Nissan 240SX (S12/S13/S14) Workshop Service Repair Manuals 1986-1998

Catalog:

Car

Make:

Nissan

Model:

240SX

Sample:

Nissan 240SX (S12 S13 S14) Workshop Service Repair Manuals 1986-1998 (p14439-p14440).pdf

Complete workshop repair service manual ith electrical wiring diagrams for Nissan 240SX (S12-S13-S14) 1986-1998. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

Nissan 240SX (S12-S13-S14) 1986-1998 service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

995 MB, 10,000+ pages, bookmarked, Searchable, Printable, high quality PDF

EXCERPT:
2.4L 4-CYL VINS [A,B,D,S] 1997-98 ENGINES Nissan 2.4L 4-Cylinder
CYLINDER HEAD
CAUTION: If cylinder head is installed and timing chain is disconnected, DO NOT rotate camshaft or crankshaft; valves will contact pistons, resulting in bent valves.
Removal (240SX, Altima & Frontier)
1. Remove outer (upper) timing chain. See TIMING CHAINS. Remove idler sprocket and shaft. Prevent camshafts from turning, and remove camshaft sprocket bolts. Remove camshaft sprocket. Mark and remove camshaft bearing caps in reverse order of installation. See Fig. 30. Remove camshafts.
2. Loosen cylinder head bolts in 2 or 3 steps, in reverse order of tightening sequence. See Fig. 31. Remove camshaft sprocket cover. Remove outer (upper) chain tensioner and guide. Remove outer timing chain. Remove idler sprocket bolt. Remove cylinder head.
…
2.0L 4-CYL VIN [B] 1997-98 ENGINES Nissan 2.0L 4-Cylinder
Installation
1. Coat components with engine oil. Install all components in original locations in reverse order of removal.
CAUTION: Air cannot be bled from lash adjuster by engine operation.
2. With lash adjuster and rocker arm components installed, push rocker arm downward at lash adjuster. Note amount of rocker arm movement. If rocker moves .04" (1.0 mm) or more, lash adjuster must be manually bled. See VALVE TRAIN under OVERHAUL. If rocker arm moves less than .04" (1.0 mm), install remaining components.
CAMSHAFT
Removal
Camshaft removal procedure assumes cylinder head is removed. See CYLINDER HEAD. Inspection
1. Inspect components for damage. Measure camshaft lobe height, journal diameter, bore diameter and oil clearance. Replace camshaft or cylinder head if measurements are not within specification. See CAMSHAFT under ENGINE SPECIFICATIONS.
2. Install camshaft in cylinder head. Ensure end play is within specification. Replace camshaft/cylinder head if end play is not within specification. See CAMSHAFT.
3. Install camshaft sprockets. Using dial indicator, check camshaft sprocket runout near timing chain area on face of camshaft sprocket. Replace camshaft sprocket if runout exceeds .010" (.25 mm).
Installation
Coat camshaft with engine oil before installing. Install camshaft using installation procedure listed in CYLINDER HEAD.
REAR CRANKSHAFT OIL SEAL
Removal

Remove transaxle, clutch assembly (if equipped) and flywheel/drive plate. Pry rear crankshaft oil seal from oil seal retainer. Use care not to scratch oil seal retainer or crankshaft sealing surfaces. Note direction of oil seal installation.
Installation

'91......2
1991 Nissan 240SX Service Manual......2
SM1E-0S13U0......2
QUICK REFERENCE INDEX......2
'92-'94 Convertible Supplement......1110
1992 Nissan 240SX Convertible - Amended......1110
SM2E-0S13C1......1110
FOREWORD......1110
CONTENTS......1111
200SX (Model S12 Series) '86......1173
INDEX......1174
GI - General Information......1175
MA - Maintenance......1194
EM - Engine Mechanical......1232
LC - Engine Lubrication & Cooling......1276
EF&EC - Fuel & Emission Control......1288
FE - Engine Control, Fuel & Exaust......1387
CL - Clutch......1393
MT - Manual Transmission......1403
AT - Automatic Transmission......1427
PD - Propeller Shaft & Differential......1508
FA - Front Axle & Suspension......1575
RA - Rear Axle & Suspension......1594
BR - Brake System......1613
ST - Steering System......1634
BF - Body......1667
HA - Heater & Air Conditioner......1715
EL - Electrical System......1748
Inch/Metric Converion Tables......1955
Quick Reference Chart......1956
200SX (Model S13 Series) '89-'94......1957
200SX (S13)......2851
GI - General Information......2852
AT - Automatic Transmission......2866
BF - Body......2952
BR - Brakes......2977
CL - Clutch......3009
EF & EC - Engine Fuel & Emission Control System......3015
EL - Electrical System......3086
EM - Engine Mechanical......3155
FA - Front Axle & Front Suspension......3179
FE - Engine Control, Fuel & Exhaust Systems......3189
HA - Heater, Air Conditioning, and Climate Control......3193
LC - Engine Lubrication & Cooling Systems......3251
MA - Maintenance......3261
MT - Manual Transmission......3282
PD - Propeller Shaft & Differential......3297
RA - Rear Axle & Rear Suspension......3315
ST - Steering System......3333
240SX '89......3352
1989 CA18DET Electrical Manual......3353
cover......3353
1......3354
C1......3365
W1......3366
W2......3368
W3......3369
W4......3370
manual notes......3374
Body Repair Manual......3375
SM9E-0S13U0......3464
Nissan 240SX 1989 Service Manual......0
Foreword......3465
Quick Reference Index......3464
GI - General Information......3466
Contents......3466
Precautions......3467
How to use this manual......3470
How to read wiring diagrams......3472
Wiring diagram......3472
Switch positions......3472
Connector symbols......3473
Multiple switch......3473
Super multiple junction......3474
How to follow flow chart in trouble diagnoses......3475
How to follow this flow chart......3476
Direction mark......3476
Key to symbols signifying measurements or procedures......3477
Identification information......3478
Model variation......3478
Identification number......3479
Serial number......3480
Dimensions......3481
Wheels and tires......3481
Lifting points and tow truck towing......3482
Garage jack and safety stand......3482
2-pole lift......3483
Tow truck towing......3483
Towing point......3484
Tightening torque of standard bolts......3485
MA - Maintenance......3486
Contents......3486
Periodic maintenance......3487
Emission control system maintenance......3487
Chassis and body maintenance......3487
Maintenance under severe driving conditions......3488
General maintenance......3489
Recommended lubricants and fluids......3491
Lubricants and fluids......3491
SAE viscosity number......3492
Engine maintenance......3493
Checking drive belts......3493
Changing engine coolant......3493
Checking fuel lines......3494
Changing fuel filter......3495
Changing air cleaner filter......3495
Changing engine oil......3496
Changing oil filter......3496
Changing spark plugs......3497
Checking ignition wires......3497
Checking vapor lines......3498
Chassis and body maintenance......3499
Checking exhaust system......3499
Checking clutch fluid level and leaks......3499
Checking M/T oil......3499
Changing M/T oil......3499
Checking A/T fluid......3500
Changing A/T fluid......3500
Checking differential gear oil......3501
Changing differential gear oil......3501
Checking brake fluid level and leaks......3501
Checking brake lines and cables......3501
Checking disc brake......3502
Rotor......3502
Caliper......3502
Pad......3502
Balancing wheels......3502
Tire rotation......3503
Checking steering gear and linkage......3503
Checking power steering fluid and lines......3503
Lubricating locks, hinges and hood latches......3504
Checking seat belts, buckles, retractors, anchors and adjusters......3504
Service data and specifications......3505
Engine maintenance......3505
Chassis and body maintenance......3506
EM - Engine Mechanical......3508
Contents......3508
Precaution......3509
Liquid gasket application procedure......3509
Preparation......3510
Special service tools......3510
Commercial service tools......3512
Outer component parts......3513
Compression pressure......3514
Measurement of compression pressure......3514
Oil pan......3515
Removal......3515
Installation......3516
Timing chain......3517
Removal......3518
Inspection......3519
Installation......3520
Oil seal replacement......3523
Valve oil seal......3523
Front oil seal......3523
Rear oil seal......3524
Cylinder head......3525
Removal......3526
Disassembly......3528
Inspection......3529
Assembly......3534
Installation......3536
Engine removal......3539
Cylinder block......3541
Disassembly......3542
Inspection......3542
Assembly......3549
Service data and specifications......3553
General specifications......3553
Inspection and adjustment......3554
LC - Engine Lubrication & Cooling Systems......3562
Contents......3562
Preparation......3563
Engine lubrication system......3564
Lubrication circuit......3564
Oil pressure check......3565
Oil pump......3566
Engine cooling system......3568
Cooling circuit......3568
System check......3568
Water pump......3569
Inspection......3569
Installation......3569
Thermostat......3570
Inspection......3570
Installation......3571
Radiator......3572
Cooling fan......3572
Disassembly and assembly......3572
Inspection......3572
Condenser fan motor electrical circuit......3573
Schematic......3573
Wiring diagram......3574
Trouble diagnoses......3575
Service data and specifications......3577
Engine lubrication system......3577
Engine cooling system......3577
EF & EC - Engine Fuel & Emission Control System......3578
Contents......3578
Preparation......3579
Precautions......3580
Engine and emission control overall system......3581
E.C.C.S. component parts location......3581
System diagram......3582
System chart......3583
Vacuum hose drawing......3584
Circuit diagram......3585
Engine and emission control parts description......3586
E.C.C.S. control unit (E.C.U.)......3586
Crank angle sensor......3586
Air flow meter......3586
Engine temperature sensor......3587
Throttle sensor & soft/hard idle switch......3587
Fuel injector......3587
Pressure regulator......3588
Exhaust gas sensor......3588
Fuel pump......3588
Power transistor......3588
Air regulator......3589
Idle air adjusting (I.A.A.) unit......3589
Auxiliary air control (A.A.C.) valve......3589
Power steering oil pressure switch......3589
Vehicle speed sensor......3589
E.G.R. control valve......3590
B.P.T. valve......3590
Air induction valve (A.I.V.)......3590
A.I.V. control solenoid valve......3591
E.G.R. control solenoid valve......3591
Pressure regulator control solenoid valve......3591
S.C.V. control solenoid valve......3591
Fuel filter......3591
Carbon canister......3591
Check connector for E.C.C.S. checker box......3592
Exhaust gas temperature sensor (for california model)......3592
Engine and emission control system description......3593
Fuel injection control......3593
Ignition timing control......3595
Idle speed control......3597
Fuel pump control......3598
Air regulator control......3598
Air induction valve (A.I.V.) control......3599
E.G.R. control......3600
Fuel pressure regulator control......3601
Swirl control valve (S.C.V.) control......3601
Acceleration cut control......3602
Fail safe system......3602
Idle speed/Ignition timing/Idle mixture ratio inspection......3603
Trouble diagnoses......3608
Contents......3608
Fuel injection control system inspection......3730
Releasing fuel pressure......3730
Fuel pressure check......3730
Injector removal and installation......3731
Evaporative emission control system......3732
Description......3732
Inspection......3732
Crankcase emission control system......3734
Description......3734
Inspection......3734
Service data and specifications......3735
General specifications......3735
Inspection and adjustment......3735
FE - Engine Control, Fuel & Exhaust Systems......3736
Contents......3736
Engine control system......3737
Accelerator control system......3737
Fuel system......3738
Exhaust system......3739
CL - Clutch......3740
Contents......3740
Precautions and preparation......3741
Special service tools......3741
Commercial service tools......3742
Clutch system......3743
Inspection and adjustment......3744
Adjusting clutch pedal......3744
Bleeding procedure......3745
Hydraulic clutch control......3746
Clutch master cylinder......3746
Disassembly and assembly......3746
Inspection......3747
Operating cylinder......3747
Inspection......3747
Clutch damper......3748
Inspection......3748
Clutch release mechanism......3749
Removal and installation......3749
Inspection......3750
Lubrication......3750
Clutch disc and clutch cover......3751
Clutch disc......3751
Inspection......3751
Installation......3751
Clutch cover and flywheel......3752
Inspection and adjustment......3752
Flywheel inspection......3752
Installation......3752
Service data and specifications......3753
General specifications......3753
Inspection and adjustment......3753
MT - Manual Transmission......3754
Contents......3754
Preparation......3755
Special service tools......3755
Commerical service tool......3756
On-vehicle service......3757
Replacing rear oil seal......3757
Removal......3757
Installation......3757
Check of position switch......3757
Removal and installation......3758
Removal......3758
Installation......3758
Major overhaul......3759
Case components......3759
Gear components......3760
Shift control components......3761
Disassembly......3762
Case components......3762
Shift control components......3763
Gear components......3764
Inspection......3767
Shift control components......3767
Gear components......3767
Gear and shaft......3767
Synchronizers......3767
Bearings......3768
Assembly......3769
Gear components......3769
Shift control components......3775
Case components......3776
Service data and specifications......3779
General specifications......3779
Inspection and adjustment......3780
AT - Automatic transmission......3781
Contents......3781
Preparation......3782
Precautions......3783
A/T control diagram......3784
Hydraulic control circuits......3784
Electrical control chart......3785
Mechanical operation......3785
Cross-sectional view......3786
On-vehicle service......3787
Control valve assembly and accumulators inspection......3787
Revolution sensor replacement......3788
Rear oil seal replacement......3788
Parking components inspection......3788
Inhibitor switch adjustment......3789
Manual control linkage adjustment......3789
Note......3790
Trouble diagnoses......3791
Contents......3791
Removal and installation......3865
Removal......3865
Installation......3865
Major overhaul......3866
Major overhaul......3866
Major overhaul......3867
Oil channel......3868
Locations of needle bearings, thrust washers and snap rings......3869
Disassembly......3870
Disassembly......3870
Repair for component parts......3881
Oil pump......3881
Disassembly......3881
Inspection......3882
Assembly......3883
Control valve assembly......3886
Disassembly......3887
Inspection......3888
Assembly......3890
Control valve upper body......3892
Disassembly......3893
Inspection......3895
Assembly......3896
Control valve lower body......3898
Disassembly......3899
Inspection......3899
Assembly......3899
Reverse clutch......3900
Disassembly......3900
Inspection......3901
Assembly......3902
High clutch......3904
Forward and overrun clutches......3906
Low & reverse brake......3910
Disassembly......3910
Inspection......3911
Assembly......3912
Forward clutch drum assembly......3914
Disassembly......3914
Inspection......3915
Assembly......3915
Rear internal gear and forward clutch hub......3917
Disassembly......3917
Inspection......3918
Assembly......3919
Band servo piston assembly......3920
Disassembly......3920
Inspection......3921
Assembly......3922
Parking pawl components......3924
Disassembly......3924
Inspection......3925
Assembly......3925
Assembly......3926
Assembly......3926
Adjustment......3931
Assembly......3935
Service data and specifications......3945
General specifications......3945
Specifications and adjustment......3945
PD - Propeller Shaft & Differential Carrier......3949
Contents......3949
Preparation......3950
Propeller shaft......3953
3S63A-T......3953
3S63A-R......3953
On-vehicle service......3954
Removal......3954
Installation......3955
Inspection......3955
Disassembly......3955
Assembly......3956
On-vehicle service (Final drive)......3957
Front oil seal replacement......3957
Side oil seal replacement......3957
Removal and installation......3959
Removal......3959
Installation......3959
Front final drive......3960
Disassembly......3961
Pre-inspection......3961
Differential carrier......3961
Differential case......3964
Inspection......3965
Ring gear and drive pinion......3965
Differential case assembly......3965
Bearing......3965
Adjustment......3966
Side bearing preload......3966
Pinion gear height and pinion bearing preload......3967
Tooth contact......3972
Assembly......3973
Differential case......3973
Differential carrier......3974
Service data and specifications......3978
Propeller shaft......3978
Final drive......3979
FA - Front Axle & Front Suspension......3981
Contents......3981
Precautions and preparation......3982
Special service tools......3982
Commercial service tools......3983
Front axle and front suspension......3984
Check and adjustment - on-vehicle......3985
Front axle and front suspension parts......3985
Front wheel bearing......3986
Front wheel alignment......3986
Front axle......3989
Front axle - wheel hub and knuckle......3990
Removal......3990
Installation......3991
Disassembly......3991
Inspection......3991
Assembly......3992
Front axle - baffle plate......3993
Removal......3993
Installation......3993
Front suspension......3994
Front suspension - coil spring and strut assembly......3995
Removal......3995
Disassembly......3995
Inspection......3995
Assembly......3996
Front suspension - tension rod and stabilizer bar......3997
Removal and installation......3997
Front suspension - transverse link and lower ball joint......3998
Removal and installation......3998
Inspection......3998
Service data and specifications......3999
General specifications......3999
Inspection and adjustment......4000
RA - Rear Axle & Rear Suspension......4001
Contents......4001
Precautions and preparation......4002
Special service tools......4002
Commercial service tools......4003
Rear axle and rear suspension......4004
Check and adjustment - on-vehicle......4005
Rear axle and rear suspension parts......4005
Rear wheel bearing......4006
Rear wheel alignment......4006
Drive shaft......4007
Rear axle and rear suspension assembly......4008
Removal and installation......4008
Rear axle - wheel hub and axle housing......4009
Removal......4009
Installation......4010
Disassembly......4011
Inspection......4012
Assembly......4012
Rear axle - drive shaft......4013
Removal......4013
Installation......4013
Disassembly......4014
Inspection......4015
Assembly......4016
Rear suspension......4019
Rear suspension - coil spring and shock absorber......4020
Removal......4020
Disassembly......4020
Inspection......4020
Assembly......4021
Rear suspension - stabilizer bar......4022
Removal......4022
Inspection......4022
Installation......4022
Rear suspension - multi-link and lower ball joint......4023
Removal and installation......4023
Inspection......4023
Service data and specifications......4024
General specifications......4024
Inspection and adjustment......4025
BR - Brake System......4026
Contents......4026
Precautions and preparation......4027
Special service tools......4027
Check and adjustment......4028
Checking brake fluid level......4028
Checking brake system......4028
Changing brake fluid......4028
Brake hydraulic line......4029
Bleeding procedure......4029
Removal and installation......4030
Inspection......4030
Brake pedal and bracket......4031
Removal and installation......4031
Inspection......4031
Adjustment......4032
Brake booster......4033
Removal and installation......4033
Inspection......4033
Vacuum piping......4035
Removal and installation......4035
Inspection......4035
Master cylinder......4037
Removal and installation......4037
Front disc brake (CL22VB, CL25VA) - caliper......4038
CL22VB......4038
CL25VA......4038
Pad replacement......4039
Removal and installation......4039
Disassembly......4039
Inspection......4040
Assembly......4040
Inspection (On-vehicle)......4040
Disc pad......4041
Front disc brake (CL22VB, CL25VA) - rotor......4042
Inspection......4042
Rear disc brake (CL9H) - caliper......4043
Pad replacement......4043
Removal and installation......4044
Disassembly......4044
Inspection......4045
Assembly......4045
Inspection (On-vehicle)......4046
Rear disc brake (CL9H) - rotor......4047
Inspection......4047
Parking brake control......4048
Removal and installation......4048
Inspection......4048
Adjustment......4049
Anti-lock braking system......4050
System components......4050
Hydraulic circuit......4050
Wiring diagram......4051
Removal and installation......4052
Trouble diagnoses......4054
Contents......4054
Service data and specifications......4079
General specifications......4079
Inspection and adjustment......4080
ST - Steering System......4081
Contents......4081
Precautions......4082
Preparation......4083
Special service tools......4083
Commercial service tools......4084
On-vehicle inspection......4085
Checking steering wheel play......4085
Checking neutral position on steering wheel......4085
Front wheel turning angle......4085
On-vehicle inspection (power steering)......4087
Checking and adjusting drive belts......4087
Checking fluid level......4087
Checking fluid leakage......4087
Bleeding hydraulic system......4087
Checking steering wheel turning force......4088
Checking hydraulic system......4088
Steering wheel and steering column......4090
Removal......4090
Installation......4091
Disassembly and assembly......4092
Inspection......4093
Power steering gear and linkage (model PR24SC)......4094
Removal and installation......4094
Disassembly and assembly......4096
Disassembly......4098
Assembly......4099
Adjustment......4104
Inspection......4105
Power steering oil pump......4107
Disassembly and assembly......4107
Pre-disassembly inspection......4107
Disassembly......4108
Inspection......4108
Assembly......4109
Service data and specifications......4111
General specifications......4111
Inspection and adjustment......4111
BF - Body......4113
Contents......4113
General servicing......4114
Precautions......4114
Clip and fastener......4114
Body end......4118
Body front end......4118
Body rear end and opener......4120
Door......4124
Power window......4126
Wiring diagram......4126
Power window amp. inspection......4127
Circuit breaker inspection......4127
Power door lock......4128
Wiring diagram......4128
Door lock timer inspection......4129
Instrument panel......4130
Interior and exterior......4132
Interior......4132
Exterior......4136
Note......4141
Seat......4142
Front seat......4142
Rear seat......4143
Automatic seat belt system......4144
Unit location......4144
Wiring diagram......4146
Description......4148
Note......4150
Trouble diagnoses......4151
Contents......4151
Sun roof......4178
Electrical sun roof......4178
Wiring diagram......4180
Manual sun roof......4181
Windshield and windows......4182
Windshield......4182
Back window - coupe......4184
Back window - fastback......4185
Side window......4186
Mirror......4189
Door mirror......4189
Wiring diagram......4189
Rear combination lamp......4190
Front and rear air spoiler......4191
Body alignment......4192
Engine compartment......4192
Underbody......4194
HA - Heater & Air Conditioner......4197
Contents......4197
Air flow and component layout......4198
Air flow......4198
Component layout......4200
Door control......4201
Control cable adjustment......4201
Mode door......4201
Water cock control rod......4201
Temperature control cable......4201
Intake door......4202
Description - push control......4203
Push control system......4203
Switches and their control functions......4203
Intake door motor......4204
Mode door motor......4204
Push control unit......4205
Removal and installation......4205
Overhaul - push control unit assembly......4205
Heater electrical circuit......4208
Wiring diagram......4208
Precautions......4209
Precautions for refrigerant connection......4210
Preparation......4211
Special service tools......4211
Service tools......4212
Discharging, evacuating, charging and checking......4213
Discharging......4214
Evacuating the system......4214
Checking airtightness......4214
Repair......4214
Evacuating the system......4215
Charging......4215
Charging......4216
Checking refrigerant level......4218
Checking refrigerant leaks......4219
General precautions for handling leak detector......4219
Measurement standard......4219
Description of air conditioner......4220
Acceleration cut system......4220
Service procedures......4221
Refrigerant cycle......4221
Refrigerant lines......4222
Compressor mounting......4223
Thermo control Amp. replacement......4223
A/C performance test......4224
Performance chart......4224
Performance test diagnoses......4225
Compressor oil - for NVR 140S (ATSUGI make)......4229
Checking and adjusting......4229
Compressor - model NVR 140S (ATSUGI make)......4231
Precautions......4231
Compressor clutch......4233
Replacement......4233
Inspection......4233
Adjustment......4233
Break-in operation......4233
Thermal protector......4234
Note......4235
A/C electrical circuit......4236
Wiring diagram......4236
A/C component layout......4238
Note......4239
Trouble diagnoses......4240
Contents......4240
Service data and specifications......4269
General specifications......4269
Inspection and adjustment......4269
EL - Electrical System......4270
Contents......4270
Harness connector......4271
Description......4271
Standardized relay......4272
Description......4272
Power supply routing......4274
Wiring diagram......4274
Fuse......4275
Fusible link......4275
Battery......4276
How to handle battery......4276
Battery test and charging chart......4279
Service data and specifications......4283
Starting system......4284
Wiring diagram......4284
Trouble-shooting......4285
Starting system - starter......4286
Construction......4286
Magnetic switch check......4288
Pinion/clutch check......4288
Brush check......4288
Pole piece check......4289
Armature check......4289
Assembly......4290
Service data and specifications......4291
Charging system......4292
Wiring diagram......4292
Trouble-shooting......4293
Charging system - alternator......4294
Construction......4294
Disassembly......4295
Rotor slip ring check......4295
Brush check......4295
Stator check......4296
Diode check......4298
Assembly......4299
Service data and specifications......4301
Combination switch......4302
Check......4302
Replacement......4303
Headlamp......4304
Schematic......4304
Wiring diagram......4305
Description......4306
Constructions......4310
Assembly......4311
Installation and adjustment......4311
Headlamp motor check......4312
Installing headlamp rubber cap......4312
aiming adjustment......4313
Exterior lamp......4315
Fastback wiring diagram......4315
Coupe wiring diagram......4316
Back-up lamp/wiring diagram......4317
Front fog lamp/wiring diagram......4318
Turn signal and hazard warning lamps/wiring diagram......4319
Combination flasher unit check......4320
Interior lamp......4321
Illumination/wiring diagram......4321
Interior lamp/wiring diagram......4322
Meter and gauges......4323
Combination meter......4323
Needle type......4323
Digital type......4324
Combination meter/wiring diagram......4326
Speedometer, tachometer, temp. and fuel gauges/wiring diagram......4327
Inspection/fuel gauge and water temperature gauge......4328
Fuel tank gauge unit check......4329
Thermal transmitter check......4329
Oil pressure switch check......4329
Speed sensor signal check......4329
Warning lamps and chime......4330
Warning lamps/schematic......4330
Warning lamps/wiring diagram......4331
Warning chime/wiring diagram......4332
Diode check......4333
Warning chime check......4333
Time control system......4334
Schematic......4334
Wiring diagram......4335
Description......4336
Trouble-shooting......4337
Wiper and washer......4344
Front wiper and washer/wiring diagram......4344
Rear wiper and washer/wiring diagram......4345
Wiper removal and installation......4346
Wiper and washer adjustment......4347
Wiper amplifier check......4349
Horn, cigarette lighter and clock......4350
Wiring diagram......4350
Rear window defogger......4351
Filament check......4352
Filament repair......4353
Audio and antenna......4354
Audio/wiring diagram......4354
Location of antenna......4355
Radio fuse check......4355
Window antenna repair......4356
Automatic speed control device (A.S.C.D.)......4357
Schematic......4357
Wiring diagram......4358
A.S.C.D. wire adjustment......4359
Trouble diagnoses......4360
Location of electrical units......4366
Engine compartment......4366
Passenger compartment......4367
Harness layout......4368
Outline......4368
Main harness......4369
Fastback......4371
Coupe......4373
Instrument harness......4375
Note......4376
Engine room harness......4377
E.F.I. harness......4380
Engine room harness no. 2......4381
Back door harness......4382
Room lamp and sun roof harness......4383
Door harness......4384
Note......4385
Super multiple junction......4386
Disconnecting and connecting......4386
Terminal arrangement......4387
1989 Nissan 240SX E.C.C.S. Wiring Diagram......4388
1989 Nissan 240SX Circuit Diagram......4389
Conversion Table......4390
Quick Reference Chart......4391
Service Bulletin (TS89-072)......4392
Contents......4392
EM Supplement......4393
Compression pressure......4393
Service data and specifications......4394
EF & EC Supplement......4395
Engine and emission control overall system......4395
Engine and emission control parts description......4399
Engine and emission control system description......4400
Idle speed/Ignition timing/Idle mixture ratio inspection......4404
Trouble diagnoses......4406
Service data and specifications......4414
240SX '90......4415
'90 240SX (S13)......4416
2.4L 4-CYL - VINS [F,H,S]......4416
A - ENGINE_VIN ID......4444
A_C COMPRESSOR OIL CHECKING......4449
A_C COMPRESSOR SERVICING......4456
A_C SYSTEM GENERAL DIAGNOSTIC PROCEDURES......4478
A_C SYSTEM PRECAUTIONS......4483
A_C-HEATER SYSTEM - MANUAL......4486
A_C-HEATER SYSTEM TROUBLE SHOOTING - MANUAL......4497
A_C-HEATER SYSTEM UNIFORM INSPECTION GUIDELINES......4519
ABBREVIATIONS......4559
ALTERNATOR & REGULATOR - HITACHI......4570
ALTERNATOR & REGULATOR - MITSUBISHI......4576
ANTI-LOCK BRAKE SAFETY PRECAUTIONS......4581
ANTI-LOCK BRAKE SYSTEM......4582
AUTO TRANS DIAGNOSIS - RE4R01A, RE4R03A & RL4R01A......4615
B - EMISSION APPLICATION......4742
BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES......4743
BRAKE SYSTEM......4777
C - SPECIFICATIONS......4807
CLUTCH......4820
COMPUTER RELEARN PROCEDURES......4826
COOLING SYSTEM SPECIFICATIONS......4828
CRUISE CONTROL SYSTEM......4831
D - ADJUSTMENTS......4844
DEFOGGER - REAR WINDOW......4851
DRIVE AXLE - REAR......4854
DRIVE AXLE......4857
DRIVETRAIN SYSTEMS UNIFORM INSPECTION GUIDELINES......4868
E - THEORY_OPERATION......4909
ELECTRICAL COMPONENT LOCATOR......4925
ELECTRICAL SYSTEM UNIFORM INSPECTION GUIDELINES......4970
ELECTROSTATIC DISCHARGE WARNING - BASIC INFORMATION......5022
EMISSION CONTROL VISUAL INSPECTION PROCEDURES......5024
ENGINE COOLING FAN......5039
ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION......5048
ENGINE SYSTEMS UNIFORM INSPECTION GUIDELINES......5088
EXHAUST SYSTEM UNIFORM INSPECTION GUIDELINES......5193
F - BASIC TESTING......5202
FRONT SAFETY BELT BUCKLE RELEASE BUTTON CAN BREAK......5211
FUSES & CIRCUIT BREAKERS......5213
G - TESTS W_CODES......5217
GEAR TOOTH CONTACT PATTERNS......5237
GENERAL COOLING SYSTEM SERVICING......5240
H - TESTS W_O CODES......5243
HEATER SYSTEM......5253
HOW TO USE SYSTEM WIRING DIAGRAMS......5272
I - SYSTEM_COMPONENT TESTS......5279
INSTRUMENT PANEL - STANDARD......5316
J - PIN VOLTAGE CHARTS......5320
JACKING & HOISTING......5326
K - SENSOR RANGE CHARTS......5328
L - WIRING DIAGRAMS......5331
M - VACUUM DIAGRAMS......5342
MAINTENANCE INFORMATION......5350
MAINTENANCE REMINDER LIGHT RESET PROCEDURES......5363
METRIC CONVERSIONS......5364
N - REMOVE_INSTALL_OVERHAUL......5368
P - EGR FUNCTION TESTING......5375
POWER WINDOWS......5376
PRE-ALIGNMENT CHECKS......5379
RIDING HEIGHT ADJUSTMENT......5380
SCHEDULED SERVICES......5382
SEAT BELTS - AUTOMATIC......5411
SERVICE INDICATOR & WARNING LIGHTS......5443
STARTER......5445
STEERING COLUMN SWITCHES......5448
STEERING COLUMN......5459
STEERING SYSTEM - POWER......5467
STEERING UNIFORM INSPECTION GUIDELINES......5482
SUSPENSION - FRONT......5532
SUSPENSION - REAR......5536
SUSPENSION UNIFORM INSPECTION GUIDELINES......5539
SYMPTOM CHECK LIST......5589
SYSTEM WIRING DIAGRAMS......5601
TRANSMISSION REMOVAL & INSTALLATION - A_T......5613
TRANSMISSION SERVICING - A_T......5618
TRANSMISSION SERVICING - M_T......5625
TROUBLE SHOOTING - BASIC PROCEDURES......5627
WAVEFORMS - INJECTOR PATTERN TUTORIAL......5690
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES......5722
WHEEL ALIGNMENT THEORY_OPERATION......5726
WIPER_WASHER SYSTEM......5731
WIRING DIAGRAM SYMBOLS......5740
WIRING DIAGRAMS......5748
SM0E-0S13U0......5758
240SX '92......6722
1992 180sx Digital Climate Control......6723
SM2E-0S13C0......6768
Front Cover......6768
Foreword......6769
Table of Contents......6770
General Information......6771
Windshield Header Trim......6782
Windshield Header Molding......6792
Weatherstrips and Retainers......6798
Rear Seat......6820
Quarter Trim Panel......6826
Quarter Window and Regulator......6832
Door and Door Window......6840
Seat Belts......6858
Back and Quarter Belt Moldings......6870
Headliner Assembly......6878
Top Cover Assembly......6886
Backlite Assembly......6896
Stay Pads, Side and Rear......6906
No. 1 Bow......6918
No. 2 Bow......6928
No. 3 Bow......6934
No. 4 Bow......6940
Rear and Side Rail......6946
Hydraulic System......6962
Electrical......6982
Deck Lid Hinge and Trunk Trim......7026
Body Structural......7036
Index......7046
Back Cover......7053
SM2E-0S13C1......7054
1992 Nissan 240SX Convertible - Amended......7054
SM2E-0S13C1......7054
FOREWORD......7054
CONTENTS......7055
SM2E-0S13U0......7117
1992 Nissan 240SX Service Manual......7117
SM2E-0S13U0......7117
QUICK REFERENCE INDEX......7117
QUICK REFERENCE CHART......8130
240SX '93......8131
alternative......8132
240SX '95......9090
AT......9091
TABLE OF CONTENTS......9091
PREPERATION AND PRECAUTIONS......9092
Special Service Tools......9092
Service Notice......9093
Supplemental Restraint System "AIR BAG"......9094
DESCRIPTION......9095
Cross-sectional View......9095
Hydraulic Control Circuit......9096
Shift Mechanism......9097
Control System......9099
TROUBLE DIAGNOSES......9101
Contents......9101
A/T Electrical Parts Location......9124
Wiring Diagram - AT -......9126
Self Diagnosis......9131
DTC P0720 VEHICLE SPEED SENSOR A/T (REVOLUTION SENSOR) CIRCUIT CHECK......9136
VEHICLE SPEED SENSOR MTR CIRCUIT CHECK......9138
DTC P1705 THROTTLE POSITION SENSOR CIRCUIT CHECK......9140
DTC P0750 SHIFT SOLENOID VALVE A CIRCUIT CHECK......9142
DTC P0755 SHIFT SOLENOID VALVE B CIRCUIT CHECK......9144
DTC P1760 OVERRUN CLUTCH SOLENOID VALVE CIRCUIT CHECK......9146
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE CIRCUIT CHECK......9148
DTC P0710 FLUID TEMPERATURE SENSOR CIRCUIT AND A/T CONTROL UNIT POWER SOURCE CIRCUIT CHECKS......9150
DTC P0725 ENGINE SPEED SIGNAL CIRCUIT CHECK......9153
DTC P0745 LINE PRESSURE SOLENOID VALVE CIRCUIT CHECK......9155
DTC P0705 INHIBITOR, OVERDRIVE AND THROTTLE POSITION SWITCH CIRCUIT CHECK......9157
DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION......9162
DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION......9164
DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION......9166
DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION......9168
Diagnostic Procedures for Symptoms......9170
TROUBLE DIAGNOSES - A/T Shift Lock System......9200
Contents......9200
Shift Lock System Electrical Parts Location......9201
Wiring Diagram - SHIFT -......9202
ON-VEHICLE SERVICE......9211
Control Valve Assembly and Accumulators Inspection......9211
Revolution Sensor Replacement......9211
Rear Oil Seal Replacement......9212
Parking Components Inspection......9212
Inhibitor Switch Adjustment......9213
Manual Control Linkage Adjustment......9213
Kickdown Switch Adjustment......9213
REMOVAL AND INSTALLATION......9214
Removal......9214
Installation......9216
MAJOR OVERHAUL......9218
Oil Channel......9220
Location of Needle Bearings, Thrust Washers and Snap Rings......9221
DISASSEMBLY......9222
Disassembly......9222
REPAIR FOR COMPONENT PARTS......9233
Oil Pump......9233
Control Valve Assembly......9237
Control Valve Upper Body......9243
Control Valve Lower Body......9248
Reverse Clutch......9250
High Clutch......9254
Forward and Overrun Clutches......9256
Low & Reverse Brake......9260
Forward Clutch Drum Assembly......9264
Rear Internal Gear and Forward Clutch Hub......9266
Band Servo Piston Assembly......9269
Parking Pawl Components......9273
ASSEMBLY......9275
Assembly (1)......9275
Adjustment......9279
Assembly (2)......9283
SERVICE DATA AND SPECIFICATIONS (SDS)......9293
General Specifications......9293
Specifications and Adjustment......9293
BF......9297
TABLE OF CONTENTS......9297
GENERAL SERVICING......9299
Precautions......9299
Supplemental Restraint System "AIR BAG"......9299
Circuit Breaker Inspection......9299
Clip and Fastener......9300
BODY END......9303
Body Front End......9303
Body Rear End and Opener......9305
DOOR......9307
Door Glass Fitting Adjustment......9308
POWER WINDOW......9311
System Description......9311
Wiring Diagram - WINDOW -......9313
Schematic......9316
Trouble Diagnosis......9317
POWER DOOR LOCK......9323
System Description......9323
Wiring Diagram - D/LOCK -......9324
Trouble Diagnosis......9326
MULTI-REMOTE CONTROL SYSTEM......9329
System Description......9329
Wiring Diagram - MULTI -......9331
Schematic......9334
Input/Output Operation Signal......9335
Trouble Diagnoses......9336
Replacing Remote Controller or Control Unit......9342
INSTRUMENT PANEL......9343
INTERIOR AND EXTERIOR......9346
Interior......9346
Exterior......9351
SEAT......9356
Front Seat......9356
Rear Seat......9358
SEAT BELTS......9359
Front Seat Belt......9359
Rear Seat Belt......9360
SUN ROOF......9361
Wiring Diagram - SROOF -......9365
WINDSHIELD AND WINDOWS......9366
Windshield and Rear Window......9366
Side Window......9367
DOOR MIRROR......9368
Wiring Diagram - MIRROR -......9369
REAR AIR SPOILER......9371
Rear Air Spoiler......9371
BODY ALIGNMENT......9372
Engine Compartment......9372
Underbody......9374
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)......9376
Precautions for SRS "Air Bag" Service......9376
Special Service Tools......9376
Commercial Service Tool......9376
Description......9377
Caution Labels and SRS Component Parts Location......9378
Maintenance Items......9380
Removal and Installation - Diagnosis Sensor Unit......9381
Removal - Air Bag Module and Spiral Cable......9382
Removal - Front Passenger Air Bag Module......9383
Installation - Air Bag Module and Spiral Cable......9384
Installation - Front Passenger Air Bag Module......9385
Disposal of Air Bag Module......9385
TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)......9389
Wiring Diagram - SRS -......9389
Schematic......9391
Self-diagnosis......9392
Diagnostic Procedure 1 ......9397
Diagnostic Procedure 2......9397
Diagnostic Procedure 3......9398
Collision Diagnosis......9399
BR......9400
TABLE OF CONTENTS......9400
PRECAUTIONS AND PREPARATION......9401
Precautions......9401
Commercial Service Tools......9401
BRAKE HYDRAULIC LINE/CONTROL VALVE......9402
Brake Hydraulic Line......9402
Dual Proportioning Valve......9403
CHECK AND ADJUSTMENT......9404
Checking Brake Fluid Level......9404
Checking Brake Line......9404
Changing Brake Fluid......9404
Bleeding Brake System......9404
BRAKE PEDAL AND BRACKET......9405
Removal and Installation......9405
Inspection......9405
Adjustment......9405
MASTER CYLINDER......9406
Removal......9406
Disassembly......9406
Inspection......9407
Assembly......9407
Installatiion......9407
BRAKE BOOSTER/VACUUM HOSE......9408
Brake Booster......9408
Vacuum Hose......9409
FRONT DISC BRAKE......9410
Pad Replacement......9410
Removal......9411
Disassembly......9411
Inspection - Caliper ......9411
Inspection - Rotor......9412
Assembly......9412
Installation......9412
REAR DISC BRAKE......9413
Pad Replacement......9413
Removal......9415
Disassembly......9415
Inspection - Caliper......9416
Inspection - Rotor......9417
Assembly......9417
Installation......9418
PARKING BRAKE CONTROL......9419
Removal and Installation......9419
Inspection......9420
Adjustment......9420
ANTI-LOCK BRAKE SYSTEM......9421
Purpose......9421
Operation......9421
ABS Hydraulic Circuit......9421
System Components......9422
System Description......9422
Removal and Installation......9424
Wiring Diagram - ABS -......9426
TROUBLE DIAGNOSES......9431
Contents......9431
How to Perform Trouble Diagnoses for Quick and Accurate Repair......9431
SERVICE DATA AND SPECIFICATIONS (SDS)......9464
General Specifications......9464
Inspection and Adjustment......9464
Body Repair Manual......9465
1995 Nissan 240SX Body Repair Manual......9465
5S1495......9465
Table of Contents......9465
CL......9497
TABLE OF CONTENTS......9497
PRECAUTIONS AND PREPARATION......9498
Precautions......9498
Special Service Tools......9498
Commercial Service Tools......9498
CLUTCH SYSTEM......9499
INSPECTION AND ADJUSTMENT......9500
Adjusting Clutch Pedal......9500
Bleeding Procedure......9501
HYDRAULIC CLUTCH CONTROL......9502
Clutch Master Cylinder......9502
Operating Cylinder......9503
CLUTCH RELEASE MECHANISM......9504
CLUTCH DISC AND CLUTCH COVER......9506
Clutch Cover and Flywheel......9506
Clutch Disc......9507
SERVICE DATA AND SPECIFICATIONS (SDS)......9508
General Specifications......9508
Inspection and Adjustment......9508
EC......9509
TABLE OF CONTENTS......9509
PRECAUTIONS AND PREPARATION......9511
Special Service Tool......9511
Supplemental Restraint System "AIR BAG"......9511
Precautions for On-Board Diagnostic (OBD) System of Engine and A/T......9511
Engine Fuel & Emission Control System......9512
Precautions......9513
ENGINE AND EMISSION CONTROL OVERALL SYSTEM......9515
Circuit Diagram......9515
System Diagram......9516
ECCS Component Parts Location......9517
Vacuum Hose Drawing......9519
System Chart......9520
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION......9521
Multiport Fuel Injection (MFI) System......9521
Distributor Ignition (DI) System......9523
Air Conditioner Cut Control......9524
Fuel Cut Control (at no load & high engine speed)......9525
EVAPORATIVE EMISSION SYSTEM......9526
Description......9526
Inspection......9526
POSITIVE CRANKCASE VENTILATION......9528
Description......9528
Inspection......9528
BASIC SERVICE PROCEDURE......9529
Fuel Pressure Release......9529
Fuel Pressure Check......9529
Injector Removal and Installation......9530
Idle speed/Ignition Timing/Idle Mixture Ratio Adjustment......9531
ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION......9537
Introduction......9537
Two Trip Detection Logic......9537
Diagnostic Trouble Code (DTC)......9537
Freeze Frame Data......9538
Malfunction Indicator Lamp (MIL)......9539
OBD System Operation Chart......9542
Consult......9547
Generic Scan Tool (GST)......9559
TROUBLE DIAGNOSIS - General Description......9561
Introduction......9561
Work Flow......9562
Description for Work Flow......9563
Diagnostic Worksheet......9564
Alphabetical & P No. Index for DTC......9565
Diagnostic Trouble Code (DTC) Chart......9566
Fail-Safe Chart......9575
Basic Inspection......9576
Symptom Matrix Chart......9579
Consult Reference Value in Data Monitor Mode......9582
Major Sensor Reference Graph in Data Monitor Mode......9585
ECM Terminals and Reference Value......9587
TROUBLE DIAGNOSIS FOR POWER SUPPLY......9593
Main Power Supply and Ground Circuit......9593
DTC 11, Camshaft Position Sensor (CMPS) (DTC: P0340)......9596
DTC 12, Mass Air Flow Sensor (MAFS) (DTC: P0100) ......9600
DTC 13, Engine Coolant Temperature Sensor (ECTS) (DTC: P0115)......9605
DTC 14, Vehicle Speed Sensor (VSS) (DTC: P0500)......9609
DTC 21, Ignition Signal (DTC: P1320)......9613
DTC 25, Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve (DTC: P0505)......9618
DTC 31, Engine Control Module (ECM)-ECCS Control Module (DTC: P0605)......9623
DTC 32, EGR Function (DTC:P0400)......9625
DTC 33, Front Oxygen Sensor (Front O2S) (DTC: P0130)......9633
DTC 34, Knock Sensor (KS) (DTC: P0325)......9638
DTC 35, EGR Temperature Sensor (DTC: P1401)......9641
DTC 36, EGRC-BPT Valve Function (DTC: P0402)......9645
DTC 37, Closed Loop Control (DTC: P0130)......9647
DTC 41, Intake Air Temperature Sensor (DTC: P0110)......9648
DTC 43, Throttle Position Sensor (DTC: P0120)......9653
DTC 65 - 71, No. 4 - 1 Cylinder Misfire, Multiple Cylinder (DTC: P0304 - P0300)......9658
DTC 72, Three Way Catalyst Function (DTC: P0420)......9662
DTC 76, Fuel Injection System Function (DTC: P0170)......9665
DTC 77, Rear Heated Oxygen Sensor (Rear HO2S) (DTC: P0136)......9670
DTC 82, Crankshaft Position Sensor (CKPS) (OBD) (DTC: P0335)......9675
DTC 84, A/T Diagnosis Communication Line (DTC: P1605)......9679
DTC 95, Crankshaft Position Sensor (CKPS) (OBD) (DTC: P1336)......9682
DTC 98, Engine Coolant Temperature (ECT) Sensor (DTC: P0125)......9686
DTC 103, Park/Neutral Position Switch (DTC: P0705)......9691
DTC 105, EGR and Canister Control Solenoid Valve (DTC: P1400)......9696
DTC P0600, A/T Control (DTC: P0600)......9700
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS......9703
Injector......9703
Start Signal......9706
Fuel Pump......9708
Cooling Fan Control......9713
Power Steering Oil Pressure Switch......9721
IACV-Air Regulator......9724
IACV-FICD Solenoid Valve......9727
5th Position Switch......9731
Rear Window Defogger Signal......9733
MIL & Data Link Connectors......9735
SERVICE DATA AND SPECIFICATIONS (SDS)......9736
General Specifications......9736
Inspection and Adjustment......9736
EL......9738
TABLE OF CONTENTS......9738
PRECAUTIONS......9740
Supplemental Restraint System "AIR BAG"......9740
HARNESS CONNECTOR......9741
Description......9741
STANDARDIZED RELAY......9742
Description......9742
POWER SUPPLY ROUTING......9745
Schematic......9745
Wiring Diagram - POWER -......9747
Fuse......9756
Fusible Link......9756
BATTERY......9757
How to Handle Battery......9757
Service Data and Specifications (SDS)......9760
STARTING SYSTEM......9761
System Description......9761
Wiring Diagram - START -......9763
Construction......9766
Removal and Installation......9766
Pinion/Clutch Check......9767
Service Data and Specifications (SDS)......9767
CHARGING SYSTEM......9768
System Description......9768
Wiring Diagram - CHARGE -......9769
Construction......9770
Removal and Installation......9771
Service Data and Specifications (SDS)......9771
COMBINATION SWITCH......9772
Combination Switch/Check......9772
Replacement......9773
Steering Switch/Check......9774
HEADLAMP......9775
System Description (For USA)......9775
Schematic (For USA)......9776
Wiring Diagram (For USA) - H/LAMP -......9777
Trouble Diagnoses (For USA)......9778
System Description (For Canada)......9779
Operation (Daytime light system for Canada)......9780
Schematic (For Canada)......9781
Wiring Diagram (For Canada) - DTRL -......9782
Trouble Diagnoses (For Canada)......9785
Bulb Replacement......9786
Aiming Adjustment......9786
EXTERIOR LAMP......9788
Clearance, License, Tail and Stop Lamps/Wiring Diagram - TAIL/L -......9788
Back-up Lamp/Wiring Diagram - BACK/L -......9790
Front Fog Lamp/System Description......9792
Front Fog Lamp/Wiring Diagram - F/FOG -......9793
Front Fog Lamp Aiming Adjustment......9794
Turn Signal and Hazard Warning Lamps/System Description......9795
Turn Signal and Hazard Warning Lamps/Schematic......9797
Turn Signal and Hazard Warning Lamps/Wiring Diagram - TURN......9798
Turn Signal and Hazard Warning Lamps/Trouble Diagnoses......9801
Combination Flasher Unit Check......9801
Bulb Specifications......9802
INTERIOR LAMP......9803
Illumination/System Description......9803
Illumination/Schematic......9804
Ilumination/Wiring Diagram - ILL -......9805
Interior, Spot and Trunk Room Lamps/System Description......9808
Bulb Specifications......9808
Interior, Spot and Trunk Room Lamps/Wiring Diagram - INT -......9809
METER AND GAUGES......9811
System Description......9811
Combination Meter......9812
Speedometer, Tachometer, Temp. and Fuel Gauges/Wiring Diagram - METER -......9813
Inspection/Fuel Gauge and Water Temperature Gauge......9814
Inspection/Tachometer......9815
Inspection/Speedometer and Vehicle Speed Sensor......9816
Fuel Tank Gauge Unit Check......9818
Fuel Warning Lamp Sensor Check......9818
Oil Pressure Switch Check......9818
Vehicle Speed Sensor Signal Check......9819
WARNING LAMPS AND BUZZER......9820
Warning Lamps/Schematic......9820
Warning Lamps/Wiring Diagram - WARN -......9821
Warning Buzzer/System Description......9823
Warning Buzzer/Wiring Diagram - CHIME -......9825
Trouble Diagnoses - Warning Buzzer......9827
Diode Check......9836
Warning Buzzer Check......9836
WIPER AND WASHER......9837
System Description......9837
Front Wiper and Washer/Wiring Diagram - WIPER -......9839
Trouble Diagnoses......9841
Wiper Amplifier Check......9843
Wiper Installation and Adjustment......9843
Washer Nozzle Adjustment......9843
Washer Tube Layout......9844
Wiper Linkage......9845
HORN, CIGARETTE LIGHTER AND CLOCK......9846
Wiring Diagram - HORN -......9846
REAR WINDOW DEFIGGER......9847
System Description......9847
Wiring Diagram - DEF -......9848
Trouble Diagnoses......9850
Filament Check......9852
Filament Repair......9853
AUDIO AND POWER ANTENNA......9855
Audio/System Description......9855
Audio/Schematic......9856
Audio/Wiring Diagram - AUDIO -......9857
Power Antenna/System Description......9861
Power Antenna/Wiring Diagram - P/ANT -......9862
Trouble Diagnoses......9863
Location of Antenna......9864
Antenna Rod Replacement......9865
Window Antenna Repair......9865
AUTOMATIC SPEED CONTROL DEVICE (ASCD)......9867
System Description......9867
Fail-safe System......9869
Component Parts and Harness Connector Location......9870
Schematic......9871
Wiring Diagram - ASCD -......9872
Trouble Diagnoses......9877
ASCD Wire Adjustment......9895
THEFT WARNING SYSTEM......9896
System Description......9896
Component Parts and Harness Connector Location......9899
Schematic......9900
Wiring Diagram - THEFT -......9901
Trouble Diagnoses......9908
LOCATION OF ELECTRICAL UNITS......9927
Engine Compartment......9927
Passenger Compartment......9928
HARNESS LAYOUT......9930
Outline......9930
Main Harness......9931
Engine Room Harness......9933
Engine Control Harness......9936
Body Harness and Tail Harness......9937
Engine Harness......9939
Room Lamp......9940
Air Bag Harness......9941
Door Harness LH......9942
Door Harness RH......9942
EM......9943
TABLE OF CONTENTS......9943
PRECAUTIONS......9944
Parts Requiring Angular Tightening......9944
Liquid Gasket Application Procedure......9944
PREPARATION......9945
Special Service Tools......9945
Commercial Service Tools......9948
OUTER COMPONENT PARTS......9949
COMPRESSION PRESSURE......9951
Measurement of Compression Pressure......9951
OIL PAN......9952
Removal......9951
Installation......9953
TIMING CHAIN......9954
Removal......9956
Inspection......9958
Installation......9958
OIL SEAL REPLACEMENT......9963
CYLINDER HEAD......9965
Removal and Installation......9966
Disassemblly......9966
Inspection......9966
Assembly......9971
Valve Clearance......9972
ENGINE REMOVAL......9974
Removal......9975
CYLINDER BLOCK......9976
Disassembly......9977
Inspection......9978
Assembly......9984
SERVICE DATA AND SPECIFICATIONS......9988
General Specifications......9988
Inspection and Adjustment......9988
FA......9996
TABLE OF CONTENTS......9996
PRECAUTIONS AND PREPARATION......9997
Precautions......9997
Special Service Tools......9997
Commercial Service Tools......9998
FRONT SUSPENSION SYSTEM......9999
ON-VEHICLE SERVICE......10000
Front Axle and Front Suspension Parts......10000
Front Wheel Bearing......10001
Front Wheel Alignment......10001
FRONT AXLE......10003
Wheel Hub and Knuckle......10003
ABS Sensor Rotor......10005
Baffle Plate......10005
FRONT SUSPENSION......10006
Coil Spring and Strut Assembly......10007
Tension Rod and Stabilizer Bar......10008
Transverse Link and Lower Ball Joint......10009
SERVICE DATA AND SPECIFICATIONS (SDS)......10010
General Specifications......10010
Inspection and Adjustment......10010
FE......10011
TABLE OF CONTENTS......10011
PREPARATION/ACCELERATOR CONTROL SYSTEM......10012
Special Service Tool......10012
Accelerator Control System......10012
Adjusting Accelerator Wire......10012
FUEL SYSTEM......10013
Fuel Tank......10013
Fuel Pump and Gauge......10015
EXHAUST SYSTEM......10017
FWD......10018
QUICK REFERENCE INDEX......10018
FOREWORD......10019
Quick Reference Chart......10020
Foldout......10021
SUPER MULTIPLE JUNCTION (SMJ)......10021
Disconnecting and Connecting......10021
Terminal Arrangement......10022
GI......10024
TABLE OF CONTENTS......10024
PRECAUTIONS......10025
Precautions for Supplemental Restraint System "AIR BAG"......10025
General Precautions......10025
Precautions for Multiport Fuel Injection System or ECCS Engine......10027
Precautions for Three Way Catalyst......10028
Precautions for Fuel......10028
HOW TO USE THIS MANUAL......10029
HOW TO READ WIRING DIAGRAMS......10031
Sample/Wiring Diagram - EXAMPL -......10031
Description......10033
Wiring Diagram Codes (Cell Codes)......10039
HOW TO PERFORM EFFICIENT DIANOSIS FOR AN ELECTRICAL INCIDENT......10040
Work Flow......10040
Incident Simulation Tests......10041
Circuit Inspection......10045
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES......10051
CONSULT CHECKING SYSTEM......10054
Function and System Application......10054
Checking Equipment......10054
IDENTIFICATION INFORMATION......10055
Model Variation......10055
Identification Number......10056
Dimensions......10058
Wheels and Tires......10058
LIFTING POINTS AND TOW TRUCK TOWING......10059
Garage Jack and Safety Stand......10059
2-pole Lift......10060
Preparation......10060
Board-on Lift......10060
Tow Truck Towing......10061
TIGHTENING TORQUE OF STANDARD BOLTS......10062
SAE J1930 TERMINOLOGY LIST......10063
SAE J1930 Terminology List......10063
HA......10067
TABLE OF CONTENTS......10067
PRECAUTIONS AND PREPARATION......10068
Supplemental Restraint System "AIR BAG"......10068
Precautions for Working with HFC-134a (R-134a)......10068
General Refrigerant Precautions......10068
Precautions for Refrigerant Connection......10069
Precautions for Servicing Compressor......10070
Special Service Tools......10070
HFC-134a (R-134a) Service Tools and Equipment......10071
Precautions for Service Equipment......10073
DESCRIPTION......10075
Refrigeration Cycle......10075
Component Layout......10076
Discharge Air Flow......10077
Control Operation......10078
V-6 Variable Displacement Compressor......10079
TROUBLE DIAGNOSES......10084
Contents......10084
Wiring Diagram - A/C -......10106
SERVICE PROCEDURES......10129
HFC-134a (R-134a) Service Procedure......10129
Maintenance of Oil Quantity in Compressor......10131
Refrigerant Lines......10133
Compressor Mounting......10134
Belt Tension......10134
Fast Idle Control Device (FICD)......10134
SERVICE PROCEDURES - Push Control......10135
Overhaul - Push Control Unit Assembly......10135
Disassembly......10135
COMPRESSOR - Model V-6 (CALSONIC make)......10136
Compressor Clutch......10136
SERVICE DATA AND SPECIFICATIONS......10139
General Specifications......10139
Inspection and Adjustment......10139
IDX......10140
LC......10147
TABLE OF CONTENTS......10147
PRECAUTION AND PREPARATION......10148
Precaution......10148
Special Service Tools......10148
ENGINE LUBRICATION SYSTEM......10149
Lubrication Circuit......10149
Oil Pressure Check......10149
Oil Pump......10150
ENGINE COOLING SYSTEM......10152
Cooling Circuit......10152
System Check......10152
Water Pump......10153
Thermostat......10154
Radiator......10155
Cooling Fan......10155
SERVICE DATA AND SPECIFICATIONS (SDS)......10156
Engine Lubrication System......10156
Engine Cooling System......10156
MA......10157
TABLE OF CONTENTS......10157
PRECAUTIONS......10158
Supplemental Restraint System "AIR BAG"......10158
GENERAL MAINTENANCE......10159
PERIODIC MAINTENANCE......10161
Schedule 1......10162
Schedule 2......10163
RECOMMENDED FLUIDS AND LUBRICANTS......10164
Fluids and Lubricants......10164
SAE Viscosity Number......10164
ENGINE MAINTENANCE......10165
Checking Drive Belts......10165
Changing Engine Coolant......10166
Checking Fuel Lines......10167
Changing Fuel Filter......10167
Changing Air Cleaner Filter......10168
Changing Engine Oil......10168
Changing Oil Filter......10169
Changing Spark Plugs......10170
Checking Vapor Lines......10170
CHASSIS AND BODY MAINTENANCE......10171
Checking Exhaust System......10171
Checking Clutch Fluid Level and Leaks......10171
Checking M/T Oil......10171
Changing M/T Oil......10171
Checking A/T Fluid......10172
Changing A/T Fluid......10172
Checking Differential Gear Oil......10172
Changing Differential Gear Oil......10173
Balancing Wheels......10173
Tire Rotation......10173
Checking Brake Fluid Level and Leaks......10173
Checking Brake Lines and Cables......10173
Checking Disc Brake......10173
Checking Steering Gear and Linkage......10174
Checking Power Steering Fluid and Lines......10174
Lubricating Locks, Hinges and Hood Latches......10175
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters......10175
SERVICE DATA AND SPECIFICATIONS (SDS)......10176
Engine Maintenance......10176
Chassis and Body Maintenance......10176
MT......10177
TABLE OF CONTENTS......10177
PREPARATION......10178
Special Service Tools......10178
Commercial Service Tool......10180
ON-VEHICLE SERVICE......10181
Replacing Rear Oil Seal......10181
Check of Position Switches......10181
REMOVAL AND INSTALLATION......10182
Removal......10182
Installation......10183
MAJOR OVERHAUL......10184
Case Components......10184
Gear Components......10185
Shift Control Components......10186
DISASSEMBLY......10187
Case Components......10187
Shift Control Components......10188
Gear Components......10188
INSPECTION......10191
Shift Control Components......10191
Gear Components......10191
ASSEMBLY......10193
Gear Components......10193
Shift Control Components......10199
Case Components......10200
SERVICE DATA AND SPECIFICATIONS......10203
General Specifications......10203
Inspection and Adjustment......10204
PD......10206
TABLE OF CONTENTS......10206
PREPARATION......10207
Special Service Tools......10207
Commercial Service Tool......10209
PROPELLER SHAFT......10210
On-vehicle Service......10211
Removal......10211
Installation......10211
Inspection......10212
Disassembly......10213
Assembly......10213
FINAL DRIVE......10214
ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION......10214
Front Oil Seal Replacement......10214
Side Oil Seal Replacement......10214
Removal......10215
Installation......10216
FINAL DRVIE......10217
DISASSEMBLY......10219
Pre-inspection......10219
Differential Carrier......10219
Differential Case......10221
INSPECTION......10223
Ring Gear and Drive Pinion......10223
Bearing......10223
Differential Case Assembly......10223
ADJUSTMENT......10224
Side Bearing Preload......10224
Pinion Gear Height and Pinion Bearing Preload......10225
Tooth Contact......10230
ASSEMBLY......10231
Differential Case......10231
Differential Carrier......10233
SERVICE DATA AND SPECIFICATIONS......10237
Propeller Shaft......10237
Final Drive......10237
RA......10239
TABLE OF CONTENTS......10239
PRECAUTIONS AND PREPARATION......10240
Precautions......10240
Special Service Tools......10240
Commercial Service Tools......10241
REAR SUSPENSION SYSTEM......10242
ON-VEHICLE SERVICE......10243
Rear Axle and Rear Suspension Parts......10243
Rear Wheel Bearing......10243
Rear Wheel Alignment......10243
Drive Shaft......10244
REAR AXLE......10245
Wheel Hub and Axle Housing......10245
Drive Shaft......10249
REAR SUSPENSION......10255
Removal and Installation......10256
Coil Spring and Shock Absorber......10257
Multi-link and Lower Ball Joint......10258
Stabilizer Bar......10259
SERVICE DATA AND SPECIFICATIONS (SDS)......10260
General Specifications......10260
Inspection and Adjustment......10261
ST......10262
TABLE OF CONTENTS......10262
PRECAUTIONS AND PREPARATION......10263
Precautions......10263
Special Service Tools......10263
Commercial Service Tools......10264
ON-VEHICLE SERVICE......10266
Checking Steering Wheel Play......10266
Checking Neutral Position on Steering Wheel......10266
Front Wheel Turning Angle......10266
Checking Gear Housing Movement......10267
Adjusting Rack Retainer......10267
Checking and Adjusting Drive Belts (For power steering)......10267
Checking Fluid Level......10267
Checking Fluid Leakage......10267
Bleeding Hydraulic System......10268
Checking Steering Wheel Turning Force (for power steering)......10268
Checking Hydraulic System......10269
STEERING WHEEL AND STEERING COLUMN......10270
Removal and Installation......10270
Disassembly and Assembly......10272
Inspection......10273
POWER STEERING GEAR AND LINKAGE (Model PR24AC)......10274
Removal and Installation......10274
Disassembly and Assembly......10276
Disassembly......10277
Inspection......10277
Assembly......10278
Adjustment......10282
POWER STEERING OIL PUMP......10284
Disassembly and Assembly......10284
Pre-disassembly Inspection......10284
Disassembly......10285
Inspection......10285
Assembly......10286
SERVICE DATA AND SPECIFICATIONS (SDS)......10287
General Specifications......10287
Inspection and Adjustment......10287
240SX '96......10289
1996 180sx Electrical Supplement......10290
1996 SR20DE Manual......10304
Cover......10304
GI: General Information......10307
EM: Engine Mechanical......10309
LC: Engine Lubrication & Cooling......10375
EF&EC: Engine Fuel & Emission Control Systems......10387
FE: Accelerator, Fuel & Exhaust......10425
CL: Clutch......10429
MT: Manual Transmission......10433
AT: Automatic Transmission......10437
PD: Propeller Shaft & Final Drive......10447
DS: Driveshaft......10451
FA: Front Axle & Front Suspension......10453
RA: Rear Axle & Rear Suspension......10457
BR: Brake System......10459
ST: Steering System......10483
BF: Body & Frame......10485
HA: Heater & Airconditioner......10493
EL: Engine Electrical System......10495
manual notes......10506
1996 SR20DET Electrical Supplement......10507
Cover......10507
5-1 ECCS C/U SR20DE......10510
5-2 ECCS C/U SR20DET......10511
5-3 (gauge cluster)......10511
5-4 ABS......10512
5-5 (body wiring)......10514
5-7 ......10516
5-8......10516
5-9......10517
5-10 (ECCS harness connectors)......10518
manual notes......10521
AT......10522
TABLE OF CONTENTS......10522
PREPARATION AND PRECAUTIONS......10524
Special Service Tools......10524
Service Notice......10525
Supplemental Restraint System (SRS) "AIR BAG"......10526
DESCRIPTION......10527
Cross-sectional View......10527
Hydraulic Control Circuit......10528
Shift Mechanism......10529
Control System......10531
TROUBLE DIAGNOSES......10534
How to Perform Trouble Diagnoses for Quick and Accurate Repair......10534
Remarks......10538
Diagnostic Trouble Code (DTC) Chart......10539
Diagnosis by CONSULT......10541
Preliminary Check......10544
A/T Electrical Parts Location......10555
Circuit Diagram for Quick Pinpoint Check......10556
Wiring Diagram - AT -......10557
Self-diagnosis......10562
DTC P0720 VEHICLE SPEED SENSOR A/T (REVOLUTION SENSOR) CIRCUIT CHECK......10568
VEHICLE SPEED SENSOR MTR CIRCUIT CHECK......10570
DTC P1705 THROTTLE POSITION SENSOR CIRCUIT CHECK......10572
DTC P0750 SHIFT SOLENOID VALVE A CIRCUIT CHECK......10574
DTC P0755 SHIFT SOLENOID VALVE B CIRCUIT CHECK......10576
DTC P1760 OVERRUN CLUTCH SOLENOID VALVE CIRCUIT CHECK......10578
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE CIRCUIT CHECK......10580
DTC P0710 FLUID TEMPERATURE SENSOR CIRCUIT AND A/T CONTROL UNIT POWER SOURCE CIRCUIT CHECKS......10582
DTC P0725 ENGINE SPEED SIGNAL CIRCUIT CHECK......10585
DTC P0745 LINE PRESSURE SOLENOID VALVE CIRCUIT CHECK......10587
DTC P0705 INHIBITOR, OVERDRIVE AND THROTTLE POSITION SWITCH CIRCUIT CHECK......10589
DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION......10593
DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION......10595
DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION......10597
DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION......10599
Diagnostic Procedures for Symptoms......10603
Diagnostic Procedure 1......10603
Diagnostic Procedure 2......10604
Diagnostic Procedure 3......10604
Diagnostic Procedure 4......10605
Diagnostic Procedure 5......10606
Diagnostic Procedure 6......10607
Diagnostic Procedure 7......10608
Diagnostic Procedure 8......10609
Diagnostic Procedure 9......10610
Diagnostic Procedure 10......10611
Diagnostic Procedure 11......10612
Diagnostic Procedure 12......10613
Diagnostic Procedure 13......10614
Diagnostic Procedure 14......10614
Diagnostic Procedure 15......10615
Diagnostic Procedure 16......10616
Diagnostic Procedure 17......10616
Diagnostic Procedure 18......10617
Diagnostic Procedure 19......10617
Diagnostic Procedure 20......10617
Electrical Components Inspection......10618
Final Check......10625
Symptom Chart......10630
TROUBLE DIAGNOSES - A/T Shift Lock System......10633
Description......10633
Wiring Diagram - SHIFT -......10634
Diagnostic Procedure......10635
Key Interlock Cable......10637
Component Check......10638
ON-VEHICLE SERVICE......10640
Control Valve Assembly and Accumulators Inspection......10640
Revolution Sensor Replacement......10640
Rear Oil Seal Replacement......10641
Parking Components Inspection......10641
Inhibitor Switch Adjustment......10642
Manual Control Linkage Adjustment......10642
REMOVAL AND INSTALLATION......10643
Removal......10643
Installation......10645
MAJOR OVERHAUL......10647
Oil Channel......10649
Locations of Needle Bearings, Thrust Washers and Snap Rings......10650
DISASSEMBLY......10651
Disassembly......10651
REPAIR FOR COMPONENT PARTS......10662
Oil Pump......10662
Control Valve Assembly......10666
Control Valve Upper Body......10672
Control Valve Lower Body......10677
Reverse Clutch......10679
High Clutch......10683
Forward and Overrun Clutches......10685
Low & Reverse Brake......10689
Forward Clutch Drum Assembly......10693
Rear Internal Gear and Forward Clutch Hub......10695
Band Servo Piston assembly......10698
Parking Pawl Components......10702
ASSEMBLY......10704
Assembly (1)......10704
Adjustment......10708
Assembly 2......10712
SERVICE DATA AND SPECIFICATIONS (SDS)......10722
General Specifications......10722
Specifications and Adjustment......10722
BR......10726
TABLE OF CONTENTS......10726
PRECAUTIONS AND PREPARATION......10727
Precautions......10727
Commercial Service Tools......10727
BRAKE HYDRAULIC LINE/CONTROL VALVE......10728
Brake Hydraulic Line......10728
Proportioning Valve......10729
CHECK AND ADJUSTMENT......10730
Checking Brake Fluid Level......10730
Checking Brake Line......10730
Changing Brake Fluid......10730
Bleeding Brake System......10731
BRAKE PEDAL AND BRACKET......10732
Removal and Installation......10732
Inspection......10732
Adjustment......10732
MASTER CYLINDER......10733
Removal......10733
Disassembly......10734
Inspection......10734
Assembly......10734
Installation......10735
BRAKE BOOSTER/VACUUM HOSE......10736
Brake Booster......10736
Vacuum Hose......10737
FRONT DISC BRAKE......10738
Pad Replacement......10738
Removal......10739
Disassembly......10739
Inspection - Caliper......10739
Inspection - Rotor......10740
Assembly......10740
Installation......10740
REAR DISC BRAKE......10741
Pad Replacement......10741
Removal......10743
Disassembly......10743
Inspection - Caliper......10744
Inspection - Rotor......10745
Assembly......10745
Installation......10747
PARKING BRAKE CONTROL......10748
Removal and Installation......10748
Inspection......10749
Adjustment......10749
ANTI-LOCK BRAKE SYSTEM......10750
Purpose......10750
Operation......10750
ABS Hydraulic Circuit......10750
System Components......10751
System Description......10751
Removal and Installation......10753
Wiring Diagram - ABS -......10755
TROUBLE DIAGNOSES......10760
Contents......10760
Component Parts and Harness Connector Location......10770
SERVICE DATA AND SPECIFICATIONS (SDS)......10794
General Specifications......10794
Inspection and Adjustment......10794
BT......10795
TABLE OF CONTENTS......10795
PRECAUTIONS......10796
Service Notice......10796
Supplemental Restraint System (SRS) "AIR BAG"......10796
GENERAL SERVICING......10797
Clip and Fastener......10797
BODY END......10800
Body Front End......10800
Body Rear End and Opener......10802
DOOR......10804
Door Glass Fitting Adjustment......10805
INSTRUMENT PANEL......10808
INTERIOR TRIM......10811
Side and Floor Trim......10811
Door Trim......10813
Roof Trim......10814
Trunk Room Trim......10815
EXTERIOR......10816
SEAT......10821
Front Seat......10821
Rear Seat......10823
SUNROOF......10824
WINDSHIELD AND WINDOWS......10828
Windshield and Rear Window......10828
Side Window......10829
MIRROR......10830
Door Mirror......10830
FRONT AND REAR AIR SPOILER......10831
Front Air Spoiler......10831
Rear Air Spoiler......10831
BODY ALIGNMENT......10832
Engine Compartment......10832
Underbody......10834
CL......10836
TABLE OF CONTENTS......10836
PRECAUTIONS AND PREPARATION......10837
Precautions......10837
Special Service Tools......10837
Commercial Service Tools......10837
CLUTCH SYSTEM......10838
INSPECTION AND ADJUSTMENT......10839
Adjusting Clutch Pedal......10839
Bleeding Procedure......10840
HYDRAULIC CLUTCH CONTROL......10841
Clutch Master Cylinder......10841
Operating Cylinder......10842
CLUTCH RELEASE MECHANISM......10843
CLUTCH DISC AND CLUTCH COVER......10845
Clutch Disc......10845
SERVICE DATA AND SPECIFICATIONS (SDS)......10847
General Specifications......10847
Inspection and Adjustment......10847
EC......10848
TABLE OF CONTENTS......10848
PRECAUTIONS AND PREPARATION......10851
Special Service Tools......10851
Supplemental Restraint System (SRS) "AIR BAG"......10851
Precautions for On Board Diagnostic (OBD) System of Engine and A/T......10851
Engine Fuel & Emission Control System......10852
Precautions......10853
ENGINE AND EMISSION CONTROL OVERALL SYSTEM......10855
Circuit Diagram......10855
System Diagram......10856
ECCS Component Parts Location......10857
Vacuum Hose Drawing......10859
System Chart......10860
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION......10861
Multiport Fuel Injection (MFI) System......10861
Distributor Ignition (DI) System......10863
Air Conditioning Cut Control......10864
Fuel Cut Control (at no load & high engine speed)......10865
EVAPORATIVE EMISSION SYSTEM......10866
Description......10866
Inspection......10866
Evaporative Emission Line Drawing......10868
POSITIVE CRANKCASE VENTILATION......10870
Description......10870
Inspection......10870
BASIC SERVICE PROCEDURE......10871
Fuel Pressure Release......10871
Fuel Pressure Check......10871
Injector Removal and Installation......10872
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment......10873
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION......10879
Introduction......10879
Two Trip Detection Logic......10879
Diagnostic Trouble Code (DTC)......10879
Freeze Frame Data......10880
Malfunction Indicator Lamp (MIL)......10881
OBD System Operation Chart......10885
CONSULT......10890
Generic Scan Tool (GST)......10903
TROUBLE DIAGNOSIS - Introduction......10905
Introduction......10905
Diagnostic Worksheet......10906
TROUBLE DIAGNOSIS - Work Flow......10907
Work Flow......10907
Description for Work Flow......10908
TROUBLE DIAGNOSIS - Basic Inspection......10909
Basic Inspection......10909
TROUBLE DIAGNOSIS - General Description......10913
Diagnostic Trouble Code (DTC) Chart......10913
Fail-Safe Chart......10930
Symptom Matrix Chart (For New CT/CS)......10931
Symptom Matrix Chart (For Old CT/CS)......10934
CONSULT Reference Value in data Monitor Mode......10937
Major Sensor Reference Graph in data Monitor Mode......10940
ECM Terminals and Reference Value......10942
TROUBLE DIAGNOSIS FOR POWER SUPPLY......10949
Main Power Supply and Ground Circuit......10949
DTC P0100, Mass Air Flow Sensor (MAFS) (DTC: 0102)......10952
DTC P0105, Absolute Pressure Sensor (DTC: 0803)......10957
DTC P0110, Intake Air Temperature Sensor (DTC: 0401)......10964
DTC P0115, Engine Coolant Temperature Sensor (ECTS) (DTC: 0103)......10969
DTC P0120, Throttle Position Sensor (DTC: 0403)......10973
DTC P0125, Engine Coolant Temperature (ECT) Sensor (DTC: 0908)......10978
DTC P0130, Front Heated Oxygen Sensor (Front HO2S) (DTC: 0303)......10983
DTC P0130, Closed Loop Control (DTC: 0307)......10988
DTC P0135, Front Heated Oxygen Sensor Heater (DTC: 0901)......10989
DTC P0136, Rear Heated Oxygen Sensor (Rear HO2S) (DTC: 0707)......10992
DTC P0171, Fuel Injection System Function (Lean side) (DTC: 0115)......10997
DTC P0172, Fuel Injection System Function (Rich side) (DTC: 0114)......11002
DTC P0180, Tank Fuel Temperature Sensor (DTC: 0402)......11006
DTC P0300 - P0304, No. 4 - 1 Cylinder Misfire, Multiple Cylinder Misfire (DTC: 0701 - 0605)......11009
DTC P0325, Knock Sensor (KS) (DTC: 0304)......11013
DTC P0335, Crankshaft Position Sensor (CKPS) (OBD) (DTC: 0802)......11016
DTC P0340, Camshaft Position Sensor (CMPS) (DTC: 0101)......11020
DTC P0400, EGR Function (DTC: 0302)......11024
DTC P0402, EGRC-BPT Valve Function (DTC: 0306)......11032
DTC P0420, Three Way Catalyst Function (DTC: 0702)......11034
DTC P0440, Evaporative Emission (EVAP) Control System (Small Leak) (DTC: 0705)......11037
DTC P0443, Evaporative Emission (EVAP) Canister Purge Control Valve/Solenoid Valve (DTC: 0807)......11046
DTC P0446, Evaporative Emission (EVAP) Canister Vent Control Valve (DTC: 0903)......11054
DTC P0450, Evaporative Emission (EVAP) Control System Pressure Sensor (DTC: 0704)......11059
DTC P0500, Vehicle Speed Sensor (VSS) (DTC: 0104)......11063
DTC P0505, Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve (DTC: 0205)......11067
DTC P0510, Closed Throttle Position Switch (DTC: 0203)......11072
DTC P0600, A/T Control......11076
DTC P0605, Engine Control Module (ECM)-ECCS Control Module (DTC: 0301)......11079
DTC P0705, Park Nuetral Position Switch (DTC: 1003)......11081
DTC P1105, Manifold Pressure (MAP)/Barometric Pressure (BARO) Switch Solenoid Valve (DTC: 1302)......11086
DTC P1320, Ignition Signal (DTC: 0201)......11092
DTC P1336, Crankshaft Position Sensor (CKPS) (OBD) (DTC: 0905)......11097
DTC P1400, EGRC-Solenoid Valve (DTC: 1005)......11101
DTC P1401, EGR Temperature Sensor (DTC: 0305)......11105
DTC P1441, Vacuum Cut Valve Bypass Valve (DTC: 0801)......11110
DTC P1445, Evaporative Emission (EVAP) Canister Purge Volume Control Valve (DTC: 1008)......11115
DTC P1447, Evaporative Emission (EVAP) Control System Purge Flow Monitoring (DTC: 0111)......11121
DTC P1605, A/T Diagnosis Communication line (DTC: 0804)......11128
DTC P1900, Cooling Fan (DTC: 1308)......11131
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS......11143
Injector......11143
Start Signal......11146
Fuel Pump......11148
Power Steering Oil Pressure Switch......11153
IACV-Air Regulator......11156
IACV-FICD Solenoid Valve......11159
5th Position Switch......11163
Rear Window Defogger Signal......11165
Electrical Load Signal......11167
MIL & Data Link Connectors......11169
TROUBLE DIAGNOSIS - Index......11170
Alphabetical & P No. Index for DTC......11170
SERVICE DATA AND SPECIFICATIONS (SDS)......11172
General Specifications......11172
Inspection and Adjustment......11172
EL......11174
TABLE OF CONTENTS......11174
PRECAUTIONS......11177
Supplemental Restraint System (SRS) "AIR BAG"......11177
HARNESS CONNECTOR......11178
Description......11178
STANDARDIZED RELAY......11179
Description......11179
POWER SUPPLY ROUTING......11181
Schematic......11181
Wiring Diagram - POWER -......11183
Fuse......11192
Fusible Link......11192
Circuit Breaker Inspection......11192
GROUND DISTRIBUTION......11193
BATTERY......11196
How to Handle Battery......11196
Service Data and Specifications (SDS)......11199
STARTING SYSTEM......11200
System Description......11200
Wiring Diagram - START -......11202
Construction......11205
Removal and Installation......11205
Pinion/Clutch Check......11206
Service Data and Specifications (SDS)......11206
CHARGING SYSTEM......11207
System Description......11207
Wiring Diagram - CHARGE -......11208
Construction......11209
Removal and Installation......11209
Trouble Diagnoses......11210
Service Data and Specifications (SDS)......11211
COMBINATION SWITCH......11212
Combination Switch/Check......11212
Replacement......11213
Steering Switch/Check......11214
HEADLAMP......11215
System Description (For USA)......11215
Wiring Diagram (For USA) - H/LAMP -......11216
Trouble Diagnoses (For USA)......11217
System Description (For Canada)......11218
Operation (Daytime light system for Canada)......11219
Schematic (For Canada)......11220
Wiring Diagram (For Canada) - DTRL -......11221
Trouble Diagnoses (For Canada)......11224
Bulb Replacement......11225
Aiming Adjustment......11226
EXTERIOR LAMP......11227
Clearance, License, Tail and Stop Lamps/Wiring Diagram - TAIL/L -......11227
Back-up Lamp/Wiring Diagram - BACK/L -......11229
Front Fog Lamp/System Description......11231
Front Fog Lamp/Wiring Diagram - F/FOG -......11232
Front Fog Lamp Aiming Adjustment......11233
Turn Signal and Hazard Warning Lamps/System Description......11234
Turn Signal and Hazard Warning Lamps/Schematic......11236
Turn Signal and Hazard Warning Lamps/Wiring Diagram - TURN -......11237
Turn Signal and Hazard Warning Lamps/Trouble Diagnoses......11240
Combination Flasher Unit Check......11240
Bulb Specifications......11241
INTERIOR LAMP......11242
Illumination/System Description......11242
Illumination/Schematic......11243
Illumination/Wiring Diagram - ILL -......11244
Interior, Spot and Trunk Room Lamps/System Description......11247
Bulb Specifications......11247
Interior, Spot and Trunk Room Lamps/Wiring Diagram - INT -......11248
METER AND GAUGES......11250
System Description......11250
Combination Meter......11251
Speedometer, Tachometer, Temp. and Fuel Gauges/Wiring Diagram - METER -......11252
Inspection/Fuel Gauge and Water Temperature Gauge......11253
Inspection/Tachometer......11254
Inspection/Speedometer and Vehicle Speed Sensor......11255
Fuel Tank Gauge Unit Check......11256
Thermal Transmitter Check......11256
Vehicle Speed Sensor Signal Check......11256
WARNING LAMPS AND BUZZER......11257
Warning Lamps/Schematic......11257
Warning Lamps/Wiring Diagram - WARN -......11258
Fuel Warning Lamp Sensor Check......11261
Oil Pressure Switch Check......11261
Warning Buzzer/System Description......11262
Warning Buzzer/Wiring Diagram - CHIME-......11264
Trouble Diagnoses - Warning Buzzer......11266
Diode Check......11275
Warning Buzzer Check......11275
WIPER AND WASHER......11276
System Description......11276
Front Wiper and Washer/Wiring Diagram - WIPER -......11278
Trouble Diagnoses......11280
Wiper Amplifier Check......11282
Wiper Installation and Adjustment......11282
Washer Nozzle Adjustment......11282
Washer Tube Layout......11283
Wiper Linkage......11284
HORN, CIGARETTE LIGHTER AND CLOCK......11285
Wiring Diagram - HORN -......11285
REAR WINDOW DEFOGGER......11286
System Description......11286
Wiring Diagram - DEF -......11287
Trouble Diagnoses......11289
Filament Check......11291
Filament Repair......11292
AUDIO AND POWER ANTENNA......11294
Audio/System Description......11294
Audio/Schematic......11295
Audio/Wiring Diagram - AUDIO -......11297
Power Antenna/System Description......11302
Power Antenna/Wiring Diagram - P/ANT -......11303
Trouble Diagnoses......11304
Location of Antenna......11305
Antenna Rod Replacement......11306
Window Antenna Repair......11306
POWER SUNROOF......11308
Wiring Diagram - SROOF -......11308
DOOR MIRROR......11309
Wiring Diagram - MIRROR -......11309
AUTOMATIC SPEED CONTROL DEVICE (ASCD)......11311
Component Parts and Harness Connector Location......11311
System Description......11312
Schematic......11314
Wiring Diagram - ASCD -......11315
Trouble Diagnoses......11320
ASCD Wire Adjustment......11334
POWER WINDOW......11335
System Description......11335
Wiring Diagram - WINDOW -......11337
Trouble Diagnoses......11339
POWER DOOR LOCK......11340
System Description......11340
Wiring Diagram - D/LOCK -......11341
Trouble Diagnosis......11343
MULTI-REMOTE CONTROL SYSTEM......11346
System Description......11346
Schematic......11348
Wiring Diagram - MULTI -......11349
Input/Output Operation Signal......11352
Trouble Diagnoses......11353
Replacing Remote Controller or Control Unit......11358
THEFT WARNING SYSTEM......11359
Component Parts and Harness Connector Location......11359
Schematic......11360
Wiring Diagram - THEFT -......11361
Trouble Diagnoses......11368
LOCATION OF ELECTRICAL UNITS......11387
Engine Compartment......11387
Passenger Compartment......11388
HARNESS LAYOUT......11390
Outline......11390
Main Harness......11391
Engine Room Harness......11393
Engine Harness......11396
Engine Control Harness......11397
Body Harness and Tail Harness......11399
Room Lamp......11401
Air Bag Harness......11402
Door Harness LH......11403
Door Harness RH......11403
EM......11404
TABLE OF CONTENTS......11404
PRECAUTIONS......11405
Parts Requiring Angular Tightening......11405
Liquid Gasket Application Procedure......11405
PREPARATION......11406
Special Service tools......11406
Commercial Service Tools......11409
OUTER COMPONENT PARTS......11410
COMPRESSION PRESSURE......11412
Measurement of Compression Pressure......11412
OIL PAN......11413
Removal......11413
Installation......11414
TIMING CHAIN......11415
Removal......11417
Inspection......11420
Installation......11420
OIL SEAL REPLACEMENT......11424
CYLINDER HEAD......11426
Removal and Installation......11427
Disassembly......11427
Inspection......11428
Assembly......11433
Valve Clearance......11433
ENGINE REMOVAL......11436
Removal......11437
CYLINDER BLOCK......11438
Disassembly......11439
Inspection......11440
Assembly......11446
SERVICE DATA AND SPECIFICATIONS (SDS)......11450
General Specifications......11450
Inspection and Adjustment......11450
FA......11458
TABLE OF CONTENTS......11458
PRECAUTIONS AND PREPARATION......11459
Precautions......11459
Special Service Tools......11459
Commercial Service Tools......11460
FRONT SUSPENSION SYSTEM......11461
ON-VEHICLE SERVICE......11462
Front Axle and Front Suspension Parts......11462
Front Wheel Bearing......11462
Front Wheel Alignment......11463
FRONT AXLE......11465
Wheel Hub and Knuckle......11465
ABS Sensor Rotor......11467
Baffle Plate......11468
FRONT SUSPENSION......11469
Coil Spring and Strut Assembly......11470
Tension Rod and Stabilizer Bar......11471
Transverse Link and Lower Ball Joint......11472
SERVICE DATA AND SPECIFICATIONS (SDS)......11473
General Specifications......11473
Inspection and Adjustment......11474
FE......11475
TABLE OF CONTENTS......11475
PREPARATION/ACCELERATOR CONTROL SYSTEM......11476
Special Service Tool......11476
Accelerator Control System......11476
Adjusting Accelerator Wire......11476
FUEL SYSTEM......11477
Fuel Tank......11477
Fuel Pump and Gauge......11479
EXHAUST SYSTEM......11481
FOLDOUT......11482
SUPER MULTIPLE JUNCTION (SMJ)......11482
Disconnecting and Connecting......11482
Terminal Arrangement......11483
ELECTRICAL UNITS......11484
Terminal Arrangement......11484
FWD......11485
QUICK REFERENCE INDEX......11485
FOREWORD......11486
QUICK REFERENCE CHART......11487
GI......11488
TABLE OF CONTENTS......11488
PRECAUTIONS......11489
Precautions for Supplemental Restraint System (SRS) "AIR BAG"......11489
General Precautions......11489
Precautions for Multiport Fuel Injection System or ECCS Engine......11491
Precautions for Three Way Catalyst......11492
Engine Oils......11492
Precautions for Fuel......11493
Precautions for Air Conditioning......11493
HOW TO USE THIS MANUAL......11494
HOW TO READ WIRING DIAGRAMS......11496
Sample/Wiring Diagram - EXAMPL -......11496
Description......11498
Wiring Diagram Codes (Cell Codes)......11504
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR ELECTRICAL INCICENT......11505
Work Flow......11505
Incident Simulation Tests......11506
Circuit Inspection......11510
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES......11516
CONSULT CHECKING SYSTEM......11519
Function and System Application......11519
Lithium Battery Replacement......11519
Checking Equipment......11519
IDENTIFICATION INFORMATION......11520
Model Variation......11520
Ientification Number......11521
Dimensions......11523
Wheels and Tires......11523
LIFTING POINTS AND TOW TRUCK TOWING......11524
Prepartion......11524
Board-on Lift......11524
Garage Jack and Safety Stand......11525
2-pole Lift......11526
Tow Truck Towing......11526
TIGHTENING TORQUE OF STANDARD BOLTS......11528
SAE J1930 TERMINOLOGY LIST......11529
SAE J1930 Terminology List......11529
HA......11533
TABLE OF CONTENTS......11533
PRECAUTIONS AND PREPARATION......11534
Supplemental Restraint System (SRS) "AIR BAG"......11534
Precautions for Working with HFC-134a (R-134a)......11534
General Refrigerant Precautions......11534
Precautions for Refrigerant Connection......11535
Precautions for Servicing Compressor......11536
Special Service Tools......11536
HFC-134a (R-134a) Service Tools and Equipment......11537
Precautions for Service Equipment......11539
DESCRIPTION......11541
Refrigeration Cycle......11541
Component Layout......11542
Discharge Air Flow......11543
Control Operation......11544
V-6 Variable Displacement Compressor......11545
TROUBLE DIAGNOSES......11550
Contents......11550
Wiring Diagram - A/C -......11571
SERVICE PROCEDURES......11594
HFC-134a (R-134a) Service Procedure......11594
Maintenance of Lubricant Quantity in Compressor......11596
Refrigerant Lines......11598
Checking Refrigerant Leaks......11599
Compressor Mounting......11601
Belt Tension......11601
Fast Idle Control Device......11601
Push Control Unit......11602
Compressor......11603
Compressor Clutch......11603
SERVICE DATA AND SPECIFICATIONS (SDS)......11607
General Specifications......11607
Inspection and Adjustment......11607
IDX......11608
LC......11615
TABLE OF CONTENTS......11615
PRECAUTIONS AND PREPARATION......11616
Liquid Gasket Application Procedure......11616
Special Service Tools......11616
ENGINE LUBRICATION SYSTEM......11618
Lubrication Circuit......11618
Oil Pressure Check......11618
Oil Pump......11619
ENGINE COOLING SYSTEM......11621
Cooling Circuit......11621
System Check......11621
Water Pump......11622
Thermostat......11623
Radiator......11624
Cooling Fan (Crankshaft driven)......11627
Cooling Fan Control system......11627
Overheating Cause Analysis......11628
SERVICE DATA AND SPECIFICATIONS (SDS)......11629
Engine Lubrication System......11629
Engine Cooling System......11629
MA......11630
TABLE OF CONTENTS......11630
PRECAUTIONS......11631
Supplemental Restraint System (SRS) "AIR BAG"......11631
GENERAL MAINTENANCE......11632
PERIODIC MAINTENANCE......11634
Schedule 1......11635
Schedule 2......11636
RECOMMENDED FLUIDS AND LUBRICANTS......11637
Fluids and Libricants......11637
SAE Viscosity Number......11637
Anti-freeze Coolant Mixture Ratio......11638
ENGINE MAINTENANCE......11639
Checking Drive Belts......11639
Changing Engine Coolant......11640
Checking Fuel Lines......11641
Changing Fuel Filter......11642
Changing Air Cleaner Filter......11642
Changing Engine Oil......11643
Changing Oil Filter......11643
Changing Spark Plugs......11644
Checking EVAP Vapor Purge Lines......11645
CHASSIS AND BODY MAINTENANCE......11646
Checking Exhaust System......11646
Checking Clutch Fluid Level and Leaks......11646
Checking M/T Oil......11646
Changing M/T Oil......11646
Checking A/T Fluid......11647
Changing A/T Fluid......11647
Checking Differential Gear Oil......11648
Changing Differential Gear Oil......11648
Balancing Wheels......11648
Tire Rotation......11648
Checking Brake Fluid Level and Leaks......11648
Checking Brake Lines and Cables......11648
Checking Disc Brake......11649
Checking Steering Gear Linkage......11649
Checking Power Steering Fluid Lines......11649
Lubricating Locks, Hinges and Hood atches......11651
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters......11651
SERVICE DATA AND SPECIFICATIONS (SDS)......11652
Engine Maintenance......11652
Chassis and Body Maintenance......11652
MT......11653
TABLE OF CONTENTS......11653
PREPARATION......11654
Special Service Tools......11654
Commercial Service Tool......11656
ON-VEHICLE SERVICE......11657
Replacing Rear Oil Seal......11657
Position Switch Check......11657
REMOVAL AND INSTALLATION......11658
Removal......11658
Installation......11659
MAJOR OVERHAUL......11660
Case Components......11660
Gear Components......11661
Shift Control Components......11662
DISASSEMBLY......11663
Case Components......11663
Shift Control Components......11664
Gear components......11664
INSPECTION......11667
Shift Control Components......11667
Gear Components......11667
ASSEMBLY......11669
Gear Components......11669
Shift Control Components......11675
Case Components......11676
SERVICE DATA AND SPECIFICATIONS (SDS)......11679
General Specifications......11679
Inspection and Adjustment......11680
PD......11682
TABLE OF CONTENTS......11682
PREPARATION......11683
Special Service Tools......11683
Commercial Service Tool......11685
PROPELLER SHAFT......11686
PROPELLER SHAFT......11686
On-vehicle Service......11687
Removal......11687
Installation......11687
Inspection......11688
Disassembly......11689
Assembly......11689
FINAL DRIVE......11690
ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION......11690
Front Oil Seal Replacement......11690
Side Oil Seal Replacement......11690
Removal......11691
Installation......11692
FINAL DRIVE......11693
DISASSEMBLY......11695
Pre-inspection......11695
Differential Carrier......11695
Differential Case......11697
INSPECTION......11699
Ring Gear and Drive Pinion......11699
Bearing......11699
Differential Case Assembly......11699
ADJUSTMENT......11700
Side Bearing Preload......11700
Pinion Gear Height and Pinion Bearing Preload......11701
Tooth Contact......11706
ASSEMBLY......11707
Differential Case......11707
Differential Carrier......11709
SERVICE DATA AND SPECIFICATIONS (SDS)......11713
Propeller Shaft......11713
Final Drive......11713
RA......11715
TABLE OF CONTENTS......11715
PRECAUTIONS AND PREPARATION......11716
Precautions......11716
Special Service Tools......11716
Commercial Service Tools......11717
REAR SUSPENSION SYSTEM......11718
ON-VEHICLE SERVICE......11719
Rear Axle and Rear Suspension Parts......11719
Rear Wheel Bearing......11719
Rear Wheel Alignment......11719
Drive Shaft......11721
REAR AXLE......11722
Wheel Hub and Axle Housing......11722
Drive Shaft......11726
REAR SUSPENSION......11732
Removal and Installation......11733
Coil Spring and Shock Absorber......11734
Multi-link and Lower Ball Joint......11735
Stabilizer Bar......11736
SERVICE DATA AND SPECIFICATIONS (SDS)......11737
General Specifications......11737
Inspection and Adjustment......11738
RS......11739
TABLE OF CONTENTS......11739
PRECAUTIONS......11740
Supplemental Restraint System (SRS) "AIR BAG"......11740
SEAT BELTS......11741
Front Seat Belt......11741
Rear Seat Belt......11742
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)......11743
Precautions for SRS "Air Bag" Service......11743
Special Service Tools......11743
Description......11744
SRS Component Parts Location......11744
Maintenance Items......11745
Removal and Installation - Diagnosis Sensor Unit......11746
Removal - Air Bag Module and Spiral Cable......11747
Removal - Front Passenger Air Bag Module......11748
Installation - Air Bag Module and Spiral Cable......11749
Intallation - Front Passenger Air Bag Module......11750
Disposal of Air Bag Module......11751
TROUBLE DIAGNOSES - Supplemental Restraing System (SRS)......11755
Schematic......11755
Wiring Diagram - SRS -......11756
How to Perform Trouble Diagnoses for Quick and Accurate Repair......11758
Self-diagnosis......11760
Trouble Diagnoses for Air Bag Warning Lamp......11773
COLLISION DIAGNOSIS......11775
ST......11776
TABLE OF CONTENTS......11776
PRECAUTIONS AND PREPARATION......11777
Precautions......11777
Special Service Tools......11777
Commercial Service Tools......11779
ON-VEHICLE SERVICE......11780
Checking Steering Wheel Play......11780
Checking Nuetral Position on Steering Wheel......11780
Front Wheel Turning Angle......11780
Checking Gear Housing Movement......11781
Adjusting Rack Retainer......11781
Checking and Adjusting Drive Belts (For power steering)......11781
Checking Fluid Level......11781
Checking Fluid Leakage......11781
Bleeding Hydraulic System......11782
Checking Steering Wheel Turning Force (For power steering)......11782
Checking Hydraulic System......11783
STEERING WHEEL AND STEERING COLUMN......11784
Removal and Installation......11784
Disassembly and Assembly......11786
Inspection......11787
POWER STEERING GEAR AND LINKAGE (Model PR24AC)......11788
Removal and Installation......11788
Disassembly and Assembly......11790
Disassembly......11791
Inspection......11791
Assembly......11792
Adjustment......11796
POWER STEERING OIL PUMP......11798
Disassembly and Assembly......11798
Pre-disassembly Inspection......11798
Disassembly......11799
Inspection......11799
Assembly......11800
SERVICE DATA AND SPECIFICATIONS (SDS)......11801
General Specifications......11801
Inspection and Adjustment......11801
240SX '97......11803
AT......11804
TABLE OF CONTENTS......11804
PREPARATION AND PRECAUTIONS......11806
Special Service Tools......11806
Supplemental Restraint System (SRS) " AIR BAG"......11807
Precautions for On Board Diagnostic (OBD) System of A/T and Engine......11807
Precautions......11808
Service Notice or Precautions......11809
OVERALL SYSTEM......11810
A/T Electrical Parts Location......11810
Circuit Diagram......11811
Wiring Diagram – AT –......11812
Cross-sectional View......11817
Hydraulic Control Circuit......11818
Shift Mechanism......11819
Control System......11821
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION......11823
Introduction......11823
One or Two Trip detection Logic......11823
Diagnostic Trouble Code (DTC)......11823
Self-diagnosis......11825
Diagnosis by CONSULT......11830
TROUBLE DIAGNOSIS – Introduction......11833
Introduction......11833
Dignostic Worksheet......11834
Work Flow......11837
TROUBLE DIAGNOSIS – Basic Inspection......11838
A/T Fluid Check......11838
Road Test......11838
Shift Schedule......11848
TROUBLE DIAGNOSIS – General Description......11850
Diagnostic Trouble Code (DTC) Chart......11850
Symptom Chart......11852
A/T Control Unit Terminals and Reference Value......11855
DTC P0705, Inhibitor, Overdrive Control Throttle Position Switches......11859
DTC P0710, A/T Fluid Temperature Sensor Circuit and A/T Control Unit Power Source......11865
DTC P0720, Vehicle Speed Sensor-A/T (Revolution sensor)......11868
DTC P0725, Engine Speed Signal......11870
DTC P0731, Improper Shifting to 1st Gear Position......11872
DTC P0732, Improper Shifting to 2nd Gear Postion......11875
DTC P0733, Improper Shifting to 3rd Gear Position......11877
DTC P0734, Improper Shifting to 4th Gear Postion......11879
DTC P0740, Torque Converter Clutch Solenoid Valve......11884
DTC P0744, Improper Lock-up Operation......11887
DTC P0745, Line Pressure Solenoid Valve......11892
DTC P0750, Shift Solenoid Valve A......11895
DTC P0755, Shift Solenoid Valve B......11898
DTC P1705, Throttle Position Sensor......11901
DTC P1760, Overrun Clutch Solenoid Valve......11903
TROUBLE DIAGNOSIS FOR VHCL SPEED SEN-MTR......11906
Vehicle Speed Sensor-MTR......11906
DIAGNOSTIC PROCEDURES FOR SYMPTOMS......11908
1. O/D OFF Indicator Lamp Does Not Come On......11908
2. Engine Cannot Be Started In "P" and "N" Position......11909
3. In "P" Postion, Vehicle Moves Forward Or Backward When Pushed......11909
4. In "N" Position, Vehicle Moves......11910
5. Large Shock. "N" - "R" Postion......11911
6. Vehicle Does Not Creep Backward In "R" Postion......11912
7. Vehicle Does Not Creep Forward In "D", "2" Or "1" Postion......11913
8. Vehicle Cannot Be Started From D1......11914
9. A/T Does Not Shift: D1 - D2 Or Does Not Kickdown: D4 - D2......11915
10. A/T Does Not Shift: D2 - D3......11916
11. A/T Does Not Shift: D3 - D4......11917
12. A/T Does Not Perform Lock-up......11918
13. A/T Does Not Hold Lock-up Condition......11919
14. Lock-up Is Not Released......11919
15. Engine Speed Does Not Return To Idle (Light Braking D4 - D3......11920
16. Vehicle Does Not Start From D1......11921
17. A/T Does Not Shift: D4 - D3, When Overdrive Control Switch "ON" - "OFF"......11921
18. A/T Does Not Shift: D3 - 22, When Selector Lever "D" - "2" Position......11922
19. A/T Does Not Shift: 22 - 11, When Selector Lever "2" - "1" Postion......11922
20. Vehicle Does Not Decelerate By Engine Brake......11923
TROUBLE DIAGNOSES......11924
Final Check......11924
TROUBLE DIAGNOSES – A/T Shift Lock System......11929
Description......11929
Wiring diagram – SHIFT –......11930
Diagnostic Procedure......11931
Key Interlock Cable......11933
Component Check......11934
ON-VEHICLE SERVICE......11936
Control Valve Assembly and Accumulators......11936
Revolution Sensor Replacement......11936
Rear Oil Seal Replacement......11937
Parking Components Inspection......11937
Inhibitor Switch Adjustment......11938
Manual Control Linkage Adjustment......11938
REMOVAL AND INSTALLATION......11939
Removal......11939
Installation......11941
MAJOR OVERHAUL......11942
Oil Channel......11944
Locations of Needle Bearings, Thrust Washers and Snap Rings......11945
DISASSEMBLY......11946
Disassembly......11946
REPAIR FOR COMPONENT PARTS......11957
Oil Pump......11957
Control Valve Assembly......11961
Control Valve Upper Body......11967
Control Valve Lower Body......11972
Reverse Clutch......11974
High Clutch......11978
Forward and Overrun Clutches......11980
Low & Reverse Brake......11984
Forward Clutch Drum Assembly......11988
Rear Internal Gear and Forward Clutch Hub......11990
Band Servo Piston Assembly......11993
Parking Pawl Components......11997
ASSEMBLY......11999
Assembly (1)......11999
Adjustment......12003
Assembly (2)......12007
SERVICE DATA AND SPECIFICATIONS (SDS)......12017
General Specifications......12017
Specifications and Adjustment......12017
BR......12021
TABLE OF CONTENTS......12021
PRECAUTIONS AND PREPARATION......12023
Precautions......12023
Commercial Service Tools......12023
BRAKE HYDRAULIC LINE/CONTROL VALVE......12024
Brake Hydraulic Line......12024
Proportioning Valve......12025
CHECK AND ADJUSTMENT......12026
Checking Brake Fluid Level......12026
Checking Brake Line......12026
Changing Brake Fluid......12026
Bleeding Brake System......12027
BRAKE PEDAL AND BRACKET......12028
Removal and Installation......12028
Inspection......12028
Adjustment......12028
MASTER CYLINDER......12029
Removal......12029
Disassembly......12030
Inspection......12030
Assembly......12030
Installation......12031
BRAKE BOOSTER/VACUUM HOSE......12032
Brake Booster......12032
Vacuum Hose......12033
FRONT DISC BRAKE......12034
Pad Replacement......12034
Removal......12036
Disassembly......12036
Inspection – Caliper......12036
Inspection – Rotor......12037
Assembly......12037
Installation......12037
REAR DISC BRAKE......12038
Pad Replacement......12038
Removal......12040
Disassembly......12040
Inspection – Caliper......12041
Inspection – Rotor......12042
Assembly......12042
Installation......12044
PARKING BRAKE CONTROL......12045
Removal and Installation......12045
Inspection......12046
Adjustment......12046
ANTI-LOCK BRAKE SYSTEM......12047
Purpose......12047
Operation......12047
ABS Hydraulic Circuit......12047
System Components......12048
System Description......12048
Removal and Installation......12050
TROUBLE DIAGNOSES......12053
How to Perform Trouble Diagnoses for Quick and Accurate Repair......12053
Preliminary Check......12054
Component Parts and Harness Connector Location......12055
Circuit Diagram for Quick Pinpoint Check......12056
Wiring Diagram – ABS –......12057
Self-diagnosis......12062
CONSULT......12065
CONSULT Inspection Procedure......12066
Ground Circuit Check......12071
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS......12072
Diagnostic Procedure 1 (Wheel sensor or rotor)......12072
Diagnostic Procedure 2 (ABS actuator solenoid valve)......12074
Diagnostic Procedure 3 (Solenoid valve relay)......12075
Diagnostic Procedure 4 (Motor relay or motor)......12078
Diagnostic Procedure 5 (Low voltage)......12081
Diagnostic Procedure 6 (Control unit)......12082
TROUBLE DIAGNOSES FOR SYMPTOMS......12083
Diagnostic Procedure 7 (ABS works frequently.)......12083
Diagnostic Procedure 8 (Unexpected pedal action)......12084
Diagnostic Procedure 9 (Long stopping distance)......12084
Diagnostic Procedure 10 (ABS does not work.)......12085
Diagnostic Procedure 11 (Pedal vibration and noise)......12085
Diagnostic Procedure 12 (Warning lamp does not come on when ignition switch is turned on.)......12086
Diagnostic Procedure 13 (Warning lamp stays on when ignition switch is turned on.)......12088
Electrical Component Inspection......12091
SERVICE DATA AND SPECIFICATIONS (SDS)......12093
General Specifications......12093
Inspection and Adjustment......12093
BT......12094
TABLE OF CONTENTS......12094
PRECAUTIONS......12095
Service Notice......12095
Supplemental Restraint System (SRS) "AIR BAG"......12095
GENERAL SERVICING......12096
Clip and Fastener......12096
BODY END......12099
Body Front End......12099
Body Rear End and Opener......12102
DOOR......12104
Door Glass Fitting Adjustment......12105
INSTRUMENT PANEL......12109
INTERIOR TRIM......12112
Side and Floor Trim......12112
Door Trim......12114
Roof Trim......12115
Trunk Room Trim......12116
EXTERIOR......12117
SEAT......12124
Front Seat......12124
Rear Seat......12126
SUNROOF......12127
WINDSHIELD AND WINDOWS......12131
Windshield and Rear Window......12131
Side Window......12132
MIRROR......12133
Door Mirror......12133
BODY ALIGNMENT......12134
Engine Compartment......12134
Underbody......12136
CL......12138
TABLE OF CONTENTS......12138
PRECAUTIONS AND PREPARATION......12139
Precautions......12139
Special Service Tools......12139
Commercial Service Tools......12139
CLUTCH SYSTEM......12140
INSPECTION AND ADJUSTMENT......12141
Adjusting Clutch Pedal......12141
Bleeding Procedure......12142
HYDRAULIC CLUTCH CONTROL......12143
Clutch Master Cylinder......12143
Operating Cylinder......12144
CLUTCH RELEASE MECHANISM......12145
CLUTCH DISC AND CLUTCH COVER......12147
Clutch Disc......12147
Clutch Cover and Flywheel......12148
SERVICE DATA AND SPECIFICATIONS (SDS)......12149
General Specifications......12149
Inspection and Adjustment......12149
EC......12150
TABLE OF CONTENTS......12150
DIAGNOSTIC TROUBLE CODE INDEX......12152
Alphabetical & P No. Index for DTC......12152
PRECAUTIONS AND PREPARATION......12154
Special Service Tools......12154
Commercial Service Tool......12154
Supplemental Restraint System (SRS) "AIR BAG"......12155
Precautions for On Board Diagnostic (OBD) System of Engine and A/T......12155
Engine Fuel & Emission Control System......12156
Precautions......12157
ENGINE AND EMISSION CONTROL OVERALL SYSTEM......12159
Circuit Diagram......12159
System Diagram......12160
ECCS Component Parts Location......12161
Vacuum Hose Drawing......12163
System Chart......12164
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION......12165
Multiport Fuel Injection (MFI) System......12165
Distributor Ignition (DI) System......12167
Air conditioning Cut Control......12168
Fuel Cut Control (at no load & high engine speed)......12169
EVAPORATIVE EMISSION SYSTEM......12170
Description......12170
Inspection......12170
Evaporative Emission Line Drawing......12172
POSITIVE CRANKCASE VENTILATION......12174
Description......12174
Inspection......12174
BASIC SERVICE PROCEDURE......12175
Fuel Pressure Release......12175
Fuel Pressure Check......12175
Injector Removal and Installation......12176
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment......12177
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION......12183
Introduction......12183
Two Trip Detection Logic......12183
Emission-related Diagnostic Information......12184
Malfunction Indicator Lamp (MIL)......12194
OBD System Operation Chart......12197
CONSULT......12202
Generic Scan Tool (GST)......12215
TROUBLE DIAGNOSIS – Introduction......12217
Introduction......12217
Diagnostic Worksheet......12217
TROUBLE DIAGNOSIS – Work Flow......12219
Work Flow......12219
Description for Work Flow......12220
TROUBLE DIAGNOSIS – Basic Inspection......12221
Basic Inspection......12221
TROUBLE DIAGNOSIS – General Description......12224
Diagnostic Trouble Code (DTC) Inspection Priority Chart......12224
Fail-Safe Chart......12225
Symptom Matrix Chart......12226
CONSULT Reference Value in Data Monitor Mode......12229
Major Sensor Reference Graph in Data Monitor Mode......12232
ECM Terminals and Reference Value......12234
TROUBLE DIAGNOSIS FOR POWER SUPPLY......12241
Main Power Supply and Ground Circuit......12241
DTC P0100, Mass Air Flow Sensor (MAFS)......12244
DTC P0105, Absolute Pressure Sensor......12249
DTC P0110, Intake Air Temperature Sensor......12256
DTC P0115, Engine Coolant Temperature Sensor (ECTS)......12261
DTC P0120, Throttle Position Sensor......12266
DTC P0125, Engine Coolant Temperature (ECT) Sensor......12271
DTC P0130, Front Heated Oxygen Sensor (Front HO2S)......12276
Closed Loop Control......12281
DTC P0135, Front Heated Oxygen Sensor Heater......12282
DTC P0136, Rear Heated Oxygen Sensor (Rear HO2S)......12285
DTC P0141, Rear Heated Oxygen Sensor Heater......12289
DTC P0171, Fuel Injection system Function (Lean side)......12293
DTC P0172, Fuel Injection System Function (Rich side)......12298
DTC P0180, Tank Fuel Temperature Sensor......12303
DTC P0300 - P0304, No. 4 - 1 Cylinder Misfire, Multiple Cylinder Misfire......12307
DTC P0325, Knock Sensor (KS)......12311
DTC P0335, Crankshaft Position Sensor (CKPS) (OBD)......12314
DTC P0340, Camshaft Position Sensor (CMPS)......12318
DTC P0400, EGR Function......12322
DTC P0402, EGRC-BPT Valve Function......12330
DTC P0420, Three Way Catalyst Function......12332
DTC P0440, Evaporative Emission (EVAP) Control System (Small Leak)......12335
DTC P0443, Evaporative Emission (EVAP) Canister Purge Control Valve/Solenoid Valve......12345
DTC P0446, Evaporative Emission (EVAP) Canister Vent Control Valve......12353
DTC P0450, Evaporative Emission (EVAP) Control System Pressure Sensor......12359
DTC P0500, Vehicle Speed Sensor (VSS)......12363
DTC P0505, Idle Air Control Valve (IACV) – Auxiliary Air Control (AAC) Valve......12367
DTC P0510, Closed Throttle Position Switch......12372
DTC P0600, A/T Control......12376
DTC P0605, Engine Control Module (ECM)-ECCS Control Module......12379
DTC P0705, Park/Neutral Position Switch......12381
DTC P1105, Mainfold Absolute Pressure (MAP)/Barometric Pressure (BARO) Switch Solenoid Valve......12386
DTC P1320, Ignition Signal......12392
DTC P1336, Crankshaft Position Sensor (CKPS) (OBD) (COG)......12397
DTC P1400, EGRC-Solenoid Valve......12401
DTC P1401, EGR Temperature Sensor......12405
DTC P1441, Vacuum Cut Valve Bypass Valve......12410
DTC P1445, Evaporative Emission (EVAP) Canister Purge Volume Control Valve......12415
DTC P1447, Evaporative Emission (EVAP) Control System Purge Flow Monitoring......12421
DTC P1605, A/T Diagnosis Communication Line......12428
DTC P1900, Overheat......12431
TROBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS......12443
Injector......12443
Start Signal......12446
Fuel Pump......12448
Power Steering Oil Pressure Switch......12453
IACV-Air Regulator......12456
IACV-FICD Solenoid Valve......12459
5th Position Switch......12463
Electrical Load Signal......12465
MIL & Data Link Connectors......12467
SERVICE DATA AND SPECIFICATIONS (SDS)......12468
General Specifications......12468
Inspection and Adjustment......12468
EL......12470
TABLE OF CONTENTS......12470
PRECAUTIONS......12473
Supplemental Restraint System (SRS) "AIR BAG"......12473
HARNESS CONNECTOR......12474
Description......12474
STANDARDIZED RELAY......12475
Description......12475
POWER SUPPLY ROUTING......12477
Schematic......12477
Wiring Diagram – POWER –......12479
Fuse......12487
Fusible Link......12487
Circuit Breaker Inspection......12487
GROUND DISTRIBUTION......12488
BATTERY......12491
How to Handle Battery......12491
Service Data and Specifications (SDS)......12494
STARTING SYSTEM......12495
System Description......12495
Wiring Diagram – START –......12497
Construction......12499
Removal and Installation......12499
Pinion/Clutch Check......12500
Service Data and Specifications (SDS)......12500
CHARGING SYSTEM......12501
System Description......12501
Wiring Diagram – CHARGE –......12502
Construction......12503
Removal and Installation......12503
Trouble Diagnoses......12504
Service Data and Specifications (SDS)......12505
COMBINATION SWITCH......12506
Combination Switch/Check......12506
Replacement......12507
Steering Switch/Check......12508
HEADLAMP......12509
System Description (For USA)......12509
Wiring Diagram (For USA) – H/LAMP –......12510
Ttouble Diagnoses (For USA)......12511
System Description (Daytime light system for Canada)......12512
Operation (Daytime light system for Canada)......12513
Schematic (Daytime light system for Canada)......12514
Wiring Diagram (Daytime light system for Canada) – DTRL –......12515
Trouble Diagnoses (Daytime light system for Canada)......12518
Bulb Replacement......12520
Aiming Adjustment......12521
EXTERIOR LAMP......12522
Parking, License, Tail and Stop Lamps/Wiring Diagram – TAIL/L –......12522
Back-up Lamp/Wiring Diagram – BACK/L –......12524
Front Fog Lamp/System Description......12526
Front Fog Lamp/Wiring Diagram – F/FOG –......12527
Front Fog Lamp Aiming Adjustment......12528
Turn Signal and Hazard Warning Lamps/System Description......12529
Turn Signal and Hazard Warning Lamps/Schematic......12531
Turn Signal and Hazard Warning Lamps/Wiring Diagram – TURN –......12532
Turn signal and Hazard Warning Lamps/Trouble Diagnoses......12535
Combination Flasher Unit Check......12535
Bulb Specifications......12536
INTERIOR LAMP......12537
Illumination/System Description......12537
Illumination/Schmatic......12538
Illumination/Wiring Diagram – ILL –......12539
Interior, Spot and Trunk Room Lamps/System Description......12542
Bulb Specifications......12542
Interior, Spot and Trunk Room Lamps/Wiring Diagram – INT/L –......12543
METER AND GAUGES......12545
System Description......12545
Combination Meter......12546
Speedometer, Tachometer, Temp. and Fuel Gauges/Wiring Diagram – METER –......12547
Inspection/Fuel Gauge and/or Water Temperature Gauge......12548
Inspection/Trachometer......12549
Inspection/Speedometer and Vehicle Speed Sensor......12550
Fuel Tank Gauge Unit Check......12551
Thermal Transmitter Check......12551
Vehicle Speed Sensor Signal Check......12551
WARNING LAMPS......12552
Warning Lamps/Schematic......12552
Warning Lamps/Wiring Diagram – WARN –......12553
Fuel Warning Lamp Sensor Check......12556
Oil Pressure Switch Check......12556
Diode Check......12556
WARNING BUZZER......12557
Warning Buzzer/System Description......12557
Warning Buzzer/Wiring Diagram – BUZZER –......12559
Trouble Diagnoses......12561
WIPER AND WASHER......12566
System Description......12566
Front Wiper and Washer/Wiring Diagram – WIPER –......12568
Trouble Diagnoses......12571
Wiper Installation and Adjustment......12573
Washer Nozzle Adjustment......12573
Washer Tube Layout......12574
Wiper Linkage......12574
HORN, CIGARETTE LIGHTER AND CLOCK......12575
Wiring Diagram – HORN –......12575
REAR WINDOW DEFOGGER......12577
System Description......12577
Wiring Diagram – DEF –......12578
Trouble Diagnoses......12580
Filament Check......12582
Filament Repair......12583
AUDIO AND POWER ANTENNA......12585
Audio/System Description......12585
Audio (4-speaker models)/Schematic......12586
Audio (4-speaker models)/Wiring Diagram – AUDIO –......12587
Audio (6-speaker models)/Schematic......12589
Audio (6-speaker models)/Wiring Diagram – AUDIO –......12590
Power Antenna/System Description......12593
Power Antenna/Wiring Diagram – P/ANT –......12594
Trouble Diagnoses......12595
Location of Antenna......12596
Antenna Rod Replacement......12596
Window Antenna Repair......12597
POWER SUNROOF......12599
Wiring Diagram – SROOF –......12599
POWER DOOR MIRROR......12600
Wiring Diagram – MIRROR –......12600
AUTOMATIC SPEED CONTROL DEVICE (ASCD)......12602
Component Parts and Harness Connector Location......12602
System Description......12603
Schematic......12605
Wiring Diagram – ASCD –......12606
Trouble Diagnoses......12611
POWER WINDOW......12624
System Description......12624
Wiring Diagram – WINDOW –......12626
Trouble Diagnoses......12628
POWER DOOR LOCK......12629
System Description......12629
Wiring Diagram – D/LOCK –......12630
Trouble Diagnoses......12632
MULTI-REMOTE CONTROL SYSTEM......12635
System Description......12635
Schematic......12637
Wiring Diagram – MULTI –......12638
Trouble Diagnoses......12641
Replacing Remote Controller or Control Unit......12648
THEFT WARNING SYSTEM......12649
Component Parts and Harness Connector Location......12649
System Description......12650
Schematic......12653
Wiring Diagram – THEFT –......12654
Trouble Diagnoses......12661
SMART ENTRANCE CONTROL UNIT......12675
Description......12675
Input/Output Operation Signal......12676
Schematic......12677
LOCATION OF ELECTRICAL UNITS......12679
Engine Compartment......12679
Passenger Compartment......12680
HARNESS LAYOUT......12682
Outline......12682
Main Harness......12683
Engine Room Harness......12685
Engine Harness......12688
Engine control Harness......12689
Body Harness and Tail Harness......12691
Room Lamp......12693
Air Bag Harness......12694
Door Harness LH......12695
Door Harness RH......12695
EM......12696
TABLE OF CONTENTS......12696
PRECAUTIONS......12697
Parts Requiring Angular Tightening......12697
Liquid Gasket Application Procedure......12697
PREPARATION......12698
Special Service Tools......12698
Commercial Service Tools......12701
OUTER COMPONENT PARTS......12702
COMPRESSION PRESSURE......12704
Measurement of Compression Pressure......12704
OIL PAN......12705
Removal......12705
Installation......12706
TIMING CHAIN......12707
Removal......12709
Inspection......12712
Installation......12712
OIL SEAL REPLACEMENT......12716
CYLINDER HEAD......12718
Removal and Installation......12719
Disassembly......12719
Inspection......12720
Assembly......12725
Valve Clearance......12725
ENGINE REMOVAL......12728
Removal......12729
CYLINDER BLOCK......12730
Disassembly......12731
Inspection......12732
Assembly......12738
SERVICE DATA AND SPECIFICATIONS (SDS)......12741
General Specifications......12741
Inspection and Adjustment......12741
FA......12749
TABLE OF CONTENTS......12749
PRECAUTIONS AND PREPARATION......12750
Precautions......12750
Special Service Tools......12750
Commercial Service Tools......12751
FRONT SUSPENSION SYSTEM......12752
ON-VEHICLE SERVICE......12753
Front Axle and Front Suspension Parts......12753
Front Wheel Bearing......12753
Front Wheel Alignment......12754
FRONT AXLE......12756
Wheel Hub and Knuckie......12756
ABS Sensor Rotor......12758
Baffle Plate......12759
FRONT SUSPENSION......12760
Coil Spring and Strut Assembly......12761
Tension Rod and Stabilizer Bar......12762
Transverse Link and Lower Ball Joint......12763
SERVICE DATA AND SPECIFICATIONS (SDS)......12764
General Specifications......12764
Inspection and Adjustment......12765
FE......12766
TABLE OF CONTENTS......12766
PREPARATION/ACCELERATOR CONTROL SYSTEM......12767
Special Service Tool......12767
Accelerator Control System......12767
Adjusting Accelerator Wire......12767
FUEL SYSTEM......12768
Fuel Tank......12768
Fuel Pump and Gauge......12770
EXHAUST SYSTEM......12772
FWD......12773
QUICK REFERENCE INDEX......12773
Comment Sheet ......12775
Quick Reference Chart......12776
GST Mode 6 - Test Value & Test Limit Chart......12777
GI......12778
TABLE OF CONTENTS......12778
PRECAUTION......12779
Precautions for Supplemental Restraint System (SRS) "AIR BAG"......12779
General Precautions......12779
Precautions for Multiport Fuel injection System or ECCS Engine......12781
Precautions for Three Way Catalyst......12782
Engine Oils......12782
Precatuions for Fuel......12783
Precautions for Air Conditioning......12783
HOW TO USE THIS MANUAL......12784
HOW TO READ WIRING DIAGRAMS......12786
Sample/Wiring Diagram – EXAMPL –......12786
Description......12788
Wiring Diagram Codes (Cell Codes)......12795
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT......12796
Work Flow......12796
Incident Simulation Tests......12797
Circuit Inspection......12801
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES......12808
CONSULT CHECKING SYSTEM......12811
Function and System Application......12811
Lithium Battery Replacement......12811
Checking Equipment......12811
IDENTIFICATION INFORMATION......12812
Model Variation......12812
Identification Number......12813
Dimensions......12815
Wheels and Tires......12815
LIFTING POINTS AND TOW TRUCK TOWING......12816
Preparation......12816
Board-on Lift......12816
Garage Jack and Safety Stand......12817
2-pole Lift......12818
Tow Truck Towing......12818
TIGHTENING TORQUE OF STANDARD BOLTS......12820
SAE J1930 TERMINOLOGY LIST......12821
SAE J1930 Terminology List......12821
HA......12825
TABLE OF CONTENTS......12825
PRECAUTIONS AND PREPARATION......12826
Supplemental Restraint System (SRS) "AIR BAG"......12826
Precautions for Working with HFC-134a (R-134a)......12826
General Refrigerant Precautions......12826
Precautions for Refrigerant Connection......12827
Precautions for Servicing Compressor......12830
Special Service Tools......12830
HFC-134a (R-134a) Service Tools and Equipment......12831
Precautions for Service Equipment......12833
DESCRIPTION......12835
Refrigeration Cycle......12835
Component Layout......12836
Discharge Air Flow......12837
Control Operation......12838
V-6 Variable Displacement Compressor......12839
TROUBLE DIAGNOSES......12845
How to Perform Trouble diagnoses for Quick and Accurate Repair......12845
Operational Check......12846
Symptom Chart......12848
Preliminary Check......12850
Performance Test Diagnoses......12856
Performance Chart......12858
Trouble Diagnoses for Abnormal Pressure......12859
Harness Layout......12862
Circuit Diagram......12864
Wiring Diagram – A/C –......12865
Main Power Supply and Ground Circuit Check......12871
Diagnostic Procedure 1......12872
Diagnostic Procedure 2......12874
Diagnostic Procedure 3......12876
Diagnostic Procedure 4......12877
Diagnostic Procedure 5......12879
Diagnostic Procedure 6......12880
Electrical Components Inspection......12883
Control Linkage Adjustment......12885
SERVICE PROCEDURES......12887
HFC-134a (R-134a) Service Procedure......12887
Maintenance of Lubricant Quantity In Compressor......12889
Refrigerant Lines......12891
Checking Refrigerant Leaks......12892
Compressor Mounting......12894
Belt Tension......12894
Fast Idle Control Device (FICD)......12894
Push Control Unit......12895
Compressor......12896
Compressor Clutch......12896
SERVICE DATA AND SPECIFICATIONS (SDS)......12900
General Specifications......12900
Inspection and Adjustment......12900
IDX......12901
LC......12908
TABLE OF CONTENTS......12908
PRECAUTION AND PREPARATION......12909
Liquid Gasket Application Procedure......12909
Special Serive Tools......12909
ENGINE LUBRICATION SYSTEM......12911
Lubrication Circuit......12911
Oil Pressure Check......12911
Oil Pump......12912
ENGINE COOLING SYSTEM......12914
Cooling Circuit......12914
System Check......12914
Water Pump......12915
Thermostat......12916
Radiator......12917
Cooling Fan (Crankshaft driven)......12920
Cooling Fan Control System......12920
Overheating Cause Analysis......12921
SERVICE DATA AND SPECIFICATIONS (SDS)......12922
Engine Lubrication System......12922
Engine Cooling System......12922
MA......12923
TABLE OF CONTENTS......12923
PRECAUTIONS......12924
Supplemental Restraint system (SRS) "AIR BAG"......12924
GENERAL MAINTENANCE......12925
PERIODIC MAINTENANCE......12927
Schedule 1......12928
Schedule 2......12929
RECOMMENDED FLUIDS AND LUBRICANTS......12930
Fluids and Lubricants......12930
SAE Viscosity Number......12930
Anti-freeze Coolant Mixture Ratio......12931
ENGINE MAINTENANCE......12932
Checking Drive Belts......12932
Changing Engine Coolant......12933
Checking Fuel Lines......12934
Changing Fuel Filter......12935
Changing Air Cleaner Filter......12935
Changing Engine Oil......12936
Changing Oil Filter......12936
Changing Spark Plugs......12937
Checking EVAP Vapor Purge Lines......12938
CHASSIS AND BODY MAINTENANCE......12939
Checking Exhaust System......12939
Checking Clutch Fluid Level and Leaks......12939
Checking M/T Oil......12939
Changing M/T Oil......12939
Checking A/T Fluid......12940
Changing A/T Fluid......12940
Checking Differential Gear Oil......12941
Changing Differential Gear Oil......12941
Balancing Wheels......12941
Tire Rotation......12941
Checking Brake Fluid Level and Leaks......12941
Checking Brake Lines and Cables......12942
Checking Disc Brake......12942
Checking Steering Gear and Linkage......12942
Checking Power Steering Fluid and Lines......12943
Lubricating Locks, Hinges and Hood Latches......12944
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters......12944
SERVICE DATA AND SPECIFICATIONS (SDS)......12945
Engine Maintenance......12945
Chassis and Body Maintenance......12945
MT......12946
TABLE OF CONTENTS......12946
PREPARATION......12946
Special Service Tools......12947
Commercial Service Tools......12949
DESCRIPTION......12950
Cross-sectional View......12950
ON-VEHICLE SERVICE......12951
Replacing Rear Oil Seal......12951
Position Switch Check......12951
REMOVAL AND INSTALLATION......12952
Removal......12952
Installation......12953
MAJOR OVERHAUL......12954
Case Components......12954
Gear Components......12955
Shift Control Components......12956
DISASSEMBLY......12957
Case Components......12957
Shift Control Components......12958
Gear Components......12958
INSPECTION......12961
Shift Control Components......12961
Gear Components......12961
ASSEMBLY......12963
Gear Components......12963
Shift Control Components......12969
Case Components......12970
SERVICE DATA AND SPECIFICATIONS (SDS)......12973
General Specifications......12973
Inspection and Adjustment......12973
PD......12975
TABLE OF CONTENTS......12975
PREPARATION......12976
Special Service Tools......12976
Commercial Service Tool......12978
PROPELLER SHAFT......12979
On-vehicle Service......12980
Removal......12980
Installation......12980
Inspection......12981
Disassembly......12982
Assembly......12982
FINAL DRIVE......12983
ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION......12983
Front Oil Seal Replacement......12983
Side Oil Seal Replacement......12983
Removal......12984
Installation......12985
FINAL DRIVE......12986
DISASSEMBLY......12988
Pre-inspection......12988
Differential Carrier......12988
Differential Case......12990
INSPECTION......12992
Ring Gear and Drive Pinion......12992
Bearing......12992
Differential Case Assembly......12992
ADJUSTMENT......12993
Side Bearing Preload......12993
Pinion Gear Height and Pinion Bearing Preload......12994
Tooth Contact......12999
ASSEMBLY......13000
Differential Case......13000
Differential Carrier......13002
SERVICE DATA AND SPECIFICATIONS (SDS)......13006
Propeller Shaft......13006
Final Drive......13006
RA......13008
TABLE OF CONTENTS......13008
PRECAUTIONS AND PREPARATION......13009
Precautions......13009
Special Service Tools......13009
Commercial Service Tools......13010
REAR SUSPENSION SYSTEM ......13011
ON-VEHICLE SERVICE......13012
Rear Axle and Rear Suspension Parts......13012
Rear Wheel Bearing......13012
Rear Wheel Alignment......13012
Drive Shaft......13014
REAR AXLE......13015
Wheel Hub and Axle Housing......13015
Drive Shaft......13019
REAR SUSPENSION......13025
Removal and Installation......13026
Coil Spring and Shock Absorber......13027
Multi-link and Lower Ball Joint......13028
Stabilizer Bar......13029
SERVICE DATA AND SPECIFICATIONS (SDS)......13030
General Specifications......13030
Inspection and Adjustment......13031
RS......13032
TABLE OF CONTENTS......13032
PRECAUTIONS......13033
Supplemental Restraint System (SRS) "AIR BAG"......13033
SEAT BELTS......13034
Front Seat Belt......13034
Rear Seat Belt......13035
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)......13036
Precautions for SRS "Air Bag" Service......13036
Special Service Tools......13036
Description......13037
SRS Component Parts Location......13037
Maintenance Items......13038
Removal and Installation–Diagnosis Sensor Unit......13039
Removal – Air Bag Module and Spiral Cable......13040
Removal – Front Passenger Air Bag Module......13041
Installation – Air Bag Module and Spiral Cable......13042
Installation – Front Passenger Air Bag Module......13043
Disposal of Air Bag Module......13044
TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)......13048
How to Perform Trouble Diagnoses for Quick and Accurate Repair......13048
Schematic......13050
Wiring diagram - SRS -......13051
Self-diagnosis......13053
Trouble Diagnoses for Air Bag Warning Lamp......13066
COLLISION DIAGNOSIS......13068
ST......13069
TABLE OF CONTENTS......13069
PRECAUTIONS AND PREPARATION......13070
Precautions......13070
Special Service Tools......13070
Commercial Service Tool......13072
ON-VEHICLE SERVICE......13073
Checking Steering Wheel Play......13073
Checking Neutral Position on Steering Wheel......13073
Front Wheel Turning Angle......13073
Checking Gear Housing Movement......13074
Adjusting Rack Retainer......13074
Checking and Adjusting Drive Belts (For power steering)......13074
Checking Fluid Level......13074
Checking Fluid Leakage......13074
Bleeding Hydraulic System......13075
Checking Steering Wheel Turning Force (For power steering)......13075
Checking Hydraulic System......13076
STEERING WHEEL AND STEERING COLUMN......13077
Removal and Installation......13077
Disassembly and Assembly......13079
Inspection......13080
POWER STEERING GEAR AND LINKAGE (Model PR24AC)......13081
Removal and Installation......13081
Disassembly and Assembly......13083
Disassembly......13084
Inspection......13084
Assembly......13085
Adjustment......13089
POWER STEERING OIL PUMP......13091
Disassembly and Assembly......13091
Pre-disassembly Inspection......13091
Disassembly......13092
Inspection......13092
Assembly......13093
SERVICE DATA AND SPECIFICATIONS (SDS)......13094
General Specifications......13094
Inspection and Adjustment......13094
foldout......13096
SUPER MULTIPLE JUNCTION (SMJ)......13096
Disconnecting and Connecting......13096
Terminal Arrangement......13097
ELECTRICAL UNITS......13098
Terminal Arrangement......13098
240SX '98......13099
At......13100
TABLE OF CONTENTS......13100
DIAGNOSTIC TROUBLE CODE INDEX......13102
Alphabetical & P No. Index for DTC......13102
PRECAUTIONS AND PREPARATION......13103
Precautions for Supplemental Restraint System(SRS) "AIR BAG and "SEAT BELT PRE-TENSIONER"......13103
Precautions for On Board Diagnostic (OBD) System of A/T and Engine......13103
Precautions......13104
Service Notice or Precautions......13105
Special Service Tools......13107
OVERALL SYSTEM......13109
A/T Electrical Parts Location......13109
Circuit Diagram......13110
Wiring Diagram......13111
Cross-sectional View......13116
Hydraulic Control Circuits......13117
Shift Mechanism......13118
Control System......13127
Control Mechanism......13129
Control Valve......13134
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION......13136
Introduction......13136
OBD-ll Function for A/T System......13136
One or Two Trip Detection Logic of OBD-ll......13136
OBD-ll Diagnostic Trouble Code (DTC)......13136
Malfunction Indicator Lamp (MIL)......13140
CONSULT......13140
Diagnostic Procedure without CONSULT......13146
TROUBLE DIAGNOSIS- Introduction......13151
Introduction......13151
Diagnostic Worksheet......13151
Work Flow......13155
TROUBLE DIAGNOSIS- Basic Inspection......13156
A/T Fluid Check......13156
Stall Test......13156
Line Pressure Test......13159
Road Test......13161
TROUBLE DIAGNOSIS- General Description......13171
Symptom Chart......13171
TCM Terminals and Reference Value......13174
DTC P0705, Inhibitor Switch......13178
DTC P0710, A/T Fluid Temperature Sensor......13182
DTC P0720, Vehicle Speed Sensor-A/T (Revolution sensor)......13186
DTC P0725, Engine Speed Signal......13189
DTC P0731, A/T 1ST Gear Function......13192
DTC P0732, A/T 2ND Gear Function......13197
DTC P0733, A/T 3RD Gear Function......13201
DTC P0734, A/T 4TH Gear Function......13205
DTC P0740, Torque Converter Clutch Solenoid Valve......13213
DTC P0744, A/T TCC S/V Function (Lock-up)......13217
DTC P0745, Line Pressure Solenoid Valve......13224
DTC P0750, Shift Solenoid Valve A......13228
DTC P0755, Shift Solenoid Valve B......13232
DTC P1705, Throttle Position Sensor......13236
DTC P1760, Overrun Clutch Solenoid Valve......13242
TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP SEN......13246
A/T Fluid Temperature Sensor Cirsuit and TCM Power Source......13246
TROUBLE DIAGNOSIS FOR VHCL SPEED SEN-MTR......13250
Vehicle Speed Sensor-MTR......13250
TROUBLE DIAGNOSIS FOR SYMPTOMS......13253
1. O/D OFF Indicator Lamp Does Not Come On......13253
2. Engine Cannot Be Started in "P" and "N" Position......13254
3. In "P" Position, Vehicle Moves Forward Or Backward When Pushed......13254
4. In "N" Position Vehicle Moves......13255
5. Large Shock. "N" - "R" Position......13256
6. Vehicle Does Not Creep Backward In "R" Position......13257
7. Vehicle Does Not Creep Forward In "D", "2" Or "1" Position......13258
8. Vehicle Cannot Be Started From D1......13259
9. A/T Does Not Shift: D1 - D2 Or Does Not Kickdown: D4 -D2......13260
10. A/T Does Not Shift : D2-D3......13261
11. A/T Does Not Shift: D3-D4......13262
12. A/T Does Not Perform Lock-up......13263
13. A/T Does Not Hold Lock-up Condition......13264
14. Lock-up Is Not Released......13264
15. Engine Speed Does Not Return To Idle (light Braking D4-D3)......13265
16. Vehicle Does Not Start From D,......13266
17. A/T Does Not Shift: D4-D3, When Overdrive Control Switch "ON" - "OFF"......13266
18. A/T Does Not Shift: D3 - 2-2, When Selector Lever "2" - "2" Position......13267
19. A/T Does Not Shift: 2-2 - 1-1, When Selector Lever "2" - "1" Position......13267
20. Vehicle Does Not Decelerate By Engine Brake......13268
21. TCM Self-diagnosis Does Not Activate (inhibitor, Overdrive Control and Throttle Position Switch Circuit Checks)......13268
TROUBLE DIAGNOSES - A/T Shift Lock System......13274
Description......13274
Wiring Diagram - SHIFT -......13275
Diagnostic Procedure......13276
Key Interlock Cable......13278
Component Check......13279
ON-VEHICLE SERVICE......13281
Control Valve Assembly and Accumulators......13281
Revolution Sensor Replacement......13281
Rear Oil Seal Replacement......13282
Parking Components Inspection......13282
Inhibitor Switch Adjustment......13283
Manual Control Linkeage Adjustment......13283
REMOVAL AND INSTALLATION......13284
Removal......13284
Installation......13286
MAJOR OVERHAUL......13287
Oil Channel......13289
Locations of Needle Bearings, Thust Washers and Snap Rings......13290
DISASSEMBLY......13291
Disassembly......13291
REPAIR FOR COMPONENT PARTS......13302
Oil Pump......13302
Control Valve Assembly......13306
Control Valve Upper Body......13312
Control Valve Lower Body......13317
Reverse Clutch......13319
High Clutch......13323
Forward and Overrun Clutches......13325
Low & Reverse Brake......13329
Forward Clutch Drum Assembly......13333
Rear Internal Gear and Forward Clutch Hub......13335
Band Servo Piston Assembly......13338
Parking Pawl Components......13342
ASSEMBLY......13344
Assembly (1)......13344
Adjustment......13348
Assembly (2)......13352
SERVICE DATA AND SPECIFICATIONS (SDS)......13362
General Specifications......13362
Specifications and Adjustment......13362
Br......13366
TABLE OF CONTENTS......13366
PRECAUTIONS AND PREPARATION......13368
Supplemental Restraint System (SRS) "AIR BAG"......13368
Precautions for Brake System......13368
Commercial Service Tools......13368
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......13369
NVH Troubleshooting Chart......13369
BRAKE HYDRAULIC LINE/CONTROL VALVE......13370
Brake Hydraulic Line......13370
Proportioning Valve......13371
CHECK AND ADJUSTMENT......13372
Checking Brake Fluid Level......13372
Checking Brake Line......13372
Changing Brake Fluid......13372
Bleeding Brake System......13373
BRAKE PEDAL AND BRACKET......13374
Removal and Installation......13374
Inspection......13374
Adjustment......13374
MASTER CYCLINDER......13375
Removal......13375
Disassembly......13375
Inspection......13375
Assembly......13375
Installation......13377
BRAKE BOOSTER/VACUUM HOSE......13378
Brake Booster......13378
Vacuum Hose......13379
FRONT DISC BRAKE......13380
Pad Replacement......13380
Removal......13382
Disassembly......13382
Inspection - Caliper......13382
Inspection - Rotor......13383
Assembly......13383
Installation......13383
Brake Burnishing Procedure......13384
REAR DISC BRAKE......13385
Pad Replacement......13380
Removal......13387
Disassembly......13387
Inspection - Caliper......13388
Inspection - Rotor......13389
Assembly......13389
Installation......13391
PARKING BRAKE CONTROL......13392
Removal and Installation......13392
Inspection......13393
Adjustment......13393
ANTI-LOCK BRAKE SYSTEM......13394
Purpose......13394
Operation......13394
ABS Hydraulic Circuit......13394
System Components......13395
System Description......13395
Removal and Installation......13397
TROUBLE DIAGNOSIS......13400
How to Perform Trouble Diagnosis for Quick and Accurate Repair......13400
Preliminary Check......13401
Component Parts and Harness Connector Location......13402
Circuit Diagram for Quick Pinpoint Check......13403
Wiring Diagram - ABS -......13404
Self-diagnosis......13409
CONSULT......13412
CONSULT Inspection Procedure......13413
Ground Circuit Check......13418
TROUBLE DIAGNOSIS FOR SELF-DIAGNOSTIC ITEMS......13419
Diagnostic Procedure 1 (Wheel sensor of rotor) ......13419
Diagnostic Procedure 2 (ABS actuator solenoid valve)......13421
Diagnostic Procedure 3 (Solenoid valve relay)......13422
Diagnostic Procedure 4 (Motor relay or motor)......13425
Diagnostic Procedure 5 (Low Voltage)......13428
Diagnostic Procedure 6 (Control unit)......13429
TROUBLE DIAGNOSIS FOR SYMPTOMS......13430
Diagnistic Procedure 7 (ABS works frequently.)......13430
Diagnostic Procedure 8 (Unexpected pedal action)......13431
Diagnostic Procedure 9 (Long stopping distance)......13431
Diagnostic Procedure 10 (ABS does not work.)......13432
Diagnostic Procedure 11 (Pedal vibration and noise)......13432
Diagnostic Procedure 12 (Warning lamp does not come on when ignition switch is turned on.)......13433
Diagnostic Procedure 13 (Warning lamp stays on when ignition switch is turned on.)......13435
Electrical Component Inspection......13438
SERVICE DATA AND SPECIFICATIONS (SDS)......13440
General Specifications......13440
Inspection and Adjustment......13440
Bt......13441
TABLE OF CONTENTS......13441
PRECAUTIONS......13442
Service Notice......13442
Supplemental Restraint System (SRS) "AIR BAG"......13442
GENERAL SERVICING......13443
Clip and Fastener......13443
BODY END......13446
Body Front End......13446
Body Rear End and Opener......13449
DOOR......13451
Door Glass Fitting Adjustment......13452
INSTRUMENT PANEL......13456
INTERIOR TRIM......13459
Side and Floor Trim......13459
Door Trim......13461
Roof Trim......13462
Trunk Room Trim......13463
EXTERIOR......13464
SEAT......13471
Front Seat......13471
Rear Seat......13473
SUNROOF......13474
WINDSHIELD AND WINDOWS......13478
Windshield and Rear Window......13479
Side Window......13480
MIRROR......13481
Door Mirror......13481
BODY ALIGNMENT......13482
Engine Compartment......13482
Underbody......13484
Cl......13486
TABLE OF CONTENTS......13486
PRECAUTIONS AND PREPARATION......13487
Precautions......13487
Special Service Tools......13487
Commercial Service Tools......13487
NOISE VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......13488
NVH Troubleshooting Chart......13488
CLUTCH SYSTEM......13489
INSPECTION AND ADJUSTMENT......13490
Adjusting Clutch Pedal......13490
Air Bleeding Procedure......13491
HYDRALULIC CLUTCH CONTROL......13492
Clutch Master Cylinder......13492
Operating Cylinder......13493
CLUTCH RELEASE MECHANISM......13494
CLUTCH DISC AND CLUTCH COVER......13496
Clutch Disc......13496
Clutch Cover and Flywheel......13497
SERVICE DATA AND SPECIFICATIONS (SDS)......13498
General Specifications......13498
Inspection and Adjustment......13498
Ec......13499
TABLE OF CONTENTS......13499
DIAGNOSTIC TROUBLE CODE INDEX......13502
Alphabetical & P N0. Index for DTC......13502
PRECAUTIONS AND PREPARATION......13504
Special Service Tools......13504
Commercial Service Tools......13504
Supplemental Restraint System (SRS) "AIR BAG"......13505
Precautions for On Board Diagnostic (OBD)......13505
System of Engine and A/T......13505
Engine Fuel & Emission Control System......13506
Precautions......13507
ENGINE AND EMISSION CONTROL OVERALL SYSTEM......13509
Circuit Diagram......13509
ECCS Component Parts Location......13510
System Diagram......13512
Vacuum Hose Drawing......13513
System Chart......13514
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION......13515
Multiport Fuel Injection (MFI) System......13515
Distributor Ignition (D) System......13517
Air Conditioning Cut Control......13518
Fuel Cut Control (at no load & high engine speed)......13519
EVAPORATIVE EMISSION SYSTEM......13520
Description......13520
Inspection......13520
Evaporative Emission Line Drawing......13523
POSITIVE CRANKCASE VENTILATION......13525
Description......13525
Inspection......13525
BASIC SERVICE PROCEDURE......13526
Fuel Pressure Release......13526
Fuel Pressure Check......13526
Fuel Pressure Regulator Check......13527
Injector Removal and Installation......13527
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment......13528
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION......13534
Introduction......13534
Two Trip Detection Logic......13534
Emission-related Diagnostic Information......13535
Malfunction Indicator Lamp (MIL)......13546
OBD System Operation Chart......13549
CONSULT......13554
Generic Scan Tool (GST)......13567
TROUBLE DIAGNOSIS-Introduction......13569
Introduction......13569
Diagnostic Worksheet......13569
TROUBLE DIAGNOSIS- Work Flow......13571
Work Flow......13571
Description for Work Flow......13572
TROUBLE DIAGNOSIS- Basic Inspection......13573
Basic Inspection......13573
TROUBLE DIAGNOSIS- General Description......13576
Diagonstic Trouble Code (DTC) Inspection......13576
Priority Chart......13576
Fail Safe Chart......13577
Symptom Matrix Chart......13578
CONSULT Reference Graph in Data Monitor Mode......13581
Major Sensor Reference Graph in Data Monitor Mode......13584
ECM Terminals and Reference Value......13586
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT......13596
Description......13596
Common l/l Report Situations......13596
Diagnostic Procedure......13596
TROUBLE DIAGNOSIS FOR POWER SUPPLY......13597
Main Power Supply and Ground Circuit......13597
DTC P0100, Mass Air Flow Sensor (MAFS)......13602
DTC P0105, Absolute Pressure Sensor......13611
DTC P0110, Intake Air Temperature Sensor......13619
DTC P0115, Engine Coolant Temperature Sensor (ECTS) (Circuit)......13625
DTC P0120, Throttle Position Sensor......13630
DTC P0125, Engine Coolant Temperature (ECT) Sensor......13641
DTC P0130, Front Heated Oxygen Sensor (Circuit) (Front HO2S)......13646
DTC P0131, Front Heated Oxygen Sensor (Lean Shift Monitoring) (Front H02S)......13652
DTC P0132, Front Heated Oxygen Sensor (Rich Shift Monitoring) (Front HO2S)......13658
DTC P0133, Front Heated Oxygen Sensor (Response Monitoring ) (Front HO2S)......13664
DTC P0134, Front Heated Oxygen Sensor (High Voltage) (Front HO2S)......13672
DTC P0135, Front Heated Oxygen Sensor Heater......13677
DTC P0137, Rear Heated Oxygen Sensor (Min. Voltage Monitoring ) (Rear HO2S)......13681
DTC P0138, Rear Heated Oxygen Sensor (Max. Voltage Monitoring) (Rear H02S)......13688
DTC P0139, Rear Heated Oxygen Sensor (Response Monitoring) (Rear HO2S)......13695
DTC P0140, Rear Heated Oxygen Sensor (High Voltage) (Rear HO2S)......13701
DTC P0141, Rear Heated Oxygen Sensor Heater......13704
DTC P0171, Fuel Injection System Function (Lean side)......13710
DTC P0172, Fuel Injection System Function (Rich side)......13715
DTC P0180, Tank Fuel Temperature Sensor......13720
DTC P0300 - P0304, No. 4 - 1 Cylinder Misfire, Multiple Cylinder Misfire......13724
DTC P0325, Knock Sensor (KS)......13727
DTC P0335, Crankshaft Position Sensor (CKPS) (OBD)......13732
DTC P0340, Camshaft Position Sensor (CMPS)......13737
DTC P0400, EGR Function (Close)......13743
DTC P0402, EGRC-BPT Valve Function......13751
DTC P0420, Three Way Catalyst Function......13756
DTC P0440, Evaporative Emssion (EVAP) Control System (Small Leak) (Negative Pressure)......13760
DTC P0443, Evaporative Emssion (EVAP) Canister Purge Volume Control Valve (Circuit)......13771
DTC P0446, Evaporative Emssion (EVAP) Canister Vent Control Valve (Curcuit)......13777
DTC P0450, Evaporative Emssion (EVAP) Control System Pressure Sensor......13782
DTC P0500, Vehicle Speed Sensor (VSS)......13787
DTC P0505, Idle Air Control Valve (IACV) – Auxiliary Air Control (ACC) Valve......13791
DTC P0510, Closed Trrottle Position Switch......13798
DTC P0600, A/T Control......13803
DTC P0605, Engine control Module (ECM)-ECCS Control Module......13806
DTC P1105, Mainfold Absolute Pressure (MAP)/Barometric Pressure (BARO) Switch Solenoid Valve......13808
DTC P1148, Close Loop Control......13816
DTC P1320, Ignition Signal......13818
DTC P1336, Crankshaft Position Sensor (CKPS) (OBD) (COG)......13824
DTC P1400, EGRC-Solenoid Valve......13829
DTC P1401, EGR Temperature Sensor......13834
DTC P1402, EGR Function (Open)......13840
DTC P1440, Evaporative Emssion (EVAP) Control System (Small Leak) (Positive Pressure)......13847
DTC P1444, Evaporative Emssion (EVAP) Canister Purge Volume Control Valve......13858
DTC P1446, Evaporative Emssion (EVAP) Canister Vent Control Valve (Close)......13865
DTC P1447, Evaporative Emssion (EVAP) Control system Purge Flow Monitoring......13870
DTC P1448, Evaporative Emssion (EVAP) Canister Vent Control Valve (Open)......13878
DTC P1490, Vacuum Cut Valve Bypass Valve......13883
DTC P1491, Vacuum Cut Valve Bypass Valve......13888
DTC P1492, Evaporative Emssion (EVAP) Canister Purge Control Valve/Solenoid Valve (Circuit)......13893
DTC P1493, Evaporative Emssion (EVAP) Canister Purge Control Valve/Solenoid Valve......13898
DTC P1605, A/T Diagnosis Communication Line......13905
DTC P1706, Park/Netural Position Switch......13908
TROUBLE DIAGNOSIS FOR OVERHEAT......13913
Overheat......13913
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS......13925
Injector......13925
Start Signal......13928
Fuel Pump......13931
Power Steering Oil Pressure Switch......13936
IACV-Air Regulator......13940
IACV-FICD Solenoid Valve......13943
5th Position Switch......13948
Electric Load signal......13950
MIL & Data Link Connectors......13952
SERVICE DATA AND SPECIFICATIONS (SDS)......13953
General Specifications......13953
Inspection and Adjustment......13953
El......13955
TABLE OF CONTENTS......13955
PRECAUTIONS......13958
Supplemental Restraint System (SRS) "AIR BAG" ......13958
HARNESS CONNECTOR......13959
Description......13959
STANDARDIZED RELAY......13960
Description......13960
POWER SUPPLY ROUTING......13962
Schematic......13962
Wiring Diagram - POWER-......13963
Fuse......13968
Fusible Link......13968
Circuit Breaker Inspection......13968
GROUND DISTRIBUTION......13969
BATTERY......13972
How to Handle Battery......13972
Service Data and Specifications (SDS)......13975
STARTING SYSTEM......13976
System Description......13976
Wiring Diagram - START - /M/T MODELS......13978
Wiring Diagram - START - /A/T MODELS......13979
Construction......13980
Removal and Installation......13980
Pinion/Clutch Check......13981
Service Data and Specifications (SDS)......13981
CHARGING SYSTEM......13982
System Description......13982
Wiring Diagram - CHARGE -......13983
Construction......13984
Removal and Installation......13984
Trouble Diagnoses......13985
Service Data and Specifications (SDS)......13986
COMBINATION SWITCH......13987
Check......13987
Replacement......13988
STEERING SWITCH......13989
Check......13989
HEADLAMP......13990
System Description (For USA)......13990
Wiring Diagram - H/LAMP-......13991
Trouble Diagnosis......13992
Bulb Replacement......13993
Aiming Adjustment......13994
HEADLAMP - Daytime Light System -......13995
System Description (For Canada)......13995
Operation......13996
Schematic......13997
Wiring Diagram -DTRL-......13998
Trouble Diagnoses......14001
Bulb Replacement......14002
Aiming Adjutment......14002
PARKING LICENSE, TAIL AND STOP LAMPS......14003
Wiring Diagram - TAIL/L -......14003
BACK-UP LAMP......14005
Wiring Diagram - BACK/L -......14005
FRONT FOG LAMP......14007
System Description......14007
Wiring Diagram - F/FOG -......14008
Aiming Adjustment......14009
TURN SIGNAL AND HAZARD WARNING LAMPS......14010
System Description......14010
Wiring Diagram- TURN -......14013
Trouble Diagnoses......14016
Electrical Components Inspection......14016
ILLUMINATION......14017
System Description......14017
Schematic......14018
Wiring Diagram - INT/L -......14019
INTERIOR SPOT AND TRUNK ROOM LAMPS......14022
System Description......14022
Wiring Diagram - INT/L......14023
METER AND GAUGES......14025
System Description......14025
Combination Meter......14026
Wiring Diagram - METER -......14027
Trouble Diagnoses......14028
Electrical Components Inspection......14031
WARNING LAMPS......14032
Schematic......14032
Wiring Diagram - WARN-......14031
Electrical Components Inspection......14036
WARNING BUZZER......14037
System Description......14037
Wiring Diagram - BUZZER- /Models With......14039
Power Door Locks......14039
Wiring Diagram - BUZZER-/Models Without......14040
Power Door Locks......14040
Trouble Diagnoses......14041
Electrical Components Inspection......14045
WIPER AND WASHER......14046
System Description......14046
Wiring Diagram - WIPER-/Without Intermittent Wiper......14048
Wiring Diagram-WIPER-/With Intermittent Wiper......14049
Trouble Diagnoses/With Intermittent Wiper......14051
Removal and Installation......14053
Washer Nozzle Adjustment......14054
Washer Tube Layout......14055
HORN......14056
Wiring Diagram - HORN -......14056
CIGARETTE LIGHTER......14057
Wiring Diagram - CIGAR -......14057
CLOCK......14058
Wiring Diagram - CLOCK ......14058
REAR WINDOW DEFOGGER......14059
System Description......14059
Wiring Diagram - DEF -......14060
Trouble Diagnoses......14062
Electrical Components Inspection......14064
Filament Check......14064
Filament Repair......14065
AUDIO......14067
System Description......14067
Wiring Diagram - AUDIO - /4-speaker......14068
Wiring Diagram - AUDIO - /6-speaker......14069
Trouble Diagnoses......14071
AUDIO ANTENNA......14072
System Description......14072
Wiring Diagram - P/ANT - ......14073
Trouble Diagnoses......14074
Location of Atenna......14074
Antenna Rod Replacement......14074
Window Antenna Repair......14075
POWER SUNROOF......14077
Wiring Diagram - SROOF-......14077
POWER DOOR MIRROR......14078
Wiring Diagram - MIRROR -......14078
AUTOMATIC SPEED CONTROL DEVICE (ASCD)......14080
Component Parts and Harness Connector Location......14080
System Description......14081
Schematic......14083
Wiring Diagram - ASCD -......14084
CONSULT......14089
Fail-safe System Description......14091
Fail-safe System Check......14092
Trouble Diagnoses......14093
Electrical Components Inspection......14101
ASCD Wire Adjustment......14102
POWER WINDOW......14103
System Description......14103
Wiring Diagram - Window -......14105
Trouble Diagnoses......14107
POWER DOOR LOCK......14108
System Description......14108
Wiring Diagram - D/LOCK......14109
Trouble Diagnoses......14111
MULTI-REMOTE CONTROL SYSTEM......14114
System Description......14114
Schematic......14114
Wiring Diagram - MULTI......14117
Trouble Diagnoses......14120
Electrical Components Inspection......14126
ID Code Entry Procedure......14127
THEFT WARNING SYSTEM......14128
Component Parts and Harness Connector......14128
Location......14128
System Description......14129
Schematic......14132
Wiring Diagram - THEFT -......14133
Trouble Diagnoses......14138
SMART ENTRANCE CONTROL UNIT......14152
Description......14152
Smart Entrance Control Unit Inspection Table......14153
Schematic......14154
LOCATION OF ELECTRICAL UNITS......14156
Engine Compartment......14156
Passenger Compartment......14157
HARNESS LAYOUT......14159
Outline......14159
Main Harness......14160
Engine Room Harness......14162
Engine Harness......14165
Engine Control Harness......14166
Body Harness and Tail Harness......14168
Room Lamp Harness......14170
Air Bag Harness......14171
Door Harness LH......14174
Door Harness RH......14174
BULB SPECIFICATIONS......14173
Headlamp......14173
Exterior Lamp......14173
Interior Lamp......14173
WIRING DIAGRAM CODES (CELL codes)......14174
Em......14175
TABLE OF CONTENTS......14175
PRECAUTIONS......14176
Parts Requiring Angular Tightening......14176
Liquid Gasket Application Procedure......14176
PREPARATION......14177
Special Service Tools......14177
Commercial Service Tools......14180
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......14181
NVH Troubleshooting Chart-Engine Noise......14182
OUTER COMPONENT PARTS......14183
COMPRESSION PRESSURE......14185
Measurement of Compression Pressure......14185
OIL PAN......14186
Removal......14186
Installation......14187
TIMING CHAIN......14188
Removal......14190
Inspection......14193
Installation......14193
OIL SEAL REPLACEMENT......14197
CYLINDER HEAD......14199
Removal and Installation......14200
Disassembly......14200
Inspection......14201
Assembly......14206
Valve Clearance......14206
ENGINE REMOVAL......14209
Removal......14210
CYLINDER BLOCK......14211
Disassembly......14212
Inspection......14213
Assembly......14219
SERVICE DATA AND SPECIFICATION (SDS)......14222
General Specifications......14222
Inspection and Adjustment......14222
Fa......14230
TABLE OF CONTENTS......14230
PRECAUTIONS AND PREPARATION......14231
Precautions......14231
Special Service Tools......14231
Commercial Service Tools......14232
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......14233
NVH Troubleshooting Chart......14233
FRONT SUSPENSION SYSTEM ON-VEHICLE SERVICE......14234
ON-VEHICLE SERVICE......14235
Front Axle and Front Suspension Parts......14235
Front Wheel Bearing......14235
Front Wheel Alignment......14236
FRONT AXLE......14238
Wheel Hub and Knuckle......14238
ABS Sensor Rotor......14240
Battle Plate......14241
FRONT SUSPENSION......14242
Coil Spring and Strut Assembly......14243
Tension Rod and Stabilizer Bar......14244
Transverse Link and Lower Ball Joint......14245
SERVICE DATA AND SPECIFICATIONS (SDS)......14246
General Specifications......14246
Inspection and Adjustment......14247
Fe......14248
TABLE OF CONTENTS......14248
PREPARATION/ACCELERATOR CONTROL SYSTEM......14249
Special Service Tool......14249
Accelerator Control System......14249
Adjusting Accelerator Wire......14249
FUEL SYSTEM......14250
Fuel Tank......14250
Fuel Pump and Gauge......14252
EXHAUST SYSTEM......14254
Foldout......14255
SUPER MULTIPLE JUNCTION (SMJ)......14255
Disconnecting and Connecting......14255
Terminal Arrangement......14256
ELECTRICAL UNITS......14257
Terminal Arrangement......14257
Fwd......14258
QUICK REFERENCE INDEX......14258
FOREWORD......14259
Comment Sheet......14260
Quick Reference Chart......14261
GST Mode 6 - Test Value & Test Limit Chart......14262
Gi......14263
TABLE OF CONTENTS......14263
PRECAUTIONS......14264
Precautions for Supplemental Restraint System (SRS) "AIR BAG"......14264
General Precautions......14264
Precautions for Multiport Fuel Injection System or EC CS ENGINE......14266
Precautions for Three Way Catalyst......14267
Precautions for Engine Oils......14267
Precautions for Fuel......14268
Precautions for Air Conditioning......14268
HOW TO USE THIS MANUAL......14269
HOW TO READ WIRING DIAGRAMS......14271
Sample/Wiring EDiagram-EXAMPLE-Description......14271
HOW TO CHECK TERMINAL......14280
Connector and Terminal Pin Kit......14280
How to Probe Connectors......14280
How to Check Entarged Contact Spring of Terminal......14281
Waterproof Connector Inspection......14282
Terminal Lock Inspection......14282
HOW TO PERFORM EFFCIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT......14283
Work Flow......14283
Incident Simulation Tests......14284
Circuit Inspection......14287
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES......14293
CONSULT CHECKING SYSTEM......14296
Function and System Application......14296
Lithium Battery Replacement......14296
Checking Equipment......14296
Loading Procedure......14297
Consult Data Link Connector (DLC) Circuit......14297
IDENTIFICATION INFORMATION......14298
Model Variation......14298
Identification Number......14299
Dimensions......14301
Wheels and Tires......14301
LIFTING POINTS AND TOW TRUCK TOWING......14302
Preparation......14302
Board-on Lift......14302
Garage Jack and Safety Stand......14303
2-pole Lift......14304
Tow Truck Towing......14304
TIGHTENING TORQUE OF STANDARD BOSTS SAE J1930 TERMINOLOGY LIST......14306
SAE J1930 Terminology List......14307
Ha......14311
TABLE OF CONTENTS......14311
PRECAUTIONS AND PREPARATION......14312
Supplemental Restraint System (SRS) "AIR BAG"......14312
Precautions for Working with HFC-134a (R-134a)......14312
General Refrigerant Precautions......14312
Precautions for Refrigerant Connection......14313
Precautions for Servicing Compressor......14316
Special Service Tools ......14316
HFC-134A (R-134a) Service Tools and Equipment......14317
Precautions for Service Equipment......14319
DESCRIPTION......14321
Refrigeration Cycle......14321
V-6 Variable Displacement Compressor......14322
Component Layout......14328
Discharge Air Flow......14329
Control Operation......14330
TROUBLE DIAGNOSIS......14331
How to Perform Trouble Diagnosis for Quick an Accurate Repair......14331
Operational Check......14332
Symptom Chart......14334
Preliminary Check......14336
Performance Test Diagnoses......14342
Performance Chart......14344
Trouble Diagnosis for Abnormal Pressure......14345
Harness Layout......14348
Circuit Diagram......14350
Wiring Diagram-A/C-......14351
Main Power Supply and Ground Circuit Check......14357
Diagnostic Procedure 1......14358
Diagnostic Procedure 2......14360
Diagnostic Procedure 3......14362
Diagnostic Procedure 4......14363
Diagnostic Procedure 5......14365
Diagnostic Procedure 6......14366
Electrical Components Inspection......14369
Control Linkage Adjustments......14371
SERVICE PROCEDURES......14373
HFC-134a (R-134a) Service Procedure......14373
Maintenance of Lubricant Quantity in Compressor......14375
Refrigerant Lines......14377
Compressor Mounting......14380
Belt Tension......14380
Past Idle Control Device (FICD)......14380
Compressor......14381
Compressor Clutch......14381
Push Control Unit......14385
SERVICE DATA AND SPECIFICATIONS......14386
General Speciifications......14386
Inspection and Adjustment......14386
Idx......14387
Lc......14395
TABLE OF CONTENTS......14395
PRECAUTION AND PREPARATION......14396
Liquid Gasket Application Procedure......14396
Special Service Tools......14396
ENGINE LUBRICATION SYSTEM......14398
Lubrication Circuit......14398
Oil Pressure Check......14398
Oil Pump......14399
ENGINE COOLING SYSTEM......14401
Cooling Circuit......14401
System Check......14401
Water Pump......14402
Thermostat......14403
Radiator......14404
Cooling Fan (Crankshaft driven)......14407
Cooling Fan Control System......14408
Overheating Cause Analysis......14409
SERVICE DATA AND SPECIFICATIONS (SDS)......14410
Engine Lubrication System......14410
Engine Cooling System......14410
Ma......14411
TABLE OF CONTENTS......14411
PRECAUTIONS AND PREPARATION......14412
Supplemental Restraint System (SRS) "AIR BAG"......14412
Special Service Tool......14412
GENERAL MAINTENANCE......14413
PERIODIC MAINTENANCE......14415
Schedule 1......14416
Schedule 2......14417
RECOMMENDED FLUIDS AND LUBRICANTS......14418
Fluids and Lubricants......14418
SAE Viscosity Number......14418
Anti-freeze Coolant Mixture Ratio......14419
ENGINE MAINTENANCE......14420
Checking Drive Belts......14420
Changing Engine Coolant......14421
Checking Fuel Lines......14422
Changing Fuel Filter......14423
Changing Air Cleaner Filter......14423
Changing Engine Oil......14424
Changing Oil Filter......14424
Changing Spark Plugs......14425
Checking EVAP Vapor Lines......14426
CHASSIS AND BODY MAINTENANCE......14427
Checking Exhaust......14427
Checking Clutch Fluid Level and Leaks......14427
Checking M/T Oil......14427
Checking M/T Oil......14427
Checking A/T FLUID......14428
Checking A/T FLUID......14428
Checking Differential Gear Oil......14429
Checking Differential Gear Oil......14429
Balancing Wheels......14429
Tire Rotation......14429
Checking Brake Fluid Level and Leaks......14429
Checking Brake Lines and Cables......14430
Checking Steering Gear and Linkage......14430
Checking Power Steering Fluid and lines......14431
Lubricationg Locks, Hinges and Hood Latches......14432
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters......14432
SERVICE DATA AND SPECIFICATIONS (SDS)......14433
Engine Maintenance......14433
Chassis and Body Maintenanace......14433
Mt......14434
TABLE OF CONTENTS......14434
PREPARATION......14435
Special Service Tools......14435
Commercial Service Tool......14437
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......14438
NVH Troubleshooting Chart......14438
DESCRIPTION......14439
Cross-sectional View......14439
ON-VEHICLE SERVICE......14440
Replacing Rear Oil Seal......14440
Position Switch Check......14440
REMOVAL AND INSTALLATION......14441
Removal......14441
Installation......14442
MAJOR OVERHAUL......14443
Case components......14443
Gear Components......14444
Shift Control Components......14445
DISASSEMBLY......14446
Case Components......14446
Shift Control Components......14447
Gear Components......14447
ASSEMBLY......14452
Gear Components......14452
Shift Control Components......14458
Case Components......14459
SERVICE DATA AND SPECIFICATIONS (SDS)......14462
General Specifications......14462
Inspection and Adjustment......14462
Pd......14464
TABLE OF CONTENTS......14464
PREPARATION......14465
Special Service Tools......14465
Commercial Service Tools......14467
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......14468
NVH Troubleshooting chart......14468
PROPELLER SHAFT......14469
On-vehicle Service......14470
Removal......14470
Installation......14470
Inspection......14471
Disassembly......14472
Assembly......14472
FINAL DRIVE......14473
ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION......14473
Front Oil Seal Replacement......14473
Side Oil Seal Replacement......14473
Removal......14474
Installation......14475
FINAL DRIVE......14476
DISASSEMBLY......14478
Pre-inspection......14478
Differential Carrier......14478
Differential Case......14480
INSPECTION......14482
Ring Gear and Drive Pinion......14482
Bearing......14482
Differential Case Assembly......14482
ADJUSTMENT......14483
Side Bearing Preload......14483
Pinion Gear Height and Pinion Bearing Preload......14484
Tooth Contact......14489
ASSEMBLY......14490
Differential Case......14490
Differential Carrier......14492
SERVICE DATA AND SPECIFICATIONS (SDS)......14496
Propeller Shaft......14496
Final Drive......14496
Ra......14498
TABLE OF CONTENTS......14498
PRECAUTIONS AND PREPARATION......14499
Precautions......14499
Special Service Tools......14499
Commercial Service Tools......14500
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......14501
NVH Troubleshooting Chart......14501
REAR SUSPENSION SYSTEM ON-VEHICLE SERVICE......14502
Rear Axle and Rear Suspension Parts......14503
Rear Wheel Bearing......14503
Rear Wheel Alignment......14503
Drive Shaft......14505
REAR AXLE......14506
Wheel Hub and Axle Housing......14506
Drive Shaft......14510
REAR SUSPENSION......14516
Removal and Installation......14517
Coil Spring and Shock Abscrber......14518
Multi-link and Lower Ball Joint......14519
Stabilizer Bar......14520
SERVICE DATA AND SPECIFICATIONS (SDS)......14521
General Specifications......14521
Inspection and Adjustment......14522
Rs......14523
TABLE OF CONTENTS......14523
PRECAUTIONS......14524
Supplemental Restraint System (SRS) "AIR BAG"......14524
SEAT BELTS......14525
Front Seat Belt......14525
Rear Seat Belt......14526
Seat Belt Inspection......14527
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)......14530
Precautions for SRS "AIR BAG" Service......14530
Special Service Tools......14530
Description......14531
SRS Component Parts Location......14531
Maintenance Items......14532
Removal and Installation - Diagnosis Sensor Unit......14533
Removal- Air Bag Module and Spiral Cable......14534
Removal- Front Passenger Air Bag Module......14535
Installation-Air Bag Module and Spiral Cable......14536
Installation-Front Passenger Air Bag Module ......14537
Disposal of Air Bag Module......14538
TROUBLE DIAGNOSIS - Supplemental Restraint System (SRS)......14542
Trouble Diagnosis Introduction......14542
How to Perform Trouble Diagnoisis for Quick and Accurate Repair......14544
Schematic......14546
Wiring Diagram- SRS-......14547
Self-diagnosis......14549
Trouble Diagnosis for Air Bag Warning Lamp......14563
COLLISION DIAGNOSIS......14565
St......14567
TABLE OF CONTENTS......14567
PRECAUTIONS AND PREPARATION......14568
Supplemental Restraint System (SRS) "AIR BAG"......14568
Precautions for Steering......14568
Special Service Tools......14568
Commercial Service Tools......14570
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......14571
NVH Troubleshooting Chart......14571
ON-VEHICLE SERVICE......14572
Checking Steering Wheel Play......14572
Checking Neutral Position on Steering Wheel......14572
Front Wheel Turning Angle......14572
Checking Gear Housing Movement......14573
Adjusting Rack Retainer......14573
Checking and Adjusting Drive Belts......14573
Checking Fluid Level......14573
Checking Fluid Leakage......14573
Bleeding Hydraulic System......14574
Checking Steering Wheel Turning Force......14574
Checking Hydraulic System......14575
STEERING WHEEL AND STEERING COLUMN......14577
Removal and Installation......14577
Disassembly and Assembly......14579
Inspection......14580
POWER STEERING GEAR AND LINKAGE (MODEL PR24AC......14581
Removal and Installation......14581
Disassembly and Assembly......14583
Disassembly......14584
Inspection......14584
Assembly......14585
Adjustment......14589
POWER STEERING OIL PUMP......14591
Disassembly and Assembly......14591
Pre-disassembly Inspection......14591
Disassembly......14592
Inspection......14592
Assembly......14593
SERVICE DATA AND SPECIFICATIONS (SDS)......14594
General Specifications......14594
Inspection and Adjustment......14594

Nissan 240SX (S12/S13/S14) Workshop Service Repair Manuals 1986-1998

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