. FE-2
Activated carbon canister.
EC-17
Air bag ... .... ........
. . RS-5
Air bag disposal...
RS-12
Air bag precautions.
.. GI-2
Air bag removal and installation
RS-9
Air bleeding for brake system. ..
BR-S
Air cleaner filter replacement........ ..
MA-15
Air conditioner cut control
EC-26
Air mix door control linkage adjustment (auto A/C).
..
HA-125
Air mix door control linkage adjust.. HA-71
ment (manual A/C)
.
.... HA-131
Air mix. door molor.
Air spoiler, front - See Front air
.. BT-38
spoiler
.. .
Air spoiler, rear - See Rear air
spoiler
........ 8T-38
Alternator
.
.. EL-41
Ambient sensor....
..
HA-129
Angular tightening application......
... EM-2
Antenna - See Power antenna...
..
EL-196
Anti-freeze coolant
MA-10
AT diagnosis communication tine
EC-139
AT control u n i ! . . .
AT-77
,
AT-81
AT fluid temperature sensor
AT removal and installation
AT-95
AT self-diagnoses
AT-41
AT trouble diagnoses
AT-i0
Audio.
..
EL-190
Audio and A/C control removal and
installation - See Instrument panel ........ 8T-14
Automatic amplifier..
. HA-130
Automatic transmission fluid.
... MA-10
Automatic transmission fluid
replacement..
MA-20
Automatic transmission number
.. GI-37
Auxiliary air control (AAC)
EC-15
Axle housing (rear)
RA-7
B

..
EL-81
Back-up lamp
..
..
MT-S
Back-up lamp switch (MT). . ..
. FA-14
Ball joint front axle
.
Battery...... .
.
.. ... EL-20
... MT-9
Baulk ring (MT)..
,
,
..
.. MA-12
Belt inspection (drive belt)
.
Bi-Ievel door control linkage adjust. HA-126
ment (auto A/C) . ...
Bi-Ievel door control linkage adjustment (manual A/C) ...... ,
HA-71
..... HA-68
Blower molor ....
Blower resistor ..
HA-68
GI-40
Board-on Lift.

IDX-2

ALPHABETICAL INDEX
Body alignment ... .,.
. '" BT-39
Boost pressure control..
.
EC-30
Boost pressure sensor..
.. .. EC-18, 128, 206
Boring/horning cylinder block
EM-62
Brake booster.
..
BRW
Brake control valve (Proportioning
Valve)
. BR4
Brake fluid
..
MA1O
Brake fluid change...
.... BR-5
Brake fluid level
MA-21
Brake fluid level and line check
BR-S
Brake hydraulic line.
..
BR-3
Brake inspection
MA-22
Brake lines and cables inspection
MA-21
Brake master cylinder
BR-8
Brake pedal
.,...... ..
BR-7
Bumper. front - See Front bumper
BT-6
Bumper, rear - See Rear bumper
BT8
C

Camshaft inspection .......

... EM-40
Camshaft position sensor (CMPS)
EC-12
Camshaft position sensor
inspection ..
........ EC-109, 201
Canister control
.
__ ....... EC-26
Canister control solenoid valve
EC-16
Center bearing assembly (propeller
shaft)
..
.. PD-8
Center bearing disassembly (propeller shaft)
.
.. .. PD-8
Charging system
..
..
EL-38
Cigarette lighter
.
.
EL-181
Circuit breaker
.
.. EL-19
Clearance lamp.
.. .... EL-72
Clock
.
..... EL-181
Clutch cover
..
..
CL-10
.
Clutch disc
.
CL-l0
Clutch fluid
.
........... MA-1O
Clutch fluid level ..
.. ......... MA-19
CI utch master cylinder ........
......... CL-6
Clutch operating cylinder ..
..
CL-7
........ CL-4
Clutch pedal......... ...
Clutch pedal free play.
......... CL-4
.
CL-4
Clutch pedal height ...
Clutch release bearing .. __
CL-B
Clutch withdrawal lever .
............... Cl-8
Coil spring (front) ..
.
FA-12
Coil spring (rear) .
..... RA-19
Combination lamp, rear, removal and
installation........
.
BT-26
Combination meter
EL-114
Combination meter removal and
installation - See Instrument panel
.. BT-14
Combination switch.
EL-46
Compression pressure
EM-12

Compressor clutch removal and

installation
. HA-146
Compressor mounting
HA-144
Compressor precaution
HA-5
Compressor special service tool
HA-5
Connecting rod......................
EM-SO
Connecting rod bearing clearance
EM-65
Connecting rod bushing clearance
EM-66
Console box - See Instrument pane!...
BT-14
Consult for ECCS
..
EC-53
Consult general information
GI-33
Control lever {MT}
MT-10
Control valve (AT)
AT-117
Converter housing installation
AT-96
Coolant replacemenL
MA12
Cooling circuit (engine)
LC-1O
Cooling fan
LC-14
Cool ing fan control
EC-29
Cooling fan control system
__
LC-14
Cooling fan motor inspection
EC-i76, 206
Cooling fan relay inspection.. .
EC-176. 206
Counter gear (MTl
MT-9
Coupling sleeve (MTl
MT-9
Crankcase emission control system
EC-212
Crankshaft assembly
EM-68
Crankshaft bearing clearance
EM-63
Crankshaft inspection.............................
EM-62
Cylinder block
EM-57
Cylinder block boring
EM-62
Cylinder head
EM-38
Cylinder head bolt tightening
EM-26

~~

j:,:~&.\

H":l
l .. ~

2JG

:;:~

I-~L

\:1'1
t'f
c I':

o
Data link connector for Consult ... " ... EC-53, 195
Daytime light system........... ... EL-56 ~~~\
Differential carrier assembly.
PO-24
Differential carrier disassembly............
PD-13
Differential gear oil... ..
MA-1O fT
Differential gear oil replacement
MA-21
Differential oil cooler system.
.. PD-29
Dimensions.......
.. 81-38 ~:!1
Direct ignition system
EC-33
Door glass
. BT-11
Door mirror

Door trim
Door, front - See Front door
Drive pin ion diff. inspection
Drive pinion height..............
Drive plate runout.
Drive shaft (rear)...........

_,

Dropping resistor (AT)

'"

~.{r

BT-19
BT-10
PO-16
. PD-17
EM-57

.,\

RA-11

AT-83

E
ECCS basic inspection..

__________.I.D.X-.3

_.

.. BT-37

II
r-:

I
EC-63

.~

ALPHABETICAL INDEX
EC-11
EGGS ci rcuit diagram_....
EGeS component parts location
.. EC-S
.. EC-31
EGCS fail-safe system.
ECeS on-board diagnostic system
EC-48
.
EG-206
EGGS relay inspection..
EC-8
EGGS system diagram and charL."
EG41
EGGS trou ble diagnoses.....
EC-196
EGM input/output signal inspection
EGR canister control solenoid valve
inspection..................................... EG-148,203
EGR control (EGRC) - BPT valve
EG16
EC-16
EGR control (EGRC) - solenoid valve
EG203
EGA valve inspection
EC-203
EGRG - BPT valve inspection
Electric sun r o o f . . . . . . . "
EL-179
Electrical load signal circuit ."
EC-192
Electrical units location
EL-249
Electronic ignition (EI) system
EC-22
Engine control module (ECM)
EC-12
Engine coolant temperature sensor
(ECTS)
EC-13
Engine coolant temperature sensor
inspection
EC-116. 201
Engine oil
__
MA-10
Engine oil filter replacement
MA16
Engine oil precautions
GI-S
Engine oil replacement
MA15
Engine outer component parts
EM-9
Engine removal..........
.
EM-55
Engine serial number.............. ..
GI-37
Evaporative emission system
EC-210
Exhaust gas recirculation (EGR)
system
..
EC-26
Exhaust gas recirculation (EGA)
valve.......
.
,.. EC-16
Exhaust system. ..
FE-?
Exhaust system inspection
' .. MA-19
Exterior
.
BT~22
Exterior lamp
EL-72

F
HA-137
Fan control amp
..
HA-68
Fan switch......
Fast idle cam (FIC)
"
EC-15
Fast idle cam (FIG) inspection and
adjustment..
"
. EC-207
Final drive disassembly.............
PD-12
PD-13
Final drive pre-inspection
Final drive removal and installation
PO1O
Finisher, rear panel - See Rear
panel finisher... .
__
BT-25
Floor trim
BT17
Fluid temperature sensor (AT)
AT-81
Fluids
MA-1O
Flywheel runoul
.. EM-67
. __ . . . ..... EL-82
Fog lamp, front

Fog lamp, rear - See Rear tog lamp

EL-90
Fork rod (MTl
MT-10
Forward clutch
__ __
AT~136
Front air spoiler...
. . BT-38
Front axle __ . .
.. .. FA-8
Front bumper.....
.
__
.. _. BT-6
Front disc brake
.. BR-12
Front door
BT-10
Front fog lamp.
.. .. __
EL82
Front seaL........
..
BT -27
Front seat bell
RS3
Front suspension
FA-11
Front washer
EL-138
Front wiper.
EL-138
EC-211
Fuel check valve inspection
Fuel filler lid
"...............
..
_
BT-8
Fuel filter
EC-17
Fuel filter replacement
MA14
Fuel gauge..
EL-115
Fuel injector
__ .. EC-14
Fuel line inspection
__ .. MA-14
Fuel precautions
"
GI-5
Fuel pressure check........
EC-208
EC14
Fuel pressure regulator
Fuel pressure release
EC-208
EC-14
Fuel pump
EC-25
Fuel pump control
Fuel pump inspection
EC-1S9. 202
Fuel pump relav inspection
EC-206
Fuel system
FE-3
Fuel tank vacuum relief vallie
inspection
EC-211
Fuse
EL-19
Fusible link....
..
EL-19

G
Garage jack and safety stand ..
.. GI-39
Gauges . .
..
.......... EL-113
Gears (MT)
..
' ... MT-9
Generator - See Alternator
.
EL-41
H

..
Harness connector
..
Harness lavout
.
Hazard warning lamp
Headlamp ..
Headlamp aiming control ........
Headlamp levelizer - See Headlamp
aiming control. .
..
.
Headlamp washer
"
..
Headlamp wiper
Heated oxygen (H02S) heater control
Heated oxygen sensor (H02S) .

IDX-4

El-5
... EL-253
EL-93
EL-49
.. EL-64
EL-64
EL-153
EL153
EC-29
. EG-14

ALPHABETICAL INDEX
Heated Oxygen sensor heater
inspection
,
EC-152, 203
,.... __ EC52
Heated oxygen sensor monitor.
Heated seat ,..
... BT29, EL-200
Heater mirror.
..
EL-185
Heater wiring diagram
HA-37
Height (Dimensions).... ..
GI-38
HFC 134a (R 134a) system precaution
, .. HA-3
HFC 134a (A 134a) system service
procedure,
_
" .. ,.,"""""'"
HA-138
HFC134a (R134a) system service
tools
..
HA-8
HFC 13-4a system service eQuipment
precaution.....................
HA-8
High clutch . .
__
AT-134
Hood
,
,
BT-6
Horn.................................
..
EL-181
How to follow flow chart in trouble
diagnoses
__
GI30, 37
How to perform efficient diagnosis
for an electrical incident
,
GI-19
How to read wiring diagrams"
GI-9
How to use this manual
,
GI7
Hydraulic lash adjuster inspection
EM-45

K
L....---

---J

Knock sensor (KS) ... __ ......

Knock sensor inspection ..
Knuckle spindle .....

' ....... , EC-16 G~

,.... EC-132, 205
~&I

FA-8

Length (Dimensions)
GI-38
License lamp......................
. EL-72 ilt
Line pressure solenoid valve
AT-81
Line pressure test (AT)
AT-8? ~t
Liquid gasket application __
EM-2
Location of electrical units
EL-249
Low and reverse brake .. "
AT-140 ~iE
Lower ball joint (rear susp.)
RA-20
Lubricant (R134a) A/C
"
,
_
HA-l40
Lubricants
MA-10 ~IL
Lubrication circuit (engine)
,
" .... LC-4
Lubrication-locks. hinges and hood
latches.................................. .
' ... MA-24 W

[--~--

IACV - FICO solenoid valve

inspection
EC-172, 205
IACV-AAC valve inspection
,
EC-169, 204
Identification pi ate...............
G1-37
Idle air control (lAC) system
EC-24
Idle air control valve (IACV)
EC-15
Idle mixture ratio inspection
EC-35
Idle speed inspection ,
,'
_
EC35
Ignition coil inspection
EC-120, 202
Ignition coil relay inspection
EC-206
Ignition control system.......
EC-120
Ignition timing inspection """
EC-35
Illumination
'
EL-103
In-vehicle sensor
,
HA128
Inhibitor switch
AT-82
Injector inspection
'''''' EC-156, 205
Injector removal and installation" ....... __ .. EC209
Instrument panel................ .......
. 8T-14
Intake door control linkage adjuslment (auto A/C)
. HA-126
Intake door control linkage adjustment (manual A/C)....
.
HA-71
Intake door motor
,
HA-135
Intake manifold
" EM-35
Interior...
."
,
BT-17
Interior lamp....................... EL-103, 110

Magnet clutch
--............
HA-146
Main drive gear (MT)
. .... MT-9
Mainshaft (MT)....................
.. .. MT-9
Maintenance (engine)
.
MA-12
Maintenance
.
.
.. __ MA-1
Maintenance general
__
MA-4
Maintenance periodic
MA~5
Malfunction indicator lamp (MIL)........... EC-195
Manual transmission number
__ , GI-37
Manual transmission oil
MA-1O
Manual transmission oil replacement..
MA~19
Mass air flow sensor (MAFS)
EC12
Mass air flow sensor inspection
EC~113. 201
Master cylinder (brake) . __
__
BR-8
Master cylinder (clutch)
__
CL~6
Meter and gauges.............. __
EL-113
MIL & Data link connectors circuit.
EC-195
Mirror, door - See Door mirror
__ ,
8T-37
Mode door control linkage adjustment (auto A/C)
HA-125
Mode door control linkage adjustment (manual A/C)
.
HA-70
Mode door motor
__
HA-133
Model variation
__
GI-34
Molding - See Exterior,
__
8T-22

~~ ~:~rhaUI.

:.'" ' .. ' '."

"
oval and installation
Multi linkllower ball joint (rear) . __
Multi purpose grease................
Multiremole control system ...

IDX-5

~1Ol

Irffil
~8l

~IR\
~'jj'
u
rg;~

1~1[

IX:!~

~ll

MT-8
MT-6
RA-20
..
MA-l0
.." __ EL-202

I~

ALPHABETICAL INDEX
Multipart fuel injection (MFI) system . . .. EC-i9
Multipart fuel injection precautions.
GI-4

Power wlndow ......... __ .

.. EL-157
Precautions (General)
.
..
81-2
Pressure plate - See Clutch cover
.... CL-l0
Pressure test (AT)
.. AT-8?
Propeller shaft. .
PD-S
Propeller shaft on vehicle service .. ,., ...
. PD-6
Propeller shalt vibration.,
.. PO-6

Neutral position switch (MT)

Neutral position switch inspection ... ,

MT-S
. EC-i87

o
Rack relainer adjustmenl..
ST-6
Radialor .. ,
LC-15
Radio - See Audio
EL-190
BT-38
Rear air spoifer .",
Rear axle (disc brake type)
,
RA-7
Rear bumper
.. .. BT-8
Rear combination ramp removal and
installation
. BT-26
Rear disc brake ,....................
.. 8R-16
Rear fog lamp...
.
EL-90
Rear panel finisher
8T-25
Rear seal........
..
_
BT-30
Rear seat bell.
RS-4
Rear side w i n d o w . . . .
BT-36
Rear suspension....
.
RA-17
Rear washer......
.
EL-147
Rear window..
..
8T-35
Rear window defogger.....
,
EL-185
Rear window signal
EC-192
Rear wiper.
.
EL147
Recirculation valve.
.
EC-17, 206
Refilling engine coolant .__
...... LC-11
Refrigeran1 connection precaution '''''''''' __ HA-4
Refrigerant general precaution
HA3
Refrigerant lines
HA-142
Refrigeration cycle
HA-l0
Release bearing (clutch}..
.. .. , . Cl-8
Reverse clutch...
AT-130
Reverse gear (MT) ..
MT-9
Reverse idler shaft (MT) .
.
MT-9
Revolution sensor (AT}.
.. AT-83
Ring gear ditt. InspectiDn .
..
PD-i6
Road wheel size
GI-38
... 8T-20
Roof trim.

Oil cooler (engine)

"
..
.. .... LC-9
:Jil pan (engine)
..
.. .. EM-13
Oil pressure (engine)
.
.. ..... LC-4
Oil pump (AT)
..
.. AT113
Oil pump (engine)
..
... '''' LC-5
Oil pump regulator valve (engine)
..... LC-7
:Jil seal replacement (engine)
.
. EM32
Jil seal replacement (front of final
drive)
.
... PD9
)i! seal replacement (side of final
drive) ,
..
.. .. , PO-9
)peraling cylinder (clutch) ...
..
CL-7
Jverdrive switch
.
.
AT-82
)verrun clutch
..
. AT-i36
)verrun clutch solenoid val lie.
.. ... AT-81
Jversize piston
.
... EM-62
P

Jarking brake control .__

..
'" BR-22
)ev (positive crankcase ventilation)
inspection
,
EC212
'CV filter replaeemenL.....
.. .. MA-17
Jilot bushing replacement
EM-66
)lnion gear height diff. ..
..
, PD-17
Jiston assembly. .
..
EM-B7
'Islon pin inspection
..
EM-59
'Iston ring inspection
,
""
,
EM-59
'Iston to bore clearance
..
EM-61
'ower antenna
,
EL-i96
'ower door lock.........
EL-169
'ower door mirror...
. EL-175
'ower steering fluid
... MA-1O
'ower steenng fluid level.
MA-23, ST-6
'ower steering gear
ST-14
'ower steering hydraulic pressure ,..
ST-8
'ower steering oil pressure switch
__ EC-15
'ower steering oil pressure switch
inspection
.
EC-184, 206
'ower steering oil pump....
..
ST-24
ower steering system bleeding. ..
5T-7
'()wer supply routing ."
.. EL-B
ower transistor & ignition coil
. EC-15
,lINer transistor inspection
EC-120, 202

S
SAE Ji930 terminology list.
. GI-43
Seat bell inspection....... .
... MA-24
Seat belt pre-tensioner
RS-5
Seal belt pre-tensioner disposal
RS-12
Seat belt pretensioner removal and
i n s t a l f a t i o n . _ .. RS-B
Seat belt, fronl - See Front seat belt
RS-3
RS-4
Seat belt. rear - See Rear seal bell.
Seal front - See Front seat
8T-27

IDX-6

ALPHABETICAL INDEX
Seat, rear - See Rear seal.
BT-30
Self-diagnostic results
.. EC-50
Shift control (MTl
MT-10
Shift fork (MT).
"., .. ,. MT-10
Shift schedule
. AT-32
Shift solenoid valve (ATl '
". AT-81
Shock absorber (rear) , ".
.. RA-19
Side bearing preload d iff.
" PD-19
Side trim ... "..
8T-17
Side Window - See Rear side window
8T-36
SMJ (super multiple junction)
Foldout page
Sodium-filled exhaust valve disposal
, EM-3
Spark plug replacement.
MA-16
Speedometer ,.
."
, .. EL-115
Spot lamp ..
..
EL-l10
SRS Trouble diagnoses
RS-17
Stabilizer bar (front)................... FA~13
Stabilizer bar (rear). ".
". RA-21
Stall test (AT).....
.."
"...
AT-84
Standardized relay.
EL-6
Starter...... " "
,,
"
, EL-32
Starting system.
.
EL-28
Steering gear and linkage inspection."
. MA-23
Steering linkage. ....
ST-14
Steering wheel and column
", ST-9
Steering wheel play, .... ,.
ST-5
Steering wheel turning force
, ST-7
Stop tamp.
EL-80
Striking (ad (MTl.
..
"
MT-10
Strut (front)"
. FA-12
Sun roof .... "... .
8T-31
Sun roof, electric - See Electric sun
EL-179
rooL ....
Sunload sensor.
..
. . HA-129
Supplemental Restraint System
, . RS-5
MT-9
Synchronizer (MT)
... " . "
.

Timing chain
EM-19
Tire rotation
.... MA-21
Tire size
........... "... GI-38
Tooth contact diH. ,
PD-23
Torque converter clutch solenoid
valve __ ..
AT~81
Torque converter installation
. AT-96
Towing points..
'" GI-41
Transmission case (MT)..
... MT-8
Transverse link (front)
.. FA-14
Tread-FR&RR (Dimensions)..
.. , GI-38
Trim.,..
8T-17
Triple pressure switch
"....
.. HA-69
Trunk lid....
... ".............
BT-8
Trunk room lamp.
EL-l10
Trunk room trim
.".................
BT-21
Turbocharger .. " . . . . .
__
. EM-49
Turbocharger precautions
.
. GI-4
Turn signal lamp..
.."
EL-93
Two-pole lift .....
GJ-40

l:~

~~

;;!~

v
Vacuum hose (brake system)...... ...
BR-l1
Vacuum hose drawing (ECCS) .
EC-1 O~'.1
Valve guide inspection
EM-42
Valve seat inspection.
EM-43
Valve spring inspection .........
EM-45 ji'TI)
Valve timing control (VTC)...
EC-27
Valve ti ming control solenoid valve...
EC~ 17
Vapor lines inspection
__ . " ,MA-17 ~,~,
Vehicle identification number. .
GI-35
Vehicle speed sensor (VSS) ...... "
EC16 ,,,.,
Vehicle speed sensor inspection._ .. EC-14S. 202 n
Viscosity number (SAE)
MA-l1
VTC solenoid valve inspection
EC-166. 205 ~,;~'i

L__
W

Tachometer....
EL-115
Tail lamp
.. ,.. EL-72
Tension rod (front)
FA-13
Theft warning system
. EL-218
Thermal protector
.................' HA-70
Thermo control amp
HA-68
Thermostat
-LC-12
Three way catalyst precautions
GI-4
Throttle position sensar (TPS)..........
.
EC13
Throttle position sensor
.. EC-135, 204
inspection ., .""".,."
Throltle position switch inspection.
. EC-203
Throwout bearing - See Clutch
release bearing
" CL-8
, PD-24
Thrust washer selection ditf.
ST-18
Tie-rod.
ST-18
Tie-rod ball Joints
GI-42
Ti ghtening torque of standard bolts,

I~~

_ _

Warning buzzer.
EL-130
EL-122
Warning lamps
"
..
EL-138
Washer. fronl
Washer, rear .,.
..
.
EL-147
Wastegate valve control solenoid
valve.... __
' EC-17. 163,205
Water pump
"
__
LC-11
Water temperature gauge "....
EL-115
Weatherstrip - See Exterior __
BT -22
Wheel alignment (IranI)
FA-S
Wheel alignment (rear).....
RA-S
Wheel balance...
MA-21
Wheel bearing (front al(le)
'" FA-5
Wheel bearing (rear) .
, RA-5
Wheel hub (front)
F A-B
Wheel hub (rear).
RA-7
Wheel hub and steering knuckle
FA-8

IDX-7

~\~~
gl'i

n,

ALPHABETICAL INDEX
Wheel sensors (ABS)
__
..
Wheelbase (Dimensions)
Width (Dimensions) .,
Window, rear - See Rear window ,,_
_.
Window, side See Rear side
window
........... _.'

BR-27
GI-38
GI-38
8T35
BT-36

IDX-8

Windshield
Wiper, front ._ .. ,
Wiper, rear .--Withdrawal lever (clutch)

..

_...... BT-35
EL-138
EL-147
-.. ,
", ... _.. CL-B

EXHAUST SYSTEMS

NISSAN
MODEL S14 SERIES

ICLUTCH

MANUAL TRANSMISSION - - -

AUTOMATIC TRANSMISSION - -

PROPElLER SHAFT &

CARRIER - - -

FOREWORD
This supplemenl contains information concerning necessary service
procedures and relevanl data 'or the
model 514 series 'ace-Iift.
All information. lIIustrallons and
specitlcatlons contained in fhis supplement are based on the lalesl product intormalion available at the time
publicallon. I' your NISSAN model
differs 'rom the specificatIons contained in Ihis supplement, consult
your NISSAN distributor lor Informalion.
The right is reserved to make
changes In specifications and methods at any time without notice.

a.

IDIFFERENTIAL

FRONT AXLE & FRONT SUSPENSI

REAR AXLE & REAR SUSPENSION

BRAKE SYSTEM - - - - -

STEERING SYSTEM

-----

RESTRAINT SYSTEM

BODY & TRIM

------

HEATER & AIR CONDITIONER -

ELECTRICAL SYSTEM - - ALPHABETICAL INDEX - - lie I NISSAN MOTOR CO., LTD.

1995 NISSAN MOTOR CO. LTD.
Printed in Japan
NOllO be reproduced in whole or in pan withoUI the prior wrilten ~nniss1an of NiS&ID Motor O:wnpany l.ld., Tokyo.

j
Specific section titles are printed white on a
black background In the QUICK REFERENCE
INDEX.

Those sections which a

white background are n
manual.

Service procedures and

service data are added
or changed.
Use this SUPPLEMENT
MANUAL.
Only the added or
changed points are
Introduced in
these chapters.

Service procedures are

the same as those for
the former models'.
Refer to the NISSAN
model S14 series
Service Manual
(Pub. No.
SM4E-OS14GO).

NISSAN

514

SUP.PLEMENT-]

SERVICE MANUAL

Former models: Models belore lhe model $14 series introduced in July, 199

IMPORTANT SAFETY NOTIC

The proper performance of service is essenlial for both the salely of the 'ec
lunctioning of the vehicle.
The service methods in this Service Manual are described in such a manne
performed salely and accurately.

Service varies with the procedures used, the skills 01 the technician and Ihe
Accordingly. anyone using service procedures, tools or parts which are not s
by NISSAN must first be completely satlstled that neither personal salely nor th
jeopardized by the service method selected.

Electrical syslem

NATS V2.0 (Nissan Anti-theft System Ver. 2.0)" has been adopted on models
('Immobiliser)
A rear log lamp warning buzzer has been adopted on models for Europe.
A seat belt warning lamp/buzzer has been adopted On models lor Australia.

CONTENTS
PRECAUTIONS..

Precaulions for NATS V2.0 (For Europej...

HOW TO USE THIS MANUAL
HOW TO READ WIRING DIAGRAMS

Wiring Diagram Codes (Cell Codesl

CONSULT CHECKING SySTE

2
3
4

Function and System App

Checking Equipment

TIGHTENING TORQUE OF S

GI-1

Regarding the procedures of NAT

ignition key ID registration, refer
manual, NATS V2.0.
Therefare, CONSULT NATS software
alion manual) must be kepi slrlclly co
Integrity of the antI-theft function.
When servicing NATS V2.0 (troubl
tialisation and additional registra
tion key IDs), it may be necessa
key identification. Therefore, be
from vehicle owner.
A maximum of four key IDs can b
When failing to start the engine fi
NATS V2.0, start as follows.
(1) Turn ignition key to "OFF'.
(2) Wait approx. 5 seconds.
(3) Turn ignition key to "START"
key apart from any others on

GI-2

Psd rst81ner

1:

(LOW"'ldel~

9J~
\

~B"'ke

"!

V~ ---------Ijj 7

Air b

~In boll
In! Zl -

POd

EEi!-

c;;1i!J

Outer shim

Dust sea!

>

'=~

Cytlnder body .-.

Piston seal m~

Piston [l

The following SYMBOLS AND ABBREVIATIONS are used:

Tightening torque
AlC
Should be lubricated with grease.
PIS
Unless otherwise indicated. use recTool
ommended multi-purpose grease.
SOS
Should be lubricated with oil.
SAE
Sealing point
Checking point
ATF
Always replace aller every disas0,
sembly.
0,
LH, RH
Left-Hand, Right-Hand
03
Front, Rear
FR, RR
D.
Apply
petroleum
jelly.
00
!!l3!I
Apply ATF
22
@
: Select with proper th ickness.
2,
."
Adjustment is required.
12
Manual Transaxle/Transmission
MIT
1,
AIT
Automatic TransaxlelTransmission

GI-3

Air Condition
Power Steerin
Special Servi
Service Data
Society of A
Inc.
Automatic Tra
Drive range 1
Drive range 2
Drive range 3
Drive range 4
Overdrive
2nd range 2n
2nd range 1s
1st range 2nd
1st range 1st

COOLIF

EC

Cooling Fan ConirDI

DEFIS

EC

Rear Window Defogger Signal

ECTS

EC

Sensor
EGR and canister Control Solenoid

EC

FIFOG

EL

Front Fog lamp

FICO

EC

IACV-FICD Solenoid Valve

Valve

FIPUMP

EC

Fuel Pump

H02S

EC

Healed Oxygen Sensor

IGNISG

EC

Ignition Signal

ILL

EL

Illumination

INJECT

EC

Injector

INTIL

EL

KS

EC
EC

MAIN

EC

METER

EL

EL

Warni

WGIV

EC

Was le
Vatve

WINDOW

EL

Powe

Engine Coolant Temperalure

EGRCIV

MAFS

WARN

In1erior, Spot and Trunk Room

Lamps

Knock Sensor

Mass Air Flow Sensor

Main Power Supply and Ground
Circuit
Speedomeler, Tachometer, Temp.
and Fuel Gauges

MIL. Data Link Connector For Con-

MIL

EC

MIRROR

EL

Door Mirror

MULTI

EL

Mulli-remote Control System

NATS

EL

Nissan Anti-Theil System

PNPISW

EC

Park/Neutral Pos-ilion Switch

POWER

EL

Power Supply Rou\ing

PSTISW

EC

RIFOG

EL

sult

Power Slee(lng Oil Pressure

Switch
Rear Fog Lamp

GI-4

a specified ra"'ge

ECM part number

ECM part number can be read.

Function lest

Conducred by CONSULT instead of a

technician lo determine whether each
system is "OK" or liNG",

Control unit initial i-

All registered ignHion key 105 in NATS

salion

componenls can be initfalised and new

IDs can be registered.

Self-funclion check

ECM checks its own NATS commullicalion inlerlace.

x: Applicable
'1: NAlS; Nissan Anti-Theft Syslem

Checking Equipment
When ordorlng the below equlpmenl contact your NISSAN dlslrlbulor.
j

TOOl name

Description

NISSAN CONSULT

CD

CONSULT unil
and accessories

Program card
AE9S0 for Australia
EE940 excepllor Australia
NATS"e940"1 lor
NATS

1: An order lor NATS program card must be placed only with N1SSAN eUROPE N.V.

GI-5

7T

97

4.2

30

1.25

43

4.

32

51

1.75

71

7.2

52

84

,.7

35

1.5

M,O

10.0

M12

12.0

MI.

14.0

M6

80

M8

8.0

MID

10.0

M12

1.25

77

7.9

57

1.5

127

13.0

94

14.0

92

1.0

12

1.2

1.25

29

3.0

22

1.0

31

3.2

23

1.5

59

6.0

43

70

1.25

62

6.3

46

7.
118

206

'.75

98

10.0

72

1.25

lOB

11.0

80

1.5

177

18.0

130

\2.0

M14

.8

15

37

137

1. Special parts are excluded.

2. "This standard Is applicable to bolls having the fallowing
marks embossed on the boll head.

Grade
4T

7T

9T

: Nominal diameler

Mark

Nominal diameter o

M&triC screw Ihreads

GI-6

ENGINE AND EMISSION CONTROL OVERALL

SYSTEM

ECGS Component Parts Location

System Char!.......
System Diagram
Vacuum Hose Drawing
Circu;t Diagram

..

2
.3
4
5
6

ENGINE AND EMISSION CO

DESCRIPTION

Boost Pressure Control

IDLE SPEEDIlGNITION TIMIN

RATIO INSPECTION
TROUBLE DIAGNOSES

Contents

When you read wiring diagrams:

Read GI section, "HOW TO READ WIRING DIAGRAMS".
See EL section, "POWER SUPPLY ROUTING" for power distribution c
When you perform trouble diegnoses, read GI secllon, "HOW TO FOLLO
IN TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAG
ELECTRICAL INCIDENT".

EC1

Engine coolant temperature sensor

VTC solenoid valve

Throllis posltlon sensor

Pressure regulator

EC-2

Throttle posilion sensor

I Park/Neutral position switch

Air conditioner switch

I Knock sensor

I Battery vollage

Power sleering oil pressure

switch

I Vehide speed sensor

r Rear window defogger switch

f-----.
EGM
IEGGS

control
module)

f---f---f----

Diagnoslic test mode II

(Heated oxygen sensor manitor &. self-diagnosis)

Malf
(On

Healed oxygen sensor heater

Hea

control

Cooling Ian control

-1

Coo

Acceleration cut control

Air

was legate valve conlrol

Was
noid

Valve liming control (VTC)

VTC

f---~

EC-3

\
II

A~tl\l31"l1l

carbon

cenis!er

(I

<cJliD1IJijLm

Three way catalyst

'"m

~
!il

Intake manilold collector

Recirculallon valve

Pressure

regulator

Activated
carbon canister

Drific.a
EGRC-8PT

valve

EGA valve
Air dueL (Ctlarge air coaler IQ throWEl

Air duel
(Mass air !Iow

sensor to
turboctlQnJer)
Waslega(B valve
control SOlenoid ...al",s

EC-5

botfy~

FUSIBLE LINK

FUSE

IGNITION SWnCH
NO.1
NO.2

IGNITION

No.3

COIL

REL.AY

NO.

rn

PO~E~
4
TRANSISTOR ;2
UNIT
I

IGNITION
COIL

~~~n5~

SENSOR
SPftPJ<
PLUG

. . N;.I

<Q

g"

N;',2

NC.::!

LHO models
A-tD mode16
All r'lIClr;I!!l!1

MIT models

NO-.od

. ------

f~~~~~S2~ANTc@

SENSOR

-----

FUSleLE LINK

FUSE

IGNITION SWITCH

N
N

IGNITION
COIL
RELA.Y

lACV-AAC VALVE

rn

2
IGNITION

COIL

,,"'.aTTLE
P0511IaN

rr==l

SENSQI:l

SPARK
PLUG

-No-,S

No.2

@ :

@ :
@ :

"

NO.3

No.4

,./T moljels
~/T models
Auto all'" c:ondiUoneJ"
Mllonua} air conditioner

~~~W~S2~ANT r@

The output signal maps of the ECM are selected

according to luel octane rating, gear posilion
(MIT model) and vehicle speed (AIT model).
The wastegale valve control solenoid valve

pressure to the accelera

Knock signs are used to
rating.

OPERATION
Fuel Delane rating

Gear position or vehicle speed

800s1

1. 2 and 3 speed gears (MIT model)

Less than 46 km/n (29 MPH) (AIT
model)

Premium

4 and 5 speed gea'. (MIT modell

More Ihan 46 km/h (29 MPH) (AIT
modell
Lower than the above

Any

EC8

Aq

l!I

Perform diagnostic leSI mode II (Self-diagnostic

OK

Repair or replace compone

sary.
!

Ru., engine at about 2,000 rpm for about 2 minu

no-load. Race engine two or lhree times under n
tnen nm engine for aboul 1 minule at idle speed

1!1

1) Selecl "IGNITION TIMING ADJ" in WO

PORT mod.
2) Touch "START".

1) Slop engine and disconnect throHle pQ

sor harness connector.
2) Start engine.
!

Race engine two {If three times to aboul2,OOO r

no-load. Then run engine al idle 5peed.

Check igniti{ln timlr'lg with B timing

Iighl
1S'2' BTDC
OK

!NG

Adjusl ignition liming by tu

positiof'l sensor alter loosen
bofls.

SMA189AA

TIMING LIGHT BY TURNING

THE CRANK ANGLE SENSDR

i====;:S~T l';::R~T ====1

Race engine two or three limes 10 abou

no-load. THen run engine al idle speed

[!l

Adjusl idle speed by turning idle speed

750 50 rpm (AIT In "N" poslllon)
.!

I!l

Touch "Back".

1) Stop engine aod connect thro

ness connector.
2) Slarl engine.
!

Race engine (wo or three times to abou

no-load. Then run engine at idle speed

!
Check idle speed.

Read idle speed in "DATA MONITOR"

Check idle $peed.

OR

800 SO rpm (AfT In "N" po.lllon)

OK

Check AAC valve and replace if necess

Check AAC valve harness and repair if

~heCk ECM
SEF913J

function" by subslilulinQ ao

ECM may be the cause of a problem,

EC-10

Dala link conneclor 'or CONSULT

(Olsconnecl [he harness.)

SEf21JLB

MONITOR

*NO FAIL

CASRPM (REF)
MIR F/C MNT

OK

200J'Ilm

END

RICH

Replace heated oxygen sensor. Connect healed

harness connector.

RECORD
SEF81RK

Run el1gine at about 2,000 rpm for about 2 minu

no-load.

(j

'~.....

Set on-board diagnoslic syslem of ECM 10 Dlag

Mode II (heated oxygen sensor monitor)_

CHECK-

\ I /

m (j

I \

Malfunction indica.tor
ramp
SEHl51PA

Check healed oxygen sensor signal.

1) See "M/R FIC MNT" in "Data monitor
2) Mainlaining engine at 2,000 rpm unde
(engine is warmed up sufficrently.}, ch
the moniler Ilucluates between "LEAN
"RICH" more Ihan 5 times during 10 s
1 cycle: RICH - J LEAN ----lo RICH
2 cycles: RICH - 0 LEAN --f RICH _ LE

RICH

OR
Make sure thal ma.lfunclion indicalor lam
on and oft more Ihan 5 limes during 10 s
at 2,000 rpm.

EC-11

Repair or re

e5
~

Healed oxygen
sensor harness
conneclor

:>

~ ~

t...m

Connec~ ECM conneclor 10 ECM

~------,-----

"=;r=E==-C=M==~'!=CO=N=NE=C~=OR="1

[ill
MEca15EJ

[!J EKeepl lor Europe

Heated o:tygen
sensor harness
c:onnec::lcr

I'iLiiiiiiI

c ItC~~rc'

!...n1

V-.,.r

~cfD~

'fD'[ J"
[~
1'--,

rFi!::\
l.3!.J
MEF661DA

EC-12

Race engine two or lhree times under no-load, t

al idle speed.

2.5 kn Teslslor

MEFWO

Check "CO %.
Idle CO: Less than 10 Clo/D (and engine runs

smDD

Alter checking CO%,

1) Disconnect the resistor from terminals of eng
perature sensor.
2) Connect engine coolant temperature sensor h
lor to engine coolant lemperalure sensor.

00

Cannet:' healed oxygen sensor harness connect

gen sensor.

1
Check fuel pressure regulator.

~
[CheCk mass air flow sensor.

1
Check injector
Clean or replace if necessary.

!
Check engine coolanl temperature sensor.

Check ECM funclfon by substituting another kno

': ECM may be lhe cause or a problem, but ttlis is

EC-13

Diagnostic Procedure 28
KNOCK SENSOR (Diagnostic trouble code No. 34) .
.......................
Diagnostic Procedure 29
THROTILE POSITION SENSOR (Diagnostic trouble code No. 43)
.......
Dlagnostlc Procedure 30
AIT CONTROL (Diagnostic trouble code No. 54)
.
..
Diagnostic Procedure 31
START SIGNAL (Not self-diagnostic item)
Diagnostic Procedure 32
VEHICLE SPEED SENSOR (Not self-diagnostic item)
Diagnostic Procedure 33
EGR AND CANISTER CONTROL (Not self-diagnostic item)
.
Diagnostic Procedure 34
HEATED OXYGEN SENSOR (Not sell-diagnostic item)
.
Diagnostic Procedure 35
INJECTOR CIRCUIT (Not self-diagnostic item)
DiagnostIc Procedure 36
FUEL PUMP (Not self-diagnostic item)
.
.
Diagnosllc Procedure 37
WASTEGATE VALVE CONTROL (Not self-diagnostic item)
Dlagnosllc Procedure 38
VTC CONTROL (Not self-diagnostic item)
Diagnostic Procedure 39
IACV-AAC VALVE (Not self-diagnostic item)
Diagnostic Procedure 40
IACV-FICD SOLENOID VALVE (Not self-diagnostic item)
Diagnostic Procedure 41
COOliNG FAN CONTROL (Not self-diagnostic item)
Diagnostic Procedure 42
POWER STEERING OIL PRESSURE SWITCH (Not self-diagnostic item)
Diagnostic Procedure 43
NEUTRAL POSITION SWITCH & AIT CONTROL UNIT
.......
(PARK/NEUTRAL POSITION SIGNAL) (Not self-diagnostic item)
Dlagnosllc Procedure 44
REAR WINDOW DEFOGGER SWITCH (Not self-diagnostic item)

EC-14

THROnLE POSITION SENSOR (Diagnostic trouble code No. 43)

Diagnostic Procedure 30
AIT CONTROL (Diagnostic trouble code No. 54)
Diagnostic Procedure 33
EGR AND CANISTER CONTROL (No1 sell-diagnostic item)
Diagnostic Procedure 34
HEATED OXYGEN SENSOR (Not self-diagnostic item)
DIagnostic Procedure 35
INJECTOR CIRCUIT (Not self-diagnostic item)....................................
Diagnostic Procedure 36
FUEL PUMP (Not self-diagnostic ilem)
Diagnostic Procedure 4D
IACV-FICD SOLENOID VALVE (Not self-diagnostic item)
Diagnostic Procedure 43
NEUTRAL POSITION SWITCH & All CONTROL UNIT
(PARK/NEUTRAL POSITION SIGNAL) (Not self-diagnostic item)

..

FOR ALL AREAS

Electrical Components Inspecllon ........

...........................................................

EC-15

Diagnostic
trouble
Delected items
code No.
II'
Camshalt posi\ion sensor

Mallunclion is detected when.

EIther 1- or 180 signal is not entered lor lhe lirst

few seconds during engine cranking.
Either 1- or 180 signal is not inpul oHen enough
wl1ile (he angine speed is higher than the specilied rpm.
Mass air flow sensor circuil The mass air flow sensor circuit is open or
shorled.
(An abnormally high or low voltage is entered.)

circuit

12

13

21'
34

43

54

Engine coolanl lempera'ure

sensor circuit

The engine coolanltemperature sensor circuit is

open or shorled.
(An abnormally high or low output vollage is
entered.)
Ignition signal circui'
The ignilion signal in Ihe primary circuit is not
entered during engine cranking or running.
Knock sensor [;ircuit
The knock sensor circuit is open or shorted.
(An abnormally high or low vollage is enlered.)
Throltle position sensor cir- Tne throttle position sensor cir'Cuit is open or
shorted.
cuit
(An abnormally high or low vortaoe is entered.)
Signal circuillrom AfT con- The AfT commUfllcation line [5 open or shorled.
1'01 unilto ECM (ArT only)

.. sensor circUli 1Ir5t, II both "" CAMSHAFT

,.. Check Ilems causing a malfunctron 01 camshaft posilion
and '"IGN SIGNAL-PRIMARY (No. 21)"" are displayed one aner the other.

EC-16

For Europe models

SELF-DIAG RESULTS. [ ]
FAILURE DETECTED
NATS MALFUNCTION

TIME

ERASE

II

PRINT

I
SEF2B1!O

II the MIL blinks or "NATS MALFUN

"SELF-DIAG RESULTS" screen, p
results mode with CONSULT usin
(NATSE940). Reier 10 EL secllon.
Confirm no sell-dlagnoslic results
before touching "ERASE" In "S
mode with CONSULT.
When replacing ECM, initiallsallon
and registration 01 all NATS V2.0 I
carried oul with CONSULT using
(NATS-E940).
Therefore, be sure 10 receive all ke
Regarding the procedures oll'lATS
Ignlllon key ID reglslrallon, refer
manual, NATS V2.0.

EC-17

Park/Neutral position switch

Power steering oil pressure switch

Baltery

Arr signal

Injectors

OUTPUT

Power transistor (ignition liming)

IACV-AAC valva

X (Ignition
signal)

X
X

Valve liming conln;>1 solenoid ....alve

EGRC-sDlefloid valve

Air condilioner relay

FLJel pump relay

X
X

Cooling tan relay

Wastegate v;;Jlve contral solenoid

va:ve
X. Applicable

EC-18

5~U

~
BIR

I~I~

-=r@Q)

RIB

BIR

ECCS
RELA

3J@
B/w

'--I I f...,

,r/ol,@ID
~(ffi
BIA

rOO
IGN

8AT

SW

GND
-C

GND

GND

-I

-I

B/W

8/

rr

Irtn If3'w

CRTN

GND

-C

RIB

GND
-E

SSDFF

VB

GND

GND

-E

-E

~i!lbiJl~~~~
B

L.. 1

eBB

. e-.-.-.-"
I

.-.
B

-! -!

:jjf~- -~-~ -~-:

:624

425

W
W
I
~--------------------~

iQ7)

~53Il
~

(il)L
2

12345571011516171819

212231

B 91011

293l JI041

1314

2324252627

EC-19

33

:li:E37

39

44;46

4B

em
L

r.:!

~i)ro~
II

ECM

INSPECTION START

r.:!

'!OTcoNNECToRl1
~

Lw-t

CHECK POWER SUPPLY.

1) Turo ignition swilch "ON".
2) Check vollage between ECM lerminals @, @ and ground.
Vollage: 8aUery vol19ge

NG

SEF527.R

IaJ

~IV~

~
,6. \J. ::l9. .I1IP. 107. 100, l1S

Lm

SEF523R

EC-20

OK

----.

1) Check voltage between terminals

ill, @ and ground.

Vollage: Baltery voltage

MEC13gB

OK

~ ~es~1
~
48, 109

'---,--'

Ii

SEFS30R

~83\&a

I:iI

[!I

SEF531R

CHECK GROUND CIRCUIT.

1) Check harness conlinuily between
ECM terminals @. @ .nd engine
ground
Continuity should exist.
II OK. check harness for sharI.
OK

~15~ ~e5

NG

f---o

OK

I~I
39.45

CHECK VOLTAGE BETWEEN ECM AND

GROUND
1) Check vollage between ECM terminals @. Q]!) and ground_
Voltage; Bettery voliEige

[!I
CHECK OUTPUT SIGNAL CIRCUIT
1) Check harness continuily between
ECM terminal @ and terminal @
Conllnully should e):lsl.
If OK, check harness lor short.

rn:

.j.OK

S'EF5.12R

EC-21

LTrouble is not fixed.

Check ECM pin terminals lor damag~
or the connection of ECM harness COnnector. Reconnecl ECM harness connector and retest

EC-22

B/W~B

I
R

"
~
1

( ,

ECCS

r--\

II AEL4Y
~~CW

I
I

I
f,~

AlB

"

B/W

r'
W

B/W

41i'iil~

SSOFF VB

~
REF

VB

ECM
(ECCS
CONTROL
MOOULE)

(ffi

~~
~GY

r;;;c.;;;;;;;",,,"-,,,~;;;J.;,'~ir~i~;:;:1;:;2;;;:;<:3r.4;;:;5;;::;;:6~7~r:::l;=oi11;'a;;~r.iir.~0iiT,~~~~r,a;;;r,:;i@l
89Wti

~D

(ffi
L

EC-23

INSPECTION START
1:1

bed

FCH-E-C-K-P-O-W-E-R-S-U-'PP-L-Y-,- - - - ' N G
1} Disconnecl camshaft position sens<Jr
harness connector.
2) Turn ignition switch 'ON".
3) Check voltage' betweel'llerminal @
and ground.
VoUage: BBltery yoUage

- MEmo.'

I.

I~ ~r~W5I

~~
01<

II]
FCH-E-C-K-G-R-O-U-N-D-C-'IR-C-U-IT-.- - - - - , NG
1) Turn ignition switch "OFF",
2) Loosen and relighten ground 5crewS.
3) Check harness continuity between
terminel @ and engine ground
ConU"ulty should exl!lL
II OK, check harness lor short.

01<

."",,.

EC-24

"-"r ~ !
[Q]

nal).

Conlfnulty should exist

II OK, check harness lor short

SEF569R

LOK
CHECK COMPONENT
(Camshaft position sensor).
Reier 10 "Electrical Campanenls
Inspection".
lOK
Disconnect and raconnecl harness connectors in (he circuit. Then retesl.

1Trouble is nOI fixed.

Check ECM pin terminars for damage
or Ihe connection or ECM harness connector. Reconnect ECM harness connector and retest.

Perform FINAL CHECK by the following

Is completed.
FINAL CHECK

1
1) Erase the diagnostic test mode II

(Self-diagnostic resulls) memory_

2) Perform test drive.
3) Perform diagnostic tesl mode II
{Self-diagnostic resulls) again.

0K

INSPECTION END

EC-25

~
NG

I---

14=!l1bidJ~

I
R

"
I!~I

,,

'1

n ECCS
u
RELAY

1
1
I

1
1
1
I

I
I

~~

I
1
1
I
'
I

AlB B/W

Ih-

I
I

1
1

,.B

AlB B/W BIH

4
3B
SSOFF VB

QA+

~~

<!@]li)

SR

EC-26

~
QA-

Ii1

iii

~i50~

INSPECTION START

CHECK POWER SUPPLY,

1) Disconnect mass air flow sensor hsrness connector,
2) Turo ignition switch 'ON".
3) Check voltage between lerminal @
and ground.
Voltage: Banery voitago
SEF5J<lR

0K

iii

~e5@a ~&5

~mr
17

NG

I--

CHECK GROUND CIRCUIT,

1) Turn ignilion switch "OFF".
2) Disconnect ECM harness connector.
3) loosen and retighten ground screws.
4) Check harness conlinuity between

terminal

and ECM lerminal @.

Conllnully shoullf ellst.

If OK, check harness for short.

[ID

fOK

SEF535R

EC-27

r':J~"~"

short.

SEF536R

0K

CHECK COMPONENT
(Mass arr flow seI1S0r~.
Refer to "Electrical Components
Inspeclion". (See page EC-137.)

0K

Disconnect and reconnect harness conoe-clors in the circuit Then relesl.

Trouble is not fixed.

Check ECM pin (erminals for damage

or the connection of ECM harness connector. Reconnect ECM harness connector and relest.

Perform FINAL CHECK by the followIn

is completed.
FINAL CHECK

1
t) Erase the d~agnosli(; lesl mode II
(Self-diagnostic results) memory.

2) Pertorm lest drive.

3) Pel10rm diagnostic lesl mode II
{Self-diagnoslic results) again.

DK

INSPECTION END

EC-28

LIOR

lillY

LIOR

I
B

!t--~--$
B

1-

B ~ 8

O-:D-O-eE:-

II L

t
LloR

Iff8it

~1

GNO

TW

BR.~ B ~O
~ llW

-A

SENS
GND

ECM
(ECCS
CONTROL
I MODULE)
(ill

~~

~GY

~iffil

'i..!.@'

.123
7 B 91011

1 2 3 4 9 10 II 121 141 1;;123 24

567 a 1617161920 122LJ 3637

456 ill)
I31H516 ..
2S
l:l41141

~
~

3)3132 33 34];
434445 ~

~
L

Ir.I"'Or.;;1:l;.1"'l;;;:r.;;a;,;al;;;Oj;;,;;:r.1;:2~3;:;4;r.5~6;:;7~1ol~15T.1a:1i:ii7r.i16ir.li9 2O;;m:21 22;;;rn:;rt32m33iii34~~37~iEiiil ern

1\1111
Hill B9111121314 LJ 23242i2627
<104142 <1445464745
L

EC-29

"Lan
m

1
I

~ Moe",.1

C!ID, @D.

Vallege: Approxlmalely 5V
OK

I!l

GlflhD ~i8~

Gil

lOTS

2) rum ignition switch "ON",

31 Check \/oltage belween lerminal (j) end grolJnd.

CHECK GROUND CIRCUIT.

1) Turn ignition switch "OFF".
2) Check harness continuity betwean
terminal ([) and engine ground.
Conllnulty sl'lould exist.
11 OK, check harness for short.

NG

I--

OK
MEC'~6B

~NG
CHECK COMPONENT
{Engine coolant temperature sen30r).
Refer to "Eleclrical ComponeOis
Inspection".

J
Disconnect and reconnect harness 000neclors In Ihe circuil. Then retest.

Trouble is nol fixed.

Check ECM pin terminals (or damage

or the conl1ectron 01 ECM harness connector. Reconnecf ECM harness connector and ralest.

EC-30

EC-31

lbjdJ

~(ffi

B/R

f.
R

B/R

~:;

IT ~]
I]

S/R

ECCS
RELAY

lbid1 ern

R/B

B/W

B/R

I~I@Q)

"T"CIT)

T
II ]1

Ih

R/B

B/W

B/W

~~ii1l'il
SS
OFF

VB

VB

B/W

B/R

nu COIL
IGNITION
RELAY
ll.iJl em

ECM
[ECCS
CONTROL
MODULE)

L.

m
L

If

o[po

1-,

em

m~

~~
~

~51
T

(E)

L'

CIT>
L

~m
~GY

r;;;;;;;;:;;;;;;;;:;;:;;;;;;:;;;;~r.l;:;:2;;;::;3;;:4;;:;;:5r.B:;;7~r;1~I;;r.l~17~1;:;:;9r.;;2!J~1;;;n:~;r.;;i:;:;;::;;:;;;;;:;~
891011

1314 LJ

24

(ill
L

EC32

I!iJI

qJl

R/Lt

:;b
8J

R/wt

R/W

BR

~
R

~---~--~---------tOJ--------(ffig)

R/L

$---~--.---------.-------R

~---~--~---------~---------

",m~ll ~ I] ~ IJ ~ 1
~~~K &

PLUG

l!.iJI 1!iJI

B/YtB!

~ii'''''~ ~ .I

lbiJl 1!iJI

WtH

l!.iJJ

W
t .!

lb

1-- 1--

rrFal3\m
~GY

r-----------------~

:crnb
:

GY

~m>:
GY

rr.:;~:;;:;;;;;;;;;;:;,:;;:;::;1:;:;2;:;:3;;:;:::;:4;:;;5:;:;6;:;:7;;:r.:1al~1;;;16~1~71""6r.;;r.;:20<;;<;;:1;;;;:;;;:;;;;;;;;;;;r.:~;;;;;;;r.;;r.;;;;] (IT)
69101112

10

24

26

EC-33

J$<8W

lbj.Jl

BIR

,....,

B/R

~
1

$~

8/RlHIW

[I] ~Eiy

U-iJ1

RIB

BIW

B~R Q@)

$~

B/R

1 ' - - - -....

BIW

1 -II

RIB

8/w

BIW

38
VB

471
VB

SS
OFF

I!
IbjJI
ECM
(ECCS

:
B

~~~E~f

B/R

:IIIbid] I,~"""
IJ

COIL RELA

CEID

LL

I
t-,

em

UZ> ~
~@2l

tmIID

rrFal3\cm>

~GY

rr.;;;r.~~;;;:,;;;:;;;r.;a:r.;:;;m:;;a~~~H;r.:;;r.~r.;;n;~~~~~
ern
L

EC-34

~---------

tIfili\rn>

'\TI]J

6Y

~lt!@~~<tW

~ GY , GY , 6Y , 6Y

: cmb
:

rr.:;::;:;;;;r.;;;;;o;;;;::;:;;;;rr.:;:~;:::::;::;~~~;;;;;:;;;:;;::=;.;::;;;;;;;:;;;;;;;;;o;;;;;;;::;;;.....~~

em
L

EC-35

6Y

T8+-1
[ill

MEC147B

f!)

fp~10~:J

Wi
CeJ 1

MEC'~lJB

I!I

~~io~

OK

f!)
CHECK POWER SUPPLY1I1.
1) Turn ignition switch "ON",
2) Check voltage belween terminals
G), and ground.
Voltage: Banery Yollage

NG

f----+

OK

I!I
CHECK GROUND CIRCUIT-I.
1) Turn ignition sWitch 'OFF".
2} Check harness conUnuHy belween
(erminal (?) and engine ground.
Continuity should exist
If OK, check harness for short
!OK
CHECK COMPONENT
(Ignilfon coil relay).
Refer 10 "Eleclrical Components
Inspection".
!OK

MEc149B

Disconnecl and reconnect harness conneclors in the circuit. Then retest

!Trouble is not fixed.

Check ECM pin terminals for damage
or (he connection of ECM harness conneclor. Reconnecl ECM harness connector and retest.

EC-36

If OK, check harness for shorl.

2) Disconnect ECM harness connector'.
3) Check harlless conlinuity
between following terminals.

I:J

MEClSOB

~i5~~i8

<!l-

.@

@-@
@-@
CQntlnully should exTs'If OK, check harness for short

LJ

OK

[ill

(I):No.1 cvlinder
(!):No.2 cylinder

:No.3 cylimfar
(!):No.4 cylinder

MEC1518

I:J

~&5 @}~15

""w

@efl"@:;p

CHECK COMPONENTS
(Ignition coil and power transistor unit).
Refer to "Eleclrical Components
Inspection".
OK
Disconnect and reconnect harness conneetors in the circuit. Then retesl
Trovble is not

fi~ed.

Check ECM pin terminals for damage

or Ihe connection 01 ECM harness COr'lneelor. Reconnecl ECM harness conneelor and retest.

fl[Q]
[Q]
SEFS31R

EC-37

EC-38


l:.flw;-J
I

,=t
fl

r
r

0
1

KNOCK

SENSOR

!,

iQLl

rr.;:;;~~~~;;:;rr7il::;;2;;;3;;:"~5r.;:6:r;7~1-;;=;]1~15r::16;r;1;;r7;:;';:;;19~~:;:;::<;;;;;;;;;;;;;"'""':Ei""!lo;;;;;;;;;o] <:ED
891011

131<1 -

232~

EC-39

Refer to "Electrical Components

Inspection"

0K

Disconnec1 and reconnect harness connectors in the circuit. Then retest.

lTroub'e is fixed.
Check ECM pin terminals lor damage
or Ihe connec\ion o( ECM harness connector. Reconnect ECM harfless connector and retesl.

Per10rm FINAL CHECK by the followin

is completed.
FINAL CHECK

1
1) Erase the diagnostic tesl mode II

{Sell-diagnostic resulls) memory.

2) Perform test drive.
3) Fiertorm diagnostic tesl mode II
(Sell-diagnostic ,esulls) again.

0K

INSPECTION END

EC-40

I
I

r
r

O-:A::-O-:E-

I
I

I
I

--::D-O

I
I
I
I
I
I

I
I
I

I
I
I

t ~r-I~---I
LG/R

1i37il~~

AVCC

TVO

GNO
-A

B
ECM
(ECCS
CONTROL
MODULE)

em

~~

Q.g@) BR

c:

'='_
I

SENS
GND

--.

trn>

~(IT)

~w

~~
~w

I~I
LJ
I
5 6 7 8 1 17 1 1

l 1

EC41

44

If OK. check harness lor shorl.

00

OK

MEFS14E

[!J

THRDTILE SENSOR CKT I

DEPRESS
THROTILE FULLY
THEN
TOUCH START

1.

I
~II

START

CHECK INPUT SIGNAL CIRCUIT.

MEF6:WL

[!J

THROTTLE SEN ADJ

ADJ MONITOR

THROTTLE SEN

O.45V

======== MONITOR ========

CAS'RPM [REFI
IDLE ~OSITION

Orpm
ON

II

~&5@a ~e5
ECM

'fICONNEclllRll

3) Perform "THROTTLE SENSOR

CKT" or "THROTTLE PDSI
SEN CKT" in "FUNCTION
TEST" mode with CONSULT
OR
3) Read "THROTTLE SEN" or
"THRTL POS SEN" signal in
"WORK SUPPDRT" mode With
CONSULT.
Throltle Yelve fully closed:
0.35 - 0.65V
Thr~ttle

MEC157B

[!J

1) Reconnect thralile posiHon

sensor harness connector.
2) Turn ignHion switch 'ON",

<TI b;ID

valve fUlly open:

ApprQx. 4.0V
OR
') Disconnect ECM harness connector.
2) Check harness continuity
between ECM lerminol @
and terminal @.

Continuity ,ghoul!:! exist

II OK, check harness lor shorl.

"

,,"OK

[lID]
EC-42

f1

FINAL CHECK

1
1) Erase the diagnostic test mode II
(Sail-diagnostic results) memory.
2) Perform lest drive.
3) Perform diagnostic lest mode Il
{Self-diagnostic results) again.

0K

INSPECTION ENO

EC-43

NG

I~J I

Lie @: L/W

L/R

@:

L/G ~: L/W

L/R

"3

~-------~-------~
~:<D

"1
"2

L/G

L/w

L/R

rrfcrn

OH

DT3

DT2

AIT
CONTRO

UNIT
~:

~@
~W

1 2 3 4 9 \0 1112

5 6 7 B \6 \7 18 \9

~~
~W

~115

1;1
I:::

42;

27:2ll29113132

404\42

EC-44

44

34

46

neelors in the circuit. Then retest

LTrQUble is not fixed.
SEF.5ol0~

Check ECM pin lermi(lals for damage

or the connection or ECM hllmss conneclor. Reconnect ECM harness connector and relest.

Perform FINAL CHECK by the following

is completed.
FINAL CHECK

1
1} Erase the diagnoslic test mode \I
(Sell-diagnostic results) memory_
2) Perform test drive.
3) Perform diagnostic lesl mode II
(Self-diagnoslic resulls) again.
!OK
INSPECTION END

EC-45

NG

I----

OR!L

.~

ORIL

OR/L

R14;l

10 l I !
111111

111
II 1 II

37

12345671011117181
8 9 10 1112131~ t:::I

444648

EC-46

CED
L

1 CLOSE THROITLE. SHIFT

CHECK OVERALL FUNCTION.

~,I

"MONITOR

"NO FAIL

STAAT SIGNAL
IDLE POSITION
AIR COND SIG
NEUTRAL SW

CONSULT.

~o

"START".
terminal @ and ground.

Vollage:

~i)ID~
\

19n1llon swllc.h "START"

Baltery vollage
Except i!lbove
ApprDxlmately OV
'I

34

ON

OR
1\ Turn ignition swilch

2) Check voltage between ECM

~l

OFF

IGN "START"

SEF384J

2) Check "START SIGNAL" in

"DATA MONITOR' mode with

IGN"ON"

RECORD

mode with CONSULT.

OR

OFF
ON
OFF
ON

1) Turn igniLion switch "ON".

2) Perform "START SIGNAL
CKT" in "FUNCTION TEST"

START

MEF4S18

TO P OR N RANGE
2 TOUCH STAAT AND
START ENGINE
IMMEDIATELY.

INSPECTION START

STAAT SIGNAL CKT.

r Check il 7.5A fuse is OK.

!OK

SEF~'F1

EC-47

NG

-Check ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness con-

nector and retest.

EC-48

COMBINATION
(SPEEO-

METER

OMETER)

r~-------------------------~I

I ~]~]"W:
: ~ ~ '="1
I
W
B
I

~~

~GY

EC-49

~lEill>

GY

Indication.

OR

RECORD

(j)

I
SEFS811

IGCMJOfCONNECTOR I
32

GJ

neclor,
3) Turn ignilion switch "ON",
4) ROlale drive wheel by hand.
51 Cheok voliage between ECM
(erminal @ and body ground.
Vollage should vary between
appro. 0 10 5V.

~e5CJ~

&:i

2) Disconnec' ECM harness con-

lwI

!NG
CHECK SPEEDOMETER FUNCTION,
Make sure thai speedometer functions
properly.

SEFSoIOR

[1te5~~1D

NG

0K

GJ
n

~II IHoH-H1
32

PJ.l

CHECK INPUT SIGNAL CIRCUIT.

1) Turn ignition swilch "OFF".
2) Dlsconnecl ECM harness connector
and combination meter harness connectar.
3) Check harness continuity between
ECM terminal @ and lerminal @.

Continuity .hould 1.1.

SEF54411

II OK. check harness for shorl.

!OK
Disconnect and reconnect harness conneclors in the circuit. Than retest.

Trouble is nol fixed.

Chec'k ECM pin terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness connector and ralest.

EC-5D

NG

~rep:

11~

L/R

L/R

~O~

L/R ~

L/R

=r~
L/R

=r

I~f - ~ - ------~~I
L/R

L/R

L/R

~ <BW
~':,
~@------~J

L...:E-o~
LHD mode ls
: RHO mode ls
*1---(1) E2,

(1):

L/R
H7

LJ
l

EGR

EC-51

ECM
IECCS
CONTROL
MODULE)

(ill

INSPECTION START

CHECK OVERALL FUNCTION.

1) Slart engine and warm it up suUj

crenlly.
2) Perform diagnostic test mode II (Selldiagnostic resulls).
Make sure that diagnostic trouble
code No. 12 is not displayed.
3) Make sure that EGR ....alve spring
moves up and down (Use your linger) under lhe following conditions.
At Idle:
Spring does not move.
Rac{ng -engine from Idle 10 3,000

'pm:
Spring moves up and down.

NG

CHECK VACUUM SOURCE TO EGR

VALVE.
1) Disccmnet;l vacuum hoses to EGR
valve 3nd activated carbon canisler
2) Ma'k~ sure Ir,al va[;uum exists under
lhe rollowing r:ondihons
AI Idle:
Vacuum should "01 exist
Racing engine from Idre to 3,000
rpR1~

Vacuum should exlsl.

NG

EC-52

OK

lw-I

SEFS4~A

~ ~_. ~

solenoid valve harness conneclor.

3) Turn ignilion swilch "ON".
4) Check vollage between lerminal @
and ground.
Vollage: Baltery voltage
OK

t)

Clogging

Improper CDnneClion
SEFEl16F

CHECK OUTPUT SIGNAL CIRCUIT.

1) Turn ignilion swHch "OFF",
2) Disconnect ECM harness connector.
3) Check harness continuity between
E.CM terminal G!D and terminal @_

Conllnulty should ellsl.

If OK. check harness lor shorl
OK

MEC16JB

~5~~i5

I~II-~
'0'

SEF546R

EC-53

.,.

Inspection".

~OK

[QrIJl ON/OFF I

SEF222N

Disconnect and reconnect harness conneelors in the circuit Then retest.

!Trouble is nOllixed.
Check ECM pin terminals ror damage
or the connection of ECM harness connector. Reconnecl ECM harness connectQr and retesl

EC-54

SR

"1"'

em

SR

~
I' [111_
3

HEATED
OXYGEN
SENSOR

4JI

*1

IF1'9i1

02H

025

(lli)

ECM
(ECC5

CONTROL

MODULE)

<ill

~([])

GY

rr.,ii'oi[;;;,~t~j~~I;ai~1 ~1;:;2~3r:4~5~6Y::7~r;;J~15:r.lii61~18iii19iii20~ii'1 ;:;miiil ~33iF.34~@!I~i@l

t '111

11111 I

B 91011

11402324

3:)

EC-55

4041

46.0

em
L

no-load.
3) Set E:CM Diagnostic Test
Mode II.
4) Keep engine speed al 2,000
rpm and make sure Ihat Ihe
malfunction indicator lamp on
the instrumenl p~nel goes on
and off more (han S limes during 10 secOnd~.

RECORD

SEFal5K

./'

CHECK"-

~,unc!,on In~,o,
lamp

(;)

MEC2HIB

f3 "i)

[;J

CHECK POWER SUPPLY.

1) Stop engine.
2) Disconllect heated olCygeo sensar
harness connector.
3) Turn ignition switcn 'ON".
4) Check voltage between terminal @
and ground.
Voltage: Battery vollege

[!]

00

I,,+,,_

00 ~

~OK

~&5<&a~i5

It1CitiICONN<
Il
,1I
cTOR

LASEFS47R

EC-56

CHECK OUTPUT SIGNAL CIRCUIT,

1) Turn ignition switch 'OFF".
2) Discannecl ECM harness connector.
3) Check harness conllnuily between
terminel @ and ECM terminal Gill,
Conllnully should ellsl.
It OK, check harne-55 for short.

SEF321J

[!]

!TJ'oubJe is not IJxed.

Replace healed oxygen senSOr.

EC-57

$~
B/R])

$lEQQ)

S/R

$~
R

1---.,---.,---.
I

~
2

IbjJ
W/B

INJECTOR

~.1

@9l

~2
1

INJECTOR

~.2

W2
1

Y/B

GIS

INJECTOR

~.3

lEW

~2
1

INJEC

~.4

LIB

~--~--~-------~-------~
YIB

w/B

mm

Iiillil

IN..!

IN,J

II

'2

: ~1lliZl:
I~W

~1lliZl:
~

G/B

LIB

iiillil

IN,J

IN,J

'3

'4

l:8l 1CW !till> ~ IillID

(!1g)B'B'e'S

I
I

~<rnl
~GY

1 2 3 4 567 r;11~.:~g
B 91Dl1 114LJ

EC-58

<il
L

o
= =

INSPECTION START

.... POWER BALANCE

=
MONITOR
=
CAS.RPM [REF)
SOOcpm
AIR FLOW MTA
O.9BV
AAC VALVE
41%

==

OK

"00]G~

DCIDDL::::J

MEF.5081BA

NG

S'EF73Ci.

EC-59

11"~'~"'um
[ill

TITIJ
-~

"'"

Lffi

CHECK OUTPUT SIGNAL CIRCUIT.

1) Turn ignilion switch "OFF",

NG

2) Disconnect ECM harness conneclar.

3) Chec'f; harness conlfnuily between
ECM terminal @)and lerminal @.

ECM (erminal @.land termina~ @,

ECM terminal @and terminal @,
ECM terminal (ill)and terminal @,
Connnuity should ex!s.t.
If OK, chec:k harness for short.

1m1i

!OK
~-

@D:No.1 cyl'fnder (@):No.3cylinder

@:No.2cy1inder @:No.4cylinder
MECt61B

CHECK COMPONENT
(Injeclorl,

Relet to "Electrical Components

Inspection"
OK

DiscDnnect and reconneci haroess connectors in the circui" Then retest.

~TrOUble ,s not fixed.

Check ECM pin lerminals lor damage

or lhe COl1l1ection of ECM harness can
neclot. Reconnect ECM harness connector and retest

EC-60

Qill) ill) ~ em

';'@'''~'''l
SlY

1
1

M
2

ll3

106
FPR

ECM
IECC5

CONTROL
MOOULE)

(ffi

);rl..<TIQ)
\.!@

GY

3334.'1>

39

4142434445E474/1

EC-61

(IT)
L

.['l]

CD, @ IlHD models I. @, @ (RHO

models) and ground.
Voltsge: Battery vol lege

(j).@.LHD models

@,@'RHO models
OK

MECIGaB

til

~i5(@j ~i5

~+
[ill

rrnJl

(!J
CHECK GROUND CIRCUIT.

1) Turn ignition switch OfF".

2) Disconnect luel PlJmp harness cQnnector.
3) Check harness continuity between
terminal @ and body ground, lerminal @ and terminal @.
Conllnulty should exlsl.
II OK, check harness lor shorl.

MEC169B

l!l

NG

OK

~&5(@d ~e5

[ECMffiNNecroR
106

0: lHDmodels

II

(j]

JIDl
(D:RHDmode's

SEP549R

CHECK OUTPUT SIGNAL CIRCUIT.

1) Disconnect ECM harness connector,
2) Check harness continuily between
ECM terminal @ and terminal
(lHD modets). G) {RHO models).
Conllnulty should exist
II OK, check harness for shott.
..OK

EC-62

NG

f-----

"I
'==~

ON/DFF

ICQ..E[J

Refer 10 "Electrical Componenls

Inspection".

'--

10K

SEF49BL

CHECK COMPONENT
(Fuel pump).
Refer to "Eleclrir;al Components
Inspection" .

0K

Disconnect and reconnect harness con-

nectors in the circuil. Then retest

!Trouble is not fixed.
Check ECM pin terminals lor damage
OT

the connection

or ECM harness con-

nector. Reconnect ECM harness connector and I'elest.

L-_

EC-ti3

~O~i
I

SR

WASTEGATE VALVE
CONTROL SOLENOID
VALVE

ru>

IWI (D:
'=r :~

DRIB

O~
~
lE@01ill)

I8Q)

OR/BIDOR/B

em

~ OR/B-:e-O

LJ
~
WGC

IT;p- <0:
[]]

: ffil

123CJ45
67B91011

~I~O~l~1~I~il~IOm:P'1~2~3~4~5i6~7~r;;J;ji1
~lilg7~18jj11i211i2Iirn3~132~j~i;6m"S/~38il
( il
I IIlll
III I 891011 1314 LJ 2425
2930 40414243
4748
L
EC64

INSPECTION START

CHECK OVERALL FUNCTION.

1} Starl engine and warm i( up suffi-

ciently.

_Alr passage hose connoctod to

WBslegall'J valve conlrol solenoid valVe

MEC171B

2) Perform diagnostic lesl mcde II (Selfdragnoslic resulls]. Make sure lhat

diagnoslic trouble code No. 55 is displayed.
3) Slcp engine.
4) Disconnect air passage hose 10
wastag8te valve control solenoid
valve and restart engine.
5) Make sure thai boost pressure exists

under Ihe following conditions.

AI Idle:

Boost pre66ure should nol exist

Engine Is racIng qulckl",
(Up 10 aboul 5,000 rpm).
Boosl pressure sbould exlsl.

~NG

EC65

OK

3) Turn ignflion switch "ON".

4) Check voltage between terminal
and ground.
Voltage: Battery voltage

Impropl!f r::onnection

SEFSl6F'

OK

iii

r=CH-E-C-K-O-U-T-PU-T-S-r.J:GN-A-L-C-I-RC-U-IT-.---, NG
1) Turn ignilion switch "OFF".
2) Dlsconnect ~CM harl1ess connector.

3) Check harness continuity between

ECM terminal
MEC1738

and terminal @.

Conllnulty should' eElsl.

It OK. check harlless for short.

OK

CHECK COMPONENT
(Waslegale valve control solenoid
valve),
Reier 10 "Eleclrical Components
(nspeclion" .

Disconnecl and reconnect harness connectors in Ihe circuit. Then retest.

!Trouble

is not fixed.

Check ECM pin terminals fOT damage

or the conneclion of EGM harness I:on
nector. Reconnect ECM harness connector and retest.

EC66

1~''8Q)

Jcm
SR

SR

VTC

SOLENOID

VALVE

lJ~

I
y

t1~

L
VTC

ECM
IECCS
CONTROL
MODULE)

(ill

.r.'i'=<EW
~

r;;;;;;;;;;:;;;;;;;;;;;r.;;:;r.:;;:;:;1r.2~3;:4~5;:;:6;;:7;::r.:10l:;'hl~5:;:;16;r.l~lB:;;:19"'20;;;;r.;21;;;;;;:iT.3:;;:1r.:32::r.33:::r:::34~15~:JI;;r.o:r=:il Cill
6 91011

14

LJ 2324 26<!1

3l 404142

EC-67

-fl

rzI

~i)ID~~

~lf%<p

~t'~'
I:;)

SEFS52R

~i5tP~

CHECK CONTROL FUNCTION.

1) Jack up drive wheels.
2) Start engine.
3) ShiH gear to any position except the
neutral position 'MfT model).
Shift sereclor lever to any position
e)licepl "N' or lOp" posiHon (Arf
model).
~) Check voltage betweell ECM lerminal
Gill and ground under the following

conditions.
Vollage:

~I

Qulckly depress accelerator

pedal, Ihen quickly relesge II.

'"

INSPECTION START

ApprOKlmately
Allole

ov

Ballery vollage

tNG

SEF553R.

EC-68

~r

lerminal

and ECM terminal

Ir OK, check harness Cor shorl,

SEF55d'A

I!I

GE).

Conllnulty should exist

[Q]

II

VALVE TIMING ofV CKT.

CHECK COMPONENT

(VTC solenoid valve).

1) Reconnect ECM harlless connector and VTC solenoid
valve harness conneclor.
2) Turn ignilion switch 'ON".

DOES THE SOLENOID

VALVE MAKE
AN OPERATING SOUND
EVERY 3 SECONDS'

J) Perform "VALVE TIMING SiV

CKT" in "FUNCTION TEST"

~1DIQ]Ci'.ill

mode with CONSULT.

5EF711L

I!I

ACTIVE TEST

VALVE TIMING SOL

SOL" in "ACTIVE TEST"

mode with CONSULT.

OFF

4) Turn VTC solenoid valve

"ON" and "OFF", and check
operating sound.

======== MONITOR ========

CAS-RPM (POS)
AACVALVE

OR
J) Perform "VALVE TIMING

Orpm
16%

OR

Refer fa "E.leclrical Components

Insp6ctiem",

[Q[]I ONiOFF IEm

lOK

MEC211'B

Disconnect and reco ....nect harness con

nectors in the circuit Tilen relesl

iTrouble is nol fixed.

Check ECM pin lerminals for damage
or the connecHon of ECM harness connector. Aeconnecl ECM harness connector and retest.

EC69

S/Y

$~
S/Y

S/Y

21

IACV-AAC
VALVE

58

58

1l3

ISC

ECM
(ECCS

CONTROL
MODULE)

(D

18l~

Q.@ BR

1.1
""0"'I"'t;;;r.;;,r.;or.l;;:;;;::10;;;1;;;:;1;:;:2;;:;:;:3;;:~;:;;:5;;;6;;;7~roJ~15or.l;;:;6:;1
111111

11111891011I2II~LJ23~

ir.18;;:;:1;;9;;;;;;;;:;;;;;:m:;:;;;;;~;;;;;;;;;;~;;-
L

EC-70

IIGN TIMING ADJ.

- - CONOITION SETTING-IGNfT FEEDBACK:

===

HOLD

===

MONITOR
CAS. RPM IREF)
800rprn
IGN TIMING
15BTDC
IDLE POSITION
ON

INSPECTION START

~m,----__-----.:l,----

---,Drops"

CHECK OVERALL FUNCTION.

1) Slart engine and warm Il up su1ficienlly.

2) Check idle speed.

aoo so rpm (AIT: In "N" poslllon)
If NG, adjusl idle speed.
~ 3). Per10rm "IGN TIMING ADJ"
~
in "WORK SUPPORT" mode
with CONSULT.
Disconnect \llrClUle position
~
sensor harness connector.
41 Make sure that idl. speed drops.

tG'\

~ Does not drop.

@

EC-71

'-

harness connector.

~=

~urABU

r!1

SEFI961

.,cr",,,,'.

MCfII OPENING

34%

~;R~ ~R~~:1OR ~5~m=

AIR FLOW MTR
ENG lEMP SEN

ij

1fiN
83D C

~~I OWN

1) Disconnect ECM harness conneclor.

2) Check harness continuity

IQill

belween ECM (erminal

SEF319l

[!]

2) Perform "AAC VALVE

SYSTEM" or "IACV-AACN
SYSTEM" in "FUNCTION
TEST" mode wilh CONSULT.
OR
2) Perform "AAC VALVE OPEN
ING TEST" or "IACV-AACfII
OPENING" in "ACTIVE TEST"
mode with CONSULT.
OR

Bnd lerminal

@)

@.

Conllnully should exist,

~i5@a ~eJ
ECM

]O[coNNECTORll

",

dfp

11 OK, check harness for short.

10K
CHECK COMPONENT
(IACV-AAC valve).
Refer to "Electrical Components
Inspection".

LPL

!OK
SEF555R

Disconnect and reconnecl harness con-

neCiors in the circuit. Then retest.

!TrOUble is not fixed.
Check ECM pin terminals for damage
or the conneclion of ECM harness connector. Reconnect ECM harness connector Bnd retest.

EC-72

11

I AIR

~~~~TIONER

-ii-l!.iJI-&-3r;---------;r~-:!;-r;J

@4J

Gj:" LlR

LtR

LlR

'""'"
IE12Y

THERMISTOR

j~~~:~~~r:Dr

I
R

G/Y

.....

~-----o----~
LIR
:
G/Y

Y/8

~----~~----~-------------------~

L~R

IACV-
FICO
SOLENOID
VALVE

4JI
8 ~

LOW
..

HIGH

TRIPLEPRESSURE
SWITCH

~::
NORMAL 9""
~

SIP

Ifill
ri4Tn
--"-A7-:C:"'------------'=AR~-, ECM

_=.........
=
...
!)

RLY

CON

(ECeS
CONT
MODU

em

~ (@)
aIID PU

~:)

ljfi;l

J:Ql@)

[ill]1.lw

Ir.j"'O;;;;1:;;;1;:1;;;;;;;;;:I"'I;;::r.;1;n::1T.2;;:;::::;3;::4~5~6:;:;7::i7-'1~;h;1 ""1'"'61;;;7;;;1;;;1;:2Il;::;;;;:1;;;:;;T.3~132=::r.;;;;;::r.=;;:;;;:;;-r (ill

1 11 11 I
11 1 Il B 9 10 1112 14 ~ 24 C5
30 l41
L

EC-73

AIR

~~~~TIONER

IU

!=

21

m
GIW

To compressor
. - L/R. (Refer to

YILB

LOW
HIGH
~~~SURE R """""
SWITCH I~I
>&Q,.
..'......
~rpi"\
NORMAL ~
R \.d.J

It

~
$QV

HA-AiC. M.l

LlR

1~~~~-

G/y@Ql

1r!ZJ1~

SOLENOID
VAL.VE

""'r'@

~ ~

GIY

IT1\il

rr.rnl

AC
RL.Y

AR
CON

r----'L7:"-------"';';~___,

t-"
~

Gr

~@

00

@)

1f3'!;11 (8])

THERMISTOR

ECM
(ECCS

~g~

CIT>

tCg)

C'<I~

<1@ PU

JSa.~

C!W

~@
~ W

1iiiiiii~~~r.;;rr:;:;:;;;miETE~~~;r.;r.:;;;;;;r.~~~~~~l
L.

EC-74

[fl1

MONITOR

CASRPM (REF)

NO FAIL

INSPECTION START

SOOrpm

r.:J

,------~-----...,OK

RECORD

MECI042B

r.:J

ID
1" .)
.. [
~\~\\\\IIII"lfJlllll.

~7
0/0 .,IX(l.lm,~ e

00

C~H

CHECK OVERALL FUNCTION

1) Starl engine and warm it up su',iciently
2) Check ;dle speed.
(f.j\ Read idle speed In "DATA
~
MONITOR" mode wilh CONSULT.
r<i\ Check Idle speed.
~
SOO 50 rpm (AIT: In "N" posllion)
If NG. adjusl idle speed.
3) Turn air conditioner switch and
brower fan switch "ON".
4) ~echcck idle speed.
aOQ rpm or more

NG
Check if air conditioner compressor
runctions normally.

OK

ME~lij4E

EC75

N~

[!1

CHECK GROUND CIRCUIT.

1) Slop engine.
2' Check harness continuiLy between
terminal @ and engine grounCi.
Conllnully should axlst.
II OK, check harness ror short

0K

CHECK COMPONENT
(IACV-FICD solenoid valve).
Refer 10 "Electrical Campananl!
Inspection".

0K

Discol1nect and reconnecl harness connectors ill the circuit. Then retest

Trouble is nalfixed.

Check ECM pin terminals for damaQe

or the connec\ion of ECM harness con
neclor. Reconnect ECM harness connector and retest.

EC-76

h
i

I]COOLING t=)COOL

I]

. FAN

, RELAY-1
3
()

ORL/L
BR1/W

~i:

~_OR/L
BR/W

W/R

COOLING
FAN
MOTOR

<b>;ffi
:rn>

<b>:
:

A
T

LHD models
RHO models

em,@
L

~m

\11Y

GY

~~

\!@ GY

EC-77

~
OR:L

TRIPLEPRESSURE
SWITCH

ON

CD:

OFF---

rn

~
8

<D: LHD models

RHO modelS

"1<D 10
*2<D A12:

DRI

r-!I.;~~
RF

26
Ai

RL

~<D:~:~
t:ill)
,
B

111~O~l;;J:1i'iffi11~f.! 'f.IOlillffij
1 II It I

1I It II

1 2 3 <I 5 6 7 r;;11516171B 19
B 9 1011121314 t::::J
4

21

3132 33

3J 40 41

EC-78

1i 36
44 4546 47

39

CE

INSPECTION START

1
CHECK OVERALL FUNCTION-I.
1) Tur'o ignition swilch '"ON".

2.) Make sure thai engine coolant temperature is low.

3) Start engine
4) Make sure thai coofing fan is not

I '

operating.

ING

.f------->-@(R
MEC178B

(LHD)

EC-79

!OK
Go 10 "CHECK OUTPUT SIGNAL
CIRCUIT" in 1 PROCEDURE A 1

[!J

RHO models

~1D&a ~5

[!J IlHD models

CHECK HARNESS CONTINUllY

BETWEEN COOLING FAN RElAY1 AND
ECM.
1) Slop engine.
2) Disconnect cooling Ian relay-1.

3) Disconnect ECM harness conneclor.

4) Check harness conlinuily belween
terminal and ECM lerminal .

[Q]

Co"lTnully should exist

II OK, check harness for short.
SEF~fI

!OK

Go to "CflECK OUTPUT SIGNAL

CIRCUIT" in 1 PROCEDURE A I

EC-80

II

Il

ID Cff~H

MEC1BOB

II

rpm unlil engine is warmed up sufficiently.

3) Make sure (hat cooling fan begins to
operale at low speed during warmup.

OK

i[~:-~
~ ~
~

~ID

CONNm

40011:

If)

Resistor

MEC161B

@
@

II
CHECK COOLING FAN HIGH SPEED
OPERATION.
1) rurn bOlh air conditioner swilch and
blower fan swHch "OFF"
2) Slop engine.
3) Connecl 400.Q resistor between terminals @ and (j) on harness connector @D. {Refer" to "Diagnoslic
Procedure 2S".}
4) Restart engine and make sure that
cooling (an operates at high speed.

10K
INSPECTION END

EC-81

NG

Lan "

~
LHD models

~es~~i5

LaJ1 _+','

Effi)

~
[!I

MEGIS3BA

Gil
CHECK GROUND CIRCUIT.
1) Turn ignilion switch "OFF".
2) Disconnect cooling fan mOlor harne:!lS tonneclor.
3) Check harnes.s continuity between
terminal @ and terminal . terminal @ and body ground.
Continuity should exIst.
If OK, check harness for shorl
OK

RHD modi:!1a

~&5~ ~i5

~II
,

lPL

[!I

RHO model5

CHECK OUTPUT SIGNAL CIRCUIT.

1) Disconnect ECM harness connector.
2) Check harness continuity between
ECM terminal and terminal @.
Conllnulty .hould exl.l.
If OK, check hemess ror' short

OK

SEF5561l

CHECK COMPONENT
(Cooling fan relay-i).
Refer to 'Eleclricar Components
Inspection".

0K

EC-82

ClJ

Inspection".

!OK
SEF82BK

Disconnect and reconnecl harness connectors in the circuit. Then !'elesi.

!Trouble is not fixed.
Check ECM pin terminals for damage
or the connecllon or ECM harness con-

neclor. Reconnect ECM harness conneclor and retest.

PROCEDURE B

A~'"""""~~

'r=n~

MEC1858

INSPECTION START

~
CHECK POWER SUPPLY.
1) Stop engine.
21 Disconneci cooling fan relay-2.
3) Turn ignition switch "ON".
4) Check Yollage between terminals
~. and ground.
Vollage: aallery vollage
OK

EC-83

NG

f-----

W
[Q]

II

SE'>5'R

RADIATOR FAN CIRCUIT.

DOES
RADIATOR FAN
ROTATE AND STOP
EVERY 3 SECONDS'

111

ACTIVE TEST

RADIATOR FAN

OFF

======== MONITOR ========

ENG TEMP SEN

0K

CHECK COMPONENT
(Cooling fan mOior).
1) Reconnect cooling fan relay-2,
..
cooling fan mo~or harness
connector and ECM harness
connector.
2) Disconnect 400 n resistor
from harness connector @D.
31 Turn ignition switch "ON".
4) Perlorm 'RADIATOR FAN
CIRCUIT" or "COOLING FAN
CIRCUIT" in "FUNCTION
TEST" mode with CONSULT
OR
4) Perform 'RADIATOR FAN
TEST"' or "COOLING FAN" in
"ACTIVE TEST" mode willi
CONSULT.
OR
Reier to "Electrical Components
Inspection",

@
MEF~E

III

~1c:::fill:JCTI:J

r n

CHECK COMPONENT
(Cooling fan relay-2).
Refer to "Electrical Componenls
Inspection".

88'C

~=

or] I LOW Iliii~EC1"8

!OK
Disconnec~ and

reconneci harness connectors in the circuit, Then reiesl.

!Trouble is not fixed.
Check ECM pin terminals tor damage
or the connection of ECM harness connector. Reconnect ECM harness cannectar and retest

EC-84

PU/W

~(fffQ)

I~I~

ti-:Re-...
[ljJ
~

ON

OFF--

POWER STEERING

~~iT~ESSURE

<D: ~
21:rn
8

I8
I

:--"'1

<D:~ <D:~
:@:~

<D:~,:rn

GY

I ~I::oI0110:::1ot1or.:!1I",I""O*,1f;l H1f+'2!*:3fi4':f5""",6;t-;7", ~ 15 16 17 18 19
t 1111 I

111 I

9 IOU

1314

L:J

2li

2122 31

33

2930 404142

EC-85

35

3839

4445464748

<.ED
L

Except above
45V

RECORD

SEFS3iK

P!

CHECK GROUND CIRCUIT.

1) Stop engine.
2) Disconnect power steering oil pressure swilch harness connector.
3) Check harness continuily between
terminal @ and body ground.
Conllnulty sl10uld eIlsL
If OK, check hamess for shorl.

~i)ID~
UMfj'CONNECTOAII
.,
cffb"\.H

I)

00

SE~S59f1

CHECK INPUT SIGNAL CIRCUIT,

1) Disconnecl ECM harness conneclor.
2) Check. harness conlinuity belween
ECM terminal @ and terminal @.
Conllnulty should exist
If OK, check harness (or shorl.

CHECK COMPONENT
(Power" sleering oil pressure switch).
Refer (0 "E[ectrical Components
Inspection".

~OK

~e5@a ~15
~

---.PL
~

NG

I-------->

OK

u;;

~.,]

OK

[!J

SEF2'7K

[!I

NG

Disconnect and reconnect harness connectors in (he circuit. Then retest

~Trouble is not fixed.

Check ECM pin terminals for damage
or the connection of ECM harness connector, Reconnecl ECM harness connectar and retest.

S'EF556~

EC-86

:$

~W)
IUjlI
iBQ)

I
A/ G A G

G/OA

~~

~L: <f
"~I/G

!m
$:
G/OR

RIG

G/OR

....-----"--i.1:'!.1_--,
NEUTRAL

NEUTRAL
POSITION
SWITCH

131
PARK/NEUTRAL
POSITION
SIGNAL

<Em>:

OTHER --

'---------'

AlT

CONTROL
UNIT

@g):<D

<D:

: R
ill: A
: M
"1

~~,.g.,<Em>

1 2 3 4

GY

L!@

123

456

7891011121141516

<:ED ~)
II

VI

raJ

9 10 111213 lH5
23 24 2i
I
I~~'SI

567816171819

rr.;;;r.;;;;::~r.:;:;;;;;:;;;::;;:;:;1;;:2;:;;:::;3;;:4;::;;:5r.6;;;7~Q=ili;1;;;1~67.;17r.;1;;r.;;;;;;r.:;:r.;;;:;:;:;;;;;r.;;;::;:;;;;;;;;:;::;;r.;;;;;o] (ill
891011 1314 LJ 242i
L
EC-87

Neulral poslllon: ON
Excepl above: OFF

RECORD

SEF384J

~1D<&a

~I

Contlnully ghould e.lsl.

If OK, cneck harness for short.

35

SEF560A

IE!

~NG

00

Turn ignilion switch "OFF".

IE!

~~85~

can

OR
1) Sel shifllever to the neutral
position.
2) Disconnect ECM harness con
nectof.
3) Check harness continuily
between ECM terminal @
end body ground.

CHECK GROUND CIRCUIT.

1) Disconnect neutral position sWitch
harness connector.
2) Check harness conlinuity beLween
terminal @ and body ground.
Conllnully should e.,.I,
If OK, check harness for short.

MEC189B

Disconnect ECM harness con-

neclor.

EC-88

--

NG

CHECK COMPONENT
(Neulral position switch).
Reier 10 "ON-VEHICLE SERVICE" in MT

section.

10K
Disconnect and reconnect harness
nedoJs fn the circuit. Then retest.

con~

Trouble is not fixed.

I
l

Check ECM pin terminals lor damage

or the conneclion 01 ECM harness conneclor, Reconnecl ECM harness conneclat and retest.

EC89

(j)

RECORD

SEF364J

I!l

~I)~~

excepl above
Appro.lmolely SV

UMJOj'CONNECTORI!

t~~rLan
IE!I

~IDII

ClUNIT

~]

IR

CONNECTOR

NG

--+

conneclor.

SEF562R

~ ~e5

CHECK INPUT SIGNAL CIRCUIT.

1) Turn ignilion switch "OFF".
2) Disconnect ECM harness connector
31 Disconnect AfT conlrol unit harness

[Q]

~..

IE!I

3>

....

2) Check vollage between ECM

terminal @ and ground under
the foHowing condit~on5.
Vollage:
"N" or "pll
ApprOXimately QV

4) Check harness continuity between

ECM terminal @ and terminal @.
Contlnully should ellis'.
If OK, check harness for short

13

CHECK INHIBITOR SWITCH FUNCTION.

Make sure ~hat inhibitor switch runclions properly. (Refer to AT section).

~OK
SEF56JR

Disconnect and reCOnnecl harness connectors in the circuit Then relest.

.lTrouble is not fixed.

Check ECM pin lerminals lor damage
or the connecl!on 01 ECM harness connector. Reconnect ECM harness connector and retesL

EC-90

NG

! ~T
I~

Lf

L1/R

L/Y

To EL

i~--I
L/R

I8TIJ

L/R

L/A

L/R

$--B~1---$

a
~
57
6

L/R CB)

~_UR."a

I
ill: AlT models
ill: L1iD models
: RHO models
"1---<0 P2,

L/R

$~

L:R
3

LJ
LOAD

M12

ECM
(ECCS
CONTRDL
MODULE)

em

CBID
SR

rr.;;l~~iiiai;a;;;;~r.1T.2~ar.4iii5m6:;:;7;:rr:r;;1'ih'iJ5~1;;:7r.i1B;r.;;r20~JiT.22;;n:;iiiJ32~33~~3'i;;;;;;;:i;i38~ Cill
I

B 91011121 14

LJ

24

26

30

EC-91

41424344454647

L~

tions.
Vollage:
Reat window defogger
~wllch

SE~56dA

(;J

~iD~ ~&5

~~

"ON"

Bsnery vollage
Rear window defogger
switch "OFF"

Approximately OV

ING

3 6

3.l

Check if rear window defogger runetions normally.

rnJ

"'-

(;J

CHECK INPUT SIGNAL CIRCUIT.

1) Turn ignition switch "OFF".
2) Disconnect ECM harness connector,
3) Disconnect rear window defogger
relay.
4) Check harness conHnuily belween
ECM lerminal @ and lerminal @,
C-onrlnulty should exist
If OK, check harness {or short

0K

Disconnect and reconnec{ harness connectors in the circuit. Then relest

!TrOUble is nollixed.
e----

Check ECM pin terminals (Dr damage

or lhe connection or ECM harness conl1ec:tor. Reconnect ECM harness connector and retest.

EC-92

NG
---

ffi
21

4JJ

~~~~NATION

I r1l

(MALFUNCTION
INDICATOR
LAMP)

II@)

L..iJ

i
I

L..jJ ~ ~

L..:J

'I' it 'I' 1" !~

G/B

OR

G/R

GIN

~~----------~-tCID-~-~-------~

III1 I
B

rrtn~mTIrrT4il

ii2"4iI

SCI

LEO-R

RX

(In)

SCI CHECK SCI

CL

TX

(Out)

ECM

(ECCS
CONTROL
MODULE)

em
,---------------------------j
I
I
iI ~o29
] ~6I1@)1
~ ~
~
I
I

10 I I I
1 I! III

1101
II i II

~<BID
~GY

123<1567101151617181202122

691011121314

t.:::

242526

2Il29:.J 4041

EC-93

333Ui
4344

3839

454748

<:ED
L

T
R

Ii5\il

CRTN

BAT

1GN
SOl

GND
-C

GND
-I
~

501
B

GND
-E

~
1

l!.jJJ

RIB

BIOI

AlB

BIN

SSOFF

VB

GND
-E
106

~I
B

REL

I ;.....

iii'6n~
GND
-E

I....J

e-e-e-e

ECC

!-

e-e

!-

:~<b)

: [lID]
I

01

10 1 I I 1 I 10 I
I llill 11111 I

f3i'[ffi @

tilllID
W

Iffi>

:I

1234567 B 910 1012122

1112 13 lH 16 17 16 1920 L. 31 32

4;S262721129~

34 :15 3i 37 38 3940

EC-94

4142
152

44 464
54 !5 56

m
II

~_'t1 ccea~
ECM

INSPECTION STAAT

'i) '" :.'

]Of CONNECTOR II

~cqJl

CHECK POWER SUPPLY.

1) Turn igniliotl switch "ON",
2) Check voHage between ECM term inals @, @ and ground.

Vollage: Batlery Ijoltege

NG

MEG131B

IiJ

~E)~

~]
I0,

~O.

SO, 60. 107. 1M. I 16

SEF749A

EC-95

~
lEI

RELAY AND GROUND.

1) Check voltage between terminals

CD
I

MEC1J9B

ECM

JOfcoN]

Lan

MEC1.4DB

,eM

~
~

OK

[iti5~
II

IiiII

and ground.

Vollage: Ballery vollage

~I ~oif),

CHECK VOLTAGE 8ETWEEN ECM AND

GROUND.

NG

1) Check voltage between ECM termina's @, aID and ground.

VoUage: Ballery voltage
OK

IiiII
CHECK GROUND CIRCUIT.
1) Check harness continuity between
EeM terminals @, @l and engine
groufld.

Conllnully should ex'sl.

" OK. check harness lor short.

MEF410D

~r?5~~i5

Ii!I

CHECK OUTPUT SIGNAL CIRCUIT.

1) Check harness conlfnuily between
ECM lermiflal @ and terminal .
Conllnulty &hOUld ex161.
Jr OK, check harness for short.
..OK

[Q]

@
MEC1418

EC9S

necIOr5 in the circuit. Then relest

1Trouble is not fixed.

Check ECM pin terminals for damage
or (he connection of ECM harness COnnector. Reconnect ECM harness connector and retest

EC-97

00

nal).
Conllnully should exlsl.

[ill

II OK, check harness for short

MEF423D

!OK
I CHECK COMPONENT

I (Camshaft position sensor).

Refer to "Electrical Components

Inspection",

0K

Disconnect and reconnect harness connectors in Ille circuil. Then retest.

lTfOub,e is nol fixed

Check ECM pin lerminals IQf damage
or the connection of ECM harness connector. Reconnect ECM harness connector end retest.

Perform FINAL CHECK by the followi

Is completed.
FINAl CHECK

1
1) Erase the diagnostic test mode II
(Self-diagnoslic results) memory.
2) Perform lest drive.
3) Perform diagnostic test mode II
(Sen-diagnostic results) again.

0K

INSPECTION END

EC-100

1!:j.JJ~~

"
IT]I
R

I]

I
I
1

ECCS

RELAY

I
I
1
I
1
I

_.--

B/w

I t,

I-

RIB B/W B/W

16
>191
SSOFF VB

-I

~lbiJJ@
RIB

591
VB

QA+

QA-

~~

<IlillD

BR

rr.l~O;;;;1~I;;:!:;;:;;;;l~I;;J!;;;;O;;;I;;::r.l:;:;2~3;::>I"'5ffi6r.7;:r.:;;B ;:;;g;r.I~O:;:r;;J~21~~~;;;~~2Ii:r-iV~r.;29;r,3l;;rr.~;:;:1 ;:;r.;;r.~~e~;r.:;j7

1 11 II! II II! 11 II

1314151617

120

l::J

3132

3ol:fi:Ji37

EC-101

3940 51

54

~ EO:.'
"""'''''0<Lea!Jo

1!1

. INSPECTION START

CHECK POWER SUPPLY.

1) Disconnect mass air flow sensor harness connector.
2) TLrrn ignilion swi\ch "ON".
3) Check voltage belween terminal @
and ground,
Voltage: BaUery vcllags
SEF566R

0K

1!1

~&5@a ~&5

~ wr
"

CHECK GROUND CIRCUIT.

1) Turn ignition swi(ch "OFF",
2) Disconnect ECM harness connector.
3) loosen and retighten ground screws.
4) Check harness continuity between
lerminal @ and ECM terminal @.
ConUnulty should 8"lsl.
If OK, check harness for short.

[Q]

+OK

SEF5&lR

EC-102

II

shari

LOK

-CHECK
- COMPONENT

(Mass air now sensor).

Reier fo "Eleclril::al Componenls
Inspeclion". (See page EG-137.)

!OK
Disconnect and roconnecl harness connectars in the circuit Then retest.

II

!Trouble is not fixed.

Check ECM pin terminals for damage
or the conneclion of ECM harness connector. Reconnect E:CM harness connector and retest.

Perform FINAL CHECK by the following

Is completed.
FINAL CHECK

1
1) Erase Ihe diagncslfc tesl mode II
(Self-diagnostic results} memory.
2) Perform lest drive.
3) Perform diagflosLic test mode II
(Self-diagnostic results) again.

0K

INSPECTION END

EC-1D3

NG

e...-.

L/OR

L/OR

I
B

L--~--$
B

1-

I~C

-eD-i

LIOR

m
TW

GND
-A

SENS
GNO

ECM
(ECCS
CONTROL
MODULE)

CW

~~
~GY

.....r.h./ffiID
'I..!1SJ' Y

123

4156

7 B 910111213141 16

9 10 111213 jH51~
24
D~ffi
I~~li~

2627 2lI
E~U

em
W

31
~~~

~
~
34li
~E

~
L

Oi:j;;<,;rr.;;;;j;;;;;;1iiiOi'r.1:Y:2;;r.:;3r.4l::ii5~6:;:;7~B;:;;9;r.l;';j0 :;:1oI~j;:r.;;j;o;;;;~~~~;;rr.:;:r.:;r;;r.;:

l"i1;;;;D;;;;1

11111'1I11112131411171120l:I31

EC104

.~

tors @. (!ill).
2) Turn ignil\on swilch "ON",
31 Check voltage between terminal (i) and ground.
Voltage: ApproxlmBtely 5V

MECI458

iii

OK

~i0ra

cah

[J
CflECK GROUND CIRCUIT,
1) Turn ignition swilch "OFF".
2) Check harness continUity between
terminal <D and engine ground.
Continuity should e.lsl.
If OK, check harness for short.

OK
MEC14SB

CflECK COMPONENT
[Engine coolant temperature sen::lor).
Rarer to "Electrical Componenls
Inspeclion".
!OK
Disconnect and reconnect harness conneclor~ in the circuit. Then retest.
!Troubla is nol fixed.
Check ECM pin terminals fat damage
Or the connection 01 ECM harness can~
l'1ector. Reconnect ECM harness conneclor Bl1d retest.

EC-1DS

EC-1D6

I~~

IWI

IJ@

,...

BIR

- . . . ,

S/R

It ]1
1L2J1

.~
OW

I
wn

ECCS

II RELAY
IL3JI <m

.,=

.,=

R/B

S/W

.S/R I8Q)
40

1 ' - - - -....
B/W

B/W

55
OFF

VB

VB

~rrf9ilrr5'9iI

f ~II]

1 III

RIB

~
B

COIL
RELAY
IGNITION

3 @

I
B....

ECM

(ECes

t-,

CONTROL

~LEl

<rn

m@ iI1Q

~rnl
qJW GY

f1T3j5j~

tIDIDJ

CH)

B/R

r;!;;;;Or.;;I;o;I~!r.;1;;;1;;;;;;!Or.;I;;;:r.l~2;:;;3;;:4~5r.6;;:;7;;:r.;:8i79IT.l~Or;:I;;l~iT.1~23~4~~~~mii::ii.i~r.ma:;;;:i
1 II II! II II! I

II

1314 1 J 17 J8

20

3132 33

EC-107

m :

I tLP

:~

RlLt

rml

1LP

R/Wt

R/W

$---~--.---------$-------R/L

$---~--.---------.-------A
W
BA

$---~--$---------$-------<!]@

R/L

R/W

I]m IJ~ I]N I

IGNITION

~~~~K&

PLUG

11 =

2J

lJ =

Wti.

lJ =

Wti.

.! I 1- 1-B/YtB.

:-;;;"'004 ;;;

II

~ iCill> ~oo~

~Gy'Gy'Gy'GY

~~
~GY

123=45
67891011

VI

:~~ruJi

1 23-4567 B 9 10 ~ 1
11 1 1~151 17181
L':'J 31

BY

33

GY

~:!i2627
:Ii ."

EC108

2ll3:l ~142
3il51

<l5

1~1iE9)
'=r"~

IWI

-r
~R
I

,...,

II ~I
R

alA

*<EW

I]
IbiJI ~

EccS

"./R@Ql
alA

RELAY

$@Q)

B/"

RIB

B/R

~'----"'I

I -.1-,

R/8

S/W

If ~]'~m~
UCOIL

B/W

~
va

SS

OFF

4JI

(eg~fAOL

to! I I

1 1111

1101
11 1 1

~51
T

<W

L'

:-,

<rn>
f3i1'j~

RELAY

L.~

ECM

~LEJ

tm:tID "

em

t1fffi\m

<TI)

\ItIDJ

123456789101011
11 1 I~ 1 1617 I 1920 L:J 3\ 32

EC-109

GY

2829
~I
383940 5\

~Hj46
54!il511

~~

~BY

1><1_ U,m,It@,mJ

~ GY

GY

GY

BY

rr.1""O1~1 1;:;;1"'1;;:;;;::;1o;;:;;:r.;:;;:r.:;::r~r.::;:;;:r:;;;:;~;rFi~~;;;;:;;;:~r.;:;r-~;;::r.~;;;:;:~
1 II tl 1 I III

:r.:

EC-11 0

T~+-l
[ill

UEC147B

l!1

OK

[!)
CHECK POWER SUPPLY-Ill.
1) Turn Ignition switch "ON",
2) Check voltage belwel;tn lerminals
G). @ and ground.

Vollage: Bal1ery vollago

fp~i5~flJ

~
1!1

MECI4118

ri ~i'v~

~c.

OK

I!J

I CHECK GROUND CIRCUIT-I.

1) Turn ignilion switch "OFF",

2) Check harness con~inuity between
lermina1 @ and engine gl'Ound.
Continuity should exlsl.
If OK, check harness for short

~OK
CHECK COMPONENT
(Ignilion coil relay).
Refer to "Electrical Componenls
Inspection".

lOK

MEC14QB

Disconnect and reConnect harness connectars in the circuit. Than retest.

~ TrOUble is nol fixed.

Check ECM pjn terminals for damage

or the connection of ECM harness connector. Reconnect ECM harness connector and retest

EC-111

fiI

If OK, check harness for shorl.

2) Discol1nect ECM harness connecfor.
3) Check harness conlinuity
between following terminals.

I:J

MECl50B

~i5~~I()

LJJ

G)-@
@-(j)

@-@

@-@}
ConUnully should exlsL
H OK, check harness for short.
OK

[ill

Q} No.' cylinder

CD, No.2 cylinder

:No.3 cylinder
CD'No.4 cylinder
MEC1518

I"' ~i8
L

ECM

"

~ ~i5

~I

CHECK COMPONENTS
(Ignition coli and power Iransistor unit).
Rerer to "Electrical Components
Inspection" .

0K

cwffuI;;)

I Disconnect and reconnect harness con-

12

nectors In Ihe cirCUlI. Then retest.

!TrOUble is not fixed.

lPL

Check ECM pin terminals (or damage

or the connection of ECM harness connetlor. Reconnect ECM harness conneclor Bnd retest.

FL
~

CR:I
[ill
~

MEC1528

EC112

EC-113

~O

'::

LG/R

.-

Ii'!siJ Ii3"ail Iifo'TI

AVCC TVO

GND
-A

em

~~

~BR

ECM
(ECCS
CONTROL
MOOULE)

t-,

SE
G

ffi

~cm
~w

EC-114

~~
~w

~l

~
[!]

If OK, check harness for short.

OK

MEF514E

THROTTLE SENSOR CKT.

DEPRESS
THROTTLE fULLY
THEN
TOUCH START

[!]
CHECK INPUT SIGNAL CIRCUIT.
1) Reconnect throttle posilion

~II

START

C!)

MEF634L

[!]

THROITLE SEN ADJ

ADJ MONITOR

THROTTLE SEN

O.45V

======== MONITOR ===='====

CAS-RPM IR~F)
IDLE POSITION

sensor harness connector.

2) Turn ignition switch "ON".

3) Perform "THROITLE SENSOR

CKT" or "THROTTLE POSt
SEN CKT" in "FUNCTION
TEST" mode with CONSULT.
OR
3) Read "THROTTLE SEN" or
"THRTL POS SEN" signar in
"WORK SUPPORT" mode wilh
CONSULT.
Throll!e valve fufty closed:

Orpm
ON

0.35 - 0.65V

Ttuollte varve fully open:

Appro.-. 4.DV

OR
MEC1578

[!]

~i0~~io

l1S&~1 cill'b

GJ

1) Disconnect ECM harness connector.

2) Check harness continuity
between ECM terminal @
and terminal @.
Con!lnully should exist
H OK, check harness for short.

-t 0K

EC-115

FINAL CHECK

1
1) Erase the diagnostic lest mode II

(Sell-diagnoslic results) memory.

2) Perform test drive.
3) Perform diagnostic lesl mode II
(SeH-diagflostrc results) again.

0K

INSPECTION END

EC-116

NG

f------

I_.~J

LIG CEZ):

L/W

L/R

L/G~:

LlW

L/R

~-------~-------~
iEW:

:
:
@:

1l1"

M2"
"3"

t
LIG

rFfan
0T1

AIT

CONTROL
UNIT

~:@

~
~w

~~

~W

1234 910U 12131415101

5 I; 7 B 16171819 21 L

I 0J

1 II II

I I I

1011

24 25

27 2B 29

3132

38

40 4142

44;

EC117

34

neclors in the circuit. Then reLesl.

lTroub,e is nolfixed
Check ECM pin terminals (or damage
or the connection of ECM harness connector. Reconnect ECM harness COll-

nector and retest.

Perform FINAL CHECK by the followin

Is complete
I d
FINAL CHECK

1
1) Erase \oe diagnostic lesl mode II
(Self-diagnoslic results) mernory.
21 Perform test drive.
3) Perform diagnoslic lest mode II
(Sell-diagnostic results) agarn.

10K
INSPECTION END

EC-118

NG

f----+

IJmJ

L/R~

il~
L/R

~O~

L/R

L/R

L/R

L/R

I
L/R

L/R

1~~~------j~1
=rffiQ)
=r

l~f~------j~1
'T"

'T"@

L/R

<D:
:

lfi' ..

L/R

~O~
I

LHD models
RHO models

E2.

LIR
H7

~
EGR

ECM
(ECCS
CONTROL
MODULE)
(IT)

r;;;;:;;;:;;;;;;;;:;;;;;;;:;;;;:;r.;;:;:;:;::::;::::;;:;;;;;;:;:;;::;;:;:;::::;;:~:;=;i~::;c;:r.;;;;~~~;;;;;;;:;;;:~43;;:;44:;;:.e;;;;;;;;~;:
53

EC-119

INSPECTION START

CHECK OVERALL FUNCTION.

') Starl engine and warm it LJp sufliclenlly.
2) Perform diagnostic lest moda II (Selfdiagnoslfc results).
Make sure that diagnoslic trouble
code No. 12 is nol displayed.
3) Make sura Ihal EGR valve spring
moves up and down (Use your finger) under (he following conditions,
AI Idle:
Spring does 110t move.
Racing engine Irom Idle fa 31 000
rpm:
Spring moves up and down.

I!l

CHECK VACUUM SOURCE TO EGR

VALVE,
1) Disconnect vacuum hoses to EGR
va[ve and aclivaled carbon canisler.
2) Make sure that vacuum exisls under
the folloWing condilion9.
At Idle:
Vacuum should not exist.
Idle 10 3,000
RacIng angIna
rpm:
Vacuum should ea:IBl

',om

+NG

EC-120

.~.~
ID G~H
0

MEF43S0

solenoid valve harness connector.

3) Turn ignition 5wilch "ON".
4) Check voHage between lerminal @

and ground.
Voltage: BaUel'Y vollage

~-

OK

".. ~_.)ii\
I)

C'O!l9ing

Improper cDnnet:lion
SERo16F

CHECK OUTPUT SIGNAL CIRCUIT

1) Turn ignition switch "OFF",
2) Disconnect ECM harness coollEelor.
3) Check harness continuity between
and lerminal @.
ECM terminal
Conlinully should exist.
II OK, check harness for short

GID

OK

MECl638

MEC1648

EC-121

NG

iii.

e---i
~IONIOFFI

"OFF" in "ACTIVE TEST"

mode will> CONSULT and

check operating sound.

SEF222N

OR

Reier to "Electrical Components

Inspection".

!OK
Disconnecl and reconnect harness conneclors In Ihe circuil. Then retest.

Trouble is not fixed.

Check ECM pin terminals lor damage

or the connection 01 ECM harness connector. Reconnect ECM harness connector and relesl

EC-122

111(

BReED

BR

HEATED
OXYGEN
SENSOR

4Jl

"1

,I,'
~
021-1

[Ill_I
m
025

ECM
IECCS

CONTROL
MODULE)

(IT)

~~
<.!Jgg) GY

2931 ~I

394) 51

EC-123

43

'154647
!Dffi57

BIR

$@@
<HI)
t$J@
BIR

B/A@
~~

1[JI11lli!)
R

.----e

INJECTOR

~.1

~ INJECTOR ~~'INJECTOR ~ INJEC

~.2

~.3

~.4

1!.iJJ<W9>

~iBB>

1!.iJJ~

~~

WIB

YIB

GIB

LIB

$--m--$r-------$-------$

WIB

y IB

GIB

LIB

~I

Ifltoil

INJ

INJ

~l

'1

'2

*3

'4

: Fill1m llliL>:
'tmGlw
I

~ llliL> :
~W

INJ

:
I
I

~ro

~GY

IO! I I ! 10 1
1 11111 1111 ill

EC-124

INJ

~~@)
~3

slY

(ffiJ) (]I) ~ CID

,;, oi!'i'> ,;y ~ .ty

l
Sly

~
11

~
e

FPR

ECM

(ECCS
CONTROL
MODULE)

(ffi

~CI!Q)
IJg) BY

Iijiii:O;;;1;;r.1~1 T.;;;l;;;l~IO~Imlr.2;:;:=;:3i'i4~5~6::r.7;;::rcBr,9;:;I~Or,r::J=o ij;2~1p;;;;ji23~4;r.;<5a26~"<I:;r.2lI;;;r.;;29:;r,3);;rr.4i'iilr.;;ji~~~;r

1 11111
III II 11 !3!~151 171 1920 t:J 31 33 :1;:1;373839> 5152

EC-125

GJ, @ (LHD models).

models) and ground.

1..- ~

0.@'LHD model,

~i5~ ~i5

~+
[ill

La

OK

l!:I
I

CHECK GROUND CIRCUIT.

1) Turn ignilion swilch "OFF".
21 Disconnect luel pump l1arness connector.
3) Check harness continuity between
terminal @ and body ground, term inal @ and lerminal .
Conllnully should exls!.
II OK, check harness ror short

ME.C'ti3e

00

II

(RHO

Vollage: Battery vollBge

.@' RHO models

MEC168E1

l!I

, @

NG

r-----.

OK

~i5teB~IO

""t;]'
@):lHD models

0' RHO modols

MEC11<1B

1!1
CHECK OUTPUT SIGNAL CIRCUIT.
1) Disconnect ECM harness connector.
2) Check harness conliouily between
ECM terminal @ and lerminal @
(LHD modelsl. (j) (RHO models).
Contlnully should exist.
If OK, check harl"less for shorl.

tOK

EC-126

NG

1--+

'-~
. . ION/OFF

If

~=

OR
Refer to "Electrical Components

~I

Iflspecllon" .

OFF'I

0K

SEF4'3~L

CHECK COMPONENT
(Fuel pump).
Refer 10 "Ereclrical Components

Inspection" .

0K

Disconnect and reconnect harness {;onnactors in (he circuit Then relest.

-1Trouble is not fixed.

Check ECM pin terminals for damage
or the connection of ECM harness conneclor. Reconnect ECM harness connector and relesl.

EC-127

Jln""l3CJL------.ll.rl

I~

AIR

~~~~~TIaNER

%
.

THERMISTOR

I1jJJ

.;;...,!,,,..-------.,--2!cr. ill)

GIl:' l / R . ~~~!i~~r:~:

L:R

HA-A/C. A.)

@Jl

L/R

VL/B

G/Y

J$r----------$
lE!Ql
G/Y

L/R

~---~----~-------------------~

L~R IACV~

II 2 II

FICO
SOLENOID

~E

H~I:H

L':,

""i"'"

I
t

~~E~RE

NORMAL

B/P

rn

I'

ffi

TRIPLE-

AC

AR
CON

RLY

1=

(ECC

CON
MOO

<il

IZI rnl

G@ PU

~@

JJIl.~

[llgJ]]

EC-12B

III"Tl""~""--------;]~-"<2To'I~g~~~TIONER
@
._

!=

Gt

$~
I

L1R

TRIPLE-

To COlllDressor
L/R..... (Refer to

.
.
I

L~

~~:~~g: nnd

"'5'"

*1lliD
G/Y

~
'='_
~J

I
R

~~i~~RE I~I iEQ)

L/R

Y[

11'1

G/W

~R <E)

G/Y @ID

IACVFICO
SOLENOID
VALVE

"""'"
1!tlJ1
ocl2Q.o
'=r' em

ffi

GIY

i'lL Y

CON

,..----"-!~-------"'!~--, ECM
AC
AR
(ECCS

---

~ @

CONTR
MOOU

CID

@~
CIIID PU

~~

till)

J::Ql@
[IIg]]J H

r.;;;;;;;;;;;;;;;;;;;;;;;;;;;;;~TiliT2:;:;:;;3;;:4:;:;;:5;:;;6;:;:;7:;:;:;;8r.:9~1~Or;:I-;;:':;Ib::;;;o;;;;;~~~~~:r.ii;;:;r.:;r.;;r
11

1314151 1718 I 20 -

EC-129

I~I~
G/OR

~@.ID

I~I~
G/OR~

$~

G/OR

G/OR

.-------'Jri1il-:ll~_.,

NEUTRAL
POSITION
SWITCH

(fm):

AIT

CONTRO
UNIT
~:<1!

:
:

<1!>:
:

IH ' .

~~

~~~~

~Gy[fj:g]8

1234 910 1112131~ 1

~w

313233

~w

:Ii

L:5=6=7=8~f=6=17=I=e=19===1==========44='!i=46=~=411:J

I..-

~I~~~I~1~1~1~1~IO~lml~2~3~4~5~6~75i8~9rnl~O~01;jji~1i23~2~~Z;i~27~28i29~rn4ml~43~44~~46~47

1...':1=11=:1=1=1:=1::1=1I=1I==11=12=13=1~=1=1 =1=7=1=:1==.:::1=3=1==~=35==37====5=1 =53=~==56=

EC-130

c=BECORD

VOn8.ge~

SEF384J

I!l

~i)

~~

:l

Gil

~"""""
eo

leJ1

~0'

MEC1'9iB

~(lIJCo~~rt'

Approx1maieTy QV
E:lIcepl above
ApproxlmEllely 5V

ING

Ij

CHECK INPUT SIGNAL CIRCUIT.

1) Turn ignilion switch "OFF",
2) Disconnecl ECM harness conneclor.
3) Disconnecl AfT control unit harness

connector.

eo

"

CHECK INHIBITOR SWITCH FUNCTION.

Make sure thai inhibilor swilch runclions properly. (Refer to AT seclion).

L[ljJL

lOK
MEF242F

4) Check harness conlinutly 'belween

ECM terminal @ and lerminal @.
Conllnully shourd exIst
If OK. check harness lor short.

hciudCONNECTOR]

00

fiN" or .4pll

~cTo;l]

ECM

2) Check volloge belween EGM

terminal @ and ground under
lhe (ollowing conditions.

Disconnect and reconnecl harness conneclors in the circuit Then relest.

1Trouble is not fixed.

Check ECM pin lerminals for damage
or the cOl1neclion or ECM harness connector. Reconnecl ECM harness conl1eclor and retesl.

EC-131

NG

S:=::f.;~A~,*",~'-';j 41

51

EC-132

L
4

ECCS relay jSell-shuloI1)

For a few seconds after turning

ignition swflch "OFF"

pgn;\ion switch "OFF"I

A lew seconds after lurning ignition

swilch "OFF" and thereafter

IEngine 15 ruooing,

Cooling ran relay [Low speed}

BATIE
Cooling fan is not operating.

IEngine is running.

BATIE

Appro

Cooling fan is operaling.

IEngine is running, I

10

Cooling fan relay (High speed)

Cooling fan is no' operaling.

Cooling fan is operaling at low
speed.

BATIE

IEngine is running. I

L Cooling fen is operaling at high

Appro

speed.
IEngine is running. I

L
11

Arr

condi~ioner

relay

Both Ale switch and blower switch

are "ON",

Appro

IEngine is running I

L Ale swilch is "OFF".

BATIE

IEngine is running. I (Warm-up condition)

16

Mass air flow sensor

L Idle speed

0,8 - 1

IEngine is running. I (Warm-up condilion)

L
18

Engine coolant temperalure 5ensor

1,4 - 2
Engine sped is 3,000 rpm.

IEngine is running_I

0- 5,O
Oulpu
coola

EC-133

27

Knock sensor

31
40

Camshafl position sensor (Rerer-

33

load signal

ence signal)

2.0 Idle speed

IEngine i~ funning.

App

pgnilion switch "ON"I

Rear window defogger swllch is

BAT

"ON".

34

pgnilion switch "ON"I

App

[!inition switch "STARr I

BAT

Slarl signal

pgnHion switch "ON"I

35

Neutral position/Inhibitor swilch

Netllral pasilion (MIT models)

"N" or lip" position (AIT models)

OV

pgnilion switch "ON"I

L
36

37
38
47

App
Except Ihe above gear posiliOI1

pgnilion switch "OFF"I

OV

pgnition swilch "ON]

BAT

pgnltion swilch "ON"I

App

pgnwonsw~

BAT

Ignilion switch

Throtlle position sensor powet

supply
Power supply for ECM

~ is running,l

L
41

Both air condi\ioner swi\ch and

App

blower swHch are "ON",

Air conditioner switch

[!:ngine is running.1

BAT
Air conditioner switch is "OFF",

EC134

IEngine is running.

102

Waslegale valve control solenoid

valve

IEngine is running.

BATIE

Idle speed

Appro
Revving engine up 10 5.000 rpm.

IEngine is running_I (Warm-up condition)

105

EGR valve & canister control

solenoid valve

Appro

Idle speed

IEngine is running_I {Warm-up condition)

BATIE
Engine speed is 2,000 rpm

pgnilion switch "ON"I

L For 5 seconds afler turning ignition

switch "ON"

106

Fuel pump relay

Appro

IEngine is running.1

pgnition switch "ON" I

5 seconds afler lurning ignilion

BATIE

switch "ON" and Ihereafter

IEngine is running.

111

Appro
Engine speed is below 4.000 rpm.

Heated oxygen sensor healer

IEngine is runnlng.1

BATIE
Engine speed is above 4.000 rpm.

IEngine is running.1

L
113

IACV-AAC valve

914V
Idle speed

IEngine Is running_I

Sleering wheel Is being lurned.

Air conditioner is operating.

Rear defogger 19 "ON".

EC-135

5 - 9V

EC-136

EC-137

MAJOR OVERHAUL................................
Case Components
"

Gear Components

2
:2

SERVICE DATA AND SPECIF

General Specifications

Inspection and Adjustmenl

MT-1

SEC. 320321

!!:

'"
~

l!

/
~ ~I b~~~lrm~ ~;.~
~

,~1

J!

_ )

Maln,haN

bushing

~~~;ln2;d
sleeve

"*

Th'uSI washe' IElI

'Q) I

"'''00

~~g~n'hal

Snep

~f;SP8edom8
~

2nd ouler baulk ring

~

Synchr'onizer cone
2nd lnrler baulk ring

Needle bearing

~j)1

Snap

~~...
~

2nd melo gre.r

Thrust washer
Roller bearIng
Washer

00 gear bushing

00 (5Ih) & reverse

synchronizer hub

00 (5Ih) main

Baulk rlog

~
Shlm*

Rj~

~,~

Reverse idrer gear

~~~ln~;::I~'~

~t

Snap rIng

*0

Soap ,log

drive tJear

Snap ring

Reverse Idler gea

Reverse idler thrust w8sh

SUb~::.:::"ng

Reverse idl

Counler gear
'Woodrutr Ikey
Counter

98

Countersha
00 counter gear
Roverse counter gear s
Counter rear bearing

Spread spring

Needre bearing

tDJ

Coupling sleeve

"----- Spread spring

ft3------- Shifting Insarl

::~~rs. mal~nN~1

Counte

(1

Salilk ,ing

Bushing

gee~~~

RevlI1rse COunter gea~

Rev~~~U~~e~~~~~r
'"

Appry gear oil lo ge

and bearings when

Sub-gear bracket

* : Seleel wiLtI. pmp

*:

Pay aUantion to

tc:l : Nom (kg-m, fllo

MT-3

Number of teeth

Mainshall

Drive

191
2nd
3'd
00
Reverse

Counlersharl

Drive

lSI

2nd
3'd

00
Reverse
Reverse Idler gear

(limp pI)

Oil capacity
RBmBrks

Sl,lb-~ear

Reverse synchrOlli:l:er

Double Mulk ring Iype

synchronizer

MT-4

10.047 - 0.0631
Main drive

1.2 - L6
(0.047 - (]'06::J)

00

1.2 - 1.6
10.047 - 0063)

2.4 (0.0941
o.a (0.03')

9
_0_0_m_a_in_5_h_a_fl_b_e_a_ri_n_

1.'0 - \55
(0.0433 - 0.0610)

Reverse

2.5 (0.098)

Allowable clearance

0.7 (0.028)

Thickness mm (ill)

2nd and 3rd baulk ring

1.1 (0.043)
Unit mm (In)

1.2 (0.047)
1.3 (0.051)
1.4 (0.05SI

Counler drive gear

Allowable clearance
Thickness mill lin)
1.4 (0.055)

Inner baulk ring

1.5 (0.059)
'....- Synchronizer cone
Dimension

Standard

0.7 - 0.9
(0.028 - 0.0351

0.6 - 1.1
(0.024 - 0.0431

SMT044B

1.6 (0053)

Wear limit

0.210.0081

MT-5

4.52 - 4.71 (0,1780 - 0.1654)

Not necassBI"y

4.42 - 4.51 (0.1740 - 0.1776)

0,1 (0.004)

3221BV5000

4,32 - 4,41 (0,1701 - 0.1736)

0,2 (0.006)

32218-V5001

4,22 - 01 (0,1661 - 0.1697)

0,3 (0.012)

32216V5002

4.12 - .21 (0.1622 - 0.1657)

0,4 (0.016)

32216.v5003

4,02 - 4.11 (0,1563 - 0.1616)

0.5 (0.020)

3221S-V5004

3,92 - 4.01 (0,1543 - 0.1579)

0.6 (0.024)

3221B-V5005

MT6

TROUBLE DIAGNOSES

Circuit Diagram for Quick Pinpoint Check

Wiring Diagram - AT -

2
2
3

SERVICE DATA AND SPECIfiC

AT-1

Ganeral Specifications.......
Specifications and Adjustm

"

,
~

~:<l

III

...--..

~~

::l

e'-='
IOl

zo"'

~-

"z

>-Z<I:
.. 00

ou,,-

THROTTLE
POSITION

'"
0>

010 ~ INDICATOR LAMP

'"

"-'

z;"'
0:

HO
Z
<OZ

"n
0

.e.; .!!l
"IJ

"0

X I

W
<U <nO
o ~
<::J ..

W :i}
L U

0 X
-' IX "- W

.-

'"

2:

-'
0

~~.

~~

0-

:;

IX
>Z
0
U

iil

..

....0-

(DU

C'.'"

Z
:::>

3'>-

8"'
>-<-

:;:
~

lila:

:::>

t:;

"-

~~

-m'"
~

:'.
N

W
III

'"

:::~

CLOSED

llJ
:;l

~~

-is}

-&-

'"
'"
N

... >-z
-.J~B

'" >l:
~

g:

-'
",0::::>

"

~.

FLUID TEMPERATURE SENSOR

g@=

H>IH
Z3:
H

It"Ir.of'G1Cl

<

w
u
-

"0,
"u

DO
E

om
o-H

AT-2

MEMORY
BIU
GNO

GND

VIGN

~~
B

VIGN

AlT

CONTROL
UNIT

CONSULT CONSULT CONSULT

DATA
DATA
DATA
IN (RX)
OUT (TX)
eLK

LJI

~
GIB

~
G/W

r1l

---~-~l4-l~6~-------

DATA LINK
CONNECTOR
FOR CONSULT

I aID

r
10....---1-----.,
B

$:

.-.
B

1 1

~~

~~
~W

~CBID

~GY

1 2 3 4 9 10!J 12 I I~ 15
5 6 7 B IS 17 I 192021
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2425

<I

291131
41

37311:J340~I42

46

AT-3

I:!J

G/OR

ii1ll

-_

..

OTHER

THROTILE

POSITION
SWITCH

21
LG

LG

~~~
R

rrl'4il

Ii2Til
WIOE

LG

OPEN
SW

LG

CLOSEO

2ND

1ST

SI;

SW

POS POS

SW

L..-

[5<L~
~GY

:
I
I

@ill
:
GY

~:
7693 ~,
65-4
GY

~~
~W

2728

132

4O~1

~44E

34li
Q

AT4

~
L

rn

DO OFF
LAMP

VSP-2

00

OFF
SW

KICKOOWN

SW

39J

41

LIB

SB

~1Iill)
T@)
LIB

~~~SSED

~
r-.,
OFF

SWITCH

ON

@W:@>

OTHER

OVERDRIVE
@

..
B

KICKOOWN
SWITCH

1,----1
B

00>

<!ill

B
..
~

.-------------------------------------,

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W
B

~~

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44454647o\B

AT-5

:I

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19j
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11-MH'

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lG/R

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AVCC

TVO

Oli

OT2

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~ill)

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llG

NEUT

[ECCS
CONTROL
MODULE}

TACHO

ICiJ1<HW

on

1
1

TVoo

l/W

LIR

RIG

R/Y

BR

lIB

11

llG

L/W

L/R

RIG

R/Y

LIB

llG

L/W

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R/Y

t~chometer . . .
(~~:~~~.)
I'

It It h It h I

101
DT1

11

13]

OT2

34

NP TH/SEN SENS
SIGNAL (IN)
POWER

C
U

34 ~
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AT-6

4746

P"eceding

page

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t
w

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1234 91 11 1.2131415101232425

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272B
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AT-7

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U'

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A/T
SOLENOID

ai- ::;;;.:$---:::--$-$---::,--- $

1c!J11I12ASSEl'BLY rh.--------~
TORQUE
CONVERTER
CLUTCH

~t~~ID

OVERRlI'l
CLUTCH
SOLENOID
VALVE

irh.-------

SHIFT
SOLENOID
VALVE A

SHIFT
SOLENOID
VALVE

~~
~8R

~m

W5I

GY

: ['L] 1112

c!m 1114

l:im 1113

~
I
1_
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-E

AT-8

~
l.dI

VIGN

MEMORY

B/U

CONSUL T CONSUL T
DATA
DATA
IN (RX)
CLK

GND

GND

l!Ji!l
B

LlI

rh

GIB

~
G/W

VIGN

AlT

CONTROL
UNIT

CONSULT
DATA
OUT (TX)

G.

m m

mI

DATA LINK
COr-lliECTOR
FOR CONSU

----...-l4J-=a--.----------- CHID

$~

l8Q)cm

L..-

1-

__

i. .~--------.i
.-.
1 1
B

@>~

~CHID

~GY

i ;;> 3 4

123

456

7 B 91011121 IH 16

em
W

34

5678

AT-9

G/OR

THROTTLE
POSITION
SWITCH

~1iJ~CIJEiJ

GY IL GY /L LG/S LG/Y

+..J I I I

._-.$.1$i

LG

GY /L

LG/B LG/Y

Gr

LGfLr

LG

GY IL

LG/B LG/Y

If1'!.ru

rrf9il

li'fsil

LG

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WIDE

CLOSeD

OPEN

SW

PIN
POS
SW

SW

D
POS
SW

rrrn rrf6il
2ND
POS
SW

1ST
POS
SW

~-------------------_

~m
:~~~:
GY
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<Iill:ID

GY

GY

123
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7 B 910111213141515

~---------------~

123-491011
5678 1 17

AT-10

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VSP-2
KICKDDWN
SW
41 1

sa

LIB

r$g

~~~~~SSED

LIB

~
ON

OFF
__

OVERDRIVE

SWITCH
(][)

~
B

KICKDOWN

SWITCH

<HIID:

OTHER
B

.'----.~OI
B

I
r- .,
a

.L

.L

2 J

ri

c@~

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,-------------------------------------.

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LIG

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LIA

AIG

A/Y

L/W

LlR

RIG

A/Y

L/W

LIA

RIG

R/Y

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ICiJI~
T

OT1

1
1

(ECCS

AVCC TVO

GND--A

TACHO

,
W

LIG

LIB

LIG

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1110 I

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t~chometep .... 1
(~E~~~.)
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rrtoll
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wm rrrn

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OT2

OT3

NP

TH SEN

SIGNAL

(IN)

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123

455

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AT-12

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page

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AT-13

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123
7 8 9 10 11

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~(ill)
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cillJ 1114

:
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AT-14

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L

OR

Specifications and Adjustment

VEHICLE SPEED WHEN SHIFTING GEARS
Vehicle speed kmJh (MPH)

Throttle posHion
0\ ..... D:;>

D2

Full throttle

64 - 60
(40 - 42)

114122
(71 -16)

HalllhroUia

51 - 5:5
(32 - 34)

93 - gg

-!'

D3

0.1

0,).--. D,

182 - 192

116 - 186

103- 111

(113- 119)

(109 -116)

(64 - 69)

146 - 154
(91 - 961

9795
(54 - 59)

39- 45
(24 - 29)

D3

(SO -62)

VEHICLE SPEED WHEN PERFORMING AND

RELEASING LOCK-UP

---a

0",

0 ..

-+

STALL REVOLUTION

Siall revolu

Vehicle speed km/h (MPH)

Throttle

00 switch

posHion

(Shill posilion]

Lock-up

loc1<-up

ON"

'OFF"

177 - laS
(110 - 1151

ON

163 - 191

(0.1

(114 - 119)

OFF

91 - 99

2,725 -

LINE PRESSURE
engine speed

Full Ihrollle

(0,1

(57 - 62)

86 - 94
153 - 58)

ON

146 - 154
191 - 96)

122 - 130
(76 - B1)

OFF

82 - 100

(0,1

157 - 62)

86 - 94
153 - 501

(0.1

line pre

'pm

D. 2 and 1

Idle

(4_320 _ 4.7

432 -

4.80.62.6

Half throttle

1.039 Stall

('0,390-

10.60 - 11.4

162

AT-15

Lower body

Pilot velva sllring

31742-41X13

Lock-up conlrol valve spring

31742-41X22

16.5

ill

Modifier accumulalor piston spring

3174227X70

31.4

1s1 reducing valve spring

31756-41XOS

25.4

Q)

3-2 timing valve spring

31742-41X06

23.0

@J

S&rvD chlirger valve spring

31742-41X06

23.0

19.69

Reverse clutch

16 pes

31505-41X02

High clutch

16

pes

3150>-21XOO

Farw8rd clL.lh:;h
(Overrun clulch)

20 pes

Law & revers", brake

18 pes

Band servo

31521-4~XOO

(Assembly)

25.7

22.1

35.77

31505-4 1X05

22.3

Spring A

31605-41X05

45.6

Spring B

31605-41XOO

53.B

Spring C

31605-41X01

29.7

Acc:umulslor A

31605-41 X02

43.0

Accumulator B

31605-41Xlo

66.0

Accumulator C

:3 1605-4 1X09

45.0

Accumuralor 0

31605-41 X06

58.4

Accumulator

AT-16

Clearance

mm (in)
0.5 - O.B (0.020 - 0.031)

Standard

1,2 (0,047)

Allowable timit

ll"llckness 01 retaining plate

clutch

ParL number

mm(inl
4.8
5,0
5.2
5,4
5.6

I OVlllrfUn

Number 01 drive plales

Thickness

Number of driven pleles

10.1B9)
ID,1B7)
10.205)
10,213)
10,2201

31531-42X02
31537-42X03

Thickness 01 drive plale

mm (in)

31537-42X04

Standard

31537-42X05
31537-42X06

Wear Ilmll

I HI,h cluleh I

Clearance

Number 01 drive plates

Standard

Number of driven prates

AllDWBblB limil

mil' (In)

Thickne.9s 01 drive prale

mill (InJ
Slandard

1,6 (0,06:1)

Wear limit

1.4 (0,055)

Thickness 01 retaining plale

Clearance

mm(in)

Standard

1,8 - 2,2 (0,071 - 0,087)

Allowable limit

3,0 (0,118)
Thlckness
mm (In)

Thickness of relalning plate

3.4
3,6
3.6
4.0
4,2
4.4
'.6
4,8

(0,134)
(0,142)
(0.150)
(0.157)
(0.165)
(0,173)
(0.181)
(0,189)

Pori number

31537-4'X71
31537-4'X61
3,537-41X62
31537-41X63
31537-41X64
31537-41X65
31537-41X66

31537-41X67

AT-17

7.0 (0.2761
7.2 (0.2831

31667-4"'X12
31667-41X13

I Brake band I
Anchor end bOil lightening
lorque
Nm (kg-m, In-Ib)

Number 01 relurnlng revolutiens for ancf\or end boll

'-6
(0.4 - 0.6, 35 - 52)
2.5

OIL PUMP AND LOW ONE-WAY CLUTCH

Oil pump cle:arGl'lce

Cam ring -

Thickness 01 oil pump thrust

washer

REMOVAL AND INSTA

Manual <:onlrollinkage

Number of returning revolulions for rock nut

mm(inl

oH pump

lock nul tightening lorque

housing
ShmdBn;1

0.Q1 - 0.024 (0.0004 - 0.0009)

Rolor, vanes and control

piston - oil pump housing

0.03 - 0.044 (0.00'2 - 00017)

Standard
St!al ring crOoranCB
Siandard

Alr(lwable Irmlt

Distance be~ween end 01 c:lutch

housing and tOfque converter

mm (in)

0.100.25 (0.00390.0098)
0.25 (0.0098)

AT-18

FRONT SUSPENSION

SERVICE DATA AND SPECIF

Inspection and Adjustmen

FA-1

~,

r-

!
~
, MI

@.,...
I
.ik
.

Lj
Front

~13-19

~ , N'm I~gm. ftlbl

(1.3 - I,

CD

Cap
Gasket

(1)
@
@
@

Strut mounting insulalor

lock washer

CD

Upper seal
(Polyu,e'hane lube)
Coil sp,ing

@
@
@l

Bound bumper

@l

SI,u! assembly
Plastic clip

Front suspension member

@
@
@>

Tr

Siabilize,
Bushing
Clamp
Stabilizer connecting rod

FA-2

@
@

Te

Te

Te

FA-3

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specificalions

""."........

.. 2

RA-1

Wheel side

'15 - 125 (4.06 - 4.41)

mm lin)

Baal length

Finall driv8 side IL,)

95 - 97 (3.74 - 3.82)
Wfteel side

ll..)

RA-2

ANTI-LOCK BRAKE SYSTEM

Wiring Diagram -

ASS -

,,

.2
2

SERVICE DATA AND SPECIF

BR-1

General Specifications
Inspeclion and Adiustmen

G/Y

<EMl

L..jJ

OR/G

$-------4!J
G/Y

G/B

""""

I
OR/G

G/Y

OR/G

G/Y

OR/G

IGN

BAT

GND

GIN

G/B

ntaTI

CONSULT
DATA IN
(RX)

CONSULT
DATA OUT
(TX)

29

GND

G/B

$-~-$-G/W f
13/8 t

rrh

.......
.......
~-~---1!.

r$~-------

L}JG

$-~-.--

OR/G

I
GIY

GND

GND

GND

U.J.JJ
!

~~

ITI.II.:JIIDIl.

:~~~:
I~~I
:

~---------------------------~

r;;TiT2TIIIIJg

L.I::illIIIIJ

CHIDG8y

I 11131415
K5l 1 1 I I I@
I 1 [l I 1
W

BR2

~~

LJ.s.l..ll..lI w

~W~W
~

.m.~

~GY

23

111
111

~I..l.1.,J1-..+1""?I'-I---.JIt;=B.L';[g~ll~ ~

1 1 ) I

IJI'I"'IQIIJ ~

rn:rzIII.IIJ

EElIffiEE

BR-3

I I] w

~
8

T
RIG

LtR,

LIR ~

.~
RIG
I
RIG

B~
l/R
I
LIR

RIG @

L!R

$~

YIR

l/R

CEID

~~
LIB
I
LIB

$~----------------$

1------1
I

M
~

STOP
LAMP

LAMP

LIB

1-

FAIL

ECCS
TACHO

RIG

23

SH

~I@)~C@
w

IlIIIIIIIJf[J

LEttt:t:tt:l!tj

[2111011111@
tiT [ 1 1
w

1. I

~-----------------------~

1
I

~l
B

[gHEEl4@) i
W

BR-4

page

1 Itit Itit Itit I

L/R iBQ) R/8

GY

BR

B/Y

L/Y

[$

$---$--$--$--~--$--

LIR

RIB

T=r~ 1iTT

Ti

IFi'iiJ

IJ2"7iI

GY

B/Y

261

L/V

SA/Y

'----v-------'

SOLENOID VALVE OUT

:A~ffi:

,~tEID
I
~--~~----~~-----~

:, ffiffiHm

rn::rgm~
~

~
98
I

ITIII:K:l I I I I I~
IT.IT:illllUJ5[IS I l7\ 18

,
:
I

~------~-----------~-------~

BR-S

AIL

LlO/A@

lOlA

--,
~~~UATOA ffi

t-

.Cffi

G/Y

LG/A

l,

G/A

m m

ffi

}-----+:::===~__r_tlSOLENOIO
VALVE
. AELAY

I
I

:~

E2Il K;J6171I I II I w
141

~@

I:I:lDI

BR-6

AIL

rrl'oil

4Jr<i@------1$
G1/V

G/B

~-~+---

ORI/G

G/8

G/v

OR/G

rF!9TI

IGN

8AT

~-~~--G/B

CONSULT
DATA IN
(RX)

GNO
2

GNO

GND

GND

GNO

~
B

I!?,jW

27

~
8

L-I

CONSULT CO
DATA OUT
O
(TX)

I ---II

t-,

2 3

1
2
:~niE
j

~@

t.:::IJillIIIIJ

BY

12

II I I 1I r) 106171811
I
[ I 1 I
W

BR-7

..~
I
I

1
I-

L ~ P

L<EID P

----

Ir,
:I

-I
I
I

I
I

I
I

I
I
I
I

$--

.-.
~

1 1 f,
I
I
I

I
I

I
I
I

I
I

I
I
1

I
I....

I..

..1

I~
'V

~B

--

__

~~

I
I

~~
~W

l'L -~

$---~rn1
I
I

I
I

L
FRO~T

WHEEL

'V

SENSOR LH

lill)

1112131
r
1 I 1

? 1(I1 I I1 1~
W

~~
~B

BR-B

I
I

RIG

~I <fill)

'f'ill)

LIR

RIG

6~
RIG

1 _ LIR

1~1~

LIB
IWI

LlR

LIS

'T'<l)

CEID

'T'

1-----1--------1

RIG

RIG

ffi~

''-i-''~
RIG

LlR

RIG

STOP
LAMP

LIB

I@J

231

FAIL
LAMP

TACHO

Eees

SIl

~---------------~-------,

ilEHHEJ~]@
I

-..1.,-1.1.1.,LI-+...,KI"-:l-+-l,-IJe19;;L1 ~W

liT

BR-9

II

LIR

RIB

Iffru

FRONT
RH

BY

BR

FRONT REAR
LH

'-y------J
SOLENOID I/ALI/E IN

:I
I

ffiffim3 M
~

98
10

B/y

ffiffii2"6n

~:I
,

~-------~----------~-------~

FRONT FRONT REAR

RH
LH

'-----y-------SOLENOID "'.LI/E OUT

III1 r011111~
111121131 U5l16wlia w

:A~~:
i~tfit7

~--~~----~~-----~

BR-10

1----_-1- _ -1
--.
6/Y~

~
G/Y~

Preceding
page

LG/R

G/Y

II

G/A

AIL

Iffoil

dl-------j===;-i-n SOLENOID
VALVE
RELAY

~~~~
t:t:tttt:J:JI
\.!l$Is
s

1 I 14150

I 1 1I..jJ

~ffi:

:mtfjj~,

~--~----~~------~~-----~

BR-11

1 I 1 ~H

I I

It

thickness

mm (In)

Recommended brake lIuid

For Europe"
Except for Europe

For Europe, never mix (hfleren

DOT4).

Inspeclion and Adjustment

DISC BRAKE

PARKING BRAKE

BrakE! model
Pad wear limit

OPF25VA

CU1H

lype
Number 01 notches
(under force of 196 N
(20 kg, 44 IblJ

2,0 (0.079)

MinImum lhickness

Rolor repair limit

mm(in)

mm (!n)

Minimum thickness

28 (1.10)

8 (0.31)

Numbel" of notches

when werning lamp switch

comss on

BRAKE PEDAL
LHD

RHD

MfT

1B' - 191
(7.13-7.52)

(7,057.44)

AfT

191201
(7,52 - 7.91)

169 - 199
(7.44 - 7.83)

Vahide madel

Free r"leJgtlt "H"

mm(ln)
179 - 159

Depressed height "0" mm(ln)

[under loree 01490 N (50 I<g,
110 Ib) wilh angina runningl

MfT

120 (4.72)
130 (5.12)'

AfT

13015.121
135 (5.31)"

Clearan~e "C" belween pedal

gtopper and IhreBded end or
stop 'amp switch or ASCD
swill;:tl
mm lin)

0.3 1.0 (0.012 - 0.039)

Wdhout ABS lor Australia

BR-12

PRECAUTION
Supplemental Restrainl Syslem (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER

2
2

TROUBLE DIAGNOSES - Su
Restraint System (SRS)
Wiring Diagram - SRS -

RS-1

RS-2

RHO medels
Itl<D R/L

1t2--'@ L :@R/L

iH!D

AIL ~

~ AIL
~~~@

!ill])

"1

I
f~
>

(AlA BAG

~~~~fNG

iH@l

B::=====

A1/G

R/G~B

~@"

I t_
~~.,
!t

R/Gl

"2

m
IGN

21

DIAGNOSIS

GNO

SENSOA
UNIT

aD:@

@:@

rn:::::QTIII] CID

a
~

~w

21

~@)
~W

~:

I
I
I

r------------------~--------------------------,

:
I
I
I

~CID:@
~

~@:<Eli>:

o::::::rrr::I.I

RS-3

I
I
I

GIs

Y/S

20 I

161
PIT

SO+

SO-

i!4=U

(OR)

DIAGNO

SSS

WARN

SENSOR
UNIT

R~

aD:

<lID:

(ORI

II

It

II

rrtil

ffi

SPIRAL
CABLE

"3

114

~
I

AIR BAG

MODL\.E
DRIVER'S
SIDE
(S~UIBl

1~6~~~G

PASSENGER
SIDE

(saUIB)

aD

~aID
~W
I

:
I

~cm:@
~

~<lID::

D:.IIIIIIJ

I~

I
J

IJI:QIJ
@IT]]

~
w

~ "3

Itll

~(l!)

\1@

RS-4

~~
~

r~

YfwR

SWIiCH
DRIVER'S

CLOSEDiEN

.S

'='_
I

___

(g)

LG

L::0: ~ 'o}
I. It

DOOR

..................,

SIDE

<0:
:

@])~

~= ~-;-jc:J1

r----,G'-i

OR

OR

GY/R

LG

OR

ilii!!~"
TENSIONER
DRIVER" S
SIDE

iID.ID

ili

TE
PA
SI

LHIJ mode Is
RHIJ mOdels

@: Models With pre-tensionel"' system only

@: Exoept @
*s<O UR. L/G
r

: ~CID:@
I~Y

~aID:@:
~W

~------------------------------~--------------~

~@
~W

[Q]
IIIg]

~.@
w

,.ffh~

GY

RS-5

--.I'>d...~

C!LW

GY

MANUAL

MANUAL A

TROUBLE DIAGNOSES

Circuit Diagram - Manual Air Conditioner

Wiring Diagram - AIC, M Diagnostic Procedure 6
Eleclrical Components Inspection

2
2
3
13
17

SERVICE PROCEDURES

Re1rigerant Lines

SERVICE DATA AND SPECI

AUTO
TROUBLE DIAGNOSES..

Wiring Diagram -

AIC, A -

18
18

HA-1

General Specifications
Inspection and Adjustme

lGNlTION SWITCH
ON

@:
@

e~tj ~

II :

RHD models
Eltcept RHD
Except for

L----t,------,-,--14

~5~~~A(M

13
22

~
:I:

23
26

Ie

FAN

RESISTOR

I\)

19

:J:

8
<:

l----

~
2

7
1

!i!

21--+--1-"'-

FAN SWITCH

'='

~~~~e~ llumination

~ 1--1-----+-

6~-+-="-

20 f-+-I--

12

11 H~-I--

25
27

21

15

24~-+":~

16

eW--l--

~,-----I1iJI

THER

~S~[

THERMISTOR

~
'

":m~

.~

1~1@9)
=rCill

3 II.j.!I
LIB LtY LlR
4

it 'L'::}
R

FAN

SWITCH

@)

roL~
IJJ:[@] W

HA-3

~
AR
eON

l$J: .I--------.'---I
G/Y
,rf71,~

rOR/L~

~~
G/Y

OR/L

ffi
4
LOW

...

To

HA-A/C.
M-05

L/R

ffi

3
HIGH

TRIPLEPRESSURE
SWITCH

__
OFF

_e

NORMAL
11111

~
SIP

~ THERMAL
PROTECTO
~ -1

~ COMPRESS
~

-2

------..0lI"l1

I~

B/P

Gm1
AC
RLY

ECM
(ECCS
CONTROL
MODULE)

+
2

<Th>

1Ql

~~

tlli;i

~-I

I!J

(IT)

Nffi

ern:>

PU

~-2
W

HA-4

IB

._

-!

l/W

l/R

l/Y

ffl~ ~
MODE
DOOR
MOTOR

~
B

B 6 4 2

7531
B

1 14
,
~:
17
115~'
B

I
I

HA-S

GIN

GIS

GIN

G/B

I t It

PreceCl1ng....-a. lOR
page
-..:..r l

IFh

INTAKE
DOOR
MOTOR

5 J

10.-

....

I....J
I

t,
<H@

CEIl

~-------------------------, I

2W 211
"T':
'~~'
II
22 I
"""""

I
I
I

[I[QI]~
~B

I
I
I

~-------------------------~

II['[QJ] ~

lID&.IJIl

HA-6

@[Q

IT.IID.

lL sr I::
OR/L

LIG

OR/L

LIG

Lj:':I/R

I[Q],
~ ,1lliI1
""i"" Qill) ""i""

I
I
OR/L
LIG
1cg'Qj, ~ ,c!Q:]j

COOLIN

FAN

OR/L
To HA-A/c.

M-02~ORIL-i

OR/L

c...:".(-,*),."-...,,..,!~ ~

LIG

~
B

Ii'!4iJ

RFR

RFR

I I

LG

Ii'!3n

MOTOR

La

""T'" CHl=w=

ECM
(ECCS

CONTROL

MOOULE)

ill)

I...J
I

I'

~~

~ru>
~ BY

HA-7

~
i!4Jl

THERMISTOR

!-------

-r
T

~~~
~

$~
i

4IFTIm

FAN

SWITCH

J::"il@J
[.!g]~

~~
~ BR

HA-8

IilITn
AR

CON

L::

G/W

L/R

Ii'!5il
LOW

HIGH

...

L/R

TRIPLEPRESSURE
SWITCtl

L/R

~ N~RMAL m~

~1 SOLEN
~~g

L---;r!-+.:;"::":c:::...J PRESSURE

I1jdJ

SWITCtl

:,:
I]ill,~

VALVE

T~

:@

'=r"(8IQ)
G/Y

@~
G/Y

~
AC
RLY

@)
L

@ f f8 i - l

~~
34
B
IT!1

L/R - . - - -

~~
12
B

~-2
W

HA-9

~~
12 PU

MODE
ODOR
MOTOR
~

8 642
7531

1 14
1 15 @gl

17

I
I

I
I

HA-l0

~~

~8

G/w

Y/L

GIB

I If U
G/w

Y/l

Preceding
page

<& l/OR,
l/OR

GIB

m rm

P/L

It I

P/l

mm

INTAKE
DOOR
MOTOR

~
1

......- - - - -.... I
B

I~

I'
CHD

~
I

:~~(@):

: tm:tttj ~
I
IL

[I[QI]~

lllIIJ

I
I

IZIIQI] ~

lID.&IJIl

HA11

rnJUI
~

-1
i
I
OR/L

LIG

ORIL

$- ~ ~

OR/L iEIQ) LIG

L1f
ON

OFF--

TRIPLEPRESSURE
SHITCH
~:<ID

I
B

= I":f-,
t I

W/R

ORIL

LIG

OR/L

LIG

HI

l[g'Q]f ~ ~[g'J1
'T" @ ""'i""

JL

L.:,,!.l-.----,-,!~H'
Ibj.!I
8

ECM

(~g~~ROL

tI

~LE)

r%

m>~

,;L5
T31

LtI

JG

~
RFR

BR/W

Ii1il IFDl
HI
It I
,lD

~<r

CIT>@
L 1 L

~~ &ffi:@
\j1y B ~ GY

HA12

.Q..rn.@
\.!Jg}

GY

prolec,cr lHD:@-1
connector RHO :@-,

SHA02E

[
Check magnet clulch coiL
NG

Corn,Dres~or

[IThonn.1

cijr

ID

Connector

LHD :@-2
RHO:Cffi)-2

B [1t

(0

La~'i5'
COO

Replace magnet clulch.

(Refer Ie HA.146 in 814 SERVICE
MANUAL. Publicalion No.: SM4EOS14GO.)

SHA493E

@
(Go

HA-13

[0

nexl

"'"
~
Gil

rr:an
[Y]

~i5

!Yes

RHA::JSSE:

CHECK AIC RELAY AFTER DISCONNECTING IT.

(Reier 10 tlA-70 in S14 SERVICE
MANUAL, Publicalion No.: SM4EOS14GO.)
!OK

(ill

Reconnect Ale relay_

[yCM-jOfcoNNECTORI]

" RHD:GIY

CHECK COIL SIDE CIRCUIT OF AlC

RELAY.

*F~rope:11~
EXCllp! ror EurOpO: 9

Do approx. 12 volts axisl belween ECM

(ECCS control module) harness 'erminal No. Or @ and body ground?

connector
~-~~LHO:@
AHDe.xoopt

&)

LHD:GIY ~rRHDlor
RtlD:GIW Europe:@)
RHA.4'\OF

II

sWitch connector

~LHO:@
I RHDexcept

~,- IorEurope: @
RHD:GIY
LHD:BIP

swilc~ coonoclor

AHOlor

Europe:@)

(Go 10 nexl page,)

Dual-pressure
switch conneCl0r

LHO:GN
RH

~ Dual-pressure

IorEurope: @)

III Tripleore"ur.

At-lM09F

Triple-pressure ~
switch connector

AIC relay

Gil

LHD:BlP

[!I

ECM

ECCNNECTORII

*
RHD:GIY
LHD:BIP

(ill

Nole: IIlhe resulils NG aller checking clrcult conlTnuny, repair harnBSs or

conneclor.

R ~e5
* For

Europe: 11
E>:cepl lor Europe: 9
RHA411F

HA-14

~
13

~
~

00 approx. 12 volts exist between

thermo conlrol amp. harness terminal

SHA498E

~~~n~i5~
v,"

II

ness conneclDr.

~.r~

(tJj LaI1

I No.

@ and body ground7

Ves

Ia
CHECK BODV GROUND CIRCUIT FOR
THERMO CONTROL AMP.
Turn Ale 5wilch or DEF switch ON.

Check for conti"uity between thermo

conlro1 amp. harness lerminal @ and

body ground.
OK
RHA40JEA

NG

CHECK THERMO CONTROL AMP.

(Refer \0 HA68 in S14 SERVICE
MANUAL, Publication No.: SM4EOS14GO.)
I

!OK
C~eck

voltage bel",een EGM IEGGS

control module) hamess terminals

@ and body ground.

Refer fa EC section {"ECM Terminals
and Reference Value", "TROUBLE
DIAGNOSES -

General Description")

In S14 SERVICE MANUAL, Publication

No.: SM4E-OS14GO.

Note:
IIlhe rElSullls NO alter checking circuit ccnllnully, r

HA-15

[ill
RHA40~A

III

III

Note

CHECK BODY GROUND CIRCUIT FOR

FAN SWITCH.
Check for conlinuily belween fan switch
harness terminal @ and body ground.

Fan Swilch
connector@

0K

1:I
~

CHECK FAN SWITCH.

(Reier to HA6B in S14 SERVICE
MANUAL, Publication No.: SM4E0514GO.)

[ill

~OK
Replace push control unit.

RHA.406EA

Nole:
U Ihe re6ullis NG aller checking clrcult continuity

HA-16

HA-17

~~~~rn
i

Ili'2iI

BAT

IGN

J""Q'"LiI@
~II

~ ~_
'"

~AIC.A-05

Y/S

ORIG L/OA
11

T"'I

L/"

ffiil

A/c
SIGNAL

fffi1~

DID

II

~~'"'
IGN
11llFANl

-II.

1M
FAN
FIB

~iIilll
~

HA18

I'~- i~-

VEHICLE
SENSOR
~

LOAD
SENSOR

BIY

e/y

II

Ic1J1<MW

AMBIENT
SENSOR

""i""CB)
Y
~~

~lill)

1~11WD

B/Y

$~
SlY

(ffiQ)

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HA-19

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P/L

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DOOR

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~------------------------------~~

HA20

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10 - 20 (1

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HA-24

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4 (0.3

Inspection and Adjustment

ENGINE IDLING SPEED
When AIC is ON
Refer 10 EC 5ecllon ("ln5peclion and
AND
Adluslmenb",
"SERVICE
DATA
SPECIFICATIONS").
BELT TENSION
Refer 10 MA secllQn ("Checking Drive Bells",
"ENGINE MAINtENANCE").

COMPRESSOR
Model
Clutch disc-pulley clearance

HA-25

mm {in)

PRECAUTIONS..
.
2
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE.TENSIONER
2
POWER SUPPLY ROUTING............

4
Schematic....................
.. 4
6
Wiring Diagram - POWER BATIERY
15
Service Data and Specilications (SDS]

15
STARTING SySTEM
..
.. 16
Construction
..
16
Service Dala and Specilicalions (SOS)

.. 16
EXTERIOR LAMP
17
Front Fog Lamp/Wiring Diagram - F/FOG _
17
Rear Fog LamplWiring Diagram - R/FOG _
19
Turn Signal and Hazard Warning Lamps/
Schemalic
21
Turn Signal and Hazard Warning
LampslWiring Diagram - TURN _
22
INTERIOR LAMP
.. 27
Iliuminalion/Schematic
27
IIluminalion/Wiring Diagram -ILL _
28
Interior, Spot and Trunk Room Lamps/Wiring
Diagram - INT/L _
33
METER AND GAUGES

35
Combination Meier
35
Speedometer, Tachometer, Temp. and Fuel
36
Gauges/Wiring Diagram - METER _
WARNING LAMPS AND BUZZER
37
Warning Lamps/Schematic
37
Warning Lamps/Wiring Diagram - WARN 38
Warning Buzzer/Wiring Diagram - CHIME _
44

POWER WiNDOW
Schematic
Wiring Diagram - WINDO
Trouble Diagnoses
POWER DOOR MIRROR
Wiring Diagram - MIRRO
MULTIREMOTE CONTROL S
Wiring Diagram - MULTI
THEFT WARNING SYSTEM
Wiring Diagram - THEFT
NATS (Nlssan AnllTflell Sys
System Description
System Compos ilion
Component Parts Location

~:~~n~eD~~~;~s~.~~~.~:::::::::
LOCATION OF ELECTRICAL
Passenger Comparlment
HARNESS LAYOUT ..
Main Harness
Engine Room Harness ..

~~~~~~r~~~~~ ~~.r.n.e.5~.::

..
Door Harness (LHD mode
Door Harness (RHO mode
SUPER MULTIPLE JUNCTION
Disconnecting and Conne
Terminal Arrangemenl ....

WIRING OIAGRAM REFEReNCE CHART

ECCS
AIT CONTROL

__
__

ANnLOCK BRAKING SYSTEM ,

AIR BAO AND SEAT BELT PRE-TENSIONER

HEATER ANO AIR CONDITIONER

__
,_,

EC s
AT s

BR S
RS S

HA S

El-1

Improper maintenance, includin

Installation of the SRS, can lead
by unintentional activation of the
Do not use electrical tesl equipm
to the SRS unless Inslructed to in
wiring harnesses are covered wit
just before the harness conn
harness, for easy Identllicallon.

EL-2

EL-3

30A

[li]

25A

[II

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CF'F ACC

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30A

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-----0--------30A

III

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ASS

II]
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@

LHD mod~ls
RHO models
All models

@ : For Europe
@
Except fIJI'"
@
LHD models

Europe
.... i trlCut

daytlme light system

@
'1
'2

Except@

CD27 . @29
CD 16 . 14

MAI

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... [ ) lOA,

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ACCESSORY
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Next page

To EL-POHER-05

+ CHARGE

G/B

L....-

---

Q
1

DO.

rr:::::IJ rr=:o
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EL-6

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page
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@

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Adjusling plate
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@
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A
B
B

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@

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B

Service Data and Specificati

STARTER MOTOR

Type

S)lslem voltage

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Terminal volt8ge
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Brush spring tension

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57
36

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PUSH CONTROL UNIT I

AUTO A!C UNIT ILLUM

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PARKING B

MALFuNCTION
INDICATOR

AIR BAG

f----

EL-37

MALFUNCTION
INDICATOR

CHARGE

OIL
AIR BAG

OR

"
U
1

RI

W/R

~ffi

$~

ECM
(ECCS
CONTROL
MOOULE)
(Refer to
EC-MIL.)

y/L

Y/L

DR

LEO-R

W/R

$~------$
~

.~
DR

Y/L

'$
RI

W/R~

RI

y~L OIL
W~R
IR
PRESSURE
L
ALTERNATOR

(IT)

1-,

<ED

SWITCH

-!-

I8L)

<i

(@

r-----------~---------------------------,

!~I [Hmj][imffil ~ ~! ejIDCW

I

~---------------------------------------~

ITI:QIII]@

eIJID::II]]

,J:TJ.,.

~ ~~ rTTT::rTl"E5r:: e

iliJ GY

Gt::t:t::j

GV

ITIIIIIIII:TI[

r----------I
I

IQ

:(gJ<ID~i

!
EL-38

RIL

L/R

L/R

l$~
RIL

L/R

WASHER

FLUID

SWITCH

~~
B

If4!Il <ID
R/W

~
~@)

11 LEVEL

R/W " " "

m'e!LJ

lbiJJ~

RIL

I
T--~

R/L~

I
~

R/W

I
m
R/W

T
L;;

[!J
ASS

HIL

CLOSEOABS

r--

S~NROL
(Refel"' to
BR-ASS.)

@g)

I'

~~
r-----------------------~

i~]~]@i

~-----~---------~-------~

EL-39

'-"'

L/R

VIR

ViR

rr.'En@W
1~liEIDl

V/PU

rm

V/PU
i

BRAKE
FLUID
LEVEL

W
I]

PULLED

,-RELEASED

SWITCH

~ru>

ON

(High

temp.'

PARKING
BRAKE

OFF , - -

(LOW

SWITCH
(@

temp.)

DIFF OIL

WARNING
LAMP

1-,

SWITCH

<ill)

@V ~

i
I

~] [HHE]

@):

1Ql<ill)

(!)

~----_!_------~-------~
~I(ill)
tgj GV

EL-40

I-

w/A

OR

1r&1@Q)

=r@
OR

W/A

[J
ill
LED-R

I
i~
<!ill!l

W/R

._~~

~~~CS
CoNTAoL
MODULE)
(Refer' to
EC-MIL.)

em

''T

RIB

~~

~~

~~

::
PAESSURE
SWITCH

W~R~
L

ALTEANA TOR

i-=

J.
-;;

(ill)

@@

~----------------------------------~----,

i~] ~OOEE] HmEJ

W

Q@)

j
I

~---------------------------------------~

Ell 8

EL-41

G
U

I!.iJlC

IR~B

QID @L)

il

W/R

~
1-,

Y/L

Y~L

W/R

T~

OR

. RIB

cfm)~

I I

~@g)

Ictil <Bg)

=W=l@

L/R

WASHER
n] FLUID
U LEVEL

i i

=w= BELT

~~"@

L: R
2

c:J
ABS
W/L

l' l'

CID

i~] [EffiEE] ~ i

I
IL

DOOR

SWITCH
OPEN ~~~~ER 'S

CLDSEO-

R'W
m

IWI SWITCH
=W=~. @

Rf

O~

~
1

FASTENED

~~-------

L/R

~1<illD
R/L

L-----.I;O'I221.--,;'
II"'SE"'""""'T=
--

~~L/
*2

I
I

....ElL~
UL) GY

EL-42

@
=

ASS
CONTROL
UNIT
(Refer to

BR-ABS. )

::~o.~ ."

.r
Y/PU

n
U

(lli)lLjdl
B

SECURITY

00

Y/R

L/R

INDICATOR
$--a\---$
@:
Y/PU @D
L/R
~
I
I
GIOR
v/Pu
L/R
m
~~
L/R

~11ffiID

YIB Qiill)

Y/R~

BRAKE
FLUID
LEVEL
SWITCH

OR/G

L/R

PULLED

Irnn

,-RELEASED

L/R

G/OR

rrh

PARKING
BRAKE
SWITCH

ON

(High

temp.l

GID

INDICATOR
OUTPUT

OFF --(Low
temp .J

SMART ENTRAN
CONTROL UNIT
(Refer to
EL-THEFT .j

DIFF OIL

WARNING
LAMP
SWITCH

it
mm

([g):

iffi)

r----------------~----~

:~]mm@:

~~
~ GY

[Q]<Bl

l.WJ

EL-43

F.l~

L1J

10

1SZI([g)

21

S IV

W/R

W/R

BAT

WARO't-fpltflER

IGN

KEV SH@

SEAT BELT
SW

10

211

p -1--------.
I
B

To seat belt
EL-WARN.)

r0l

GND

~~~n~g t;am

B(.P

~lH!ID
BIP

I
G/V

VIG

y IG

vis

~l!ill)

I~I@)
VIG

UNFASTENED

--_....

FASTENED

l:Ql~

C!ITIJ w

~@@

I.IJ]]

n-,..r:-]
WQJ.gJ

EL-44

~
B

rm ~

OFF-~:

113

""'-'..-d-...----'

LIGHTING
SWITCH
@W:@

0-(8)

RIL

~-;r.~.k2"-------.J

R/L
R/L ~ RIL
~I~

-0-

R/l

RIL

fiITTI

~~ (ffi l1J
Y
OF

~O

.,...-------,--='~~25!:':"_::::_:
LIGHT SW

l~~~fM5NIT
(Refer to
El-DTRl .)

--J~:@

L-

I
IL

R/l

TAIL
lAMP
SW

: l!

;:,'

:;B

*3"'@

*4"'@

m :

(lliID: @> 12
W

II

1lliID: : ~
W

I
I

tlli:j:f:;J

EL-45

@
GY

[IjQ[gJ @)

ITIJ.J

SR

I IGNlT

ON o

POWER WINDOW MAIN SWITCH

(Driver"s side)
DRIvER' 5 5IOE
ONE TOUCH
MANUAL
N

SWITCH

PASSENGER
SIDE

ON OFF

LOCK

{AutO) (iol)

I---

ITI

r;.co
0'1

~ ILL.

AMP.

excepf for- Finland.

BREAKER

~~
W/A

W/A

I
II~r~

WINDOW

21

RELAY
51 (@

W/B

1...

---------

WIB

I!i@ @)

w/B

EL-47

H/B -

H/B

(*2)

AMP.

I-I--

4Jl~
G

II h

UNLOCK

i
I

r l.!

4Jl

~ @)

4J
cHIID
B

(~

PASSENGER
SIDE

DRIVER'S SIDE
lOCK
lOCK
SWITCH

-------

AUTO MANUAL

I
POWER WINDOW
REGULATOR
ORIVER'S SIDE
(@

<h>:
:

lI2"'

~------------------------------------~

:~<h>:@)
I~

~:CQ[):
~

W,
I
I

~------------------------------------~

EL-48

~<W

L!J..gj

m::IQII] @) @Qg)

[ID]JZ[IIJ

~@@

tm.iD.IJ

II

EL-49

Passenger power windows cannol l. Power window subswilch

2. Passenger side power window
be operated.
regulators
3. Power window main swilch
4. Power window circuit

1. ChecSl: power window

2. ChecSl: passenger side

3 Check power' window

4-1. Check harnesses b

switch and power
short circuil.
4-2. Check harnesses b
switch and passeng
lator for open/sheri

Passenger power window cannal 1. Power window main switch

be operated using power window
main swilch bul can be operated
by power window sub-switch.

1. Check power window

Driver's side power window aula 1. Power window maill switch

Iunction cannot be operated using
power window main swilch.

1. Check power window

EL-50

OR

~ ~~~
Y/L

:.
:

23

5746

L/R

ll-

Ii-,
~

Y/R

--

I
I

OO:
W

~OO::
~GY
I

EL-51

~"

PU/I!@

YIL

L/R

pU/'li @@

YIL

L/R

T 'If
pUll!

$----4Jt---1$J

DOOR
MIRAOR

ACTUATOR

UP-

LH

WARD ~

c.r::J.!g@

<liW
W '

Y/R

L/

~----4Jt--~
pU/W
Y/R
L/

~@
~W'W

EL-52

L/R

4ill>

RIB

(]I)

R/L

RIB

R/L

rm~
Ii'til KEY
~ ~CH

L/R

1 1

~
A~g~

~~~~~
lIilll

~
R/W

~2W <ED

BIP

'L..j-I'

W'R

R'W ~

iLCll

W/R

R/W

BIP

@:

~
B/P

OFF

~~~aLLER

@:

"1

BIP 4ill>

~
~
'-~B~A~T"-----------;RO='D~M";-L"'"A::;MP:;-----7:K=:EY~S;-;-W------!J.A~C'=!C"-OUTPUT

37 ANT

'---------------------------

~<ED

[Ilg[IJ

[Q]@@
I1J:g] W' W

EL-53

~IW)

I1J:g]

$:
LlR

L/R

GY/R

L/R

OPEN

DOOR
SWITCH
DRIVER'S
SIDE

@)

CLOSEO-- -

,..,
B

B
B
~
~
@~

P..~

L!J

SR

--li4-~
(.ELJ GY

EL-54

I
OPEN

DO
PA
S

rm m
lH..OCK

LOO<.EIl

m m m
~

LOCK

...

DOOR LOCK
ACTUATOR
DRIVER'S
SIDE
lH..OCK

LOCK

DOOR
UNLOCK
SENSOR

rep

BCQV

B@9>

I
B

!-

QID

~CID

DIIIIJll[J w.

@.OJ)

~CQV~
~~~
~ w, w
t:!lY
GY' GY

EL-55

IT ~ ]I~n~

REMOTE
CONTROL

lIR:'/I:..:r

~ ~ ~ ~Y-l ~

iJ,m

REMOTE
CONTROL
RELAY-2

Gill)

i 't.:.,,,"+}

- - - - - - - - - : ; ; ; ; ; . G/Y.

Te

G/B.
DR ill)

OR

r-

DR

FLASHER
OUTPUT

Y/G

To EL

Y/G

rm

PANIC
OUTPUT

SMART
EII/TRA
CONTR

UNIT

@])

572

36

~
~~l~Bl
BR

"

EL56

W/R

rrm

rrm

BAT

ACC

IGN

DOOR SW
t...,;:G::;.:N<TD,--_ _,;:(O;;,R;;;l

GY/R

Sio/

DOOR

.....:;,(P~AS;;:S;;:.)---------~;;
16

.~-------------$

$:

GY/R

L/R

rm

L/R

DOOR
OPEN

_---

....
CLOSED

SWITCH
DRIVER'S

ODOR SWITCH

(@)
OPEN

3 1
B
B

l'

QID iEQ7)

SIDE

CLDSEO---

PASSENGER
SIDE

"

S
B
~
~
@)~

....JSlL..~

Ulli

~@

GY

EL-51

\oj

~ - ~-~
R
aD

GliB

LOC;~~CKED (~~~~g~)

LOCKE

repB~
B

(ffi)

OPEN

TRUNK
ROOM
LAMP
SWITCH

. ._ -_ _. .

GIB

EiJ,

BETWEEN
FULL S1ROKE
TRUNK KEY
AND N
CYLINDER
SWITCH
(UNLOCK
SWITCH)

ill)

---_ ....

CID

CLOSED

1Jidl
B

..._------'.I

B
I

IB

-!-

-!-

<:lID

(lli)

~@)@QD
W W

CJIIJIJillJ

~@)~
W W

ITIIIIJ

EL-58

~(lli)O
GY GY

tjy

~ CQD

8ETWEEN
FULL
STROKE
AND N

.' '.

FULL
STRlJI<E

~-l~--- -$1--

J CQD

lbiJJ
G/Y@)
ffi

LG/R

LG/R

ffi

8ETWEEN
FULL
STROKE
ANO N

UNLOCK SW L-LD_C_K_SW
DOOR KEY CYLINDER
SWITCH DRIVER'S SIDE

fill])

---KEY
CYLINDER
WITHDRAWN
~ TAMPER SW

FULL
STROKE

8ETWEEN
FULL

~~~O~E

NOR

F ULL
STROKE

UNLOCK SW L-LO_C_K_S_W

I!4=Jl

llijJl

G/Y

.' '.

NORMAL

FULL
STROKE

@QD

DOOR KEY CYLINDER

SWITCH PASSENGER SlOE

<Dill)

@)

IB

11----------~

Gill

~ @) @QD
~
W W

[I[]Q[I] @)

IT:II.TIIJ

EL-S9

rfi"2\(ill)<Dill)

BY' GY

n
I[[!I~'
11

HORN
RELAY

~i!4JI~em
6

6/1o!

Y/G

m
2

'I] CONTROL
REMOTE

R
C
R

RELAY-1
~

lIR~I/~f

21

i 'I..

B_G/_

m
Y16

i-----'
QJ QJ QJ
1

HORN
(LOW)

Wem
2

57

36

lI@

SR' SR

Y /G I81Q)

HORN
(HIGH)

Y/G

6/W

llliD

THEFT
WARNING
HORN

Illi)

F.'lU!l <Hll~

WS'S'S

EL-60

PANIC
OUTPUT

FLA
OU

I~---t
1SIGNAL
~~~T

G/Y

~ ~

1
1
2

G/B

~5~~INATION

LAMP RH
(TURN
~ SIGNAL)

(flZl

~ Iffi)

.-__1.

!-

(ill)

(ill)

n-n:r--n]
~w

l!@

~m~
<m> ~
BR ' SR GY' GY

EL61

~B~~T

SIGNAL
LAMP LH

~~I-

-1

o::r:TIQIillIII

NATION
LAMP LH
(TL!'IN
SIGNAL)

1......

~~

Q~~

G/B

SIGNAL
LAMP RH

LAMP RH

G/Y

L,~

1
1
1 .
G/Y

!-

~!R:G

~~~y
o

~H2rr.----=---,r-~'hi4

~I
IkjJI

*1-

aD

~-eE-----'

LG

$1 ([ill)

*1

LG

OR/G

THEFT
WARNING
RELAY

'-}'

~2/R

LG iffiQ)

SECURITY
INDICATOR
LAMP

.0
. "2 1

INHIBITOR
SWITCH

~:ill

[Do B/W - - _

G/OR

INDICATOR
OUTPUT

STARTER
CUT
OUTPUT

SMART
ENTRANCE
CONTROL
UNIT

IffiID

r----------,

',@'
I
,

..

rn

~~:

.1

EL-62

~_
BATTERY

B/R

carried oul.
Regarding the procedures of NATS initialisation and NATS ignition key ID reg
SULT operation manual, NATS V2.0.
When diagnosing NATS V2.0 using CONSULT. adapter and adapter harness
necessary. although a direct DOL cable connection between CONSULT a
required.
When servicing a malfunction of the NATS V2.0 (indicated by flashing of Malfu
or registering another NATS ignition key 10 no., it may be necessary to re-reg
tilieation. Therefore, be sure to receive all keys from vehicle owner.

System Composition

The immobiliser function of the NATS for the S14 model consisls ot the following
NATS ignition key
NATS antenna amp. located in the ignition key cylinder
NATS immobiliser control unit (NATS IMMU)
Engine control module (ECM)
NATS security indicator (NATS security ind.)
Malfunction indicator lamp (MIL)
NATS anlenna

NATS ignmon key

))))

((((

EL-63

am~.

NATS

EL-64

SECURITY

INDICATOR

lbiJI@!)

W/R

METER (MIL)

<BW

OR

~R

$~~OR

G/Y

AMP

~~

I'illZl

IQ]@!)

Ilill.I

~W

~-------------------------,

~'illZl
~W

~ ~] "'20' :
1~~'.l:!SlV1

G/Y

It It
m

NATS
ANTENNA
-~-----------

OR ~G/Y

EL-65

I
R

<HQl

lbjJJ

DR

W/R

~w

:~]~]~:
I~~I

lEW

It

~W

OR

1E5]il@
IillJ 8

~~

~lflID

OR cm

$ :6~

EL-66

CONSULT.

SULT.

(ThiS means thai engine IrQuble da

ECM")

ITurn ignition swi[cn "OFF",

Repair NATS
111 necessary, carry oul "SLF-FUNCTION CHECK" or "C/U

Turn ignllion switch "OFF',

INITIALISATION" with CONSULT.)

[Turn ignition switch "ON"

Erase (hB NATS 'SELF-OIAG RESULTS" by using CONSUL T. (Touch "ERASE")

Repair NAT5.
(H necessary. carry out 'SELF-FUN
INITIALISATION" with CONSULT.)

t
Don', er8se the NATS "SElFDIAG
CONSULT.

SIIITL Ihe engine.

rv.;-;;;:;-;-,--,-::-:-==
~~nklng 01 MIL".

Starl the engine.

O~

NG Verify no blinking 01 MIL'.

OK

ICHEC~ OUT

Cheek the engil'1D "SELFDIAG REusing the CONSULT generic progra

(Engine diagnostic softwara include

-----

Perlorm running lesl with CONSULT in engine SELf-OIAG

RESULTS" mode.

NG Verity "NO FAILURE" displayed on the CONSULT screen.

ITurn ignition swilch "ON",

O~

CHECK OUT

Era5ff Ihn ongine "SELFD1AG RES

"SocU_L,...T",...<T_O_U_Ch,..."_'E_R_A_SE_"_"I_-=-Slart Ihe engine.

EL-67

~==ij======11
START

SEl3:21U

[~

SELECT NATS SYSTEM

IV1. 0

Iv. 2. 0 (GASOLINE)

IV.2. 0 (DIESEL)
I
I

OJ

6. Touch "V.2.0 (GASOLINE)".

Gi]=::::J

:==J

I
I
I

SEL3~~

I~
I
I

SELECT DIAG MODE

oj

CIU INITIALISATION
SELFOIAG RESULTS

Perlorm each diagnostic test mod

vice procedure.
For further Information, see the CON
NATS V2.0.
7.

ISELFFUNCTION CHECK

SEL329U

EL-68

DIFFERENCE OF KEY

ERASE

II

PRINT

When touched. the

self-diagnostic results

I; ERASE

II

PRINT ~W

:~:~,i~~uren(~~eM)

are erased.

Ir trip number is more than 1, MIL do

SELF-DIAGNOSTIC RESULTS ITEM CHART
Detecled items (Screen terms)

Description

loat IMMU is mellunclioning.

IMMU

ECM received the signal Irom IMMU

ECM

ECM is mallunctioning.

CHAIN OF ECM-IMMU

Communication Impossible belwaen ECM aM IMMU.

DIFFERENCE OF KEV

IMMU can receivB Um key ID signal but the result of 10 vurilil;;fliloo

betwe-en key ID end IMMU Is NG

CHAIN OF IMMU-KEY

IMMU <:annot receiVB the key ID signal

10 DISCORD, IMM-ECM

Thll result 0110 verification betwBen IMMU and ECM Is NG. Syst8m
iniliellsalion is requrred.

MINGLE NOISE
DON'T ERASE BEFORE: CHECKING ENG DIAG

Noise (inlerlerence) mingled inlo NATS communication lines during

cDmmLlnjcal~ng

Engine trouble data and NATS trouble dala have been detecled in

ECM.

EL-69

ground Irne or IMMU

clrcuil

C3

Opon circuil in com-

munication line
between IMMU and
ECM

C4

CHAIN OF E
IMMU

Shorl circuil belWeen

IMMU Bnd ECM com-

munication line and

baltery voltage line
Shorl cfrcuH between

IMMU and ECM communicplion Irne and

ground line

c.

source line or ANTI

AMP clrcllil

E3

Open cirCUli in power

ECM

IMMU

Unregistered key

IMMU

"

El

E2

Communicalion line
between ANTfAMP
and IMMU:
Open circuit or sMrt
circuit of baUery voltage line or shorl circuit 01 ground line

D1FFERENCE

Open circuil In power

source line 01 ANTf
AMP circuil

E3

Open circuil in
ground line or ANTI
AMP circuit

E'

Malfunction 01 key ID

chlp

CHAIN OF IM

E5

IMMU

Antenna amp.

E6

EL-70

SYMPTOM MATRIX CHART 2

(Non selfdiagnosis related item)
SYSTEM
(MaUunclioning parI Cit mode)

SYMPTOM

NATS sec:urily Ind. does f10t light up.

NATS security ind.

Open circuit between Fuse and NATS IMMU

X
Continuallon 01 inilialisa.tion mode
NATS IMMU

DIAGNOSTIC SYSTEM DIAGRAM

~.:r.RT.
O~K~eY~

10 chip (PART ES.)

~ (((0 ~
NATS ignilion

"f

','...:::cL----1-

PART

C2~GN+1/

",----IMMU

+_

PART

key

NATS antanna amp_

'---

---,_...J

-------------------------

EL-71

 Rei. parl No.: reference prul No. 01 D1Bgnoslfc Sys

Ii!

SELFDlAG RESULTS.
FAlLURE DETECTED
ECM

DIAGNOSTIC PROCEDURE 2

Self-lliagnoslic results:
"ECM" displayed on CONSULT scree

TIME
0

r.i.1

@
I

ERASE

PRINT

Conlirm SELF-DIAGNOSTIC RESULTS

CONSULT screen.
Ref. part No. B.

SEl331U

Replace ECM.

00

Perform initialisation with CONSULT.

For (he operation of initialisation, refe
manual NATS V2.0".

EL-72

~cr~

l!l
Check voltage belween terminal @ or
IMMU end ground wilh CONSULT or

SElJ34UC

lesler,

IMMU conneclor

Voltage: Banery voltage

~i8
W~t1iirii1dn ID ~

~
~

NG

f---+

OK

LWJl

I!l

SEL335UC

Check harness continuity between

IMMU termillal @ or and ground.
Continuity shDuld ea:l,t
OK

~
Check harness continuity between lhe
following ECM terminals and IMMU lerminals.
ECM and EMMU @
ECM @ and IMMU @
Continuity should exlsl.
SElJ3IiUC

OK

~~85~~fi)

~ IMMU conneclor@

1~12

34

"" 'laJ"""

SEL5Q6U

EL-73

NG

f--o

~tLJ~
SEL508U

~i0

~@D

~J

OK

1:1
CHECK NATS ANTENNA AMP. CIRCUIT.

1) Disconnect NATS antenna amp. connectar.

2) Turn ignition switch "ON".
3) Check vollage belween antenna
amp. terminal GJ and ground.
Vcllage: Mote tllan 4.7V

NATS antenna amp.

connec1.or

1:1

Conllnulty should not exIst

l5n

OK

00

SEL377UC

0 I~

SELECT DIAD MODE

ICIU INITIALISATION
ISELF-DIAG RESULTS
ISELF-FUNCTION CHECK
I
I
I

SELF-FUNCTION CHECK

1) Connecl ECM connec(or and

disconnec(IMMU connector.
2) Turn ignilion switch "ON"
3) Touch "SELF-FUNCTION
CHECK" on CONSULT
"SELECT DIAG MODE"

01

screen_

ijJ

II

I
I
I

00

Touch "START". ECM will then

check its communication interlace by ilsell.

OK

II

SEl34DU

II

SELFFUNCTION CHECK
I

TOUCK START.

IMMU is maHunclioning.
Replace IMMU.
ReI. port No. A

THEN ECM CHECK THE

IMMU COMMUNICATION

INTERFACE BY ITSELF.

START

I!]~
SEL141U

EL-74

(See nexi page.)

NG

PRINT

SEL34:J,U

SELFDrAG RESULTS

DIAGNOSTIC PROCEDURE 4

TIME
0

FAILURE DETECTED
DIFFERENCE OF KEY

Sell-diagnosllc resulls:
"DIFFERENCE OF KEY" displayed on

Conlirm SElF-OIAGNOSTIC
RESULTS "DIFFERENCE OF
KEY" displayed on CONSULT

screen.

I
~

ERASE

II

PRINT

1
0K

SELJ.44U

C/U INITIALISATION

II

PRINT

with
SUlT

For the operation of initialisation,

reler to "CONSULT operation

TURN IGN KEY SW OFF"

AND ON". AFTER CONFIRMING SELF-DIAG
RESULTS, PERFORM C/U
INITIALISATION AGAI N,

ERASE

SUlT,
IDs.

STOPPED or FAILEO

Or'

Re-l"egisler all NATS ignition key

INI1lALISATION

manual NATS V2.0",

-l,lni\ialisalion

completed

Initia
incom
fa

Perform initialisation with CON-

Stan engine.

5'ELJ12U

END

(Ignition key ID was unregistered.)

Rei. par' No. D

EL-75

pj
[!JlMMU connectDr

IW

ClISCDIIIIE&1

~I:D

[JliliJBJ9ITifufuil

(3)

El

<D

E2

Conllnulty should elisl.

NATS antenna amp.

connector

IW .,,,,,,,,

t...mIO~

L... --...L....

Iilll?ID@

J!ElJ1
SELJ15UC

Check continuity between the following

terminals and ground.

NG

I---

Ref. p8lrl
No.

IMMU
lerminal

NATS anlenna
amp. Lermina.1

(3)

E1

<D

E2

ConllntJlly shourd nol exist

l' n
0K

I!l
F'~---_--L------NG'
~~Ci~:I~I~;: :r:::: ~he

following

terminal

NATS anlenna
amp, termina.l

ReI. pari
No.

El

<D

E2

IMMU

Von.ge: OV

';===::;:;.;;;;=;::::=====:SE:L:3':6U=G~

r:

NATS anlenna amp.

co~nnecto~~~C(]I<!!ol~C1
~

C!I!I.!lU @

~i0~

~
r=---------'L-------K

CHECK ANTENNA AMP. POWER

SOURCE CIRCUIT
1~ Connect IMMU connector.
2) Check voltage between NATS
anlenna amp. terminal G) and
ground.
Vollage: More Ihan 4.7V

SELJnuc

EL-76

~...

Starl NG

--

~i50~

OK

IMMU conneclor@ID

I~
[Y]

1:1
CHECK IMMU GROUND CIRCUIT.
1) Turn the ignition 5will:h "OFF".
2) DisconnecllMMU conneclor.
3) Check continuity between IMMU lerminal @ and grouod.
ConUnull)' should exist.

SEL499U

r~
~i5~
[lflffl]
IMMU conneclor@

1
I

SElsooul

[iJ ~i)0~

IMMU connector @ID

"

Y
p.r

OK

NG

CHECK IMMU OUTPUT VOLTAGE.

1) Turn the ignition switch "ON".
2} Check voltage be\ween IMMU lerminal and ground.
Voltage: More Ihan 4.7V

CHECK IMMU FUNCTION 1.

1) Connect IMMU connector and NATS
antenna amp. conneclor.
2) Check voltage between IMMU termiI1al ill and ground.

I
I

Vollsge
TIme (Aller lurrll(lg ignilion s......itch "ON".}

Voltage

For apptOlC, 0,5 sec.

Approlt. 2.3 - 5

Alter 1 sec.

J
0K

l!W1

5EL50'U

EL-77

NG

When replacing the amp. hold on 10

amp_ body. Take care not to pull on

amp. harness.

SELF-DJAG RESULTS.

FAILURE DETECTED
10 DISCORD,IMMECM

DIAGNOSTIC PROCEDURE 6
Self-diagnostic resulls:
"10 DISCORD, IMMECM" displayed

TIME

screen.

I
(;J

ERASE

II

PRINT

CIU INtTIALISAnON
INITIALISATION

SL333U

PRINT

Re-regisler arl NATS ignilion key

For the operation of il1ilialisation,
refer to "CONSULT operation

TURN tGN KEY SW "OFF"

AND 'ON", AFTER CON
FIRMING SELFDlAG
RESULTS, PERFORM C/U
INITIALISATION AGAIN.

ERASE

Perlorm initialisation 'with CONSULT.

IDs.

STOPPED or FAILED

Conli,m SELF-DIAGNOSTIC
RESULTS "10 DISCORD. IMMECM'" displayed on CONSULT

manual NATS

V2.0".

Ilnitialisa,;on

completed
Slarl engine.
I

SEL372U

END

Ref. pari No. F

EL-78

~nil

lnco
er t

with
SUL

~E

If

PRINT

___________r=_K

END

SELlB5U

DIAGNOSTIC PROCEDURE 8

"NATS SECURITY IND. DOES NOT LIG

NATS INITIALISATION
Perform inilialisation with CONSULT.

For Ihe operation 01

initialisalion. refer to "CONSULT
operalion manual NATS V2.0"

Turn ignition switch "OFF'".

Start engine a.nd lurn ignition swHch

"OFf",

[iheCk NATS security indo blin'king.

NG

EL-79

nal @ and NATS IMMLJ cannector

terminal @.
Conllnulty should ex1st.

[Q]

SEL504U

[i

liJ

~i)~

CHECK NATS IMMLJ FUNCTION

1) Connect NATS IMMU connector.

2) Disl:Dnnact NATS security indo connector.
3) Check conlil1uily belween NATS
IMMU terminal @ and ground.
Conllnulty should exlsl IntermUlenlly.

IMMU conneclor ~

L;

OK
SEl505U

NATS securlty indo is mar1unclioning.

Pullout NATS security indo with harness and conneclor
Check harness connecllon

0K

NATS security indo cerl is mallunclionlng.

Replace NATS security indo

EL-80

EL81

Circuit bleaker

SMJ

Rear wiper amplifier

Power wil"ldcM' ralay {Blue}

R.., fog lemp '.'ay

(8tue : Without daytime light system)
(Gray: Wilh daytime light Syslem)

Rear windo'N delO'il"iler ,@Isy (Brown)

Ignition relay-2 (alue)

Accessory telay (BluliI)

Ignition relay-1 (Blue)

EL-B2

Warning bUlzer

Rear window defogger relay (Brownl

EL83

//

....m
0:.

@
I/~~~~I'
~

3@

:--..

.1>0

r.?

/ r=\..

"'-1
' "
~
I
BCD
A

@D:
@:
@:

Fuel pump relay

AS

@:
@:

Rear fog lamp relay (Models without daytime light system)

AS

@;

Rear fog lamp relay (Models with dayHme light system)

@:

Fuse block
Data link COnneclOr fOr CONSULT

B5
85
AS
AS

B4
84
84

A3
A3

@@: To ffi 15MJ)

@): To @ 15MJ)

B3
83

@):ToJ
@1): Circuit breaker

A3

@9:To@

A3

04

@ID:To@
@IT>: Pillar speaker lH
@.@: Smart entrance control unit
@: Kickdown switch (A/T modols)
@: Combination meier
@D: lIIumlnaUon conlrol switch
@: AIT control unit {AIr models)
@: Combination flasher unit
@: Buzzer
@: Slop lamp switch
@: Air mill. door molor
@ID: MOCIe door motor

E3

@!);

82
C3
C3
83
83
C3
C4

':'"
C

C3

(II

Power windDW relay

@:
@:

83

In

Body ground
Rear wiper amplilier

03

Rear window defogger relay

8i-lavel door motor

@!l: TO@
@: Push control unit
D2 @: Fan 5wilch
E3 @: Hazard ~witch
E3 @ID:: Headlamp washer switch
03 @ID: Rear window defogger switch
03 @: Rear fog lamp swilch
1:4 @ill: Radio
E4 @ill: Not used
E4 @: Crgarette lighter
D2 @ID: JoInt connector

E3
02

E1

@):

E2

~: Intake door motor

NATS security indicalor (fOr Europal

:l:

--------

11

~~. ~~~
r
\~\\tr~
j

31

en

Mlm

' - " (M65)

41

'-=Y

~lM

Bodv ground

!!~
""""

(~)

ill

5'~
--j
A

//0/
I

It

F5
COS
G5
G5
F5
F4
F4
F4
F3
F3
F3
G3
G3
CO2
F2
F4
F3
E3
E3
E3
E3
E4
E4
D2
D3
D3
C3
84
D2
C3
C2
C3
D4
C3
C3
D4
C4

m
....

Co
....,

C4
C4

: Body ground
@) : Rear wiper amplifier (Except
@ : Fuel pump relBy

: Power windOW relay

@
@

: F~JS9 block
: Data liok connector for CONSULT

@
@ID
(ill)
@

:
:
:
:

@ill
<.HI!)
@Q)
@Do

: Smart entrance control unit

: Kickdown switch (A/T mOdelS)
: Combination meter
: illumination control switch

ReBr rog lamp relay (For Europe)

Rear window defogger relay

To @(5MJI
To ill) (5MJI
Circuit breaker
@:To@
@:To@
@:To@
@ : Piliat' s~aakBr AH

@ : AfT control unit (Afl models)

@ : Combination ilashar unit
@: Buzzer
@

: Slop lamp switch

~ : In~vahlclQ sensor (AllIO A/C)

@
@

: Mode door molor

: Bi-Ievel door motor

Air mix door molor

@:To@
@ : Aulo Alc unil (AuIO AlGI
@ : Push control unit (c~Cepl Allio A{CJ
@ : Fan swilch (Except auto A/C)
@ : H.QZBId switch

@
@
@
@

: Headlamp washer switch {For Europe)

: Rear window defogger swilch
: RaBr fog lamp switch (For Europe)
; Secl,Jrlfy' indlcatoc (Except for Europe)

@:

Radio

<Bill: Not used

<Hill : Cigarette Iightoer

:l:

for Auslralia)

r.=(/Ar.Jk:'

21

ITI

.........~~

'

~~~~

31

CD
CD

41

",rv
"-~~
@~
....
000

Body ground

5
ili ~ I

I I

(]I) :

Cooling fan relay-2 (Except for Europe)

: Fusible link and fuse block-1

: Cooling fan (0'0)11

: Theft warning relay (Excep1 for Europe)

@ :
@ :

Air conditlonar relay

(Fusible link a

Horn relay

: Theft warning horn relay {~l;ept for ~l,IrQpe}

Front fOg lAmp relay (FOr EUJope)

D2
01

@):

Theft warnil1Q horn {Ekcept for Europe)

D2

Front wheel s.anSOr RH (For ASS)

D2

(fill:
@:
@:

C2

(ill):

Revolution sensor

03

(ill'):

To terminal code assembfy

03
03
03

(ili): To ~
@D: To~

01

C2
82

r-

82

CD

83

C3

C3
82
A3
A3

A3
A3
A4

A4
A2
B3
B3
B4

64
S4

iii

@ : Fusible link and fuse block2

@ : Fuslbla link and fuse block-3
@. Brake fluid level switch

Side tum signal IBmp AH

Inhibitor switch {A/T models)

lAIr

models}

(Air

models)

@J:To@
~: SaHo",

<TIID:

Hood 3wi1ch (Except for Europe)

(]ID: Washer fluid level switch

@: Headlamp wash'llr molOr (For
@: Front washer motor

Europa)

@: F1ear washer motor (Except for Australia)

@: Headlamp washer amplifier (For Europe)
(ill): Clearance lamp RH
@ID: Headlamp AH ouler
@: Haadlamp aiming motor AH (For Europa)
@ID: Headlamp RH inner
(E4i): Front tog lamp RH
~: Front lurn signal lamp RH
@: Body ground
~: Cooling ran molar (Except for Europe)
COOling fan molor (For Europe)
Ambient sensor (For auLo AlGI

(E45):
~:
@:
@El:

Horn (High)
Horn (Low)

I'll

r;-

:g

"

---------....m
....eO

till]) : To (iill) ISMJI

~ = Diode (For Europe)
~ : Fuse block
(E!06) ; Front reg lamp relav (Except for EurOpa)

: Ignition switch
~ : Kev 5wilch
~ : Lighting [milCh

@@ :

Turn signal switch (For Europe)

~ : Turn signal switch (Except for Europe)
Front wiper and washer switch
(fiE) : Rear wiper and washer switch {ElCcepl for Auslralial
(ill) : Rear fog lamp swilch (For Europe)
@.ID : HOln swilch

(@ :

cITID : Front fog lamp swilch (Excepl

@ill :

for Europa)

NATS antenna amp. fFor Europa)

Di

21

ITl
....
I

UI
N

r--...
~

///

31~

~~
F33

FilS

~.

51

!~~
A

E2

(IT):

01

@: ECCS reley

01

01

:TO~

El

@:To@
@:; Front wiper motOr
@: Fronl wipe, amplirilr

C1

62

Side turn sionei lamp ~H

C1

@:

@: ASS actuator
@: To (ill)

D4

E3
F3

F3 @:

Ignition coil relay

B1

83

Sub-harne

ECM (EGeS control module)

':'"
CD

@:

Front wheel sensor AH (For ABS)

@!):
@!).

Tripl&-pressura switch

E2
01

(fID:

TO ~ (AfT models)

63
C2

Engine ground

II

~:
~;

@l
@

E2

@D

C3
C3
C3
C4

E2

.@

E3
E3
1::'3
03
[)3

@: Mass air flow sensor

(ill): To<mD
@. Heeled oxygen sensor

@: Engine groun~
E2 @):To@D
02 (ill): To ffi
E2 @: IACV.FICD solenoid val....e
02 @: ICA\(-AAC valve
03 @): VTC solenoid valve
04 @: Camshah position senSor
63 @: Thro~le ~i1ion sensor (Srown)
83 ([34): Throt1le posilion .9witch (Gray) (A/T

F3

<ffi

C4

(fill

02

(@
@

03

models)

<BID

@ID
(fill
@

c")

':""

__

~~~-i __
51

"

:
:

E;CM (ECCS control module)

Sub-ha

ECCS relay
Ignition coil fijlay

D2
02

@:

C3

(f

C3

G4

D)
@:
@ IModel w;'h A8S)
(IT): To @D IAIT models)

C3

~
~

F2
F3
F4

@:

Front wiper motOr

Front wiper amplifier
Side lurn signal 'amp LH
ASS actuator (For ASS)

C3

@):

82

Fronl wheel sensor LH (For ABS)

82

F3

G4
G3
G3
G3

':""

U'I

To
To

02

82

E4

;
;

03
03

C@:

Power 1mnsistor unit

(@:

A3

<till:

Wasteg8t~ val....o control solenoid valve

04

(AIr

83

lT

C4
C3
C3
D3
D3
D3
C1
C,
82

@: Comprassor
@: M6$S olr flow sensor
@): PowQr steering oil pressure
(ill): To(E@
@: Heated oxygen sensor
(@: Engine ground
@D: To@j)
@l: To D

82
63

C@
@

c.3

CD

82

@:
@:
@.
@:
@:
@:

C4
A2
A3
C1

A2
ll1odels)

@:To(EID

C:2
B3

Dropping roslstor

swilch

IACV-ACO solenoid valve

IACV-AAC valve
VTC solenoid valve
Camshaft position sensor
Throttle position sensor (Brown)
ThrQttl$ position switch (Gray) (A/T mOdels)
Engina ground

'"

II

~
~

~~

m
~

A3
A3
83
83
C2

82
82
B3
C2'
C04

C2

eEl: To@j)
@: Body ground

aD:

:
:
00:
:
@:

Sub-harn
02
02

F2

([

Headlamp EI\mil'1l;' switch

E2

@!B

Door mirror control switch

Front tog lamp swilch
Overdrive .switch A/T illumination
Hea.1M seat switch RH

@:
([@): Heated seal
@:To@

5wirl:h LH

C3 @:ro@
54 @>: Door switch (Driver'S side)
84 @: Seat belt pra-tensioner (Driller'S side)
C4 @: 80dy ground
C2 @]): Condenser (For rGar window defogger)
F2 @: Rear speaker AH
F3
E3
E2

03
04
C2
02

r-

C3
E3
E3
E3
G3
G3

Healed seat LH
Perking blake lJWilch

@): Trunk room ramp

@: Rear wiper mOlor
@: Rear 5peAker lH
(ill): To (IT)
@:To@
@:ro@El
@:ro@
@:To@
@): Healed seat RH
~: Door switch (Posoongel side]
(Passenger side)

@): Seat belt pre-tenslonar

@:To@
@l: To (ill)

:z:

II

Body jJ,oond

"'~ '"0
-h~

- EJ -

2 I

=- __.~

8103

r;;;:;;-.

(86OJ

rI

31

CC

CD

41~~

511

-f

~
~

I I

G3 (]I): To@])
@: Body 'lfound

G3
F3
F2
F2
F2
F3
E2
F4
F3
F3

E4
E3
E2

C2
83
83
82
D3
D4
E4
G3

rn

':'""

D2

co

D3

co

C3
C3
82

em:

(]I):
@:

Parking brake swilch

Headlamp aiming switch (For Europe)
Door mirror control .swItch
Front fog 'amp switch (For Europe)
OVl:N'drive switch AfT i!lumination

@:
@):TO@
(: Door swilch (Driller's side)
@: Seal bell pre-Iensioner (Driver's side) (For ~urope)
@: MUllHemol~ control re-Iay-' (E);Cepl for Europa)
@): Mulli-remole control relay-2 (Except for Europe)
@: Body Q(ound
@. Condenser (For rear window defogger)
(@: Rear speaker RH
@: Trun~ rOOm lamp
~: Rear wiper motor IE.capt for Australia)

@: Rear speaker LH
@D:To@
@:To@
@ill: To @ID
@: Seat belt switch (For ALJslralia)
@: To @ (Modals wilt' ASS)
@): Body grolInd
@W: Door swilCh (Passenger side)

<!ID:

Seal belt pre-lenS Loner (P6ssenger side) (For Europe)

@:

Body ground (Models with ASS)

63
83

@.D: To @ IModels wi\~ ASS)

E3
E2

@: To@ID
(ill): To @ (Models with

~. ABS cOfltrol unit (For ASS)

i'!

II

ASS)

EL-100

~To

@:Ta@
@ ; Door 5peaker

: Power window regulator

@
@
@
@!)

: Door mirror defogger

: Door mirtor
: Power window main switch
: Key cylinder swilch IE,.;capt

for Europe}

@ :

Door lock acluator (Excepl ror EurOpe)

C :

Lock knob switch (For Europe)

ELl0l

IDX-1

C
Camshaft position sensor inspection
(Except for Europe)
"
Camshaft position sensor inspection
(For Europe)..............................
Combination meter __
__
CONSULT for ECCS.
__
CONSULT general information __
Cooling fan motor inspection (For
Europe) ,
,
Cooling fan relay inspection (For
Europe)
"
"
Counter gear (MT)
Coupling sleeve (MT)
"

EC-98

EC-23
.. EL-35
__. EC-18
GI-5
" .. EC-77
EC-77
" .. MT-3
". MT-3

D
Data link connector for Consult (For
Europe) __
"
,"
Dual pressure switch

Gauges ,
Gears (MT)

EC-93
HA-17

E
ECCS circuit diagram
. EC-6
ECCS component parts location
EC-2
EC-3
ECCS system diagram and chart
ECCS trouble diagnoses (Except for
Europe).,
"
,
, EC-94
ECCS trouble diagnoses (For Europe)
EC-19
__
__ .. EC-14
ECCS trouble diagnoses
EGR & canister control solenoid valve
EC-119
inspection (Except for Europe)
EGR & canister control solenoid
valve inspection (For Europe)
EC-51

Harness layout."
Hazard warning lamp
Heated oxygen sensor
tion (Except for Europ
Heated oxygen sensor
tion (For Europe)
How to read wiring diag
How to use this manua

IACV - FICD solenoid v

tion (Except for Europ
IACV - FICD solenoid v
tion (For Europe) ."
IACV-AAC vaive inspec
..
Europe)....
Ignition coil inspection
Europe)
",
Ignition coil inspection
Ignition control system
Europe)
Ignition control system
Illumination
Injector inspection (Exc
Europe)
Injector inspection (For

IDX-2

Malfunction indicator lamp (MIL) (For

Europe)
Mass air flow sensor inspection
(Except for Europe)
Mass air flow sensor inspection (For
Europe)
Mass air flow sensor inspection
Meier and gauges
MIL & Data link connectors circuit
(For Europe)
MT overhaul
Multi-remote control system

EC-93

Symbols and abbreviatio

Synchronizer (MT)

EC-101

EC-26
EC-137
EL-3S
EC-93
MT-2
EL-S3

NATS (Nissan Anti-Theft System)

NATS V2.0 precautions (For Europe)
Neutral position switch inspection
(Except for Europe)
Neutral position switch inspection
(For Europe)

EL-63
GI-2

EC-130
EC-87

Power door mirror

Power steering oil pressure switch
inspection (For Europe)................
Power supply routing
Power transistor inspection (Except
for Europe)
Power transistor inspection (For
Europe).........
..
Power window

Tachometer
Theft warning system
Throttle position sensor
(Except for Europe)
Throttle position sensor
(For Europe)
Tightening torque of sta
Transmission case (MT)
Trunk room lamp
Turn signal lamp

Vacuum hose drawing (

Vehicle speed sensor (V
tion (For Europe)
VTC solenoid valve insp
Europe).............

EL-S1
EC-BS
EL-4
EC-107
EC-32
EL-46

Warning buzzer..............
Warning lamps
Wastegate Valve Contro
Valve (For Europe)
Water temperature gaug

IDX-3