Nissan X-Trail MODEL T30 SERIES 2003 2004 Service Repair Manual

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Page 1

MODEL T30 SERIES

QUICK REFERENCE INDEX

A GENERAL INFORMATION B ENGINE

C TRANSMISSION/

TRANSAXLE

D DRIVELINE/AXLE

E SUSPENSION

F BRAKES

G STEERING H RESTRAINTS

I BODY

J AIR CONDITIONER

K ELECTRICAL

L MAINTENANCE M INDEX

GI General Information

EM Engine Mechanical

LU Engine Lubrication System CO Engine Cooling System EC Engine Control System

FL Fuel System EX Exhaust System

ACC Accelerator Control System

CL Clutch MT Manual Transaxle

AT Automatic Transaxle

TF Transfer PR Propeller Shaft

RFD Rear Final Drive FAX Front Axle RAX Rear Axle FSU Front Suspension RSU Rear Suspension

WT Road Wheels & Tires BR Brake System PB Parking Brake System

BRC Brake Control System

PS Power Steering System SB Seat Belts

SRS Supplemental Restraint System (SRS)

BL Body, Lock & Security System

GW Glasses, Window System & Mirrors

RF Roof

EI Exterior & Interior IP Instrument Panel

SE Seat

ATC Automatic Air Conditioner MTC Manual AIr Conditioner

SC Starting & Charging System

LT Lighting System

DI Driver Information System

WW Wiper, Washer & Horn BCS Body Control System LAN LAN System

AV Audio Visual, Navigation & Telephone System PG Power Supply, Ground & Circuit Elements MA Maintenance

IDX Alphabetical Index

A B C D

All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan Europe S.A.S., Paris, France.

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FOREWORD

This manual contains maintenance and repair procedures for the NISSAN X-TRAIL, model T30 series.

In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.

All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE

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

NISSAN EUROPE S.A.S.

Service Operations Section

Paris, France

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GENERAL INFORMA TION

A GENERAL INFORMATION

SECTION GI

CONTENTS

PRECAUTIONS .......................................................... 3

Description ............................................................... 3

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TEN-

SIONER” .................................................................. 3

Precautions for NATS (NISSAN ANTI-THEFT SYS-

TEM) ........................................................................ 3

General Precautions ................................................ 4

Precautions for All Mode 4 × 4 System .................... 5

Precautions for Three Way Catalyst ......................... 5

Precautions for Fuel ................................................. 5

GASOLINE ENGINE ............................................. 5

DIESEL ENGINE ................................................... 5

Precautions for Multiport Fuel Injection System or

Engine Control System ............................................ 6

Precautions for Turbocharger (If Equipped) ............. 6

Precautions for Hoses .............................................. 6

HOSE REMOVAL AND INSTALLATION ............... 6

HOSE CLAMPING ................................................ 7

Precautions for Engine Oils ...................................... 7

HEALTH PROTECTION PRECAUTIONS ............. 7

ENVIRONMENTAL PROTECTION PRECAU-

TIONS ................................................................... 7

Precautions for Air Conditioning ............................... 7

HOW TO USE THIS MANUAL ................................... 8

Description ............................................................... 8

Terms ....................................................................... 8

Units ......................................................................... 8

Contents ...................................... ............................. 8

Components ................................ ............................. 9

SYMBOLS ................... .......................................... 9

How to Follow Trouble Diagnoses .......................... 10

DESCRIPTION ................................ .................... 10

HOW TO FOLLOW TEST GROUPS IN TROU-

BLE DIAGNOSES ............................................... 10

HARNESS WIRE COLOR AND CONNECTOR

NUMBER INDICATION ........................................11

KEY TO SYMBOLS SIGNIFYING MEASURE-

MENTS OR PROCEDURES ................. ....... ....... 12

How to Read Wiring Diagrams ............................... 14

GENERAL INFORMATION

CONNECTOR SYMBOLS ................................... 14

SAMPLE/WIRING DIAGRAM - EXAMPL - ..........15

DESCRIPTION ............................ ........................16

Abbreviations ........ ................................. ................. 22

SERVICE INFORMATION FOR ELECTRICAL INCI-

DENT .............................. ........................................... 23

How to Perform Efficient Diagnosis for an Electrical

Incident ........................ ...........................................23

WORK FLOW ......................................................23

INCIDENT SIMULATION TESTS ........................ 23

CIRCUIT INSPECTION ....................................... 26

Control Units and Electrical Parts ...........................31

PRECAUTIONS .................................................. 31

CONSULT-II CHECKING SYSTEM .......................... 33

Description ................... ...... ....... ...... ........................ 33

Function and System Application ........................... 33

Nickel Metal Hydride Battery Replacement ............ 33

Checking Equipment ..............................................34

CONSULT-II Start Procedure ................. ...... ....... .... 34

CONSULT-II Data Link Connector (DLC) Circuit ....35

INSPECTION PROCEDURE .............................. 35

LIFTING POINT .........................................................36

Special Service Tools ............................................. 36

Garage Jack and Safety Stand ...............................36

2-Pole Lift ...............................................................37

Board-On Lift ..........................................................38

TOW TRUCK TOWING .............................................39

Tow Truck Towing ................................................... 39

TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND ...39 TOWING THE VEHICLE WITH REAR WHEELS RAISED (WITH FRONT WHEELS ON GROUND)

OR FRONT WHEELS RAISED ........................... 40

Vehicle Recovery (Freeing a Stuck Vehicle) ........... 40

TIGHTENING TORQUE OF STANDARD BOLTS .... 41

Tightening Torque Table ......................................... 41

IDENTIFICATION INFORMATION ............................ 42

Model Variation .......................................................42

IDENTIFICATION NUMBER ................................ 43

IDENTIFICATION PLATE .................................... 44

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ENGINE SERIAL NUMBER ..... ....... ...... ....... .......44

AUTOMATIC TRANSAXLE NUMBER .................45

MANUAL TRANSAXLE NUMBER ....................... 45

Dimensions .............................................................45

Wheels & Tires ........................................................45

TERMINOLOGY ........................................................46

SAE J1930 Terminology List ...................................46

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PRECAUTIONS

PRECAUTIONS PFP:00001

Description EAS000FN

Observe the following precautions to ensure safe and proper servicing. Thes e precautions are not described in each individual section.

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

The Supplemental Rest raint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to redu ce th e risk or se verit y of i njury to the driv er and front passenge r for ce rtain types of col lision. Infor mation necess ary to servic e the system safely is included in the SR S and SB section of this Service Manual.

WARNING:

● To avoid rendering the SRS inoperativ e, which coul d 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/INFINITI dealer.

● I mproper maintenance, including incorrect remov al and installation of the SRS, can lead to per-

sonal injury ca use d by unintentional ac tiv atio n o f the system. For remo va l of Spiral Cable and Air Bag Module, see the SRS section.

● Do not use e lectrical te st equipm ent on any circuit re lated to the SRS un less instruc ted to in this

Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

EAS000P8

Precautions for NATS (NISSAN ANTI-THEFT SYSTEM) EAS000FP

NATS will immobilize the engine if someone tries to start it without the registered key of NATS. Both of the originally supplied ignition key IDs have been NATS registered. The security indic ator i s lo cated on the in strum ent panel. T he in di cato r blin ks wh en th e im mobi lizer sys tem i s functioning. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.

● When NATS detects trouble, the security indicator lamp lights up while ignition switch is in "ON" position.

This lighting up indicates that the anti-theft is not functioning, so prompt service is required.

● W hen servicing N ATS (trouble diag noses, system initializatio n and addition al registration of other NATS

ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary. Regarding the procedure s of NATS initialization and NATS ignition key ID registration, refer to CONSULTII operation manual, NATS.

Therefore, CONSULT-II NATS software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function.

● W hen servicing N ATS (trouble diag noses, system initializatio n and addition al registration of other NATS

ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NATS.

● When failing to start the engine first time using the key of NATS, start as follows.

1. Leave the ignition key in "ON" position for approximately 5 seconds.

2. Turn ignition key to "OFF" or "LOCK" position and wait approxim ately 5 seconds .

3. Repeat step 1 and 2 again.

4. Restart the engine while keeping the key separate from any others on key -chain.

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PRECAUTIONS

General Precautions EAS000FQ

● Do not operate the engi ne f or an ex tend ed pe rio d of ti me wit hout

proper exhaust ventilat ion. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or pois onous materials, suc h as gasoline, refrig erant gas, etc. When working in a pit or other enclosed area, be sure to properly ventila te the area before working with haza rdous materials. Do not smoke while working on the vehicle.

SGI285

● Before jacking up the vehicle, apply wheel chocks or other tire

blocks to the wheel s to prevent the vehicle from movin g. After jacking up the vehicle, support the vehicle weight with safety stands at the points designat ed for proper lifting be fore working on the vehicle. These operations should be done on a level surface.

● When removing a heav y c om po ne nt s uc h as th e engine or tran-

saxle/transmiss io n, be care fu l not to los e yo ur ba la nc e an d dro p them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder .

SGI231

● Before starting repairs which do not require battery power:

Turn off ignition switch. Disconnect the negative battery terminal.

● If the b attery terminals are disconne cted, recorded memory of

radio and eac h control unit is erased.

SEF289H

● To prevent serious burns:

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

● Dispo se of drained oil or th e solvent used for cl eaning parts in

an appropriate manner.

● Do not atte m pt to to p o ff the fue l tank after the fuel pump noz zl e

shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and poss ibly a fire.

● Clean all disassembled parts in the designated liquid or solvent

prior to inspection or assembly.

● Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new

SGI233

ones.

● Replace inner and outer races of tapered roller bearings and needle bearings as a set.

● Arrange the disassembled parts in accordance with their assembled locations and sequence.

● Do not touch the terminals of electrical components which use microcomputers (such as ECM).

Static electricity may damage internal electronic components.

● After disconnecting vacuum or air ho ses, attach a tag to indicate the proper connection.

● Use only the fluids and lubricants specified in this manual.

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PRECAUTIONS

● Use approved bonding agen t, sealants or their equiv alents when required.

● Use tools and recommended special tools where specified for safe and efficient service repairs.

● When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.

● B efo r e se rvicing the vehicl e:

Protect fenders, u pholstery and carp eting with appropriat e covers. Take caution that keys, bu ckles or button s do not scratch paint.

SGI234

WARNING:

To prevent ECM from storing the diagnostic trouble codes, do not careless ly disconnect the harness connectors which are related to the engine control system and TCM (transmission control module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

Precaution s for All Mode 4 × 4 System EAS000GQ

Even if the 2WD mod e is sele cted, the All mode 4 × 4 system occas ionally chan ges from 2WD to 4W D automatically depending on the driving condit ions. When spinning the front wheels by running the engine with the front wheels jacked up or mounted on the free rollers / or a cha ssis dynamometer, be careful bec ause the vehicle may su ddenly move due to th e driving force from the rear wheels. To avo id personal injury an d vehicle damage, use one of the follo wing methods when working with the fro nt wheels drive force and spinning freely.

● Rem ov e the prop el ler shaft.

● Use free rollers / chassis dy namometer designed for 4WD vehicles.

Precautions for Three Way Catalyst EAS000FR

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the ins tru cti on s.

● Use unleaded gasoline only. Leaded gasoline will seriously damage the three w ay catalyst.

● W hen checking for igni tion spark or measuring engine compressio n, make tests quickly an d only when

necessary.

● Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to

the catalyst.

Do not place the vehicle on flammable ma terial. Keep flamm able material off the exha ust pipe and the thre e way catalyst.

Precautions for Fuel EAS000P9

GASOLINE ENGINE

Use unleaded gasoline with an octane rating of at least 95 (RON).

CAUTION:

Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel other than that specified cou ld adversel y affect the emis sion control de vices and systems, and could also affect the warranty coverage validity.

DIESEL ENGINE

Diesel fuel of at least 50 cetane. If two types of diesel fuel are available, use summer or winter fuel properly according to the following temperature conditions.

● Above –7°C (20°F) ... Summer type diesel fue l.

● Below –7°C (20°F) ... Winter type diesel fuel.

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PRECAUTIONS

CAUTION:

● Do not u se home heating oil, gaso line or other alternate fuels in your diesel engine. Th e use of

those can cause engine damage.

● Do not us e summer fuel at temperatures belo w –7 °C (20°F). The cold temperature s will cause wax

to form in the fuel. As a result, it may prevent the engine from running smoothly.

● Do not add gasoline or other alternate fuels to diesel fuel.

Precautions for Multiport Fuel Injection System or Engine Control System EAS000FT

● Before connecting or disconnecting an y harness connector for

the multiport fuel injection system or ECM: Turn ignition switch to “OFF” position. Disconnect negative battery terminal. Otherwise, there may be damage to ECM.

● Before disconnecting pressurized fuel line from fuel pump to

injectors, be sure to release fuel pressure.

● Be careful not to jar components such as ECM and mass air

flow sensor.

SGI787

Precautions for Turbocharger (If Equipped) EAS000FU

The turbocharger turbine revolves at extremely high speeds and becomes ve ry ho t. The ref ore, i t is e sse ntial to mai ntain a clea n su pply of oil flowing through the turbocharger and to follow all required maintenance instructions and operating procedures.

● Always use the recommended oil. Follow the instructions for

proper time to change the oil and proper oil level.

● Avoid accele rating engin e to a high rpm imm ediately aft er start-

ing.

● If engine had been opera ting at high rpm f or an extended per iod

of time, let it idle for a few minutes prior to shutting if off.

SGI292

Precautions for Hoses EAS000FV

HOSE REMOVAL AND INSTALLATION

● To prevent damage to rubber hose, do not pry off rubber hose

with tapered tool or screwdriver.

SMA019D

● To reinstall the rubber hose securely, make sure that hose inse r-

tion length and orientation is correct. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

SMA020D

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PRECAUTIONS

HOSE CLAMPING

● If old rubber hose is re-used, install hose clamp in its original

position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position.

● Discard old clamps; replace with new ones.

SMA021D

● A fter install ing plat e clamps, ap ply forc e to them in the d irection

of the arrow, tightening rubber hose equally all around.

SMA022D

Precautions for Engine Oils EAS000FW

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

HEALTH PROTECTION PRECAUTIONS

● Avoid prolonged and repeated contact with oils, particularly used engine oils.

● Wear protective clothing, including impervious gloves where practicable.

● Do not put oily rags in pockets.

● Avoid contaminating clothes, particularly underpants, with oil.

● He av il y soiled clothing and oil-imp r eg na te d foo t we ar s hould not be w orn . O ve ralls must be cl ea ne d regu-

larly.

● First aid treatment should be obtained immediately for open cuts and wounds.

● Use barrier creams, applying them before each work period, to help the removal of oil from the skin.

● Wash with s oap a nd wate r to en sure a ll oil is rem oved (ski n cleans er s and nail b rushe s will help) . Prepa-

rations containing lanolin repla c e the natural skin oils which have been removed.

● Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.

● If skin disorders develop, obtain medical advice without delay.

● Where practical, degrease components prior to handling.

● Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face

shields; in addition an eye wash facility should be provided.

ENVIRONMENTAL PROTECTION PRECAUTIONS

Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities. It is illegal to pour used oil on to the grou nd, down sewer s or drains, or into water sources. The regulations co nc ern in g pol lu tio n va ry between regions.

Precautions for Air Conditioning EAS000FX

Use an approved refrig erant recov ery unit any time the air condi tioning syst em must be disc harged. Refe r to ATC/MTC section “HFC-134 a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions.

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HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL PFP:00008 Description EAS000FY

This volume expla ins “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.

Terms EAS000FZ

● The ca ptions WARNING and CAUTION warn you of steps that must be followed to prevent personal

injury and/ or damage to some part of the vehicle.

WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.

Standard value:Tolera nc e at insp ec tio n an d adj us tment. Limit value:The maximum or minimu m limit value that sh ould not be exceed ed at inspection an d adjustment.

Units EAS0015F

● The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit),

and alternatively expressed in the metric system and in the yard/pound system. Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the standard tightening torque.

“Example”

Range

Outer Socket Lock Nut : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)

Standard

Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)

Contents EAS000G1

● ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and

page you are searching for.

● A QUICK REFERENCE INDEX, a blac k tab ( e.g. ) is provided on th e firs t page. You can quickly find

the first page of each section by matching it to the section's black tab.

● THE CONTENTS are listed on the first page of each section.

● THE TITLE is indicated on the upper portion of each page and shows the part or system.

● THE PAGE NUMBER of each section con sists of t wo or t hree let ters wh ich de signat e the partic ular se c-

tion and a number (e.g. “BR- 5”).

● THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks

of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjus tment procedures for the complicated units such a s the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary.

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HOW TO USE THIS MANUAL

Components EAS0015G

● TH E LARGE ILLUSTRATIONS are ex ploded views (See the followin g) and contain tightening torques ,

lubrication points, section number of the P ARTS CATALOG (e.g . SEC . 440) an d oth er info rma tio n neces - sary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG . Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.

SYMBOLS

SYMBOL DESCRIPTION

Tightening torque The tightening torque specifications of bolts and nuts may be presented as either a range or a standard tightening torque.

Should be lubricated with grease. Unless otherwi se indicated, use recommended multi-purp ose grease.

Should be lubricated with oil.

Sealing point

Checking point

SAIA0399E

Always replace after every disassembly.

Apply petroleum jelly.

Apply ATF. Select with proper thickness.

Adjustment is required.

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HOW TO USE THIS MANUAL

How to Follow Trouble Diagnoses EAS000G3

DESCRIPTION

NOTICE:

Trouble diagnoses indi cate work proce dures req uired to diag nose proble ms effec tivel y. Observe the following instructions before diagnosing.

1. Before performing trouble dia gnoses, rea d the “P reliminary Check” , the “Symp tom Chart” or the

“Work Flow”.

2. After repairs, re-check that the problem has been completely eli min ate d.

3. Refer to Component Parts and Harness C onnector Location for the Systems desc ribed in each

section for identification/location of components and harness connectors.

4. Refer to the Circuit Diagram for quick pinpoint check.

If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors.

5. When checking circuit continuity, ignition switch should be OFF.

6. Before checking voltage at connectors, check battery voltage.

7. After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure

that all harness connectors are reconnected as they were.

HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES

1. Work and diagno stic procedure Start to diagnose a problem using procedures indicated in enclosed test groups.

2. Questions and required results Questions and required results are indicated in bold type in test group. The meaning of are as follows:

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SAIA0256E

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HOW TO USE THIS MANUAL

a. Battery voltage → 1 1 - 14V or approximately 12V b. Voltage : Approxima tely 0V → Less than 1V

3. Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize y ourself with ea ch symbol. R efer to "Connec tor Symbols" in GI Section a nd "KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES" below.

4. Action items Next action for ea ch te st gr o up is ind ic at e d base d on r es ult o f e ach qu es ti o n. Test group numb er is sh ow n in the left upper portion of each test group.

HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION

There are two types of harness wire color and connector number indication.

TYPE 1: Harness Wire Color and Connector Number are Shown in Illustration

● Letter designations next to test meter probe indicate harness

wire color.

● Connector numbers in a single circle (e.g. M33) indicate har-

ness connectors.

● Connector numbers in a double circle (e.g. F211) indicate com-

ponent connectors.

AGI070

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TYPE 2: Harness Wire Color and Connector Number are Shown in Text

KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES

Symbol Symbol explanation Symbol Symbol explanation

Check after disconnecting the con nector to be measured.

Check after connecting the conn ector to be measured.

Insert key into ignition switch. A/C switch is “OFF”.

Remove key from ignition switch. A/C switch is “ON”.

Turn ignition switch to “OFF” position. REC switch is “ON”.

Turn ignition switch to “ON” position. REC switch is “OFF”.

Turn ignitio n swit ch to “START” position.

Turn ignition switch from “OFF” to “ACC” position.

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

Procedure without CONSULT, CONSULT-II or GST

Fan switch is “ON”. (At any position except for “OFF” position)

Fan switch is “OFF”.

SGI144A

Turn ignition switch from “ACC” to “OFF” position.

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Apply positive voltage from battery with fuse directly to components.

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HOW TO USE THIS MANUAL

Symbol Symbol explanation Symbol Sy mb ol ex planat i on

Turn ignition switch from “OFF” to “ON” position.

Turn ignition switch from “ON” to “OFF” position.

Do not start engine, or check with engine stopped.

Start engine, or check with engine running.

Apply parking brake. Depress accelerator pedal.

Release parking brake. Release accelerator pedal.

Check after engine is warmed up sufficiently.

Voltage should be measured with a voltmeter.

Circuit resistance should be measured with an ohmmeter.

Drive vehicle.

Disconnect battery negative cable.

Depress brake pedal.

Release brake pedal.

Pin terminal check for SMJ type ECM and TCM connectors.

For details regarding the terminal arrangement, refer to the “ELECTRICAL UNITS” electrical reference page at the end of the manual.

Current should be measured with an ammeter.

Pulse signal should be checked with an oscilloscope.

Procedure with CONSULT-II

Procedure without CONSULT-II

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How to Read Wiring Diagrams EAS000G4

CONNECTOR SYMBOLS

Most of connector symbols in wiring diagrams are shown from the terminal side.

● Connector symbols shown from the terminal side are enclosed

by a single line and followed by the direction mark.

● Connector symbols shown from the harness side are enclosed

by a double line and followed by the direction mark.

● Certain systems and components, especially those related to

OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to PG section, “Description”, “HARNESS CONNECTOR”.

● Male and female terminals

Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

SAIA0257E

SGI363

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HOW TO USE THIS MANUAL

SAMPLE/WIRING DIAGRAM - EXAMPL -

● For detail, refer to following “DESCRIPTION”.

SGI091A

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Optional Splice

HOW TO USE THIS MANUAL

DESCRIPTION

Num-

ber

1 Power condition

2 Fusible link

Fusible link/fuse loca-

tion

4Fuse

5 Current ra ting

6 Connectors

7 Optional splice 8 Splice

9 Page crossing

10 Common connect or 11 Option abbreviation

12 Relay

13 Connectors

SGI942

Item Description

● This shows the condition when the system receives battery positive voltage (can be oper-

ated).

● The double line show s th at thi s is a fusibl e link.

● The open circ le sh ows current flow in, and the shaded circle shows current flow out.

● This shows the loca tion of the fusibl e link or fuse in the fusi ble link or fus e box. Fo r arran ge-

ment, refer to PG section, POWER SUPPLY ROUTING.

● The single line shows that this is a fuse.

● The open circ le sh ows current flow in, and the shaded circle shows current flow out.

● This shows the curr ent rati ng of the fu sibl e link or fuse .

● This shows tha t con nect or E3 is fem ale and connector M1 is male.

● The G/R wire is located in the 1A terminal of both connectors.

● Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connec-

tor. Refer to PG section, SMJ (SUPER MULTIPLE JUNCTION).

● The open circ le sh ows th at the spl i ce is optional depending on vehicle application.

● The shaded circle shows that the splice is always on the vehicle.

● This arrow sh ow s tha t the circu it cont i nues to an adjacent page.

● The A will match with the A on the pre ceding or next page.

● The dotted lines between terminals show that these terminals are part of the same connector.

● This shows tha t the ci rcu it is optional depending on vehicle application.

● This shows an in ternal representation of the relay. For details, refer to PG section, STAN -

DARDIZED RELAY.

● This shows tha t the connector is connected to the body or a terminal with bolt or nut .

GI-16

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HOW TO USE THIS MANUAL

Num-

ber

Item Description

14 Wire color

15 Option descr ip tion

16 Switch

17 Assembly parts

18 Cell code

19 Current flow arrow

20 System branch

21 Page crossin g

22 Shielded line

Component box in

wave line

24 Compone nt name

25 Connector num ber

26 Ground (GND )

27 Ground (GND )

28 Connecto r views

29 Common component

30 Connecto r color

● This shows a code fo r the col or of the wire .

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green

BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green

When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe

● This shows a descr ip tion of the option abbreviation used on the page.

● This shows that cont i nuity exi sts between te rmi nal s 1 and 2 when t he sw i tch is in the A posi-

tion. Continuity exists between terminals 1 and 3 when the switch is in the B positio n.

● Connecto r term inal in component shows that it is a harness incorporated assembly.

● This identifies each page of the wiring diagram by section, system and wiring diagr am page

number.

● Arrow indicates electric current flow, especially where the direction of standard flow (vertically

downward or horizontally from left to right) is difficult to follow.

● A double arrow “ ” shows that current can flow in either direction depe ndi ng on cir-

cuit operation.

● This shows that the syst em bran ches to another system identified by cell code (sec tion and

system).

● This arrow shows that the circui t contin ues t o anot her page identified by cell code.

● The C will match with the C on another page within the system other than the next or preced-

ing pages.

● The line enclosed by broken line circle shows shield wire.

● This shows that anot her part of the comp onent is also shown on another page (indicated by

wave line) within the system.

● This shows the name of a com ponent.

● This shows the con nect or num ber.

● The letter shows whi ch harness the connector is located in.

● Example: M : main harness. For detail and to locate the connector, refer to PG section "Main

Harness", “Harness Layout”. A coordina te grid is included for complex harnesses to aid in locating connectors.

● The line spliced and gr ounded under wire color shows that ground line is spliced at the

grounded connector.

● This shows the ground connection. For detailed ground distribution information, refer to

"Ground Distribution" in PG section.

● This area shows t he con nect or face s of the com p o nents in the wi ring diagram on the page.

● Connecto rs encl osed in bro ken lin e show th at thes e connectors belong to the same compo-

nent.

● This shows a code for the color of the connector. For code meaning, refer to wire color codes,

Number 14 of this chart.

Fusible link and fuse

box

32 Reference ar ea

● This shows the arrangement of fusible link(s) and fuse(s), used for connector views of

"POWER SUPPLY ROUTING" in PG section. The open square shows current flow in, and the shaded square shows current flow out.

● This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors

(J/C) exists on the PG section. Refer to "Reference Area" for details.

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HOW TO USE THIS MANUAL

Harness Indication

● Letter designations next to test meter probe indicate harness

(connector) wire color.

● Conne ctor nu mbers in a single circle M33 ind icat e harne ss con-

nectors.

Component Indication

Connector numbers in a double circle F211 indicate component connectors.

Switch Positions

Switches are shown in wiring diagrams as if th e vehicle is in the “normal” condition. A vehicle is in the “normal” condition when:

● ignition switch is “OFF”,

● doors, hoo d an d tr un k lid /b ac k do or ar e cl os ed ,

● pedals are not depressed, and

● parking brake is released.

AGI070

SGI860

GI-18

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HOW TO USE THIS MANUAL

Detectable Lines and Non-Detectable Lines

In some wiring diagrams, two kind s of lin es , rep res en tin g w ire s, with different weight are used.

● A line with regular weight (wider line) represents a “detectable

line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circu it in which ECM can detect its malf unctions with the on board diagnostic system.

● A line with less weight (thinner line) represents a “non-detect-

able line for DTC”. A “non-dete ctable line for DT C” is a circuit in which ECM cannot detect its malfunctions with the on board diagnostic system.

SGI862-B

GI-19

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HOW TO USE THIS MANUAL

Multiple Switch

The continuity of multiple sw itch is described in two ways as sh own below.

● The switch chart is used in schematic diagrams.

● The switch diagram is used in wiring diagrams.

SGI875

GI-20

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HOW TO USE THIS MANUAL

Reference Area

The Reference Area of the wiring diagram contains references to additional electrical reference pages at the end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram, these connector symbols are not shown in the Connector Area.

SGI092A

GI-21

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HOW TO USE THIS MANUAL

Abbreviations EAS000G5

The followi ng ABBREVIATIONS are used:

ABBREVIATION DESCRIPTION

A/C Air Conditioner

A/T Automat ic Transaxle/Transmission

ATF Automatic Transmission Fluid

1 Drive range 1st gear 2 Drive range 2nd gear

3 Drive range 3rd gear

D D

4 Drive range 4th gear

FR, RR Front, Rear LH, RH Left-Hand, Right-Hand

M/T Manual Transaxle/Transmission

OD Overdrive

P/S Power Steering SAE Society of Automotive Engineers, Inc. SDS Service Data and Specifications SST Special Service Tools

2WD 2-Wheel Drive

2 2nd range 2nd gear

1 2nd range 1st gear

2 1st range 2nd gear

1 1st range 1st gear

GI-22

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

SERVICE INFORMATION FOR ELECTRICAL INCIDENT PFP:00000

How to Perform Efficient Diagnosis for an Electrical Incident EAS000G6

WORK FLOW

SGI838

STEP DESCRIPTION

Get detailed information about the conditions and the envir onment when the incident occurred. The following are key pieces of information requi red to make a good analysis:

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

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5 Repair or replace the incident circuit or componen t.

STEP 6

WHEN Date, Time of Day, Weather Conditions, Frequency. WHERE Road Conditions, Altitude and Traffic Situation.

HOW

Operate the system, road test if necessa ry. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulat ion Tests”.

Get the proper diagnosis materials together inc lud ing:

● Power Supply Routing

● System Operation Descriptions

● Applicabl e Serv ice Ma nual Sectio ns

● Check for any Service Bulletins

Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments. Inspect the system for mechanical binding , loose connectors or wiring damage.

Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts.

Operate the system in all modes. Verify the system work s properly under all conditions. Make sur e you have not inadvertently created a new incident during your diag nosi s or repair steps.

System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories ha ve been installed.

INCIDENT SIMULATION TESTS Introduction

Sometimes the sym ptom is not present when the ve hicle is brought in for servi ce. If possible, re-create th e conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following section illu st rates ways to s imula te th e co nditi ons/ envi ron ment unde r whic h t he own er ex perie nces an electrical incident. The section is broken into the six following topics:

● Vehicle vibration

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

● Heat sensitive

● Freezing

● Water intrusion

● Electrical load

● Cold or hot start up

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

Vehicle Vibration

The problem may occ ur or b ecome worse w hil e driv ing o n a ro ugh r oad o r whe n en gine is vi bratin g (idl e wi th A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration.

CONNECTORS & HARNESS

Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each conn ector and harness while mo nitoring the system for the in cident you are trying to dup licate. This test may indicate a loose or poor electrical connection.

HINT

Connectors can b e exposed to mois ture. It is possible t o get a thin film o f corrosion on the co nnector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is ca used by corros ion. It is a go od idea to dis connect, insp ect and clea n the terminals on related co nnectors in the system.

SENSORS & RELAYS Gently apply a slight vibration to sensors and relays in the system you are inspecting.

This test may indicate a loose or poorly mounted sensor or relay.

SGI839

ENGINE COMPARTMENT

There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to chec k for are:

● Connectors not fully seated.

● Wiring harness not long enough and is being stressed due to engine vibrations or rocking.

● Wires laying across brackets or moving components.

● Loose, dirty or corroded ground wires.

● Wires routed too clo se to hot components.

To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounde d. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity.

BEHIND THE INSTRUMENT PANEL

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

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

UNDER SEATING AREAS

An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or pinching.

Heat Sensitive

The customer's con cern may occur during hot we ather or after car has sat for a short time. In such cases you will want to check for a heat sensiti v e condition. To determine if an electrical component is heat sensitive, heat the component with a heat gun or equ ivalent. Do not heat compon ents above 60°C (140°F). If in cident occurs while heating th e u ni t, either replace or properly insulate t he c om po nent.

Freezing

The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. The second me thod is to put the s uspect component i nto a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

SGI842

SGI843

Water Intrusion

The incident may occur only during high humidity or in rainy/snowy weather. In such cases the in cident cou ld be ca used by wat er intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash.

Do not spray water directly on any electrical compone nts.

Electrical Load

The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

SGI844

SGI845

GI-25

Page 28

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

Cold or Hot Start Up

On some occasions an electrical incident may occur only when the car is started cold, or it may occur when the car is resta rt ed hot shor tl y aft er bein g t urne d off. In these cases you may have to keep the car ove rni gh t to make a proper diagnosis.

CIRCUIT INSPECTION Introduction

In general, testin g electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system op eration. Then you will be abl e to use the ap propriate equi pment and follo w the correct test procedure . You may have to sim ulate veh icle v ibr atio ns w hile t estin g e lect rical c omp on ents. G ently shak e the wirin g har ness or electrical component to do this.

OPEN

SHORT

A circuit is open when there is no continuity through a section of the circuit.

There are two types of shorts.

● SHORT CIRCUIT

● SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit.

When a circuit contacts another circuit and causes the normal res is tance to change.

NOTE:

Refer to “How to Check Terminal” to probe or check terminal.

Testing for “Opens” in the Circuit

Before you begi n to diagnose and test the s ystem, you s hould rough s ketch a schem atic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

SGI846-A

CONTINUITY CHECK METHOD

The continuit y che ck is u sed t o find an op en in the c ircuit . The d igital m ultim et er (DMM) set on the re sistanc e function will i nd icat e a n op en ci r cuit as ov er l im it (n o b ee p ton e o r no oh ms sym bo l). Ma ke su r e to a l ways start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic.

● Disconnect 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 example)

● Connect one probe of the DMM to the fuse block terminal on the load side.

● Conne ct the other probe t o the fuse block (powe r) side of SW1. Little or no resistance will ind icate that

portion of the circuit has g ood co ntinuit y. If there were an open in t he circui t, the D MM wo uld ind icate an over limit or infinite resistance condition. (point A)

● Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the cir-

cuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B)

● Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of

the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C)

Any circuit can be diagnosed using the approach in the previous example.

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

VOLTAGE CHECK METHOD

To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function.

● Co nn ec t one probe of the DMM to a known good grou nd.

● Begin probing at one end of the circuit and work your way to the other end.

● With SW1 open, probe at SW1 to check for voltage.

voltage; open is further down the circuit than SW1. no voltage; open is betwee n fus e bloc k an d SW 1 (po in t A).

● Close SW1 and probe at relay.

voltage; open is further down the circuit than the relay. no voltage; open is betwe en SW1 and relay (point B).

● Close the relay and probe at the solenoid.

voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C).

Any powered circuit can be diagnosed using the approach in th e previous exam ple.

Testing for “Shorts” in the Circuit

To simplify the discussion of shorts in the system, please refer to the following schematic.

SGI847-A

RESISTANCE CHECK METHOD

● Disconnect the battery negative cable and remove the blown fuse.

● Di sconnect all loads (SW1 op en, relay disconnected an d solenoid disconnected ) powered through the

fuse.

● Co nn ec t one probe of th e DM M to the load side of the fuse termin al . C o nn ec t t he other probe to a k no w n

good ground.

● With SW1 open, check for continuity.

continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1.

● 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 furth er down the ci rcu it tha n the rela y.

● Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and

a known good ground. Then, chec k for continuit y. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace s teps.

VOLTAGE CHECK METHOD

● Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid discon-

nected) powered through the fuse.

● Turn the ign ition k ey to the O N or START position. Verify battery voltage at the ba ttery + side of the fuse

terminal (one lea d on t he ba tte r y + te rmi na l sid e of t he fu se bl ock and on e l ea d o n a k now n go od gr o un d).

● With SW1 open and the DMM leads across both fuse terminals, check for voltage.

voltage; short is between fuse block and SW1 (point A).

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Page 30

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

no voltage; short is further down the circuit tha n SW1 .

● With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check

for voltage. voltage; short is between SW1 and the relay (point B). no voltage; short is further down the circuit tha n the relay.

● With SW1 closed, relay contacts jumped with fused jumper wire check for voltage.

voltage; short is d own th e circ uit of t he rel ay or b etw een th e re lay a nd the disc onne cted soleno id ( poin t C). no voltage; retrace steps and check power to fuse block.

Ground Inspection

Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an el ectronically controlled circ uit. A poor or corroded gr ound can easily affect the ci rcuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules:

● Remove the ground bolt or screw.

● Inspect all mating surfaces for tarnish, dirt, rust, etc.

● Clean as required to assure good contact.

● Reinstall bolt or screw securely.

● Inspect for “add-on” accessories which may be interfering with the ground circuit.

● If several wires are c rimped into one ground eyelet terminal, check for proper crimps. Make sure all of the

wires are clean, secu rely fastened and providing a good grou nd path. If multiple wire s are cased in one eyelet make sure no ground wires have excess wi re insulation.

For detailed ground distribution information, refer to “Ground Distribution” in PG section.

SGI853

Voltage Drop Tests

Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation. Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wir e 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 v oltage drop. Unwanted resistance can be caused by many situations as follows:

● Undersized wiring (single strand example)

● Corrosion on switch contacts

● Loose w ire conn ec ti ons or splices.

GI-28

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

If repairs are needed always use wire that is of the same or larger gauge.

MEASURING VOLTAGE DROP — ACCUMULAT ED METHOD

● Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the

DMM should be clo s er to power and the negative lead closer to ground.

● Operate the circuit.

● The DMM will indicate how many volts are being used to “push” current through that part of the circuit.

Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

SGI974

MEASURING VOLTAGE DROP — STEP-BY-STEP

The step-by- step method is most useful for isolating excessive drops in low voltage systems ( such as those in “Computer Controlled Systems”). Circuits in the “Computer Controlled System” operate on very low amperage. The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such res istance variation may be caused by poor connection, imprope r installation, improper wire gauge or corrosion. The step by step voltage drop test can identify a component or wire with too much resistance.

SAIA0258E

GI-29

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

Control Unit Circuit Test

System Description:When the switch is ON, the control unit lights up the lamp.

MGI034A

INPUT-OUTPUT VOLTAGE CHART

Pin No.

1 Switch

2Lamp

The voltage value is based on the body ground. *:If high resistance exists in the switch side circ uit (caused by a single strand), ter minal 1 does not detect batte ry voltage. Control unit does not detect the switch is ON even i f the swi tch does not turn ON. Therefore, the con trol unit does not suppl y power t o light up the lamp.

Item Condition

Switch ON Battery voltage Lower than battery voltage Approx. 8 (Example) Switch OFF Approx. 0 Approx. 0 Switch ON Battery voltage Approx. 0 (Inoperative lamp) Switch OFF Approx. 0 Approx. 0

Voltage

value [V]

In case of high resistance such as single strand [V] *

MGI035A

INPUT-OUTPUT VOLTAGE CHART

Pin No.

1Lamp

2 Switch

The voltage value is based on the body ground. *:If high resistance exists in the swi tch sid e circui t (caused by a single str and), terminal 2 does no t det ect app rox. 0V. Control unit does not detect the switch is ON even if the switch does not tu rn ON . Theref or e, the contr ol uni t does not co ntrol grou nd to light up the lamp.

Item Condition

Switch ON Approx. 0 Battery voltage (Inoperative lamp) Switch OFF Battery voltage Battery voltage Switch ON Approx. 0 Higher than 0 Approx. 4 (Example) Switch OFF Approx. 5 Approx. 5

Voltage

value [V]

In case of high resistance such as single strand [V] *

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

Control Units and Electrical Parts EAS000PC

PRECAUTIONS

● Never reverse polarity of battery terminals.

● Install only parts specified for a vehicle.

● Before replacing the control unit, check the input and output and

functions of the component parts.

● Do not apply excessive force when disconnecting a connector.

● If a connector is installed by tightening bolts, loosen bolt mount-

ing it, then take it out by hand.

SAIA0251E

● Before installing a connector, make sure the terminal is not bent

or damaged, and then correctly connect it. When installing a connector b y tighteni ng bolts, fix it by tighten ing the mou nting bolt until the painted proj ection of the conn ector becomes even with the surface.

● F or removal of the lever type co nnector, pull the lever up to the

direction pointed to by the arrow A in the figure, and then remove the connector.

SAIA0252E

SAIA0253E

● For installation of the lever type connector, pull down the lever to

the direction pointed by the arrow B in the figure, and then push the connector until a clicking noise is heard.

GI-31

SAIA0254E

Page 34

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

● Do not apply excessive shock to the control unit by dropping or

hitting it.

● Be careful to prevent condensation in the control unit due to

rapid temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle.

● Be careful not to let oil to get on the control unit connector.

● Avoid cleaning the control unit with volatile oil.

● Do not disassemble the control unit, and do not remove the

upper and lower covers.

● When using a DMM, be careful not to let test probes get close to

each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiti ng.

● When checking input and output signals of the control unit, use

the specified check adapter.

SAIA0255E

SEF348N

GI-32

Page 35

CONSULT-II CHECKING SYSTEM

CONSULT-II CHECKING SYSTEM PFP:00000

Description EAS000G8

● CONSULT-II is a hand-held type tester. When it is connected with a diagnostic connector equipped on the

vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests.

● Refer to “CONSULT-II Software Operation Manual” for more information.

Function and System Application EAS000G9

Diagnostic test

mode

Work support

Self-diagnostic results

Trouble diagnostic record

Data monitor Input/Output data in the ECM can be read. x x - x x x -

Active test

CAN diagnosis support monitor

DTC confirmation DTC work support Select the operating condition to confirm Di agnosis Trouble Codes. - x - - - - -

ECM (ECU/TCM) part number

ECU discriminated No.

Function test

Control unit initialization

x: Applicable *1: Nissan Anti-Theft System *2: Gasoline engine models

This mode enables a technician to adjust some devices faster and more accurately by following the indication s on C O NS U LT-II.

Self-diagnostic results can be read and erased quickl y. x x x x x x x

Current self-diagnostic results and all trouble diagnostic records previously stored can be read.

Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also shifts some parameters in a specified rang e.

Indicates the communication condition of CAN communication line. x x - x x x -

The results of SRT (System Readiness Test) and the self-diagnosis status/ result can be confirmed.

ECM (ECU/TCM) part number can be read. x x - x x x -

Classification number of a replacement EC U can be re ad to prevent an incorrect ECU from being installed.

Conducted by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”.

All registered ignition key IDs in NATS components can be initialized and new IDs can be registered.

Function

A/T

ENGINE

x--x--

--x----

x--xxx-

------

--x----

xxxxx - -

----- -x

ABS

AIR BAG

ABS (Including ESP)

NATS*1

ALL MODE 4WD

Nickel Metal Hydride Battery Replacement EAS000GA

CONSULT-II contains a nickel metal hydrid e battery. When replacing the battery obey the following:

WARNING:

Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another battery may present a risk of fi re or explos ion. The battery may present a f ire or che mical bu rn hazard if mistreated. Do not recharge, disassemble or dispose of in fire. Keep the battery out of reach of children and discard used battery conforming to the local regulations.

GI-33

Page 36

CONSULT-II CHECKING SYSTEM

Checking Equipment EAS000GB

When ordering the following equipment, contact your NISSAN/INFINITI distributor.

Tool name Description

NISSAN CONSULT-II

1.CONSULT -II unit (T ester internal soft: Resident version 3.3.0) and accessories

2.Program card AED03E and AEN02C-1 (For NATS)

3.CONSULT-I I CONVER TER

SAIA0362E

NOTE:

● The CONSULT-II must be used in conjunction with a program card.

CONSULT-II does not require loading (Initialization) procedure.

● Be sure the CONSULT-II is turned off before installing or removing a program card.

CAUTION:

● If CONSULT-ll is used with no connection of CONSULT-ll CONVERTER, malfunctions might be

detected in self-diagnosis depending on control unit which carries out CAN communication.

● If CONVERTER is not co nnected w ith CONSULT-ll, vehicle occur the "FAIL-SAFE MODE" which is

"LIGHT UP the HEADLIGHT" and/or "Cooling FAN ROTATING" when CONSULT -ll is started.

CONSULT-II Start Procedure EAS0017Y

1. Turn off the ignition switch.

2. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector.

PAIA0070E

3. Turn on the ignition switc h.

4. Touch “START (NISSAN BASED VHCL)” or “System Shortcut” (eg : Engine) on the screen.

SKIA3098E

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CONSULT-II CHECKING SYSTEM

CONSULT-II Data Link Connector (DLC) Circuit EAS0015H

SOM801

INSPECTION PROCEDURE

If the CONSULT-II cannot diagnose the system properly, check the following items.

Symptom Check item

CONSULT-II cannot access any system.

CONSULT-II cannot access individual system. (Other systems can be accessed.)

NOTE:

The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to mo re than one syste m . A short in a DDL circuit connected to a control unit in one system may affect CONSULT-II access to other systems.

● CONSULT-II DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4) (For detailed

circuit, refer to “MIL & Data Link Connectors Wiring Diagra m” in EC section.)

● CONSULT -I I DLC cable and CONSULT-II CONVERTER.

● CONSU LT-II program card (Check the appropriate CONSULT-II program card for the system.

Refer to "Checking Equipment".)

● Power supp ly an d grou nd circ uit fo r the cont rol uni t of the system (For detailed circuit , refer to wi r-

ing diagram for each system.)

● Open or short circuit between the system and CONSULT-II DLC (For detailed circuit, refer to wiring

diagram for each system.)

GI-35

Page 38

LIFTING POINT

LIFTING POINT PFP:00000 Special Service Tools EAS000FH

Tool number

Tool name

LM4086-0200 Board on lift attachment

LM4519-0000 Safety stan d attachmen t

Description

S-NT001

S-NT002

CAUTION:

● Every time the vehicle is lifted up, maintain the complete vehicle curb condition.

● Since the ve hic le's cen ter of grav ity cha nge s whe n remo ving main parts on the front side (engine,

transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission jack or equivalent.

● Since the vehicle's cen ter of grav ity c han ges when r emovi ng m ain parts on the rear si de (r ear a xle ,

suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equivalent.

● Be careful not to smash or do not do anything that would affect piping parts.

Garage Jack and Safety Stand EAS000FI

WARNING:

● Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes,

tubes, etc. under the vehicle.

● Never get under the vehicle w hil e it is supported on ly by the jack. Always use s afe ty stands wh en

you have to get under the vehicle.

GI-36

Page 39

LIFTING POINT

● Place wheel chocks at both front and back of the wheels on the ground.

PAIA0001E

2-Pole Lift EAS000FJ

WARNING:

When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the li ft arm, do not all ow the arm to contact the brake tu bes, brake cable, fue l lines and sill spoiler.

PAIA0002E

GI-37

Page 40

LIFTING POINT

Board-On Lift EAS000FK

CAUTION:

Make sure vehicle is empty when lifting.

● The boar d-on lift attachment (LM40 86-02 00) set at fr ont e nd

of vehicle should be set on the front of the sill under the front door opening.

● Position attachments at front and rear ends of board-on lift.

AGI016

GI-38

Page 41

TOW TRUCK TOWING

TOW TRUCK TOWING PFP:00000

Tow Truck Towing EAS000FL

CAUTION:

● All applicable local laws regarding the towing operation must be obeyed.

● I t is necessary to use proper towing e quipment to avoid possible dama ge to the vehicle during

towing operation. Towing is in accordance with Towing Procedure Manual at dealer.

● Always attach safety chains before towi ng.

● When towing, make sure that the transmission, steering system and power train are in good order.

If any unit is damaged, dollies must be used.

● Neve r tow an au tomatic transmissio n model from the rear (that is backward) with four wh eels on

the ground. This may cause serious and expensive damage to the transmission.

NISSAN recommends that towing dollies be used when towing your vehicle beplaced on a flat bed truck as illustrated.

PAIA0012E

TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND

Observe the following restricted towing speeds and distances.

Speed :Below 50 km/h (30 MPH) Distance :Less than 65 km(40 miles)

CAUTION:

Never tow an automatic transaxle model from the rea r (i. e., ba ck ward) with four wheels on the ground as this may cause serious and expensive damage to the transaxle.

GI-39

Page 42

TOW TRUCK TOWING

TOWING THE VEHICLE WITH REAR WHEELS RAISED (WITH FRONT WHEELS ON GROUND) OR FRONT WHEELS RAISED

Never tow the ve hicle with rear wheels ra ised (wi th front w heels o n ground) or front wheels raised as this may cause serious and expensive damage to the transaxle. If it is necessary to tow it with rear wheels raised or front wheels raised, always use a towing dolly under the front wheels. If the speed or distance must necessarily be greater, remove the front and rear propeller shafts beforehand to prevent damage to the transaxle.

PAIA0013E

Vehicle Recovery (Freeing a Stuck Vehicle) EAS000FM

● Use the towing hook only, not other parts of the vehicle. Other-

wise, the vehicle body will be damaged.

● Use the towing hook only to free a vehicle stuck in sand, snow,

mud, etc. Never tow the vehicle for a long distance using only the towing hook.

● The towing hook is under tremendous force when used to free a

stuck vehicle. Alwa ys pull the cable st rai gh t out from the front or rear of the vehicle. Never pu ll on the hoo k at an angl e.

● Stand clear of a stuck vehicle.

WARNING:

● Do not spin the tires at high spee d. This could cause them

to explode and result in serious injury. Parts of the vehicle could also overheat and be damaged.

PAIA0145E

GI-40

Page 43

TIGHTENING TORQUE OF STANDARD BOLTS

SMA for ISO bolts/nuts

TIGHTENING TORQUE OF STANDARD BOLTS PFP:00000

Tightening Torque Table EAS000GD

Bolt diam-

Grade Bolt size

M6 6.0 1.0 5.5 0.56 4 49 7 0.71 5 62

M8 8.0

*: Nominal diameter

1. Special parts are excluded.

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

M10 10.0

M12 12.0

M14 14.0 1.5 80 8.2 59 — 100 10 74 — M6 6.0 1.0 9 0.92 7 80 11 1.1 8 97

M8 8.0

M10 10.0

M12 12.0

M14 14.0 1.5 130 13 96 — 170 17 125 — M6 6.0 1.0 11 1.1 8 — 13.5 1.4 10 —

M8 8.0

M10 10.0

M12 12.0

M14 14.0 1.5 170 17 125 — 210 21 155 —

eter *

Pitch

N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb

1.25 13.5 1.4 10 — 17 1.7 13 —

1.0 13.5 1.4 10 — 17 1.7 13 —

1.5282.921—353.626—

1.25 28 2.9 21 — 35 3.6 26 —

1.75 45 4.6 33 — 55 5.6 41 —

1.25 45 4.6 33 — 65 6.6 48 —

1.25 22 2.2 16 — 28 2.9 21 —

1.0222.216—282.921—

1.5454.633—555.641—

1.25 45 4.6 33 — 55 5.6 41 —

1.75 80 8.2 59 — 100 10 74 —

1.25 80 8.2 59 — 100 10 74 —

1.25 28 2.9 21 — 35 3.6 26 —

1.0282.921—353.626—

1.5555.641—808.259—

1.25 55 5.6 41 — 80 8.2 59 —

1.75 100 10 74 — 130 13 96 —

1.25 100 10 74 — 130 13 96 —

Hexagon head bolt Hexagon flange bolt

Tightening torque (Without lubricant)

MGI044A

GI-41

Page 44

IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATIO N PFP:00010 Model Variation EAS000GE

Destination

Body Engine Transaxle Grade

RS5F51A (5 speed M/T)

QR20DE

RE4F04B (4 speed A/T)

RS5F51A

MPV

QR25DE

YD22DDT

(5 speed M/T) RE4F04B

(4 speed A/T)

RS6F51A (6 speed M/T)

Prefix and suffix desi gn ati ons:

RHD

LE TDANRAF-EEA TDANLAF-EGA TDANLAF-ESA GX TDANRFF-EEA TDANLFF-EGA TDANLFF-ESA GX TDANRFA-EEA TDANLFA-EGA TDANLFA-ESA

SLX TDANRJA-EEA TDANLJA-EGA TDANLJA-ESA

GX TDBNRFF-EEA TDBNLFF-EGA TDBNLFF-ESA

SLX TDBNRJF-EEA TDBNLJF-EGA TDBNLJE-ESA

GX TDBNRFA-EEA TDBNLFA-EGA TDBNLFA-ESA

SLX TDBNRJA-EEA TDBNLJA-EGA TDBNLJA-ESA

LE TVHNRAY-UEA TVHNLAY-UGA TVHNLAY-USA GX TVHNRFY-UEA TVHNLFY-UGA TVHNLFY-USA

SLX TVHNRJY-UEA TVHNLJY-UGA TVHNLJY-USA

Southern/Central

Europe

Northern Europe

PAIA0082E

GI-42

Page 45

IDENTIFICATION NUMBER

IDENTIFICATION INFORMATION

PAIA0130E

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT For Europe except Israel

PAIA0146E

GI-43

Page 46

For Israel

IDENTIFICATION PLATE

IDENTIFICATION INFORMATION

PAIA0147E

ENGINE SERIAL NUMBER

PAIA0148E

PAIA0036E

GI-44

Page 47

IDENTIFICATION INFORMATION

AUTOMATIC TRANSAXLE NUMBER

PAIA0008E

PAIA0009E

MANUAL TRANSAXLE NUMBER

PAIA0010E

Dimensions EAS000GF

Unit: mm (in) Overall length 4,455 Overall width 1 ,76 5

Overall height

Front tr ead 1,530 Rear trea d 1, 530 Wheelbase 2,625

1,675 (Standard) 1,750 (With Rear spoiler or Roof rail with Driving ligh t)

Wheels & Tires EAS000GG

Conventional Spare

Road wheel/offset mm (in)

Tire size

15 × 6JJ Steel/40 (1.57) 16 × 6.5JJ Steel/Aluminum/40 (1.57)

215/70 R15 215/65 R16

GI-45

Conventional

Page 48

TERMINOLOGY

TERMINOLOGY PFP:00011 SAE J1930 Terminology List EAS000GH

All emission rela ted te rms u sed in th is pu blic ation in ac cordan ce with SAE J1 930 a re list ed. Ac cordi ngly, new terms, new acronyms/abbreviations and old terms are listed in the following chart.

NEW TERM

Air cleaner ACL Air cleaner Barometric pressure BARO *** Barometric pressure sensor-BCDD BAROS-BCDD BCDD Camshaft position CMP *** Camshaft position sensor CMPS Crank angle sensor Canister *** Canister Carburetor CARB Carburetor Charge air cooler CAC Intercooler Closed loop CL Closed loop Closed throttle position switch CTP switch Idle switch Clutch pedal position switch CPP switch Clutch switch Continuous fuel injection system CFI system *** Continuous trap oxidizer system CTOX system *** Crankshaft position CKP *** Crankshaft position sensor CKPS *** Data link connector DLC *** Data link connector for CONSULT-II DLC for CONSULT-II Diagnostic connector for CONSULT-II Diagnostic test mode DTM Diagnostic mode Diagnostic test mode selector DTM selector Diagnostic mode selector Diagnostic test mode I DTM I Mode I Diagnostic test mode II DTM II Mo de II Diagnostic trouble code DTC Malfunction code Direct fuel injection system DFI system *** Distributor ignition system DI system Igniti on tim i ng control Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater Early fuel evaporation system EFE system Mixture heater control Electrically erasable programmable read

only memory Electronic ignition system EI system Ignition timing control Engine control EC *** Engine control module ECM ECCS control unit Engine coolant temperature ECT Engine temperature Engine coolant temperature sensor ECTS Engine temperature sensor Engine modification EM *** Engine speed RPM Engine speed Erasable programmable read only memory EPROM *** Evaporative emission canister EVAP canister Canister Evaporative emission system EVAP system Canister control solenoid valve Exhaust gas recirculation valve EGR valve EGR valve

EEPROM ***

NEW ACRONYM /

ABBREVIATION

OLD TERM

GI-46

Page 49

TERMINOLOGY

NEW TERM

Exhaust gas recirculation control-BPT valve

Exhaust gas recirculation control-sol enoi d valve

Exhaust gas recirculation temperature sensor

EGR temperature sensor Flash electrically erasable programmable

read only memory Flash erasable programmable read only

memory Flexible fuel sensor FFS *** Flexible fuel system FF system *** Fuel pressure regulator *** Pr essu re re gul at or Fuel pressure regulator control solenoid

valve Fuel trim FT *** Heated Oxygen sensor HO2S Exhaust gas sensor Idle air control system IAC system Idle speed control Idle air control valve-air regulator IACV-air regulator Air regulator Idle air control valve-auxiliary air contro l

valve Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve Idle air control valve-idle up control sole -

noid valve Idle speed control-FI pot ISC-FI pot FI pot Idle speed control system ISC system *** Ignition control IC *** Ignition control module ICM *** Indirect fuel injection system IFI system *** Intake air IA Air Intake air temperature sensor IAT sensor Air temperature sensor Knock *** Detonation Knock sensor KS D et onation sensor Malfunction indicator lamp MIL Check engine light Manifold absolute pressure MAP *** Manifold absolute pressure sensor MAPS *** Manifold differe nt ia l pr e ssu re MDP *** Manifold differential pressure sensor MDPS *** Manifold surface temperature MST *** Manifold surface temperature sensor MSTS *** Manifold vacuum zone MVZ *** Manifold vacuum zone sensor MVZS *** Mass air flow sensor MAFS Air flow meter Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve Multipo rt fuel injec tion Syste m MFI sys te m Fuel i n jection con trol

EGRC-BPT valve BPT valve

EGRC-solenoid valve EGR control solenoid valve

EGRT sensor Exhaust gas temperature se nsor

FEEPROM ***

FEPROM ***

*** PRVR control solenoid valve

IACV-AAC valv e Auxiliary air control (AAC) valve

IACV-idle up control solenoid valve Idle up control solenoid valve

NEW ACRONYM /

ABBREVIATION

OLD TERM

GI-47

Page 50

TERMINOLOGY

NEW TERM

Nonvolatile random access memory NVRAM *** On board diagnostic system OBD system Self-diagnosis Open loop OL Open loop Oxidation catalyst OC Catalyst Oxidation catalytic converter sys te m OC system *** Oxygen sensor O2S Exhaust gas sensor Park position switch *** Park switch

Park/neutral position switch PNP switch

Periodic trap oxidizer system PTOX system *** Positive crankcase ventilation PCV Positive crankcase ventilation Positive crankcase ventilation valve P C V val ve P CV valve Powertrain control module PCM *** Programmable read only memory PROM *** Pulsed secondary air injection control sole-

noid valve Pulsed secondary air injection system PAIR system Air induction valve (AIV) control Pulsed secondary air injection valve PAIR valve Air induction val ve Random access memory RAM *** Read only memory ROM *** Scan tool ST *** Secondary air injection pump AIR pump *** Secondary air injection system AIR system *** Sequential multiport fuel injection system SFI syst em Sequential fuel inj ecti on Service reminder indicator SRI *** Simultaneous multiport fuel injection sys-

tem Smoke puff lim iter system SPL system *** Supercharger SC *** Supercharger bypass SCB *** System readiness test SRT *** Thermal vacuum valve TVV Thermal vacuum valve Three way catalyst TWC Catalyst Three way catalytic converter system TWC system *** Three way + oxidation catalyst TW C + OC Catalyst Three way + oxidation catalytic converter

system

Throttle body TB

Throttle body fuel injection system TBI system Fuel injection control Throttle position TP Throttle position Throttle position sensor TPS Throttle sensor Throttle position switch TP switch Throttle switch

Torque converter clutch solenoid valve TCC solenoid valve

PAIRC solenoid valve AIV co ntrol sol enoi d val ve

*** S imultaneo us fu el inject ion

TWC + OC system ***

NEW ACRONYM /

ABBREVIATION

Park/neutral switch Inhibitor switch Neutral position switch

Throttle chamber SPI body

Lock-up cancel solenoid Lock-up solenoid

OLD TERM

GI-48

Page 51

TERMINOLOGY

NEW TERM

Transmission control module TCM A/T control unit Turbocharger TC Turbocharger Vehicle speed sensor VSS Vehicle speed sensor Volume air flow sensor VAFS Air flow meter Warm up oxidation catalyst WU-OC Catalyst Warm up oxidation catalytic converter sys-

tem Warm up three way cata ly st WU-TWC Catalyst Warm up three way catalytic converter sys-

tem Wide open throttle position switch WOTP switch Full switch

***: Not applicable

WU-OC system ***

WU-TWC system ***

NEW ACRONYM /

ABBREVIATION

OLD TERM

GI-49

Page 52

TERMINOLOGY

GI-50

Page 53

ENGINE MECHANICAL

B ENGINE

SECTION EM

CONTENTS

PRECAUTIONS .......................................................... 5

Precautions for Drain Engine Coolant ...................... 5

Precautions for Disconnecting Fuel Piping .............. 5

Precautions for Removal and Disassembly ............. 5

Precautions for Inspection, Repair and Replace-

ment ......................................................................... 5

Precautions for Assembly and Installation ............... 5

Parts Requiring Angle Tightening ............................. 5

Precautions for Liquid Gasket .................................. 6

REMOVAL OF LIQUID GASKET .......................... 6

LIQUID GASKET APPLICATION PROCEDURE ..... 6

PREPARATION ........... ................... .................... ......... 7

Special Service Tools ............................................... 7

Commercial Service Tools ........................................ 9

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING .......................... .....................11

NVH Troubleshooting — Engine Noise ...................11

Use the Chart Below to Help You Find the Cause

of the Symptom. ................................. ...... .............. 12

DRIVE BELTS ........................................................... 13

Checking Drive Belts .............................................. 13

Tension Adjustment ................................................ 13

Removal and Installation ........................................ 13

REMOVAL ........................................................... 13

INSTALLATION ................................................... 14

Removal and Installation of Drive Belt Auto-Ten-

sioner ..................................................................... 14

REMOVAL ........................................................... 14

INSTALLATION ................................................... 14

AIR CLEANER AND AIR DUCT ............................... 15

Removal and Installation ........................................ 15

REMOVAL ........................................................... 15

INSTALLATION ................................................... 16

Changing Air Cleaner Filter ......... ....... .................... 16

REMOVAL ........................................................... 16

INSTALLATION ................................................... 16

INTAKE MANIFOLD ................................................. 17

Removal and Installation (QR20DE) ...................... 17

ENGINE MECHANICAL

REMOVAL ........................................................... 17

INSTALLATION ...................................................18

INSPECTION AFTER INSTALLATION ................ 19

Removal and Installation (QR25DE) ......................20

REMOVAL ........................................................... 20

INSPECTION AFTER REMOVAL ....................... 21

INSTALLATION ...................................................22

INSPECTION AFTER INSTALLATION ................ 22

EXHAUST MANIFOLD AND THREE WAY CATA-

LYST ..................................... ................................. ....23

Removal and Installation ........................................23

REMOVAL ........................................................... 23

INSPECTION AFTER REMOVAL ....................... 24

INSTALLATION ...................................................24

OIL PAN AND OIL STRAINER ................................. 25

Removal and Installation ........................................25

REMOVAL ........................................................... 25

INSPECTION AFTER REMOVAL ....................... 27

INSTALLATION ...................................................27

INSPECTION AFTER INSTALLATION ................ 28

IGNITION COIL .........................................................29

Removal and Installation ........................................29

REMOVAL ........................................................... 29

INSTALLATION ...................................................29

SP ARK PLUG ........................................................... 30

Removal and Installation ........................................30

REMOVAL ........................................................... 30

INSPECTION AFTER REMOVAL ....................... 30

INSTALLATION ...................................................31

FUEL INJECTOR AND FUEL TUBE ........................32

Removal and Installation (QR20DE) ......................32

REMOVAL ........................................................... 32

INSTALLATION ...................................................34

INSPECTION AFTER INSTALLATION ................ 36

Removal and Installation (QR25DE) ......................37

REMOVAL ........................................................... 37

INSTALLATION ...................................................39

INSPECTION AFTER INSTALLATION ................ 41

EM-1

Page 54

ROCKER COVER .....................................................42

Removal and Installation ........................................42

REMOVAL ...........................................................42

INSTALLATION ............ ............. ............. .............. 43

TIMING CHAIN .......................................................... 44

Removal and Installation ........................................44

REMOVAL ...........................................................44

INSPECTION AFTER REMOVAL ........................48

INSTALLATION ............ ............. ............. .............. 49

CAMSHAFT .............................. ...... ....... ....................53

Removal and Installation ........................................53

REMOVAL ...........................................................53

INSPECTION AFTER REMOVAL ........................55

INSTALLATION ............ ............. ............. .............. 58

Valve Clearance ......................................................61

INSPECTION ............................ ............. ..............61

ADJUSTMENT ....................................................62

OIL SEAL ..................................................................64

Removal and Installation of Valve Oil Seal .............64

REMOVAL ...........................................................64

INSTALLATION ............ ............. ............. .............. 64

Removal and Installation of Front Oil Seal ............. 64

REMOVAL ...........................................................64

INSTALLATION ............ ............. ............. .............. 65

Removal and Installation of Rear Oil Seal ..............65

REMOVAL ...........................................................65

INSTALLATION ............ ............. ............. .............. 65

CYLINDER HEAD .....................................................67

On-Vehicle Service .................................................67

CHECKING COMPRESSION PRESSURE ......... 67

Removal and Installation ........................................68

REMOVAL ...........................................................68

INSPECTION AFTER REMOVAL ........................69

INSTALLATION ............ ............. ............. .............. 69

Disassembly and Assembly ....................................71

DISASSEMBLY ...................................................71

ASSEMBLY .........................................................72

Inspection After Disassembly ................................. 73

VALVE DIMENSIONS ......... ...... ....... ...... ....... ....... 73

VALVE GUIDE CLEARANCE ..............................73

VALVE GUIDE REPLACEM ENT .........................74

VALVE SEAT CONTACT ....................... ....... ....... 75

VALVE SEAT REPLACEMENT ...........................75

VALVE SPRING SQUARENESS .................. .......77

VALVE SPRING DIMENSIONS AND VALVE

SPRING PRESSURE LOAD ...............................77

ENGINE ASSEMBLY ................................................78

Removal and Installation ........................................78

REMOVAL ...........................................................78

INSTALLATION ............ ............. ............. .............. 81

INSPECTION AFTER INSTALLATION ................81

CYLINDER BLOCK ................................................... 82

Disassembly and Assembly ....................................82

DISASSEMBLY ...................................................83

ASSEMBLY .........................................................87

How to Select Piston and Bearing ..........................92

DESCRIPTION ....................................................92

HOW TO SELECT PISTON .................................92

HOW TO SELECT CONNECTING ROD BEAR-

ING .......................................................................93

HOW TO SELECT MAIN BEARING ....................95

Inspection After Disassembly ..................................99

CRANKSHAFT END PLAY ..................................99

CONNECTING ROD SIDE CLEARANCE ...........99

PISTON TO PISTON PIN OIL CLEARANCE .......99

PISTON RING SIDE CLEARANCE ...................100

PISTON RING END GAP ..................................100

CONNECTING ROD BEND AND TORSION .....101

CONNECTING ROD BIG END DIAMETER ......101

CONNECTING ROD BUSHING OIL CLEAR-

ANCE .............................. ...................................101

CYLINDER BLOCK DISTORTION ........... ....... ..102

MAIN BEARING HOUSING INNER DIAMETER .103 PISTON TO CYLINDER BORE CLEARANCE ..103 CRANKSHAFT MAIN JOURNAL DIAMETER ...104

CRANKSHAFT PIN JOURNAL DIAMETER ......105

OUT-OF-ROUND AND TAPER OF CRANK-

SHAFT ...............................................................105

CRANKSHAFT RUNOUT ..................................105

CONNECTING ROD BEARING OIL CLEAR-

ANCE .............................. ...................................105

MAIN BEARING OIL CLEARANCE ...................106

MAIN BEARING CRUSH HEIGHT ....................107

CONNECTING ROD BEARING CRUSH

HEIGHT .............................................................107

LOWER CYLINDER BLOCK MOUNTING BOLT

OUTER DIAMETER ...........................................107

CONNECTING ROD BOLT OUTER DIAMETER .107

FLYWHEEL DEFLECTION (M/T MODELS) ......108

MOVEMENT AMOUNT OF FLYWHEEL (M/T

MODELS) ........................ ...................................108

SERVICE DATA AND SPECIFICATIONS (SDS) ....109

Standard and Limit ................................................109

GENERAL SPECIFICATIONS ...........................109

DRIVE BELT ......................................................109

INTAKE MANIFOLD AND EXHAUST MANI-

FOLD .................................................................109

SPARK PLUG ........................................... ....... ..109

CYLINDER HEAD ........................ ....... ...... ....... ..109

VALVE ....................... .........................................110

CAMSHAFT AND CAMSHAFT BEARING ....... ..113

CYLINDER BLOCK ................ ............................114

PISTON, PISTON RING AND PISTON PIN ......115

CONNECTING ROD ..........................................116

CRANKSHAFT ....................... ...... ....... ...... ....... ..116

MAIN BEARING .................................................118

CONNECTING ROD BEARING .......... ...... ....... ..119

Tightening Torque .................................................119

YD22DDTi

PRECAUTIONS .................... ...................................122

Precautions for Draining Engine Coolant ..............122

Precautions for Disconnecting Fuel Piping ...........122

Precautions for Removal and Disassembly ..........122

Precautions for Inspection, Repair and Replace-

ment ............................. .........................................122

Precautions for Assembly and Installation ............122

EM-2

Page 55

Parts Requiring Angle Tightening ......................... 122

Precautions For Liquid Gasket ............................. 123

REMOVAL OF LIQUID GASKET ...................... 123

LIQUID GASKET APPLICATION PROCEDURE . 123

PREPARATION ........... ................... .................... ..... 124

Special Service Tools ........................................... 124

Commercial Service Tools .................................... 127

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING .......................... .................. 129

NVH Troubleshooting — Engine Noise ................ 129

Use the Chart Below to Help You Find the Cause

of the Symptom. ................................. ...... ............ 130

DRIVE BELTS ......................................................... 131

Checking Drive Belts ............................................ 131

Tension Adjustment .............................................. 131

A/C COMPRESSOR BELT ............................... 132

ALTERNATOR AND WATER PUMP BELT ....... 132

Removal and Installation ...................................... 132

REMOVAL ......................................................... 132

INSTALLATION ................................................. 132

AIR CLEANER AND AIR DUCT ............................. 133

Removal and Installation ...................................... 133

REMOVAL ......................................................... 133

INSTALLATION ................................................. 133

CHANGING AIR CLEANER FILTER ................. 134

CHARGE AIR COOLER ......................................... 135

Removal and Installation ...................................... 135

REMOVAL ......................................................... 135

INSPECTION AFTER REMOVAL ..................... 135

INSTALLATION ................................................. 135

INTAKE MANIFOLD ............................................... 136

Removal and Installation ...................................... 136

REMOVAL ......................................................... 136

INSPECTION AFTER REMOVAL ..................... 137

INSTALLATION ................................................. 137

INSPECTION AFTER INSTALLATION ............. 138

CATALYST ............................................ .................. 139

Removal and Installation ...................................... 139

REMOVAL ......................................................... 139

INSTALLATION ................................................. 140

EXHAUST MANIFOLD AND TURBOCHARGER .. 141

Removal and Installation ...................................... 141

REMOVAL ......................................................... 141

INSTALLATION ................................................. 142

INSPECTION AFTER INSTALLATION ............. 142

Disassembly and Assembly ................................. 143

DISASSEMBLY ................................................. 143

ASSEMBLY ....................................................... 143

INSPECTION AFTER DISASSEMBLY ............. 143

Turbocharger ...................................... .................. 144

ROTOR SHAFT CLEARANCE ......................... 144

ROTOR SHAFT END PLAY .............................. 144

TURBINE WHEEL .............. ...... ....... ...... ....... ..... 145

COMPRESSOR WHEEL ................ ...... ....... ..... 145

TURBOCHARGER BOOST CONTROL ACTU-

ATOR ................................................................ 145

TROUBLE DIAGNOSIS OF TURBOCHARGER . 146

OIL PAN AND OIL STRAINER ...............................147

Removal and Installation ......................................147

REMOVAL .........................................................147

INSPECTION AFTER REMOVAL .....................149

INSTALLATION .................................................149

INSPECTION AFTER INSTALLATION ..............151

GLOW PLUG ....................... ....... ...... ....... ...... ....... ..152

Removal and Installation ......................................152

REMOVAL .........................................................152

INSTALLATION .................................................152

VACUUM PUMP ......................................................153

Removal and Installation ......................................153

INSPECTION BEFORE REMOVAL ..................153

REMOVAL .........................................................153

INSTALLATION .................................................154

INSPECTION AFTER INSTALLATION ..............155

Disassembly and Assembly ..................................155

DISASSEMBLY .................................................155

ASSEMBLY .......................................................156

INJECTION TUBE AND FUEL INJECTOR ............157

Removal and Installation ......................................157

REMOVAL .........................................................157

INSTALLATION .................................................159

INSPECTION AFTER INSTALLATION ..............160

FUEL PUMP ............................................................161

Removal and Installation ......................................161

REMOVAL .........................................................161

INSPECTION AFTER REMOVAL .....................165

INSTALLATION .................................................165

ROCKER COVER ...................................................168

Removal and Installation ......................................168

REMOVAL .........................................................168

INSTALLATION .................................................169

INSPECTION AFTER INSTALLATION ..............169

CAMSHAFT ............................................................170

Removal and Installation ......................................170

REMOVAL .........................................................170

INSPECTION AFTER REMOVAL .....................171

INSTALLATION .................................................174

Valve Clearance ...................................................175

INSPECTION ....................................................175

ADJUSTMENTS .................... ............................177

SECONDARY TIMING CHAIN ................................180

Removal and Installation ......................................180

REMOVAL .........................................................180

INSPECTION AFTER REMOVAL .....................182

INSTALLATION .................................................182

PRIMARY TIMING CHAIN ......................................185

Removal and Installation ......................................185

REMOVAL .........................................................187

INSPECTION AFTER REMOVAL .....................190

INSTALLATION .................................................190

CYLINDER HEAD ...................................................196

On-Vehicle Service ............ ....... ............................196

CHECKING COMPRESSION PRESSURE .......196

Removal and Installation ......................................197

REMOVAL .........................................................197

INSPECTION AFTER REMOVAL .....................198

EM-3

Page 56

INSTALLATION ............ ............. ............. ............199

Disassembly and Assembly ..................................201

DISASSEMBLY .................................................201

ASSEMBLY .......................................................202

INSPECTION AFTER DISASSEMBLY ..............203

ENGINE ASSEMBLY ..............................................208

Removal and Installation ......................................208

REMOVAL .........................................................209

INSTALLATION ............ ............. ............. ............211

INSPECTION AFTER INSTALLATION ..............211

CYLINDER BLOCK .................................................212

Disassembly and Assembly ..................................212

DISASSEMBLY .................................................213

ASSEMBLY .......................................................217

How to Select Piston and Bearing ........................222

DESCRIPTION ..................................................222

HOW TO SELECT PISTON ...............................222

HOW TO SELECT CONNECTING ROD BEAR-

ING ....................................................................223

HOW TO SELECT MAIN BEARING ..................224

Inspection After Disassembly ...............................226

CRANKSHAFT END PLAY ................................226

CONNECTING ROD SIDE CLEARANCE .........226

PISTON TO PISTON PIN CLEARANCE ...........226

PISTON RING SIDE CLEARANCE ...................227

PISTON RING END GAP ..................................227

CONNECTING ROD BEND AND TORSION .....228

CONNECTING ROD BIG END INNER DIAME-

TER ...................................................................228

CONNECTING ROD BUSHING OIL CLEAR-

ANCE ........................... ............. ............. ....... .....228

CYLINDER BLOCK TOP SURFACE DIST OR-

TION ..................................................................229

MAIN BEARING HOUSING INNER DIAMETER .229 PISTON TO CYLINDER BORE CLEARANCE ..230 CRANKSHAFT JOURNAL OUTER DIAMETER .231

CRANKSHAFT PIN OUTER DIAMETER ..........231

CRANKSHAFT OUT-OF-ROUND AND TAPER .231

CRANKSHAFT RUNOUT ..................................232

CONNECTING ROD BEARING OIL CLEAR-

ANCE .............................. ...................................232

MAIN BEARING OIL CLEARANCE ...................233

CRUSH HEIGHT OF MAIN BEARING ..............233

CRUSH HEIGHT OF CONNECTING ROD

BEARING ........................ ...................................233

MAIN BEARING CAP BOLT DEFORMATION ...234

CONNECTING ROD BOLT DEFORMATION ....234

OIL JET ..............................................................234

OIL JET RELIEF VALVE ....................................234

FLYWHEEL DEFLECTION ................................235

MOVEMENT AMOUNT OF FLYWHEEL ...........235

SERVICE DATA AND SPECIFICATIONS (SDS) ....236

Standard and Limit ................................................236

GENERAL SPECIFICATIONS ...........................236

INTAKE MANIFOLD AND EXHAUST MANI-

FOLD .................................................................236

DRIVE BELTS ....................................................236

CYLINDER HEAD ........................ ....... ...... ....... ..237

VALVE ....................... .........................................237

CAMSHAFT .......................................................241

CYLINDER BLOCK ................ ............................241

PISTON, PISTON RING AND PISTON PIN ......242

CONNECTING ROD ..........................................243

CRANKSHAFT ....................... ...... ....... ...... ....... ..243

AVAILABLE MAIN BEARING .............................244

AVAILABLE CONNECTING ROD BEARING .....244

MISCELLANEOUS COMPONE NTS ... ...... ....... ..244

Tightening Torque .................................................245

EM-4

Page 57

PRECAUTIONS

[QR]

PRECAUTIONS PFP:00001

Precautions for Drain Engine Coolant EBS00KN0

Drain engine coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping EBS00KN1

● Before starting work, make sure no fire or spark producing items are in the work area.

● Re le as e fue l pre ss ure befo re di sa ss em bly.

● After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly EBS00KN2

● W hen instructed to use specia l service tools, use the spec ified tools. Always be carefu l to work safely,

avoid forceful or uninstructed operation s .

● Exercise maximum care to avoid damage to mating or sliding surfaces.

● Cover openings of engine s ystem with ta pe or the equivalent, if necessary, to seal out foreign materials.

● Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

● When loosening nuts an d b ol ts, as a bas ic ru le , start with the on e fu rt he st o ut si de , the n th e on e d iag on al ly

opposite, and so on. If the order of loosening is specified, do exactly as specified.

Precautions for Inspection, Repair and Replacement EBS00KN3

Before repairing or repla cing, thorou ghly inspec t parts. Inspect new repl acement parts in the s ame way, and replace if necessary.

Precautions for Assembly an d Installation EBS00MRZ

● Use torque wrench to tighten bolts or nuts to specification.

● When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as spe ci fied.

● Replace with new gasket, packing, oil seal or O-ring.

● Thoroughly wash, clean, an d air- blo w each p art . Car efull y chec k oil or cool ant p as sage s for an y res trict ion

and blockage.

● Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.

Before assembly , oil sliding surfaces well.

● Release air within route when refilling after draining coolant.

● Before starting engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine

stopped). Then make sure there are no leaks at fuel line connections.

● After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and

exhaust systems for leakage.

Parts Requiring Angle Tightening EBS00KN5

● Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine

parts.

– Cyli nd er he ad bolts – Lower cylinder block bol ts – Connecting rod cap bolts – Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular

tightening)

– Balancer unit

● Do not us e a torq ue value for fin al tigh ten in g.

● The torque value for these parts are for a preliminary step.

● Ensure thread and seat surfaces are clean and coated with engine oil.

EM-5

Page 58

PRECAUTIONS

[QR]

Precautions for Liquid Gasket EBS00MRW

REMOVAL OF LIQUID GASKET

● After removing the mounting bolts and nuts, separate the mating

surface usin g a seal cutter (special service tool) and remove the old liquid gasket sealing.

CAUTION:

Be careful not to damage the mating surfaces.

● In areas where seal cutter (special service tool) is difficult to use,

use a plastic ha mmer to lig htly tap (1) se al cutter whe re the li quid gasket is applied. Use a plastic hammer to slide seal cutter (2) by tapping on the side.

CAUTION:

If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces.

LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper, remove the old liquid gasket adhering to the liquid gasket app lication surf ace and the mating surface.

● Remove the liquid gas ket completely from the groove of the

liquid gasket application surface, mounting bolts and bolt holes.

2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials.

PBIC0275E

3. Attach liquid gasket tube to the tube presser (special service tool).

Use Genuine Liquid Gasket or equivalent.

4. Apply the liquid gasket without breaks to the specified location with the specified dimensions.

● If there is a groove for the liq uid gask et appli cati on, apply the

liquid gasket to the groove.

● As for the bolt holes, normally apply the liquid gasket inside

the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of service manual.

● Within five minutes of liquid gasket application, install the mat-

ing component .

● If the liquid gasket protrudes, wipe it off immediately.

● Do not ret ighten mounting bolts or nut after the i nstallation.

● Wait 30 minutes or more after installation before refilling

engine oil and engine coolant.

CAUTION:

If there are instruction s in this manual, observe them.

PBIC0003E

PBIC2160E

SEM159F

EM-6

Page 59

PREPARATION

[QR]

PREPARATION PFP:00002

Special Service Tools EBS00L7N

Tool number Tool name

KV10111100 Seal cutter

ST0501S000 Engine stand assembly

1. ST05011000 Engine stand

2. ST05012000 Base

KV10106500 Engine stand shaft

KV10115300 Engine sub-attachment

S-NT046

NT042

NT028

Description

Removing oil pan and timing chain case

Disassembling and assembli ng

KV10116200 Valve spring compressor

1. KV10115900 Attachment

2. KV10109220 Adapter

KV10112100 Angle wrench

KV10117100 Heated oxygen sensor wrench

ZZA1078D

PBIC1650E

S-NT014

Disassembling and assembli ng valve mechanism Part (1) is a component of KV10116200, but Part (2) is not so.

Tightening bolts for bearing cap, cylinder head, etc.

Loosening or tightening heated oxygen sensors with 22 mm (0.87 in) hexagon nut

NT379

EM-7

Page 60

PREPARATION

[QR]

Tool number Tool name

KV10107902 Valve oil seal puller

1. KV10116100 Valve oil seal puller adapter

KV10115600 Valve oil seal drift

EM03470000 Piston ring compressor

ST16610001 Pilot bushing puller

Description

Removing valve oil seal

S-NT605

Installing valve oil seal

Use side A. a: 20 (0.79) dia. d: 8 (0.31) dia. b: 13 (0.51) dia. e: 10.7 (0.421) dia. c: 10.3 (0.406) dia. f: 5 (0.20) dia.

Unit: mm (in)

S-NT603

Installing piston assembly into cylinder bore

S-NT044

Removing pilot convertor

S-NT045

WS39930000

Pressing the tube of liquid gasket

Tube presser

S-NT052

KV11103000

Removing crankshaft pulley

Pulley puller

NT676

Quick connector release Removing fuel tube quick connectors i n

engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210)

PBIC0198E

EM-8

Page 61

PREPARATION

[QR]

Commercial Service Tools EBS00L7O

Tool name Description Spark plug wrench Removing and installing spark plug

S-NT047

Pulley holder Crankshaft pulley removing and installing

ZZA1010D

Valve seat cutter set Finishing val ve sea t dim ensi ons

S-NT048

TORX socket Removing and installing flywheel

Size: T55

PBIC1113E

Piston ring expander Removing and installing piston ring

S-NT030

Valve guide drift Removing and installing valve guide

Intake & Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia.

S-NT015

Valve guide reamer 1: Reaming valve guide inner hole

2: Reaming hole for oversize valve guide

Intake & Exhaust: d1: 6.0 mm (0.236 in) dia. d2: 10.2 mm (0.402 in) dia.

S-NT016

EM-9

Page 62

PREPARATION

[QR]

Tool name Description Oxygen sensor thread cleaner Reconditioning the exhaust system threads

before installing a new air fuel ratio sensor and heated oxygen sensor (Use with antiseize lubricant shown below.)

a = 18 mm (0.71 in) dia. for zirconia heated oxygen sensor and air fuel ratio sensor b = 12 mm (0.47 in) dia. for titania heated

AEM488

Anti-seize lubricant i.e.: (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

Manual lift table caddy Removing and installing engine

AEM489

oxygen sensor

Lubricating oxygen sensor thread cleani ng tool when reconditioning exhaust syst em threads

ZZA1210D

EM-10

Page 63

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

[QR]

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting — Engine Noise EBS00L7P

PBIC2347E

EM-11

Page 64

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

[QR]

Use the Chart B elow to Help You Find the Ca use of the Symptom. EBS00L7Q

1. Locate the area where noise occurs.

2. Confirm the type of noise.

3. Specify the operating condition of engine.

4. Check specified noise source.

If necessary, repair or replace these parts.

Operating condition of engine

Location

of noise

Top of engine Rocker cover Cylinder head

Crankshaft pul ley Cylinder block (Side of engine) Oil pan

Front of engine Front cover

Front of engine

A: Closely related B: Related C: Sometimes related —: Not related

Type of

noise

Ticking or clicking

Rattle C A — A B C

Slap or knock

Slap or rap

Knock A B CBBB

Knock A B — A B C

T apping or ticking

Squeaking or fizzing

Creaking A B A B A B

Squall Creak

Before

warm-

CA—AB—

—A—BB—

A ——BBA

A A—BBB

AB—B—C

A B—BAB

After

warm-

When

start-

ing

When

idling

When racing

While

driving

Source of

noise

Tappet noise

Camshaft bearing noise

Piston pin noise

Piston slap noise

Connecting rod bearing noise

Main bearing noise

Timing chain and chain tensioner noise

Drive belt (Sticking or slipping)

Drive belt (Slipping)

Water pump noise

Check item

Valve clearance EM-61

Camshaft journal oil clearance Camshaft runout

Piston to piston pin oil clearance Connecting rod bushing oil clearance

Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

Connecting rod bushing oil clearance Connecting rod bearing oil clearance

Main bearing oil clearance Crankshaft runout

Timing chain cracks and wear Timing chain tensioner operation

Drive belt deflection

Idler pulley bearing operation

Water pump operation

Refer-

ence page

EM-56 EM-55

EM-99

EM-101

EM-104 EM-100 EM-100 EM-101

EM-101 EM-105

EM-106 EM-105

EM-48 EM-44

EM-13

CO-20,

"WATER

PUMP"

EM-12

Page 65

DRIVE BELTS

[QR]

DRIVE BELTS PFP:02117

Checking Drive Belts EBS00KN7

PBIC1234E

WARNING:

Be sure to perform this step when the engine is stopped.

● Ma ke su re that th e indi cato r (singl e line notch on fixe d side ) of driv e belt a uto-te nsio ner is wit hin the pos-

sible use rang e (between three line notches on moving side).

NOTE:

● Check the drive belt aut o-tensioner indicator (sin gle line notch on fixed side) when engine is cold.

● When new drive belt is installed, the indicator (single line notch on fixed side) should be within the

range “A” in the figure.

● Visually check entire belt for wear, damage or cracks.

● If the indicator (single line notch on fixed side) is out of the possible use range or belt is damaged, replace

drive belt.

Ten sio n Adju st ment EBS00KN8

Belt tensioning is not necessary, as it is automatically adj usted by drive belt auto-tensioner.

Removal and Installation EBS00KN9

REMOVAL

1. Remove splash guard on RH undercover.

2. With box wrench, and while securely holding the hexagonal part in center of drive belt auto-tensioner pulley, move the wrench handle in the direction of arrow (loosening direction of tensioner).

CAUTION:

Avoid placing hand in a lo ca tion whe r e pinc hin g m ay occur if the holding tool accidentally comes off.

3. Insert a rod approximately 6 mm (0.24 in) in diameter such as short-length screw driver into th e hole of the retain ing boss to fix drive belt auto-tensioner pulley.

4. Loosen drive belt from water pump pulley in sequence, and remove it.

PBIC2169E

EM-13

Page 66

DRIVE BELTS

[QR]

INSTALLATION

1. With box wrench, and whi le s ec ure ly ho ldi ng the hexagonal part in cente r of dri ve be lt au to -tensioner pulley, move the wrench handle in the direction of ar row (loosening direction of tensioner).

CAUTION:

Avoid placing hand in a loc ati on where pinching may occu r if the ho ldin g tool accidentally comes off.

2. Insert a rod approxim ately 6 mm (0.24 in) in diamet er such as short-length screw driver into the hole of retaining boss to fix drive belt auto-tensioner pulley.

3. Hook drive belt onto a ll pulleys exce pt for water pump, and then onto water pump pulley finally.

CAUTION:

Confirm belt is completely set to pulleys.

4. Releas e drive belt auto-tensioner, and apply tension to drive belt.

5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.

6. Confirm tension of drive belt at indicator is within the range of possible use. Refer to EM-13, "

Drive Belts" .

Checking

Removal and Installation of Drive Belt Auto-Tensioner EBS00KNA

1. Drive belt auto-tensioner 2. Water pump pulley

REMOVAL

1. Remove splash guard on RH undercover.

2. Remove drive belt. Refer to EM-13, "

3. Remove drive belt auto-tensioner.

Removal and I nstallation" .

INSTALLATION

Install in the reverse order of removal.

CAUTION:

When installing drive belt auto-tensioner, be careful not to damage water pump pulley.

EM-14

PBIC2170E

Page 67

AIR CLEANER AND AIR DUCT

[QR]

AIR CLEANER AND AIR DUCT PFP:16500

Removal and Installation EBS00KNB

PBIC2171E

1. Air cleaner filter 2. Clip 3. Air cleaner case upper

4. Clamp 5. Air duct 6. PCV hose

7. Clamp 8. Bracket 9. Mass air flow sensor

10. O-ring 11. Air duct 12. Air duct (inlet)

13. Clip 14. Collar 15. Grommet

16. Resonator 17. Bracket (A/T models) 18. Mounting rubber

19. Collar 20. Grommet 21. Air cleaner case lower

REMOVAL

1. Remove mass ai r flow sensor harness clamp.

2. Disconnect harness connector from mass air flow sensor.

3. Remove air duct (inlet), air ducts and air cleaner case/mass air flow sensor assembly disconnecting their joints.

● Add marks as necessary for easier installation.

4. Remove mass air flow sensor from air cleaner case upper.

CAUTION:

Handle mass air flow sensor with follow ing ca res .

● Do not shock it.

● Do not disassemble it.

● Do not touch its sensor.

5. Remove resonator in fend er lifting lef t fender protector.

EM-15

Page 68

AIR CLEANER AND AIR DUCT

[QR]

INSTALLATION

Note the following, and install in the reverse order of removal.

● Align marks. Attach each joint. Screw clamps firmly.

Changing Air Cleaner Filter EBS0123Q

REMOVAL

1. Unfasten clips and lift up air cleaner case upper.

2. Remove air cleaner filter.

INSTALLATION

Install in the reverse order of removal.

EM-16

Page 69

INTAKE MANIFOLD

[QR]

INTAKE MANIFOLD PFP:14003

Removal and Installation (QR20DE) EBS00KNC

PBIC2172E

1. Vacuum hose 2. Intake manifold 3. P C V hose

4. Bracket 5. Gasket 6. Electric throttle control actuator

7. Gasket 8. Intake manifold support 9. Gasket

10. Vacuum hose 11.

13. Bracket 14. Bracket

EVAP canister purge volume control solenoid valve

12. Vacuum hose

REMOVAL

1. Release fu el pres sure. Re fer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,

"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).

2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "

CLEANER AND AIR DUCT" .

3. Remove quick co nn ec tor c ap s, an d disco nn ec t qui ck co nn ec tor s at engine side an d vehicle side . Refer to EM-32, "

Removal and

Installation (QR20DE)" .

AIR

4. Remove elec tric throttl e control actuator with the following procedure:

a. Disconnect harness connector .

EM-17

PBIC2175E

Page 70

INTAKE MANIFOLD

[QR]

b. Loosen mounting bolts in reverse order as shown in the figure,

and remove electric throttle control actuator and gasket.

CAUTION:

● Handle carefully to avoid any shock to electric throttle

control actu ator.

● Do not disassemble.

EMJ1612D

5. Disconnect harness, power steering piping, vacuum hose and PCV hose from intake manifold, and move them aside.

6. Remove intake manifold support and gasket.

7. Disconnect sub-harness from fuel injector. Refer to EM-32, "

8. Loosen mounting bolts and nuts in reverse order as shown in the figure, and remove intake manifold (with fuel tube and fuel injector assembly) and gasket.

CAUTION:

● Do not disassemble intake manifold.

● Cover engine openings to avoid entry of foreign materi-

als.

NOTE:

Disregard No. 6 when loosenin g.

Removal and Installation (QR20DE)" .

9. Remove fu el tu be an d fue l inje ctor asse mbly from in t ake ma nifol d. R efer to EM-32, "

tion (QR20DE)" .

INSTALLATION

Note the following, and install in the reverse order of removal.

Intake Manifold

● If stud bolts were removed, install them and tighten to the specified torque below.

: 10.8 N·m (1.1 kg-m, 8 ft-lb)

● Check if gasket is not dropped from the installation groove of intake manifold.

● Tighten in numerical order as shown in the figure.

NOTE:

No. 6 means double tightening of bolt No. 1.

PBIC2173E

Removal and Installa-

PBIC2173E

EM-18

Page 71

INTAKE MANIFOLD

Electric Throttle Control Actuator

● Tighten mo unting bolts equally and diagon ally in several steps

and in numerical order as shown in the figure.

● Perform the “Throttle Valve Closed Pos iti on Lea r ning ” when har -

ness connector of electric throttle control actuator is disconnected. Refer to EC-46, "

Learning" (WITH EURO-OBD) or EC-508, "Throttle Valve Closed Position Learning" (WITHOUT EURO-OBD).

● Perform the “Idle Air Volume Learning” and “Throttle Valve

Closed Position Learn ing” when electric thro ttle control ac tuator is replaced. Refer to EC-46, " EURO-OBD) or EC-508, " EURO-OBD).

Throttle Valve Closed Position

Idle Air Volume Learning" (WITH

Idle Air Volume Learning" (WITHOUT

[QR]

EMJ1612D

INSPECTION AFTER INSTALLATION

Make sure there are no fuel leaks at connections with the following procedure:

1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then make sure there are no fuel leaks at connections.

NOTE:

Use mirrors for checking on invisible points.

2. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.

CAUTION:

Do not touch engine immediately after stopped as engine becomes extremely hot.

EM-19

Page 72

INTAKE MANIFOLD

[QR]

Removal and Installation (QR25DE) EBS011TH

PBIC2174E

1. Bracket 2. PCV hose 3. Intake manifold collector

4. Gasket 5. Electric throttle control actuator 6. Intake manifold rear support EV A P ca ni st er pu r ge vol um e c on t ro l

7. solenoid valve

10. Vacuum reservoir tank 11. VIAS cont ro l soleno id valve 12. Vacuum hose

13. Bracket 14. Intake manifold su ppor t 15. Vacuum reservoir tank bracket

8. Vacuum hose 9. Intake manifold

REMOVAL

1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,

"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).

2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "

CLEANER AND AIR DUCT" .

3. Remove quick connector caps, and disconnect quick connectors at engine side and vehicle side. Refer to EM-37, "

Removal and

Installation (QR25DE)" .

AIR

PBIC2175E

4. Remove e lectric throt tle control actuator with t he following procedure:

EM-20

Page 73

INTAKE MANIFOLD

a. Disconnect harness connector . b. Loosen mounting bolts in reverse order as shown in the figure,

and remove electric throttl e control actuator and gasket .

CAUTION:

● Handle carefully to avoid any shock to electric throttle

control actuator.

● Do not disassemble.

[QR]

EMJ1612D

5. Disconnect harness, vacuum hose and PCV hose from intake manifold colle c tor, and move them as ide.

6. Remove intake manifold rear support and intake manifold support.

7. Loosen mounting bolts and nuts in reverse order as shown in the figure, and remove intake manifold collector and gasket.

CAUTION:

Cover engine openings to avoid entry of foreign materials. NOTE:

Disregard No. 8 when loosening.

SBIA0230E

8. Disconnect power steering piping from in take manifold, and move them aside.

9. Disconnect sub-harness from fuel injector. Refer to EM-37, "

Removal and Installatio n (QR25DE)" .

10. Loosen mounting bolts and nuts in reverse order as shown in the figure, and remo ve intake manifold (with fuel tub e and fuel injector assembly) and gasket.

CAUTION:

Cover engine openings to avoid entry of foreign materials. NOTE:

Disregard No. 6 when loosening.

1 1. Remo ve fu el t ube and f uel inje ctor a ssemb ly fr om i nta ke man ifo ld. Refer t o EM-37, "

tion (QR25DE)" .

INSPECTION AFTER REMOVAL Surface Distortion

● Using straightedge and feeler gauge, check the surface distor-

tion of both the intake mani fold coll ector mati ng surfac e and the intake manifold mating surfaces.

Limit : 0. 1 mm (0.0 04 in)

● If it exceeds the limit, re pl a ce in t ak e man ifo ld a nd /or i nt a ke ma n-

ifold collector.

EM-21

SBIA0231E

Removal and I nst alla -

KBIA0235E

Page 74

INTAKE MANIFOLD

INSTALLATION

Note the following, and install in the reverse order of removal.

Intake Manifold

● If stud bolts were removed, install them and tighten to the specified torque below.

: 10.8 N·m (1.1 kg-m, 8 ft-lb)

● Tighten in numerical order as shown in the figure.

NOTE:

No. 6 means double tightening of bolt No. 1.

Intake Manifold Collector

Tighten in numerical order as shown in the figure.

NOTE:

No. 8 means double tightening of bolt No. 1.

[QR]

SBIA0231E

SBIA0230E

Electric Throttle Control Actuator

● Tighten mounting bolts equally and diagonally in several steps

and in numerical orde r as show n in the figu re.

● Perform the “Throttle Valve Closed Position Learning” when har-

ness connector of electric throttle control actuator is disconnected. Refer to EC-46, "

Throttle Valve Closed Position Learning" (WITH EURO-OBD) or EC-508, "Throttle Valve Closed Posi tion Learning" (WITHOUT EURO-OBD).

● Perform the “Idle Air Volume Learning” and “Throttle Valve

Closed Position Learning” when electric throttle control actuator is replaced. Refer to EC-46, " EURO-OBD) or EC-508, "

Idle Air Volume Learning" (WITH

Idle Air Volume Learning" (WITHOUT

EMJ1612D

EURO-OBD).

INSPECTION AFTER INSTALLATION

Make sure there are no fuel leaks at connections with the following procedure:

1. Apply fuel pressure to fuel lines with turning ignitio n switch “ON” (w ith engine stop ped). Then m ake sure there are no fuel leaks at connections.

NOTE:

Use mirrors for checking on invisible points.

2. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.

CAUTION:

Do not touch engine immediately after stopped as engine becomes extremely hot.

EM-22

Page 75

EXHAUST MANIFOLD AND THREE WAY CATALYST

[QR]

EXHAUST MANIFOLD AND THREE WAY CATAL YST PFP:14004

Removal and Installation EBS00KND

PBIC2176E

1. Heated oxygen sensor 1 2.

4. Three way catalyst cover 5. Exhaust manifold cover (low er) 6. Heated oxygen sensor 2

7. Exhaust manifold cover (upper)

Exhaust manifold and three way catalyst assembly

3. Gasket

REMOVAL

1. Remove heated oxygen sensors with the following procedure: a. Disconnect harness connector of each heated oxygen sensor, and harness from bracket and middle

clamp.

b. Using heated oxygen sensor wrench (special service tool),

remove heated ox yg en sensors.

CAUTION:

● Be careful not to damage heated o x ygen sensor.

● Discard any heated oxygen sensor which has been

dropped from a height of more tha n 0. 5 m (19 .7 in) onto a hard surface such as a concre te floor; replace with a new one.

2. Remove exhaust front tube. Refer to EX-2, "

3. Remove alternator. Refer to SC-12, "

CHARGING SYSTEM" .

4. Remove exhaust manifold cove r (upper).

KBIA0094E

EXHAUST SYSTEM" .

EM-23

Page 76

EXHAUST MANIFOLD AND THREE WAY CATALYST

[QR]

5. Loosen nuts in reverse order as shown in the fi gure to remove exhaust manifold and three way catalyst assembly.

NOTE:

Disregard No. 6 and 7 when loosening.

KBIA0045E

6. Remove gasket.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

7. Remove exhaust manifo ld cover (lower) and three way catalyst cover from exha ust manifold and three way catalyst assembly. .

INSPECTION AFTER REMOVAL Surface Distortion

● Using straightedge and feel er gauge, check th e surface distor-

tion of exh aust ma nifo ld a nd thr ee wa y cat aly st as semb ly mat ing surface.

Limit : 0.3 mm (0.012 in)

● If it exceeds the limit, replace exhaust manifold and three way

catalyst assemb ly.

INSTALLATION

Note the following, and install in the reverse order of removal.

Exhaust Manifold

● If stud bolts were removed, install them and tighten to the specified torque below.

: 14.7 N·m (1.5 kg-m, 11 ft-lb)

● Tighten nuts in numerical orde r as sho wn in the figure.

NOTE:

No. 6 and 7 mean double tightening of bolts No. 1 and 3.

KBIA0046E

KBIA0045E

Heated Oxygen Sensor

CAUTION:

● Before installing a new heated oxygen sensor, clean exhaust system threads using heated oxygen

sensor thread cleaner and apply anti-seize lubricant (commercial service tool).

● Do not over t orque th e he ated o xygen sensor. Doing so may cau se dama ge to the heat ed ox ygen

sensor, resulting in the “MI” coming on.

EM-24

Page 77

OIL PAN AND OIL STRAINER

[QR]

OIL PAN AND OIL STRAINER PFP:11110

Removal and Installation EBS00KNE

1. Oil level gauge 2. Oil level gauge guide 3. O-ring

4. Oil pan (upper) 5. Cylinder block 6. O-ring

7. Oil filter 8. O-ring 9. Drain plug w asher

10. Oil strainer 11. Drain plug 12. Oil pan (lower)

13. Rear plate cover

REMOVAL

WARNING:

To avoid the danger of being scalded, do not drain the engine oil when the engine is hot.

1. Remove RH and LH undercovers.

2. Drain engine oil. Refer to LU-8, "

3. Remove oil pan (lower) with the followi ng procedure: a. Loosen mounting bolts in reverse order as shown in the figure.

Changing Engine Oil" .

PBIC2177E

KBIA0096E

EM-25

Page 78

OIL PAN AND OIL STRAINER

b. Insert seal cutter (specia l service tool) between oil pan (upper)

and oil pan (lower).

CAUTION:

Be careful not to damage the mating surface.

c. Slide seal cutter by tapping on the side of the tool with a ham-

mer.

[QR]

SEM365EA

KBIA2024J

4. Remove oil st rainer.

5. Remove oil pan (upper ) with the follo wing procedure:

a. Remove drive belt. Refer to EM-13, "

DRIVE BELTS" .

b. Remove A/C compressor with piping connected. And locate it aside temporarily with ropes or equivalent

not to disturb the following work. Refer to ATC-144, "

Removal and Installation of Compressor" .

c. Remove oil level gauge guide. d. Remove e xhaust front tube and its su pport. Refer to EX-2, "

EXHAUST SYSTEM" .

e. Set a suitable transmission jack under transaxle and hoist

engine with engine slinger, and then remove center member. Refer to EM-78, "

f. Remove rear plate cover, and four transaxle joint bolts. Refer to MT-17, "

models) or AT-413, "

ENGINE ASSEMBLY" .

PBIC0257E

TRANSAXLE ASSEMBLY" (M/T

REMOVAL AND INSTAL LATION" (A/T models).

g. Loosen bolts in reverse order as shown in the figure.

NOTE:

Disregard No.12 and 17 when loosening.

SBIA0233E

EM-26

Page 79

OIL PAN AND OIL STRAINER

h. Insert seal cutter (special service tool) between oil pan (upper)

and cylinder block, and slide it by tapping on the side of the tool with a hammer.

CAUTION:

Be careful not to damage the mating surface.

6. Remove O-rings at front cover side.

INSPECTION AFTER REMOVAL

Clean oil strainer if any ob jec t atta ch ed .

INSTALLATION

1. Install oil pan (upper) with the following procedure: a. Use a scraper to remove old liquid gasket from mating surfaces.

● Also remove the old liquid gasket from mating surface of cyl-

inder block.

● Remove old liquid gasket from the bolt holes and threads.

CAUTION:

Do not scratch or damage the mating surfac es when clean ing off old liquid gasket.

[QR]

SEM365EA

b. Apply a continuous bead of liquid gasket with a tube presser

(special service tool: WS39930000) as shown in the figure.

Use Genuine Liquid Gasket or equivalent.

CAUTION:

Apply liquid gasket to outside of bolt hole for the positi ons shown by arrows.

c. Install new O-rings at front cover side. d. Tighten bolts in numerical order as shown in the figure.

No. 12 and 17 mean double tightening of bolts No. 1 and 2.

NOTE:

Refer to the following for locating bolts.

M6 × 20 mm (0.79 in) : No. 18, 19 M8 × 25 mm (0.98 in) : No. 1, 2, 3, 11 M8 × 45 mm (1.77 in) : No. 4, 10, 13, 14, 15, 16 M8 × 100 mm (3.97 in) : No. 5, 6, 7, 8, 9

MEM108A

SBIA0253E

e. Tighten transaxle joint bolts. Refer to MT-17, "

"REMOV A L AND INSTALLATION" (A/T models).

f. Install rear plate cover.

EM-27

SBIA0233E

TRANSAXLE ASSEMBLY" (M/T models) or AT-413,

Page 80

OIL PAN AND OIL STRAINER

2. Install oil strainer.

3. Install oil pan (lower) with the following procedure: a. Use a scraper to remove old liquid gasket from mating surfaces.

● Also remove old liquid gasket from mating surface of oil

pan (upper).

b. Apply a continuous bead of liquid gasket with a tube presser

(special service tool: WS39930000) as shown in the figure.

Use Genuine Liquid Gasket or equivalent.

[QR]

SEM958F

c. Tighten bolts in numeric al order as shown in the figure.

4. Install oil pan drain plug.

● Refer to the figure of components of former page for installation direction of washer. Refer to EM-25,

"Removal and Ins talla tio n " .

5. Install in the reverse order of removal after this step.

NOTE:

Pour engine oil at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION

1. Check en gine oil level and add engine oi l. Refer to LU-7 , "ENGINE OIL" .

2. Start engine, and make sure there is no leaks of engine oil.

3. Stop engine and wait for 10 minutes.

4. Check en gine oil level again. Refer to LU-7, "

ENGINE OIL" .

SBIA0254E

KBIA0096E

EM-28

Page 81

IGNITION COIL

[QR]

IGNITION COIL PFP:22448

Removal and Installation EBS00KNF

1. Ignition coil 2. Spark plug 3. Rocker cover

REMOVAL

1. Disconnect harness conne ctor from ignition coil.

2. Remove ignition coil.

CAUTION:

Do not drop or shock it.

INSTALLATION

Install in the reverse order of removal.

KBIA1974J

EM-29

Page 82

SPARK PLUG

[QR]

SPARK PLUG PFP:22401 Removal and Installation EBS00KNG

KBIA1974J

1. Ignition coil 2. Spark plug 3. Rocker cover

REMOVAL

1. Remove ignition coil. Refer to EM-29, "IGNITION COIL" .

2. Remove spark plug with spark plug wrench (commercial service

tool).

CAUTION:

Do not drop or shock it .

SEM294A

INSPECTION AFTER REMOVAL

Use standard type spark plug for normal condition.

Hot type sp ark plug is suitable when fouling occurs with standard type spark plug under condi tions such as:

● Frequent engine starts

● Low ambient temperatu res

Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions such as:

● Extended highway driving

● Frequent high engine revolution

Make NGK Standard type LFR5A-11 Hot type LFR4A-11 Cold type LFR6A-11

EM-30

Page 83

SPARK PLUG

● Check plug gap of each spark plug.

Standard :1.0 - 1.1 mm (0.039 - 0.043 in)

● If out of standard, adjust or replace s park plug.

● Use a wire brush for cleaning, if necessary.

INSTALLATION

Install in the reverse order of removal.

[QR]

SMA476

EM-31

Page 84

FUEL INJECTOR AND FUEL TUBE

[QR]

FUEL INJECTOR AND FUEL TUBE PFP:16600 Removal and Installation (QR20DE) EBS00KNH

PBIC2178E

1. Fuel feed hose 2. Quick connector cap (engine side) 3. Quick connector cap (vehicle side)

4. Centralized under-floor pipin g 5. Sub-harness 6. Fuel tube protector

7. Fuel tube 8. O-ring (black) 9. Clip

10. Fuel injector 11. O-ring (green)

CAUTION:

Do not remove or disassemble parts unless instructed as shown in the figure.

REMOVAL

1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,

"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).

2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "

CLEANER AND AIR DUCT" .

3. Disconnect quick connectors at engine side and vehicle side as

follows, and remove fuel fee d ho se.

CAUTION:

Disconnect quick connector by using quick connector release (special service tool), not by picking out retainer tabs.

NOTE:

There is quick connector for the engine side and for the vehicle side, and they have different shapes. But disconnection is same procedure. The following procedure shows the engine side.

AIR

PBIC2175E

a. Remove quick connector ca p (engine side).

KBIA0701E

EM-32

Page 85

FUEL INJECTOR AND FUEL TUBE

[QR]

b. With the sleeve side of quick connector release facing quick connector, install quick connector release

onto fuel tube.

c. Insert quick connector release into quick connector until sleeve

contacts and goes no furt her. Hold quick connect or release on that positio n.

CAUTION:

Inserting quick co nnector release hard will not d isconnect quick connector. Hold quick connector release where it contacts and goes no further.

d. Draw and pul l out quick conn ector straight from fuel tube.

CAUTION:

● Pull quick connector holding “A” position in the figure.

● Do not pull with lateral force applied. O -ring inside quick

KBIA0702E

connector may be damaged.

● Prepare container and cloth beforehand as fuel will leak out.

● Avoid fire and sparks.

● Keep parts away from heat source. Especially, be careful when welding is performed around

them.

● Do not expose parts to battery electrolyte or other acids.

● Do not bend or twist connection between qui ck connector and fuel feed hose during installa-

tion/removal.

● To keep clean the con necting portion and to avoid dam-

age and foreign materials, cover them completely with plastic bags or something similar.

4. Remove PCV hose. Refer to EM-17, "

Removal and Installation (QR20DE)" .

5. Disconnect harness conne ctor from ignition coil.

6. Remove sub-harness for fuel injector.

7. Remove electric throttle control actuator and intake manifold support. Refer to EM-17, "

Installation (QR20DE)" .

8. Loosen mounting bolts in reverse order as shown in the figure.

9. Remove fuel tube protector.

PBIC2205E

Removal and

PBIC2180E

10. Pull out fuel tube and fuel injector asse mb ly rearwa rd of engine.

CAUTION:

● When removing, be careful to avoid any interference with fuel injector.

● Use a shop cloth to absorb any fuel leaks from fuel tube.

EM-33

Page 86

FUEL INJECTOR AND FUEL TUBE

11. Remove fu el i nj ec t or f r om fu el tu be wi th t he f oll ow i ng pr o ce du re: a. Open and remove clip. b. Remove fuel injector from fuel tube by pulling straight.

CAUTION:

● Be careful with remaining fuel that may go out from fue l

tube.

● Be careful not to damage fuel injector nozzle during

removal.

● Do not bump or drop fuel injector.

● Do not disassemble fuel injector.

[QR]

INSTALLATION

1. Note the following, and install O-rings to fuel injector.

CAUTION:

● Upper and lower O-rings are different. Be careful not to confuse them.

Fuel tube side : Black Nozzle side : Green

● Handle O-ring with bare hands. Do not wear gloves.

● Lubricate O-ring with new engine oil.

● Do not clean O-ring with solvent.

● Make sure that O-ring and its matin g part are free of forei gn material.

● When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to

twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube.

● Insert O-ring straight into fuel tube. Do not decenter or twist it.

SBIA0364E

EM-34

Page 87

FUEL INJECTOR AND FUEL TUBE

2. Install fuel injector to fuel tube with the following procedure:

a. Insert clip into clip mounting groove on fuel injector.

● Insert clip so that lug “A” of fu el inject or matches no tch “A” of

clip.

CAUTION:

● Do not reuse clip. Replace it with a new one.

● Be careful to keep clip from interfering with O-ring . If

interference occurs, replace O-ring.

b. Insert fuel injector into fuel tube with clip attached.

● Insert it while matching it to the axial center.

● Insert fuel injector so that lug “B” of fuel tube matches notch

“B” of clip.

● Make sure that fuel tube flange is securely fixed in flange fix-

ing groove on clip.

c. Make sure that installation is complete by checking that fuel

injector does not rotate or come off.

[QR]

SBIA0439E

3. From the eng ine rea r side , set fu el tub e and fuel in je ctor a ssemb ly at its po siti on for in stallat ion on in take manifold.

CAUTION:

For installation, be careful not to interfere with fuel injector nozzle.

4. Set fuel tube protecto r onto fuel tube .

5. Tighten mounting bolts with the following procedure.

● Tighten bolts evenly in two steps in nume ric al order as shown

in the figure.

1st step

: 10.1 N·m (1.0 kg-m, 7 ft-lb)

2nd step

: 23.6 N·m (2.4 kg-m, 17 ft-lb)

PBIC2180E

6. Connect sub-harness for fuel injector.

7. Note the followi ng , and con ne ct quic k co nn ec tors at engine side and vehicle side to install fuel fee d ho se .

NOTE:

There is qui ck c on ne c tor fo r th e engine side an d for the vehicle side, and the y ha ve different shapes . But connection is sam e pr oc e du re. The following procedure sh ow s the en gi ne side .

a. Check the connec tio n for fore ig n ma terial and damage. b. Align center to insert quick connector straightly into fuel tube.

● Insert fuel tube into quick co nn ec to r unt il th e top spool on fuel

tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end.

CAUTION:

● Hold “A” position in the figure when inserting fuel tube

into quick connector.

● Carefully align center to avoid inclined insertion to pre-

vent damage to O-ring inside quick connector.

KBIA0272E

EM-35

Page 88

FUEL INJECTOR AND FUEL TUBE

[QR]

● Insert until you hear a “click” sound and actually feel the engagement.

● To avoid misidentificati on of engagement with a simi lar sound, be sure to perform th e next

step.

c. Bef ore cl am pi ng fu el feed hose with hose clamps, pull qu ic k c on ne c tor h ard by h an d h ol din g “A” position.

Make sure it is completely en gaged (connected) so that it does not come out f rom fuel tube.

d. Install quick connector cap to quick connector connection. (On

both the engine side and the vehicle side)

● Install so that the arrow mark on the side faces up.

CAUTION:

● Make sure that quick connector and fuel tube are

securely fit into quick connector cap installation groove.

● If quick connector cap cannot be installed smoothly,

quick connector may have not been installed correctly. Check connection again.

NOTE:

There is quick connector cap for the engine side and for the vehicle side, and they have different shapes. The figure shows engine side as an example.

8. Install fuel feed hose to hose cla mp .

9. Install in the reverse order of removal after this step.

INSPECTION AFTER INSTALLATION Check on Fuel Leaks

1. Apply fuel pressure to fuel lines with turning ignitio n switch “ON” (w ith engine stop ped). Then m ake sure there are no fuel leaks at connections.

NOTE:

Use mirrors for checking on invisible points.

2. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.

CAUTION:

Do not touch engine immediately after stopped as engine becomes extremely hot.

PBIC2348E

EM-36

Page 89

FUEL INJECTOR AND FUEL TUBE

[QR]

Removal and Installation (QR25DE) EBS011SY

PBIC2179E

1. Fuel feed hose 2. Quick connector cap (engine side) 3. Quick connector cap (vehicle side)

4. Centralized under-floor piping 5. Sub-harness 6. Fuel tube

7. O-ring (black) 8. Clip 9. Fuel injector

10. O-ring (green) 11. Insulator

CAUTION:

Do not remove or disassemble parts unless instructed as shown in the figure.

REMOVAL

1. Release fu el pres sure. Re fer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,

"FUEL PRESSURE CHECK" (WITHOUT EURO-OBD).

2. Remove air cleaner case upper, mass air flow sensor and air duct assembly. Refer to EM-15, "

CLEANER AND AIR DUCT" .

3. Disconnect quick connectors at engine side and vehicle side as follows, and remove fuel feed hose.

CAUTION:

Disconnect quick connector by using quick connector release (special service tool), not by picking out retainer tabs.

NOTE:

There is quick connector for the engine side and for the vehicle side, and they have different shapes. But disconnection is same procedure. The following procedure shows the engine side.

a. Remove quick connector cap (engine side).

AIR

PBIC2175E

KBIA0701E

EM-37

Page 90

FUEL INJECTOR AND FUEL TUBE

[QR]

b. With the sleeve side of qu ick connector release facing quic k connector, install quick connector release

onto fuel tube.

c. Insert quick connector release into quick connector until sleeve

contacts and goes no furthe r. Hold quick connecto r release on that position.

CAUTION:

Inserting quick connec tor release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.

d. Draw and pull out quick connector straight from fuel tube.

CAUTION:

● Pull quick connector holding “A” position in the figure .

● Do not pull with lateral force applie d. O-ring inside q uick

connector may be damaged.

● Prepare container and cloth beforehand as fuel will leak out.

● Avoid fire and sparks.

● Keep parts away from heat source. Especially, be careful when weldi ng is performed around

them.

● Do not expose parts to battery electrolyte or other acids.

● Do not bend or twist connection between qu ick connector and fuel feed hose during installa-

tion/removal.

● To keep clean the co nnecting portion and to a void dam-

age and foreign materials, cover them completely with plastic bags or something similar.

KBIA0702E

4. Remove i ntake manif old collecto r. Refer to EM-20, "

Removal and Installatio n (QR25DE)" .

5. Disconnect sub-harness for fuel injector.

6. Loosen mounting bolts in reverse order as shown in the figure.

7. Remove fuel tube and fuel injector assembly and insulators.

CAUTION:

● When removing, be carefu l to av oid any inte rf ere nce w ith

fuel injector.

● Use a shop cloth to absorb any fuel leaks from fuel tube.

PBIC2205E

KBIA0239E

EM-38

Page 91

FUEL INJECTOR AND FUEL TUBE

8. Remove fuel injector from fuel tube with the following procedure:

a. Open and remove clip. b. Remove fuel injector from fuel tube by pulling straight.

CAUTION:

● Be careful with remaining fuel that may go out from fuel

tube.

● Be careful not to damage fuel injector nozzle during

removal.

● Do not bump or drop fuel injector.

● Do not disassemble fuel injector.

[QR]

INSTALLATION

1. Note the following, and install O-rings to fuel injector.

CAUTION:

● Upper and lower O-rings are different. Be careful not to confuse them.

Fuel tube side : Black Nozzle side : Green

● Handle O-ring with bare hands. Do not wear gloves.

● Lubricate O-ring with new engine oil.

● Do not clea n O-ring with solve nt.

● Make sure t hat O-ring and its mating part are free of foreign mat erial.

● When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to

twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube.

● Insert O-ring straight into fuel tube. Do not decenter or twist it.

SBIA0364E

EM-39

Page 92

FUEL INJECTOR AND FUEL TUBE

2. Install fuel injector to fuel tube with the following procedure: a. Insert clip into clip mounting groove on fuel injector .

● Insert clip so that lug “A” of fuel injec tor matches no tch “A” of

clip.

CAUTION:

● Do not reuse clip. Replace it with a new one .

● Be careful to keep clip from interfering with O -ring. If

interfer ence occurs, r eplace O-r ing.

b. Insert fuel injector into fuel tube with clip attached.

● Insert it while matching it to the axi al ce nt er.

● Insert fuel injector so tha t lug “B” of fuel tube matches notch

“B” of clip.

● Make sure that fuel tube fla nge is securel y fixed in fla nge fix-

ing groove on clip.

c. Make sure that installation is complete by checking that fuel

injector does not rotate or come off.

[QR]

SBIA0439E

3. Install fuel tube and fuel injector assembly with the following procedure: a. Insert the tip of each fuel injector into intake manifold. b. Tighten mounting bolt s evenly in two steps in numerical order as

shown in the figure.

1st step

: 10.1 N·m (1.0 kg-m, 7 ft-lb)

2nd step

: 23.6 N·m (2.4 kg-m, 17 ft-lb)

KBIA0239E

4. Connec t sub-harness for fuel injector.

5. Install intake manifold collector. Refer to EM-20, "

Removal and Installation (QR25DE)" .

6. Note the following, and connect quick co nnectors at engine side and vehicle side to install fuel feed hose.

NOTE:

There is quick connector for the e ng in e side and for the v eh ic le s ide , an d they have differen t shapes. But

connection is same procedure. The following procedure shows the engine side. a. Check the connection for foreign material and damage. b. Align center to insert quick connector straightly into fuel tube.

NOTE:

The figure shows engine side as an example.

● Insert fuel tube into quick c on ne cto r un til the top spool on fuel

tube is inse rte d com pl ete ly an d the se co nd leve l sp oo l is po si tioned sligh tly below quick co nnector bottom end.

CAUTION:

● Hold “A” position in the figure when inserting fuel tube

into quick connector.

● Carefully align center to avoid inclined insertion to pre-

vent damage to O-ring inside quick connector.

● Insert until you hear a “click” sound and actually feel the engagement.

KBIA0272E

EM-40

Page 93

FUEL INJECTOR AND FUEL TUBE

[QR]

● To avoid misidentific ation of engagement with a simil ar sound, be sure to perform the next

step.

c. Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding “A” position.

Make sure it is completely engaged (connected) so that it does not come out from fuel feed tube.

d. Install quick connector cap to quick connector connection. (On

both the engine side and the vehicle side)

● Install so that the arrow mark on the side faces up.

CAUTION:

● Make sure that quick connector and fuel tube are

securely fit into quick connector cap installation groove.

● If quick connector cap cannot be installed smoothly,

quick connector may have not been installed correctly. Check connection again.

NOTE:

There is quick connector cap for the engine side and for the vehicle side, and they have different shapes. The figure shows engine side as an example.

7. Install fuel feed hose to hose clamp.

8. Install in the reverse order of removal after this step.

INSPECTION AFTER INSTALLATION Check on Fuel Leaks

1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then make sure there are no fuel leaks at connections.

NOTE:

Use mirrors for checking on invisible points.

2. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.

CAUTION:

Do not touch engine immediately after stopped as engine becomes extremely hot.

PBIC2348E

EM-41

Page 94

ROCKER COVER

[QR]

ROCKER COVER PFP:13264 Removal and Installation EBS00KNI

1. PCV hose 2. O-ring 3. PCV valve

4. Oil filler cap 5. Rocker cover 6. Rocker cover gasket

REMOVAL

1. Discon nect PCV hose from rocker cover.

2. Remove ignition coil. Refer to EM-29, "

3. Loosen bolts in reverse order shown in the figure.

IGNITION COIL" .

PBIC2349E

KBIA0242E

EM-42

Page 95

ROCKER COVER

INSTALLATION

1. Apply liquid gasket of 3.0 mm (0.12 in) diameter to the position shown in the figure with the following procedure:

a. Refer to figure “a” to apply liquid gasket to joint part of camshaft

bracket (No. 1) and cylinder head.

b. Refer to figure “b” to apply liquid gasket in 90 degrees to figure

“a”.

Use Genuine Liquid Gasket or equivalent.

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2. Install rocker cover.

● Check if r ocker cover gasket is not dropped from the installation groove of rocker cover.

3. Tighten bolts in two steps separately in numerical order as shown in the figure.

1st step

: 2.0 N·m (0.2 kg-m, 18 in-lb)

2nd step

: 8.3 N·m (0.85 kg-m, 73 in-lb)

4. Install in the reverse order of removal after this step.

PBIC2350E

KBIA0242E

EM-43

Page 96

TIMING CHAIN

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TIMING CHAIN PFP:13028 Removal and Installation EBS00KNL

1. O-ring 2. Camshaft sprocket (INT) 3. C am shaft sprocket (EXH)

4. Chain tensioner 5. Spring 6. Chain tensioner plunger

7. Timing chain slack guide 8. Timing chain 9. Front cover

10. Chain guide 11.

13. RH engine mounting bracket 14. Crankshaft pulley bolt 15. Crankshaft pulley

16. Front oil seal 17. Balancer unit timing chain tensioner 18. Oil pump drive spacer

19. Crankshaft sprocket 20. Timing chain tension guide 21. Bal ancer unit timing chain

22. Balancer unit 23. Oil ring

Intake valve timing control solenoid valve

12. Intake valve timing control cover

REMOVAL

1. Remove the following parts.

EM-44

PBIC2181E

Page 97

TIMING CHAIN

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● Hood assembly; Refer to BL-12, "HOOD" .

● RH and LH undercovers

● PCV hose; Refer to EM-17, "INTAKE MANIFOLD" .

● Ignition coil; Refer to EM-29, "IGNITION COIL" .

● Rocker cover; Refer to EM-42, "ROCKER COVER" .

● Engine coolant reservoir tank; Refer to CO-12, "RADIATOR" .

● Drive belt; Refer to EM-13, "REMOVAL" .

● Alternator; Refer to SC-12, "CHARGING SYSTEM" .

● Drive belt auto-tensioner; R efe r to EM-14, "REMOVAL" .

● Exhaust front tube; Refer to EX-2, "EXHAUST SYSTEM" .

2. Remove A/C compressor from engine. Temporarily secure A/C compressor to vehicle side with a rope to avoid putting a load on them.

3. Remove brac ket mounting bolts for fix ing A/C piping on right s trut housing and exha ust manifold cover. Doing so simplifies moving.

4. Remove power st ee rin g o il pump wi th pi p in g conn ec te d, an d sec ur e i t to veh ic le side te mpo rar il y. Refer to

PS-34, "

5. Remove power steering reservoir tank from bracket to move power steering piping. Refer to PS-34,

"HYDRAULIC LINE" .

CAUTION:

To avoid power steering fluid leakage, temporarily fix power steering reservoir tank vertically.

6. Install engine slingers into front left of cylinder head and rear right of cylinder head.

● Use alter nator bracket mounting bolt holes for the front side.

HYDRAULIC LINE" .

Slinger bolts:

Front

: 57.9 N·m (5.9 kg-m, 43 ft-lb)

Rear

: 28.0 N·m (2.9 kg-m, 21 ft-lb)

7. Lift with hoist, and support the engine posture.

8. Remove RH engine mounting insulator and bracket. Refer to EM-78, "

ENGINE ASSEMBLY" .

9. Remove center member and rear engine mounting bracket. Refer to EM-78, "

10. Drain engine oil. Re fer to LU-8, "

11. Remove oil pan (upper and lower), and oil strainer. Refer to EM-25, "

Changing Engine Oil" .

OIL PA N AND OIL STRAINER" .

12. Remove intake valve timing control cover.

● Loosen bolts in reverse order as shown in the figure .

● Use a seal cutter (special service tool: KV10111100) or equiv-

alent tool to cut liquid gasket for removal.

CAUTION:

Be careful not to damage mounting surface.

SBIA0271E

ENGINE ASSEMBLY" .

13. Pull chain guide between camshaft sprockets out through front cover.

14. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:

EM-45

KBIA0085E

Page 98

TIMING CHAIN

a. Rotate crankshaft pulley clockwise and align TDC mark to timing

indicator on front cover.

b. At the same time, make sure that the mating marks on camshaft

sprockets are located as shown in the figur e.

● If not, rotate crankshaft pulley one more turn to align mating

marks to the positions in the figure.

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KBIA0190E

15. Remove crankshaft pulley with the following procedure: a. Fix crankshaft pulley with a pulley holder (commercial service

tool), loosen crankshaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position.

b. Attac h a pu lley pull er (s peci al se rvice t ool ) in th e M 6 t hre ad hole

on crankshaft pulley, and remove crankshaft pulley.

PBIC2351E

PBIC2434E

16. Remove front cover with the following procedur e:

EM-46

PBIC2413E

Page 99

TIMING CHAIN

a. Loosen mounting bolts in reverse order as shown in the figure,

and remove them.

b . U s e a s e a l cutt er (sp e cial s ervice tool: KV1 01111 0 0 ) o r e q u i v a-

lent tool to cut liquid gasket for removal.

CAUTION:

Be careful not to damage mounting surface.

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17. If front oil seal needs to be replaced, lift it with a suitable tool, and remove it.

CAUTION:

Be careful not to damage front cover.

18. Remove timing chain and camshaft sprockets with the f ollowing proc edure:

a. Push in ch ai n te ns ione r p lu ng er. Insert a stopper pin in t o ho le on

chain tensioner body to secure chain tensioner plunger and remove chai n ten si oner.

NOTE:

Use approx. 0. 5 mm (0.02 in) dia. ha rd metal pin as a stopper pin.

b. Secure hexag on al part of camshaft wi th a w re nc h. Lo os en c am -

shaft sprocket mounting bolts and remove timing chain and camshaft sprockets.

CAUTION:

Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston.

KBIA0083E

KBIA0048E

19. Remove timing chain slack guide, timing chain tension guide and oil pump drive spacer.

20. Remove balancer unit timing chain tensioner with the following procedure:

EM-47

KBIA0049E

Page 100

TIMING CHAIN

a. Lift lever up, and release ratchet claw for return proof. b. Push tensioner sleeve in, and hold it. c. Matching the hole on l ever with the one on bo dy, insert a stopper

pin to secure tensioner sl eeve.

NOTE:

Use approximately 1 mm (0.04 in) dia. hard metal pin as a stopper pin.

d. Remove balancer unit timing chain tensioner.

21. Remove balancer unit timing chain and crankshaft sprocket.

22. Loosen mounting bolts in reverse order as shown in the figure, and remove balancer uni t.

CAUTION:

Do not disassemble balancer unit. NOTE:

Use TORX socket (size E14).

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KBIA0121E

INSPECTION AFTER REMOVAL Timin g Chai n

Check timing chain for cracks and any excessive wear at the roller links of timing chain. Replace timing chain if necessary.

Balancer Unit Mounting Bolt Outer Diameter

● Measure the outer diameters (“d1” , “d2” ) at two positions as

shown in the figure.

● If reductio n ap pe ars in “A” ran ge , rega rd it as “d2 ”.

Limit (“d1 ” - “d2 ”) : 0.15 mm (0.0059 in)

● If it exceeds the limit (large difference in dimensions), replace it

with a new one.

KBIA0122E

PBIC0282E

PBIC1137E

EM-48