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Данный электронный сервисный мануал предназначен для сервисных центров Nissan. В нем вы найдете:
Как правильно разобрать и собрать интересующий вас узел;
Какие необходимы для этого инструменты;
Как пользоваться системой самодиагностики;
Как правильно читать разъемы и проводку.
В данном мануале имеется весь модельный ряд, включая праворульные модели:
Все кузова данной модели;
Все двигатели, которыми оснащалась модель;
Все трансмиссии;
Все проводки и разъемы.
А также работа с диагностикой, самодиагностикой, коды ошибок и порядок работы по их обнаружению и устранению.

Одним словом полная инструкция по правильной разборке, сборке с учетом всех моментов затяжки, смазки, герметизирования N16…

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Источник

Get your hands on the complete Nissan factory workshop software

BRAKE SYSTEM
SECTION

CONTENTS
PRECAUTIONS AND PREPARATION……………………….1
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’……………1
Precautions for Brake System……………………………….1
Commercial Service Tools …………………………………….1
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ……………………………………………..2
NVH Troubleshooting Chart…………………………………..2
CHECK AND ADJUSTMENT ……………………………………3
Checking Brake Fluid Level…………………………………..3
Checking Brake Line ……………………………………………3
Changing Brake Fluid …………………………………………..3
Bleeding Brake System ………………………………………..4
BRAKE HYDRAULIC LINE/CONTROL VALVE…………..5
Brake Hydraulic Line ……………………………………………5
Load Sensing Valve……………………………………………..6
BRAKE PEDAL AND BRACKET…………………………….10
Removal and Installation …………………………………….10
Inspection………………………………………………………….10
Adjustment ………………………………………………………..10
MASTER CYLINDER……………………………………………..12
Removal……………………………………………………………12
Disassembly………………………………………………………13
Inspection………………………………………………………….13
Assembly ………………………………………………………….13
Installation…………………………………………………………14
BRAKE BOOSTER………………………………………………..15
Brake Booster ……………………………………………………15
VACUUM PIPING (LHD models)…………………………….17
Vacuum Hose ……………………………………………………17
VACUUM PIPING (RHD models) ……………………………18
Vacuum Hose ……………………………………………………18
VACUUM PIPING…………………………………………………..19
VACUUM PUMP ……………………………………………………20
Removal and Installation …………………………………….20
FRONT DISC BRAKE ……………………………………………21
Pad Replacement ………………………………………………21
Removal……………………………………………………………23
Disassembly………………………………………………………23

Inspection — Caliper ………………………………………….23
Inspection — Rotor…………………………………………….24
Assembly ………………………………………………………….24
Installation…………………………………………………………24
REAR DISC BRAKE………………………………………………25
Pad Replacement ………………………………………………25
Removal……………………………………………………………27
Disassembly………………………………………………………27
Inspection — Caliper ………………………………………….27
Inspection — Rotor…………………………………………….28
Assembly ………………………………………………………….28
Installation…………………………………………………………28
PARKING CENTER BRAKE CONTROL ………………….29
Removal……………………………………………………………29
Inspection………………………………………………………….29
Installation…………………………………………………………30
Adjustment ………………………………………………………..30
PARKING CENTER BRAKE …………………………………..31
Removal and Installation …………………………………….31
Inspection — Drum…………………………………………….32
Inspection — Lining ……………………………………………32
ANTI-LOCK BRAKE SYSTEM………………………………..33
Purpose…………………………………………………………….33
Operation ………………………………………………………….33
ABS Hydraulic Circuit …………………………………………33
System Components ………………………………………….34
System Description…………………………………………….34
Removal and Installation …………………………………….36
TROUBLE DIAGNOSES ………………………………………..39
How to Perform Trouble Diagnoses for Quick
and Accurate Repair …………………………………………..39
Preliminary Check………………………………………………40
Component Parts and Harness Connector
Location ……………………………………………………………41
Circuit Diagram for Quick Pinpoint Check……………..42
Wiring Diagram — ABS — ………………………………….43
Self-diagnosis ……………………………………………………47
CONSULT …………………………………………………………50
CONSULT Inspection Procedure………………………….51

Ground Circuit Check …………………………………………56
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMS…………………………………………………………………..57
Diagnostic Procedure 1 (Wheel sensor or rotor) ……57
Diagnostic Procedure 2 (ABS actuator solenoid
valve and solenoid valve relay) ……………………………59
Diagnostic Procedure 3 (Motor relay or motor)………61
Diagnostic Procedure 4 (Low voltage) ………………….63
Diagnostic Procedure 5 (G sensor)………………………64
Diagnostic Procedure 6 (Control unit) …………………..65
TROUBLE DIAGNOSES FOR SYMPTOMS……………..66
Diagnostic Procedure 7 (ABS works frequently.) ……66
Diagnostic Procedure 8 (Unexpected pedal
action) ………………………………………………………………67

Diagnostic Procedure 9 (Long stopping distance) ….67
Diagnostic Procedure 10 (ABS does not work.) …….68
Diagnostic Procedure 11 (Pedal vibration and
noise) ……………………………………………………………….68
Diagnostic Procedure 12 (Warning lamp does
not come on when ignition switch is turned ON.) …..69
Diagnostic Procedure 13 (Warning lamp stays on
when ignition switch is turned ON.)………………………71
SERVICE DATA AND SPECIFICATIONS (SDS) ……….72
General Specifications………………………………………..72
Inspection and Adjustment ………………………………….73

When you read wiring diagrams:
+ Read GI section, ‘‘HOW TO READ WIRING DIAGRAMS’’.
+ See EL section, ‘‘POWER SUPPLY ROUTING’’ for power distribution circuit.
When you perform trouble diagnoses, read GI section, ‘‘HOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSES’’ and ‘‘HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN
ELECTRICAL INCIDENT’’.

PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’
The Supplemental Restraint System such as ‘‘AIR BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’ used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The composition varies according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral Cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.

Precautions for Brake System
Use brake fluid ‘‘DOT 3’’.
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+ To clean master cylinder parts, disc brake caliper parts or
wheel cylinder parts, use clean brake fluid.
+ Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of hydraulic system.
+ Use flare nut wrench when removing and installing brake
tubes.
+ Always torque brake lines when installing.
WARNING:
Clean brakes with a vacuum dust collector to minimize risk of
health hazard from powder caused by friction.
+
+
+

SBR686C

Commercial Service Tools
Tool name

Description

j
1 Flare nut crowfoot
j
2 Torque wrench

Removing and installing each brake piping

a: 10 mm (0.39 in)

NT360

Brake fluid pressure gauge

Measuring brake fluid pressure

NT151

BR-1

Symptom
BRAKE
—
—
BR-23, 27, 31
BR-23, 27, 31

Shims damaged
Rotor or drum imbalance
Rotor or drum damage
Rotor or drum runout

X
X
X
X

Shake
X

Shimmy, Judder
X
X

X: Applicable

BR-2
X
X
X
X

—

Rotor or drum rust
X
X

NHV in PD section
NHV in PD section
NHV in FA, RA section
NHV in FA section
NHV in FA section
NHV in FA section
NHV in ST section

DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
AXLE SHAFT
STEERING

BR-31
PROPELLER SHAFT

Drum out of round

BR-23, 27

—

Rotor or drum deflection

Rotor thickness variation

—

Rotor or drum deformation

BR-31
—

Noise
Return spring damaged

Possible cause and
SUSPECTED PARTS
Linings or pads — uneven wear

BR-20, 24, 31

Reference page

Linings or pads — damaged

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X
X
X
X
X
X
X

X
X
X
X
X
X

X
X
X
X

CHECK AND ADJUSTMENT
Checking Brake Fluid Level
+
+
+

Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
If fluid level is extremely low, check brake system for leaks.
If the brake warning lamp comes on, check brake fluid level
switch and parking brake switch.

SBR451D

Checking Brake Line
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.

SBR389C

Changing Brake Fluid

SBR419C

CAUTION:
+ Refill with new brake fluid ‘‘DOT 3’’.
+ Always keep fluid level higher than minimum line on reservoir tank.
+ Never reuse drained brake fluid.
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and refill with new brake fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
4. Refill until brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to ‘‘Bleeding Brake System’’, BR-4.

BR-3

CHECK AND ADJUSTMENT
Bleeding Brake System

SBR995

CAUTION:
+ Carefully monitor brake fluid level at master cylinder during bleeding operation.
+ If master cylinder is suspected to have air inside, bleed air
from master cylinder first. Refer to ‘‘Installation’’, ‘‘MASTER CYLINDER’’, BR-14.
+ Fill reservoir with new brake fluid ‘‘DOT 3’’. Make sure it is
full at all times while bleeding air out of system.
+ Place a container under master cylinder to avoid spillage
of brake fluid.
+ For models with ABS, turn ignition switch OFF and disconnect ABS actuator connectors or battery ground cable.
+ Bleed air in the following order.
1. LSV air bleeder
2. Left rear brake
3. Right rear brake
4. Left front brake
5. Right front brake

1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release
air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2. through 5. until clear brake fluid comes out of
air bleeder valve.
7. Tighten air bleeder valve.
: 7 — 9 Nzm (0.7 — 0.9 kg-m, 61 — 78 in-lb)
SBR419C

BR-4

BRAKE HYDRAULIC LINE/CONTROL VALVE
Brake Hydraulic Line

YBR146

SBR161E

BR-5

BRAKE HYDRAULIC LINE/CONTROL VALVE
Brake Hydraulic Line (Cont’d)
REMOVAL

SBR992

CAUTION:
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+ All hoses must be free from excessive bending, twisting
and pulling.
1. Connect vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
3. Remove flare nut connecting brake tube and hose, then withdraw lock spring.
4. Cover openings to prevent entrance of dirt whenever disconnecting brake line.

INSPECTION
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.

INSTALLATION

SBR686C

CAUTION:
+ Refill with new brake fluid ‘‘DOT 3’’.
+ Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Flare nut:
: 15 — 17 Nzm (1.5 — 1.7 kg-m, 11 — 12 ft-lb)
Connecting bolt:
: 17 — 19 Nzm (1.7 — 1.9 kg-m, 12 — 14 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to ‘‘Bleeding Brake System’’, BR-4.

Load Sensing Valve
INSPECTION
CAUTION:
+ Carefully monitor brake fluid level at master cylinder.
+ Use new brake fluid ‘‘DOT 3’’.
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on paint
areas, wash it away with water immediately.
+ Depress pedal slowly when raising front brake pressure.
+ Check rear brake pressure 2 seconds after front brake
pressure reaches specified value.
+ For models with ABS disconnect harness connectors from
ABS actuator relay before checking.

BR-6

BRAKE HYDRAULIC LINE/CONTROL VALVE
Load Sensing Valve (Cont’d)
1. Ensure vehicle is unladen condition*.
* Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
2. Have a driver sit in the driver’s seat and one person sit on the
rear end. Then have the person on the rear end slowly get off
the vehicle. This is necessary to stabilize suspension deflection.
3. Gradually depress brake pedal and attach a lever to the stopper bolt, then adjust length ‘‘L’’ as follows:
Length ‘‘L’’: Approx. 175.2 — 178.2 mm (6.90 — 7.02 in)
SBR287E

4. Remove front LH tire.
5. Connect tool to air bleeders on front LH brake caliper and rear
LH or RH brake wheel cylinder.

SBR822BA

6. Install front LH tire.
Before installing front LH tire, confirm the tool is not touching
the front LH wheel.
7. Bleed air from Tool.

SBR823BA

8. Raise front brake pressure to 4,904 kPa (49.0 bar, 50 kg/cm2,
711 psi) and 9,807 kPa (98.1 bar, 100 kg/cm2, 1,422 psi) and
check rear brake pressure.
Rear brake pressure:
Refer to table on next page.

SBR377D

BR-7

BRAKE HYDRAULIC LINE/CONTROL VALVE
Load Sensing Valve (Cont’d)
9. Set down weight slowly over axle center so that sensor spring
length becomes the same as when in loaded condition (Refer
to table below). Check rear brake pressure in the same way
described in step 7.
4-door rear disc brake
Unit: kPa (bar, kg/cm2, psi)

Sensor spring
length ‘‘L’’*
mm (in)

Front brake
pressure
4,904 (49.0, 50,
711)

Front brake
pressure
9,807
(98.1, 100,
1,422)

Without
weight

175.2 — 178.2
(6.90 — 7.02)

2,158 — 3,138
(21.58 — 31.38,
22.0 — 32.0,
313 — 455)

3,629 — 4,609
(36.29 — 46.09,
37.0 — 47.0,
526 — 668)

With
weight

193.6 — 196.6
(7.62 — 7.74)

2,746 — 4,707
(27.46 — 47.07,
28.0 — 48.0,
398 — 683)

4,217 — 6,178
(42.17 — 61.78,
43.0 — 63.0,
611 — 896)

SBR378D

Rear brake
pressure

*: Depressed brake pedal.

10. Bleed air after disconnecting the tool. Refer to ‘‘Bleeding Brake
System’’, BR-4.
11. Install front LH tire.

REMOVAL AND INSTALLATION
CAUTION:
+ Refill with new brake fluid ‘‘DOT 3’’.
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+ Do not reuse Load Sensing Valve once it is disassembled.
+ Replace damaged Load Sensing Valve as an assembly.
+ When disassembling, apply multi-purpose grease to all rubbing
areas.

BR-8

BRAKE HYDRAULIC LINE/CONTROL VALVE
Load Sensing Valve (Cont’d)

SBR162E

1. Tighten all flare nuts and mounting bolts.
Flare nut:
: 15 — 17 Nzm (1.5 — 1.7 kg-m, 11 — 12 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to ‘‘Bleeding Brake System’’, BR-4.

BR-9

BRAKE PEDAL AND BRACKET
Removal and Installation

SBR163E

Inspection
Check brake pedal for following items.
+ Brake pedal bend
+ Clevis pin deformation
+ Crack of any welded portion
+ Crack or deformation of clevis pin stopper

Adjustment
Check brake pedal free height from dash lower panel.
H:
Free height
Refer to SDS (BR-72).
D:
Depressed height
Refer to SDS (BR-72).
Under force of 490 N (50 kg, 110 lb)
with engine running
C1, C2: Clearance between pedal stopper and
threaded end of stop lamp switch and ASCD
switch
0.3 — 1.0 mm (0.012 — 0.039 in)
A:
Pedal free play
1 — 3 mm (0.04 — 0.12 in)
If necessary, adjust brake pedal free height.
SBR463CB

BR-10

BRAKE PEDAL AND BRACKET
Adjustment (Cont’d)

SBR824B

1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
Make sure that tip of input rod stays inside.
2. Adjust clearance ‘‘C1’’ and ‘‘C2’’ with stop lamp switch and
ASCD switch respectively. Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamp is off when pedal is released.
4. Check brake pedal’s depressed height while engine is running.
If depressed height is below specified value, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.). Then make necessary repairs.

BR-11

MASTER CYLINDER
Removal
CAUTION:
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+ In the case of brake fluid leakage from the master cylinder,
disassemble the cylinder. Then check piston cups for
deformation or scratches and replace necessary parts.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake
pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.

SBR164E

BR-12

MASTER CYLINDER
Disassembly
1. Bend claws of stopper cap outward.

SBR165E

2. Remove piston stopper while piston is pushed into cylinder
(Models with ABS only).
3. Remove piston assemblies.
If it is difficult to remove secondary piston assembly, gradually
apply compressed air through fluid outlet.
4. Draw out reservoir tank.

SBR166E

Inspection
Check master cylinder inner wall for pin holes or scratches.
Replace if damaged.

Assembly
1. Insert secondary piston assembly. Then insert primary piston
assembly.
+ Pay attention to direction of piston cups in figure at left.
Also, insert pistons squarely to avoid scratches on cylinder bore.
+ Pay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body (Models with
ABS only).
SBR354C

2. Install stopper cap.
Before installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.

SBR167E

BR-13

MASTER CYLINDER
Assembly (Cont’d)
5. Install valve stopper while piston is pushed into cylinder (Model
with ABS only).

SBR168E

Installation

SBR169E

CAUTION:
+ Refill with new brake fluid ‘‘DOT 3’’.
+ Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mounting
nuts lightly.
2. Torque mounting nuts.
: 12 — 15 Nzm (1.2 — 1.5 kg-m, 9 — 11 ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 — 17 Nzm (1.5 — 1.7 kg-m, 11 — 12 ft-lb)
8. Bleed air. Refer to ‘‘Bleeding Brake System’’, BR-4.

BR-14

BRAKE BOOSTER
Brake Booster
ON-VEHICLE SERVICE
Operating check
+
+
SBR002A

Depress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.

Airtight check
+
+

Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change after
holding pedal down for 30 seconds.

SBR365AA

REMOVAL
CAUTION:
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+ Be careful not to deform or bend brake pipes, during
removal of booster.

SBR170E

INSPECTION
Output rod length check
1. Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to
brake booster with a hand vacuum pump.
2. Check output rod length.
Specified length:
10.275 — 10.525 mm (0.4045 — 0.4144 in)

SBR281A

INSTALLATION

SBR116BF

CAUTION:
+ Be careful not to deform or bend brake pipes during installation of booster.
+ Replace clevis pin if damaged.
+ Refill with new brake fluid ‘‘DOT 3’’.
+ Never reuse drained brake fluid.
+ Take care not to damage brake booster mounting bolt
thread when installing. Due to the narrow angle of
installation, the threads can be damaged by the dash
panel.

BR-15

BRAKE BOOSTER
Brake Booster (Cont’d)
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
brake booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
Specification: 13 — 16 Nzm (1.3 — 1.6 kg-m, 9 — 12 ft-lb)
5. Install master cylinder. Refer to ‘‘Installation’’ in ‘‘MASTER
CYLINDER’’, BR-14.
6. Adjust brake pedal height and free play.
Refer to ‘‘Adjustment’’ in ‘‘BRAKE PEDAL AND BRACKET’’,
BR-10.
7. Secure lock nut for clevis.
: 16 — 22 Nzm (1.6 — 2.2 kg-m, 12 — 16 ft-lb)
8. Bleed air. Refer to ‘‘Bleeding Brake System’’, BR-4.

BR-16

VACUUM PIPING (LHD models)
Vacuum Hose

YBR147

BR-17

VACUUM PIPING (RHD models)
Vacuum Hose

YBR148

BR-18

VACUUM PIPING
REMOVAL AND INSTALLATION
CAUTION:
When installing vacuum hoses, pay attention to the following
points.
+ Do not apply any oil or lubricants to vacuum hose and
check valve.
+ Insert vacuum tube into vacuum hose as shown.
+ Install check valve, paying attention to its direction.

SBR454D

INSPECTION
Hoses and connectors
Check vacuum lines, connections and check valve for airtightness,
improper attachment chafing and deterioration.

Check valve
Check vacuum with a vacuum pump.
Connect to booster
side

Vacuum should exist.

Connect to engine
side

Vacuum should not exist.

SBR844B

Vacuum warning switch*
Test continuity through vacuum warning switch with an ohmmeter and vacuum pump.
Less than 26.7 kPa
(267 mbar, 200 mmHg, 7.87 inHg)

0Ω

33.3 kPa
(333 mbar, 250 mmHg, 9.84 inHg) or more

∞Ω

Vacuum

* Diesel engine models except Australia
SBR321E

BR-19

VACUUM PUMP
Removal and Installation
RD28 engine models
17 — 22 (1.7 — 2.2 kg-m, 12 — 16 ft-lb)
Vacuum pump

Rocker cover gasket

Rocker cover

SBR319E

1. Rotate crankshaft so intake cam nose for No. 1 cylinder faces
straight up when viewed through oil filler cap mounting hole.
2. Rotate crankshaft approximately 240° counterclockwise.
3. Remove vacuum pump.
CAUTION:
Loosen mounting nuts equally and gradually.
Always remove mounting nuts by pushing to keep the
vacuum pump from jumping up.
Do not disassemble vacuum pump.
4. Install the vacuum pump in the location from which it was
removed with cam nose set in position.

BR-20

FRONT DISC BRAKE
Pad Replacement

SBR171E

WARNING:
Clean brakes with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
+ When cylinder body is removed, do not depress brake
pedal, or piston will pop out.
+ Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
+ If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
+ It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to stretch
brake hose.
+ Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
+ Always remove pad retainer in the direction of the arrow.
Failure to do so will damage pawl areas, causing pad
retainer to be unsuitable for further use.

1. Remove master cylinder reservoir cap.
2. Remove upper and lower pin bolts.
3. Remove cylinder body from torque member. Then remove
pads, pad retainers, and inner and outer shims.
Standard pad thickness:
12.0 mm (0.472 in)
Pad wear limit:
2.0 mm (0.079 in)
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
SBR172E

BR-21

FRONT DISC BRAKE

SBR173E

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Main pin
Pin boot
Shim cover
Inner shim
Inner pad
Torque member fixing bolt

j
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j
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j
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j
12

Washer
Torque member
Outer pad
Outer shim
Pad retainer
Connecting bolt

BR-22

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j
18

Copper washer
Main pin bolt
Cylinder body
Piston seal
Piston
Piston boot

FRONT DISC BRAKE
Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
Suspend caliper assembly with wire so as not to stretch brake
hose.

Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.

SBR174E

Disassembly
WARNING:
Do not place your fingers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
1. Push out piston with dust seal with compressed air.
2. Remove piston seal with a suitable tool.

SBR085A

Inspection — Caliper
CYLINDER BODY
Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign objects. If any of the above conditions
are observed, replace cylinder body.
+ Minor damage from rust or foreign objects may be eliminated
by polishing surface with a fine emery paper. Replace cylinder
body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
+

PISTON
Check piston for score, rust, wear, damage or presence of foreign
objects. Replace if any of the above conditions are observed.
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign objects are stuck to sliding surface.

SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks, rust or other damage. Replace if any of the
above conditions are observed.

BR-23

FRONT DISC BRAKE
Inspection — Rotor
RUNOUT

SBR019B

1. Secure rotor to wheel hub with at least two nuts (M12 × 1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to FA section (‘‘Front
Wheel Bearing’’, ‘‘ON-VEHICLE SERVICE’’).
Maximum runout:
0.1 mm (0.004 in)
3. If the runout is out of specification, find minimum runout position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with
nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can
be found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe (‘‘MAD, DL-8700’’, ‘‘AMMCO 700 and 705’’ or
equivalent).

THICKNESS
Thickness variation (At least 8 positions):
Maximum 0.015 mm (0.0006 in)
If thickness variation exceeds the specification, turn rotor with oncar brake lathe.
Rotor repair limit:
30.0 mm (1.181 in)

SBR020B

Assembly
1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
3. Properly secure piston boot
CAUTION:
Secure dust seal properly.

SBR574

Installation
CAUTION:
+ Refill with new brake fluid ‘‘DOT 3’’.
+ Never reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to ‘‘Bleeding Brake System’’, BR-4.

SBR175E

BR-24

REAR DISC BRAKE
Pad Replacement
WARNING:
Clean brakes with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
+ When cylinder body is open, do not depress brake pedal,
or piston will pop out.
+ Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
+ If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
+ It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to stretch
brake hose.
+ Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.

1. Remove master cylinder reservoir cap.
2. Remove lower pin bolt.
3. Open cylinder body upward. Then remove pad retainers, and
inner and outer shims.
Standard pad thickness:
10.0 mm (0.394 in)
Pad wear limit:
2.0 mm (0.079 in)
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
SBR181E

BR-25

REAR DISC BRAKE

SBR182E

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Main pin
Pin boot
Shim cover
Inner shim
Inner pad
Torque member fixing bolt

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9
j
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j
11
j
12

Washer
Torque member
Outer pad
Outer shim
Pad retainer
Connecting bolt

BR-26

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15
j
16
j
17
j
18

Copper washer
Main pin bolt
Cylinder body
Piston seal
Piston
Piston boot

REAR DISC BRAKE
Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
Suspend caliper assembly with wire so as not to stretch brake
hose.

SBR183E

SBR772

SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks, rust or other damage. Replace if any of the
above conditions are observed.

BR-27

REAR DISC BRAKE
Inspection — Rotor
RUNOUT

SBR389A

1. Secure rotor to wheel hub with at least two nuts (M12 × 1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to ‘‘Rear Wheel Bearing’’ in RA section.
Maximum runout:
0.1 mm (0.004 in)
3. If the runout is out of specification, find minimum runout position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with
nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can
be found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe (‘‘MAD, DL-8700’’, ‘‘AMMCO 700 and 705’’ or
equivalent).

SBR390A

Assembly
1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
3. Properly secure piston boot

SBR574

SBR184E

BR-28

PARKING CENTER BRAKE CONTROL

SBR437A

Removal
1.
2.
3.
4.

Disconnect harness connector.
Disconnect control cable from control lever and bracket.
Remove control lever and bracket.
Disconnect control cable from center brake and remove control
cable.

SBR209E

Inspection
1. Check control lever and ratchet for evidence of wear or other
damage. Replace if necessary.
2. Check wires for evidence of discontinuity or other deterioration.
Replace if necessary.
3. Check parts at each connection for deformation or damage.
Replace if necessary.
4. Check warning lamp and switch. Replace if necessary.

BR-29

PARKING CENTER BRAKE CONTROL
Installation
1. Apply a coating of grease to sliding contact surfaces.
2. Insert clevis pin from left side.
3. After installation is completed, adjust entire system.

Adjustment
1. Pull control lever with specified amount of force. Check lever
stroke and ensure smooth operation.
Number of notches: 7 — 9

SBR033A

2. Bend parking brake warning lamp switchplate so that brake
warning lamp comes on when ratchet at parking brake lever is
pulled notches and goes out when fully released.
Number of notches: 2

SBR438A

BR-30

PARKING CENTER BRAKE

SBR251E

Removal and Installation

SBR180E

WARNING:
Clean brake lining with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
CAUTION:
Make sure parking brake lever is released completely.
1. Release parking brake lever fully.
2. Remove rear propeller shaft and drum.
3. After removing shoe hold pin by rotating push retainer, remove
leading shoe then remove trailing shoe.
Remove spring by rotating shoes in direction arrow.
4. Remove adjuster and return spring.
5. Disconnect parking brake cable from center brake lever.
Be careful not to damage parking brake cable when separating it.
6. Remove retainer ring with a suitable tool. Then separate center brake lever and brake shoe.

BR-31

PARKING CENTER BRAKE
Removal and Installation (Cont’d)
When installing, measure brake drum inside diameter and diameter
of brake shoes. Check that the difference between diameters is the
correct shoe clearance.
Shoe clearance:
0.25 — 0.4 mm (0.0098 — 0.0157 in)
If necessary, adjust by rotating adjuster.

SBR367A

Inspection — Drum

+
SBR095A

+
+

Standard inner diameter:
203.2 mm (8 in)
Maximum inner diameter:
204.5 mm (8.05 in)
Out-of-roundness (Ellipticity):
0.03 mm (0.0012 in) or less
Radial runout (Total indicator reading):
0.05 mm (0.0020 in) or less
Contact surface should be finefinished with No. 120 to 150
emery paper.
Using a drum lathe, lathe brake drum if it shows scoring, partial wear or stepped wear.
After brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.

Inspection — Lining
Check lining thickness.
Lining wear limit:
1.5 mm (0.059 in)
Lining standard thickness:
5.1 mm (0.201 in)
Before installing new shoes, rotate nut until adjuster rod is at its
shortest point.
After installation, adjust shoe-to-drum clearance. Refer to Removal
and Installation.
+

SBR021A

BR-32

ANTI-LOCK BRAKE SYSTEM
Purpose
The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of
braking force so locking of the wheels can be avoided.
The ABS:
1) Improves proper tracking performance through steering wheel operation.
2) Eases obstacle avoidance through steering wheel operation.
3) Improves vehicle stability.

Operation
+
+

+
+

When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.
The Anti-Lock Brake System (ABS) has a self-test function. The system turns on the ABS warning lamp
for 1 second each time the ignition switch is turned ‘‘ON’’. After the engine is started, the ABS warning
lamp turns off. The system performs a test the first time the vehicle reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs this self-test. This is a normal part of the self-test feature. If
a malfunction is found during this check, the ABS warning lamp will stay on.
While driving, a mechanical noise may be heard during ABS operation. This is a normal condition.
While DIFF-LOCK is on, the anti-lock brake warning light flashes. This indicates that anti-lock may not be
fully operated. (ABS only)

ABS Hydraulic Circuit

SBR211E

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Inlet solenoid valve
Outlet solenoid valve
Reservoir

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Pump
Motor
Inlet valve

BR-33

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Outlet valve
Bypass check valve
Damper

ANTI-LOCK BRAKE SYSTEM
System Components

SBR185E

System Description
WHEEL SENSOR
The sensor unit consists of a gear-shaped sensor rotor and a sensor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back of the brake rotor.
As the wheel rotates, the sensor generates a sine-wave pattern.
The frequency and voltage increase(s) as the rotating speed
increases.

CONTROL UNIT (built in ABS actuator and electric unit)
The control unit computes the wheel rotating speed by the signal
current sent from the sensor. Then it supplies a DC current to the
actuator solenoid valve. It also controls ON-OFF operation of the
valve relay and motor relay. If any electrical malfunction should be
detected in the system, the control unit causes the warning lamp
to light up. In this condition, the ABS will be deactivated by the
control unit, and the vehicle’s brake system reverts to normal
operation. (For control unit layout, refer to ABS ACTUATOR AND
ELECTRIC UNIT, BR-34.)
SBR186E

BR-34

ANTI-LOCK BRAKE SYSTEM
System Description (Cont’d)
G SENSOR
The G sensor senses deceleration during braking to determine whether the vehicle is being driven on a high
µ road (asphalt road, etc.) or a low µ road (snow-covered road, etc.). It then sends a signal to the ABS control unit.

SBR189E

The reed switch turns on when it is affected by a magnetic field. During sudden deceleration (braking on a
high µ road), the weight moves and the magnet in the weight moves away from the reed switch. The magnetic field then diminishes and the reed switch turns off.

ABS ACTUATOR AND ELECTRIC UNIT

SBR176E

The ABS actuator and electric unit contains:
+ An electric motor and pump
+ Two relays
+ Six solenoid valves, each inlet and outlet for
— LH front
— RH front
— Rear
+ ABS control unit
This component controls the hydraulic circuit and increases, holds
or decreases hydraulic pressure to all or individual wheels. The
ABS actuator and electric unit are not disassemble.

ABS actuator operation
Inlet solenoid
valve

Outlet solenoid
valve

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is directly transmitted to wheel cylinder via the inlet solenoid valve.

Pressure hold

ON (Closed)

OFF (Closed)

Hydraulic circuit is shut off to hold the wheel cylinder
brake fluid pressure.

Pressure
decrease

ON (Closed)

ON (Open)

Wheel cylinder brake fluid is sent to reservoir via the
outlet solenoid valve. Then it is pushed up to the
master cylinder by pump.

Pressure
increase

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is transmitted to
wheel cylinder.

Normal brake operation

ABS operation

BR-35

ANTI-LOCK BRAKE SYSTEM
Removal and Installation
CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
When removing the front wheel hub or rear axle shaft
assembly, disconnect the ABS wheel sensor from the assembly and move it away.

FRONT WHEEL SENSOR

SBR187E

BR-36

ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont’d)
REAR WHEEL SENSOR

SBR188E

G SENSOR
Always replace G sensor if bumped or dropped. Otherwise,
performance characteristics of G sensor will be changed,
which in turn changes ABS control performance characteristics.

SBR190E

BR-37

ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont’d)
ABS ACTUATOR AND ELECTRIC UNIT

SBR191E

Removal
1.
2.
3.
4.

Disconnect battery cable.
Drain brake fluid. Refer to ‘‘Changing Brake Fluid’’, BR-3.
Remove mounting bracket fixing bolts and nuts.
Disconnect connector, brake pipes and remove fixing nuts.

Installation
CAUTION:
After installation, refill brake fluid. Then bleed air. Refer to
Bleeding Brake System’’, BR-4.
1. Connect brake pipes temporarily.
2. Tighten fixing bolts and nuts.
3. Tighten brake pipes.
4. Connect connector and battery cable.

BR-38

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair
INTRODUCTION

SEF233G

SEF234G

The ABS system has an electronic control unit to control major
functions. The control unit accepts input signals from sensors and
instantly drives the actuators. It is essential that both kinds of signals are proper and stable. It is also important to check for conventional problems: such as air leaks in booster lines, lack of brake
fluid, or other problems with the brake system.
It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are
caused by poor electric connections or faulty wiring. In this case,
careful checking of suspicious circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems, so a
road test should be performed.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a ABS complaint. The customer
is a very good source of information on such problems; especially
intermittent ones. Through the talks with the customer, find out what
symptoms are present and under what conditions they occur.
Start your diagnosis by looking for ‘‘conventional’’ problems first.
This is one of the best ways to troubleshoot brake problems on an
ABS controlled vehicle.

BR-39

TROUBLE DIAGNOSES
Preliminary Check

Check brake fluid level in reservoir
tank.
——————————————————————————————————————————————————-Low fluid level may indicate brake pad
wear or leakage from brake line.
SBR451D
.

Check brake line for leakage.

Repair.
c

OK
b
.

Check brake booster for operation and air
tightness. Refer to BR-15.

Replace.
c

OK
b
SBR389C

Check brake pads and rotor. Refer to
BR-21, 25.

Replace.
c

OK
.

Check brake fluid level in reservoir tank
again.

Fill up brake fluid.
c

OK
.
SBR058C

Check warning lamp activation.
When ignition switch is turned on, warning
lamp turns on.

NG
c

Check fuse, warning lamp
bulb and warning lamp circuit.

OK
.

Check warning lamp for deactivation after
engine is started.

NG
c

Go to Self-diagnosis,
BR-46, 50.

OK
.

Drive vehicle at speeds over 30 km/h (19
MPH) for at least 1 minute.
SBR059C
.

Ensure warning lamp remains off while
driving.
OK
.

END

SBR186E

BR-40

TROUBLE DIAGNOSES
Component Parts and Harness Connector
Location

SBR192E

BR-41

TROUBLE DIAGNOSES
Circuit Diagram for Quick Pinpoint Check

TBR098

BR-42

TROUBLE DIAGNOSES
Wiring Diagram — ABS —

TBR099

BR-43

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR100

BR-44

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR101

BR-45

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR102

BR-46

TROUBLE DIAGNOSES
Self-diagnosis
FUNCTION
+

When a problem occurs in the ABS, the warning lamp on the
instrument panel comes on. To start the self-diagnostic results
mode, ground the self-diagnostic (check) terminal located on
‘‘Data Link Connector for CONSULT’’. The location of the malfunction is indicated by the warning lamp flashing.
While DIFF-LOCK is on, anti-lock warning light flashes.

SELF-DIAGNOSIS PROCEDURE
Turn off DIFF-LOCK switch.
Drive vehicle over 30 km/h (19 MPH) for
at least one minute.
.

Turn ignition switch ‘‘OFF’’.
.
SBR193E

Ground terminal ‘‘4’’ of ‘‘Data link connector for CONSULT’’ with a suitable harness.
.

Turn ignition switch ‘‘ON’’ while grounding terminal ‘‘4’’.
Do not depress brake pedal.
.

After 3.0 seconds, the warning lamp
starts flashing to indicate the malfunction
code No. (See NOTE.)
SBR186E
.

Verify the location of the malfunction with
the malfunction code chart. Refer to
BR-48. Then make the necessary repairs
following the diagnostic procedures.
.

After the malfunctions are repaired, erase
the malfunction codes stored in the control unit. Refer to BR-47.
SBR194E

Rerun the self-diagnostic results mode to
verify that the malfunction codes have
been erased.

Disconnect the check terminal from the
ground. The self-diagnostic results mode
is now complete.
.

j
A

BR-47

NOTE: The indication terminates
after five minutes.
However, when the ignition
switch is turned from
‘‘OFF’’ to ‘‘ON’’, the indication starts flashing again.

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
j
A
.

Check warning lamp for deactivation after
driving vehicle over 30 km/h (19 MPH)
for at least one minute.
.

After making certain that warning lamp
does not come on, test the ABS in a safe
area to verify that it functions properly.

HOW TO READ SELF-DIAGNOSTIC RESULTS (Malfunction codes)
+
+
+
+

Determine the code No. by counting the number of times the warning lamp flashes on and off.
When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first.
The indication begins with the start code 12. After that a maximum of three code numbers appear in the
order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will
stay on for five minutes at the most).
The malfunction code chart is given on the next page.

SBR457D

HOW TO ERASE SELF-DIAGNOSTIC RESULTS
(Malfunction codes)
1. Disconnect the check terminal from ground (ABS warning lamp
will stay lit).
2. Within 12.5 seconds, ground the check terminal 3 times. Each
terminal ground must last more than 1 second. The ABS warning lamp goes out after the erase operation has been completed.
3. Perform self-diagnosis again. Refer to BR-47. Only the startcode should appear, no malfunction codes.
ABR256

BR-48

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
MALFUNCTION CODE/SYMPTOM CHART
Code No.
(No. of warning lamp flashes)

Malfunctioning part

Diagnostic procedure

Actuator front left outlet solenoid valve

Actuator front left inlet solenoid valve

Actuator front right outlet solenoid valve

Actuator front right inlet solenoid valve

Actuator rear outlet solenoid valve

Actuator rear inlet solenoid valve

.1 Front left sensor (open-circuit)

.1 Front left sensor (short-circuit)

.1 Front right sensor (open-circuit)

.1 Front right sensor (short-circuit)

.1 Rear right sensor (open-circuit)

.1 Rear right sensor (short-circuit)

.1 Rear left sensor (open-circuit)

.1 Rear left sensor (short-circuit)

.1 Sensor rotor

17
61

G sensor and circuit

63
57

.3 Actuator motor or motor relay
Solenoid valve relay

.2 Power supply (Low voltage)

Control unit

Warning lamp stays on when ignition switch is turned on

Control unit power supply circuit
Warning lamp bulb circuit
Control unit or control unit connector
Solenoid valve relay stuck
Power supply for solenoid valve relay coil

Warning lamp does not come on
when ignition switch is turned on

Fuse, warning lamp bulb or warning lamp circuit
Control unit

Pedal vibration and noise

—

Long stopping distance

—

Unexpected pedal action

—

ABS does not work

—

ABS works frequently

—

.1: If one or more wheels spin on a rough or slippery road for 40 seconds or more, the ABS warning lamp will illuminate. This does
not indicate a malfunction. Only in the case of the short-circuit (Code Nos. 26, 22, 32 and 36), after repair the ABS warning lamp
also illuminates when the ignition switch is turned ‘‘ON’’. In this case, drive the vehicle at speeds greater than 30 km/h (19 MPH)
for approximately 1 minute as specified in ‘‘SELF-DIAGNOSIS PROCEDURE’’, BR-47. Check to ensure that the ABS warning
lamp goes out while the vehicle is being driven.
.2: The trouble code ‘‘57’’, which refers to a low power supply voltage, does not indicate that the ABS control unit is malfunctioning.
Do not replace the ABS control unit with a new one.
.3: The trouble code ‘‘61’’ can sometimes appear when the ABS motor is not properly grounded. If it appears, be sure to check the
condition of the ABS motor ground circuit connection.

BR-49

TROUBLE DIAGNOSES
CONSULT
CONSULT APPLICATION TO ABS
EE960 program card is not applicable to ABS. Use on board diagnostic system with ABS warning lamp until
the next program card will be introduced. (Refer to ‘‘Self-diagnosis’’, BR-47.)
SELF-DIAGNOSTIC
RESULTS

DATA MONITOR

ACTIVE TEST

Front right wheel sensor

—

Front left wheel sensor

—

Rear right wheel sensor

—

Rear left wheel sensor

—

G switch (G sensor)

Stop lamp switch

—

Front right inlet solenoid valve

Front right outlet solenoid valve

Front left inlet solenoid valve

Front left outlet solenoid valve

Rear inlet solenoid valve

Rear outlet solenoid valve

Actuator solenoid valve relay

—

Actuator motor relay
(ABS MOTOR is shown on the Data Monitor
screen.)

ABS warning lamp

—

Battery voltage

—

ITEM

X: Applicable
—: Not applicable

ECU (ABS control unit) part number mode
Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order
the ECU.

BR-50

TROUBLE DIAGNOSES
CONSULT Inspection Procedure
SELF-DIAGNOSIS PROCEDURE
1) Turn ignition switch OFF.
2) Connect CONSULT to Data Link Connector for CONSULT.

.
SBR195E

1) Start engine.
2) Drive vehicle over 30 km/h (19 MPH)
for at least one minute.

1) Stop vehicle with engine running
and touch ‘‘START’’ on CONSULT
screen.
2) Touch ‘‘ABS’’.

SBR455D

3) Touch ‘‘SELF-DIAG RESULTS’’.
+ The screen shows the detected malfunction and how many times the ignition switch has been turned since the
malfunction.

Make the necessary repairs following the
diagnostic procedures.

SBR080E

After the malfunctions are repaired, erase
the self-diagnostic results stored in the
control unit by touching ‘‘ERASE’’.

Check warning lamp for deactivation after
driving vehicle over 30 km/h (19 MPH) for
at least one minute.

Test the ABS in a safe area to verify that it
functions properly.
SST412B

Note: ‘‘SELF-DIAG RESULTS’’ screen shows the detected malfunction and
how many times the ignition switch has been turned since the malfunction.

SBR950C

BR-51

TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Cont’d)
SELF-DIAGNOSTIC RESULTS MODE
Diagnostic item
FR RH SENSOR
.1
[OPEN]
FR LH SENSOR
.1
[OPEN]
RR RH SENSOR
.1
[OPEN]
RR LH SENSOR
.1
[OPEN]
FR RH SENSOR
.1
[SHORT]
FR LH SENSOR
.1
[SHORT]
RR RH SENSOR
.1
[SHORT]
RR LH SENSOR
.1
[SHORT]
ABS SENSOR
.1
[ABNORMAL SIGNAL]
FR RH IN ABS SOL
[OPEN]
FR LH IN ABS SOL
[OPEN]
RR IN ABS SOL
[OPEN]
FR RH IN ABS SOL
[SHORT]
FR LH IN ABS SOL
[SHORT]
RR IN ABS SOL
[SHORT]
FR RH OUT ABS SOL
[OPEN]
FR LH OUT ABS SOL
[OPEN]
RR OUT ABS SOL
[OPEN]
FR RH OUT ABS SOL
[SHORT]
FR LH OUT ABS SOL
[SHORT]
RR OUT ABS SOL
[SHORT]
ABS ACTUATOR RELAY
[ABNORMAL]
ABS MOTOR RELAY
[ABNORMAL]
BATTERY VOLT
[VB-LOW]
CONTROL UNIT
G-SENSOR
[ABNORMAL]

Diagnostic item is detected when …
+ Circuit for front right wheel sensor is open.
(An abnormally high input voltage is entered.)
+ Circuit for front left wheel sensor is open.
(An abnormally high input voltage is entered.)
+ Circuit for rear right sensor is open.
(An abnormally high input voltage is entered.)
+ Circuit for rear left sensor is open.
(An abnormally high input voltage is entered.)
+ Circuit for front right wheel sensor is shorted.
(An abnormally low input voltage is entered.)
+ Circuit for front left wheel sensor is shorted.
(An abnormally low input voltage is entered.)
+ Circuit for rear right sensor is shorted.
(An abnormally low input voltage is entered.)
+ Circuit for rear left sensor is shorted.
(An abnormally low input voltage is entered.)
+ Teeth damage on sensor rotor or improper installation of wheel sensor.
(Abnormal wheel sensor signal is entered.)
+ Circuit for front right inlet solenoid valve is open.
(An abnormally low output voltage is entered.)
+ Circuit for front left inlet solenoid valve is open.
(An abnormally low output voltage is entered.)
+ Circuit for rear inlet solenoid valve is open.
(An abnormally low output voltage is entered.)
+ Circuit for front right inlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)
+ Circuit for front left inlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)
+ Circuit for rear inlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)
+ Circuit for front right outlet solenoid valve is open.
(An abnormally low output voltage is entered.)
+ Circuit for front left outlet solenoid valve is open.
(An abnormally low output voltage is entered.)
+ Circuit for rear outlet solenoid valve is open.
(An abnormally low output voltage is entered.)
+ Circuit for front right outlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)
+ Circuit for front left outlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)
+ Circuit for rear outlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)
+ Actuator solenoid valve relay is ON, even if control unit sends off signal.
+ Actuator solenoid valve relay is OFF, even if control unit sends on signal.
+ Circuit for ABS motor relay is open or shorted.
+ Circuit for actuator motor is open or shorted.
+ Actuator motor relay is stuck.

Diagnostic
procedure
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
3

+ Power source voltage supplied to ABS control unit is abnormally low.

+ Function of calculation in ABS control unit has failed.

+ G sensor circuit is open or shorted.

BR-52

TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Cont’d)
DATA MONITOR PROCEDURE
1) Turn ignition switch OFF.
2) Connect CONSULT to Data Link Connector for CONSULT.
3) Turn ignition switch ON.
.

SBR455D

1) Touch ‘‘START’’ on CONSULT screen.
2) Touch ‘‘ABS’’.
3) Touch ‘‘DATA MONITOR’’.
.

1) Touch ‘‘SETTING’’ on ‘‘SELECT MONITOR ITEM’’ screen.
2) Touch ‘‘LONG TIME’’ on ‘‘SET RECORDING COND’’ screen.
3) Touch ‘‘START’’ on ‘‘SELECT MONITOR ITEM’’.

SBR080E

SST412B

SBR936C

SBR937C

BR-53

TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Cont’d)
ACTIVE TEST PROCEDURE
+
+

When conducting Active test, vehicle must be stationary.
When ABS warning lamp stays on, never conduct Active test.

1) Turn ignition switch OFF.
2) Connect CONSULT to Data Link Connector for CONSULT.
3) Start engine.
.
SBR455D

1) Touch ‘‘START’’ on CONSULT screen.
2) Touch ‘‘ABS’’.
3) Touch ‘‘ACTIVE TEST’’.
.

1) Select active test item by touching screen.
2) Touch ‘‘START’’.
.

Carry out the active test by touching screen key.

SBR080E

SST412B

SBR857D

SBR934C

BR-54

TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Cont’d)
DATA MONITOR MODE
MONITOR ITEM

CONDITION

SPECIFICATION

FR RH SENSOR
FR LH SENSOR
RR SENSOR
RR RH SENSOR
RR LH SENSOR

Drive vehicle.
(Each wheel is rotating.)

Wheel speed signal
(Almost the same speed as speedometer.)

STOP LAMP SW

Brake is depressed.

Depress the pedal: ON
Release the pedal: OFF

G-SWITCH

Vehicle is driven.
Vehicle is stopped.
Brake is applied.

During sudden braking while driving on high µ roads (asphalt
roads, etc.): OFF
While vehicle is stopped or during constant-speed driving: ON

1. Drive vehicle at speeds over
30 km/h (19 MPH) for at
least one minute.
2. Engine is running.

Operating conditions for each solenoid valve are indicated.
ABS is not operating: OFF

FR RH IN SOL
FR RH OUT SOL
FR LH IN SOL
FR LH OUT SOL
RR IN SOL
RR OUT SOL
MOTOR RELAY

ABS is not operating: OFF
ABS is operating: ON

ACTUATOR RELAY

Ignition switch ON (Engine stops): OFF
Engine running: ON

WARNING LAMP

Ignition switch is ON or
engine is running.

BATTERY VOLT

ABS warning lamp is turned on: ON
ABS warning lamp is turned off: OFF
Power supply voltage for control unit

ACTIVE TEST MODE
TEST ITEM

CONDITION

JUDGEMENT
Brake fluid pressure control operation

FR RH SOLENOID
FR LH SOLENOID
REAR SOLENOID
Engine is running.

UP (Increase):
KEEP (Hold):
DOWN (Decrease):

IN SOL

OUT SOL

OFF
ON
ON

OFF
OFF
ON

ABS MOTOR

ABS actuator motor
ON: Motor runs (ABS motor relay ON)
OFF: Motor stops (ABS motor relay OFF)

G SWITCH

G SWITCH (G SENSOR),
ON: Set G SWITCH MONITOR ‘‘ON’’
(G switch circuit is closed.)
OFF: Set G SWITCH MONITOR ‘‘OFF’’
(G switch circuit is open.)

Ignition switch is ON.

Note: Active test will automatically stop ten seconds after the test starts. (LIMIT SIGNAL monitor shows
ON.)

BR-55

TROUBLE DIAGNOSES
Ground Circuit Check
ABS ACTUATOR AND ELECTRIC UNIT GROUND
+

Check resistance between ABS actuator and electric unit connector terminals and ground.
Resistance: approximately 0Ω

SBR045EB

BR-56

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 1 (Wheel sensor or rotor)
Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18
No
INSPECTION START
Inspection end
c
——————————————————————————————————————————————————-1. Disconnect connectors from ABS actuator and electric unit and wheel sensor
of malfunction code No. Check terminals for damage or loose connections.
Then reconnect connectors.
SBR196E
2. Carry out self-diagnosis again.
Does warning lamp activate again?
Yes
.

CHECK WHEEL SENSOR ELECTRICAL. OK
A (Go to next page.)
cj
——————————————————————————————————————————————————-1. Disconnect ABS actuator and electric
unit connector.
2. Check resistance between ABS actuator and electric unit connector E18
SBR048EB
(body side) terminals.
Code No. 21 or 22 (Front RH wheel)
Terminals j
4 and j
5
Code No. 25 or 26 (Front LH wheel)
Terminals j
6 and j
7
Code No. 31 or 32 (Rear RH wheel)
Terminals j
1 and j
2
Code No. 35 or 36 (Rear LH wheel)
Terminals j
8 and j
9
Resistance: 1.44 — 1.76 kΩ
NG
SBR197E

OK
CHECK WHEEL SENSOR.
Check the following.
c
——————————————————————————————————————————————————-+ Harness connectors
Check each sensor for resistance.
E18 , E77 , E62 , C6 ,
Resistance: 1.44 — 1.76 kΩ
C5
+ Harness for open or
NG
short between wheel
sensor connectors and
ABS actuator and electric unit
If NG, repair harness or
connectors.
.

REPLACE.
——————————————————————————————————————————————————-Replace wheel sensor.

BR-57

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 1 (Wheel sensor or rotor)
(Cont’d)
j
A

Note

Note
.
NG
CHECK TIRE.
Adjust tire pressure or
c
——————————————————————————————————————————————————-replace tire(s).
Check for inflation pressure, wear and
size of each tire.
OK

Note

CHECK WHEEL BEARING.
——————————————————————————————————————————————————-Check wheel bearing axial end play.
OK
Note

Note

CHECK SENSOR ROTOR.
——————————————————————————————————————————————————-Check sensor rotor for teeth damage.

NG
c

Replace sensor rotor.

OK
.

CHECK HARNESS CONNECTOR.
——————————————————————————————————————————————————-Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector. Reconnect ABS actuator and
electric unit harness connector. Then
retest.

Note: Wheel position should be distinguished by code numbers except code No. 18 (sensor rotor).

BR-58

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 2 (ABS actuator solenoid
valve and solenoid valve relay)
Malfunction code No. 41, 45, 55, 42, 46, 56, 63
NG
CHECK FUSIBLE LINK.
A (Go to next page.)
cj
——————————————————————————————————————————————————-Check 30A fusible link i . For fusible link
layout, refer to POWER SUPPLY ROUTING in EL section.
OK
.

NG
CHECK FUSE.
B (Go to next page.)
cj
——————————————————————————————————————————————————-Check 7.5A fuse 7 . For fuse layout, refer
to POWER SUPPLY ROUTING in EL section.
OK
.

No
CHECK CONNECTOR.
Inspection end
c
——————————————————————————————————————————————————-1. Disconnect ABS actuator and electric
unit connector. Check terminals for
SBR198E
damage or loose connection. Then
reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
Yes
.

CHECK ABS ACTUATOR AND ELECTRIC NG Repair harness and conc
UNIT GROUND CIRCUIT.
nector.
——————————————————————————————————————————————————-Refer to ABS ACTUATOR AND ELECTRIC
UNIT GROUND in Ground Circuit Check,
SBR052EB
BR-56.
OK
.

NG
CHECK SOLENOID VALVE RELAY
Check the following.
c
POWER SUPPLY CIRCUIT.
+ Harness connector E18
——————————————————————————————————————————————————-+ Harness for open or
1. Disconnect ABS actuator and electric
short between ABS
unit connector.
actuator and electric unit
2. Check voltage between ABS actuator
and fusible link
and electric unit connector E18 (body
If NG, repair harness or
side) terminal j
18 and ground.
connector.
Battery voltage should exist.
OK
.

REPLACE.
——————————————————————————————————————————————————-Replace ABS actuator and electric unit.

BR-59

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 2 (ABS actuator solenoid
valve and solenoid valve relay) (Cont’d)
j
A
.

No
Inspection end
REPLACE.
c
——————————————————————————————————————————————————-Replace fusible link.
Does the fusible link blow out when
ignition switch is turned ‘‘ON’’?
Yes

SBR053EB
.

NG Check the following.
CHECK SOLENOID VALVE RELAY
c
POWER SUPPLY CIRCUIT.
+ Harness connector E18
——————————————————————————————————————————————————-+ Harness for open or short
1. Disconnect ABS actuator and electric
between ABS actuator
unit connector.
and electric unit and
2. Check continuity between ABS actuator
fusible link
and electric unit connector E18 (body
If NG, repair harness or
connector.
side) terminal j
18 and ground.
Continuity should not exit.
OK
.

REPLACE.
——————————————————————————————————————————————————-Replace ABS actuator and electric unit.

j
B
.

Yes Check the following.
REPLACE.
c
——————————————————————————————————————————————————-+ Harness connector E18
Replace fuse.
+ Harness for open or
Does the fuse blow out when ignition
short between ABS
switch is turned ‘‘ON’’?
actuator and electric unit
and fuse
No
If NG, repair harness or
connector.
.

END
——————————————————————————————————————————————————-INSPECTION END

BR-60

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 3 (Motor relay or motor)
Malfunction code No. 61
NG
CHECK FUSIBLE LINK.
cj
A (Go to next page.)
——————————————————————————————————————————————————-Check 30A fusible link d . For fusible link
layout, refer to POWER SUPPLY ROUTING in EL section.
OK
.

No
CHECK CONNECTOR.
Inspection end
c
——————————————————————————————————————————————————-1. Disconnect ABS actuator and electric
unit connector. Check terminals for
damage or loose connection. Then
reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
Yes
.

NG
Check the following.
CHECK MOTOR RELAY POWER SUPc
+ Harness connector E18
PLY
CIRCUIT.
SBR199E
——————————————————————————————————————————————————-+ Harness for open or
1. Disconnect ABS actuator and electric
short between ABS
unit connector.
actuator and electric unit
2. Check voltage between ABS actuator
and fusible link
and electric unit connector E18 (body
If NG, repair harness or
connector.
side) terminal j
17 and ground.
Battery voltage should exist.
OK
.

CHECK ABS ACTUATOR AND ELECTRIC NG Repair harness and termic
nals.
UNIT GROUND.
SBR055EB ——————————————————————————————————————————————————-Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit
Check, BR-56.
OK
.

REPLACE.
——————————————————————————————————————————————————-Replace ABS actuator and electric unit.

BR-61

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 3 (Motor relay or motor)
(Cont’d)
j
A
.

SBR056EB
.

NG
Check the following
CHECK ABS ACTUATOR MOTOR
c
+ Harness connector E18
POWER SUPPLY CIRCUIT.
——————————————————————————————————————————————————-+ Harness for open or
1. Disconnect battery cable and ABS
short between ABS
actuator and electric unit connector
actuator and electric unit
and fusible link
E18 .
If NG, repair harness or
2. Check continuity between ABS actuator
connector.
and electric unit connector E18 (body
side) terminal j
17 and ground.
Continuity should not exist.
OK
.

CHECK HARNESS CONNECTOR.
——————————————————————————————————————————————————-Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.

BR-62

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 4 (Low voltage)
Malfunction code No. 57
CHECK CONNECTOR.
——————————————————————————————————————————————————-1. Disconnect ABS actuator and electric
unit connector. Check terminals for
damage or loose connection. Then
reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?

No
c

Inspection end

Yes

SBR200E
.

CHECK ABS CONTROL UNIT POWER
SUPPLY CIRCUIT.
——————————————————————————————————————————————————-1. Disconnect ABS actuator and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector E18 (body
side) terminal j
15 and ground.
Battery voltage should exist when
ignition switch is turned ON.

NG
cj
A

(See below.)

OK
SBR058EB

CHECK ABS CONTROL UNIT GROUND.
——————————————————————————————————————————————————-Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit
Check, BR-56.

NG
c

Repair harness and connector.

OK
.

CHECK FUSE.
——————————————————————————————————————————————————-Check 7.5A fuse 7 . For fuse layout, refer
to POWER SUPPLY ROUTING in EL section.

NG
c

Replace fuse.

OK
.

CHECK ABS CONTROL UNIT POWER
SUPPLY CIRCUIT.
——————————————————————————————————————————————————-Check continuity between battery and
ABS actuator and electric unit connector
E18 (body side) terminal j
15 .
OK
.

CHECK BATTERY.
——————————————————————————————————————————————————-Check battery. Refer to BATTERY in EL
section.

BR-63

NG
c

Check the following.
+ Harness connector E18
+ Harness for open or
short between ABS
actuator and electric unit
and fuse
If NG, repair harness or
connector.

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 5 (G sensor)
Malfunction code No. 17
NG Replace fuse.
CHECK G SENSOR POWER SUPPLY
c
CIRCUIT.
——————————————————————————————————————————————————-Check 7.5A fuse 7 . For fuse layout, refer
to POWER SUPPLY ROUTING in EL section.
OK
SBR201E

CHECK CONNECTOR.
——————————————————————————————————————————————————-1. Disconnect ABS actuator and electric
unit connector. Check terminals for
damage or loose connection. Then
reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
.

No
c

Inspection end

Yes

NG Replace G sensor.
CHECK G SENSOR.
c
——————————————————————————————————————————————————-Refer to G SENSOR in Electrical CompoSBR202E
nents Inspection, BR-64.
OK
.

NG Check the following.
CHECK G SENSOR POWER SUPPLY
c
CIRCUIT.
+ Harness connectors
——————————————————————————————————————————————————-: B34 , B33 , E18 ,
1. Disconnect G sensor connector.
: B121 , B120 , E18
2. Check voltage between G sensor con+ Harness for open or short
nector
between G sensor and
: B34 , B33 ,
: B121 ,
ABS actuator and electric
B120 (body side) terminal j
15 and
unit
ground.
If NG, repair harness or
Battery voltage should exist.
SBR203E
connectors.
OK
.

NG Check the following.
CHECK G SENSOR GROUND.
c
——————————————————————————————————————————————————-+ Harness connectors
1. Disconnect ABS actuator and electric
: B34 , B33 , E18 ,
unit connector and G sensor connectors.
: B121 , B120 , B18
2. Check continuity between ABS actuator
+ Harness for open or short
and electric unit connector E18 (body
between G sensor and
ABS actuator and electric
side) terminals j
10 , j
20 and G sensor
unit
connectors
: B34 , B33 ,
:
If NG, repair harness or
B121 , B120 (body side) terminals j
10 , j
20 .
connectors.
Continuity should exist.
OK
.

BR-64

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 5 (G sensor) (Cont’d)
ELECTRICAL COMPONENTS INSPECTION
G sensor
CAUTION:
The G sensor is easily damaged if it sustains an impact. Be
careful not to drop or bump it.
1. Measure resistance between terminals j
15 and j
20 of G sensor
unit connector.
G sensor condition
SBR844DC

Resistance between
terminals j
15 and j
20

G sensor switch
condition

Installed in vehicle

1.4 — 1.6 kΩ

‘‘ON’’

Tilted as shown in figure

4.7 — 5.5 kΩ

‘‘OFF’’

2. Measure resistance between terminals j
10 and j
15 of the G
sensor unit connector.
70 — 124 Ω

Resistance:

Diagnostic Procedure 6 (Control unit)
Malfunction code No. 71
CHECK CONNECTOR.
——————————————————————————————————————————————————-1. Disconnect ABS actuator and electric
unit connector.
Check terminals for damage or loose
connections. Then reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
SBR204E
.

No
c

Inspection end

Yes

ABS CONTROL UNIT POWER SUPPLY
CHECK
——————————————————————————————————————————————————-Check voltage. Refer to
in Diagnostic
Procedure 4, BR-63.
.

CHECK SELF-DIAGNOSTIC RESULTS
——————————————————————————————————————————————————-Does warning lamp indicate code No. 71
again?
.

INSPECTION
——————————————————————————————————————————————————-Inspect the system according to the code
No.

BR-65

Yes
c

Replace ABS actuator and
electric unit.

TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 7 (ABS works
frequently.)
NG
CHECK BRAKE FLUID PRESSURE.
Perform Preliminary
c
——————————————————————————————————————————————————-Check, refer to BR-40.
Check brake fluid pressure distribution.
Refer to proportioning valve inspection.
OK
.

NG
CHECK WHEEL SENSOR.
Repair.
c
——————————————————————————————————————————————————-1. Check wheel sensor connector for terminal damage or loose connections.
2. Perform wheel sensor mechanical
check.
Refer to Diagnostic Procedure 1,
BR-57.
OK
.

NG
CHECK FRONT AXLES.
Repair.
c
——————————————————————————————————————————————————-Check front axles for excessive looseness. Refer to FA section (‘‘Front Wheel
Bearing’’, ‘‘ON-VEHICLE SERVICE’’).
OK
.

Go to
BR-66.

in Diagnostic Procedure 8,

BR-66

TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 8 (Unexpected pedal
action)
CHECK BRAKE PEDAL STROKE.
——————————————————————————————————————————————————-Check brake pedal stroke. Is stroke
excessively large?

Yes
c

Perform Preliminary
Check, refer to BR-40.

Carry out self-diagnosis.
Refer to BR-47, 51.

Repair.

No
.
SBR540A

CHECK BRAKE PERFORMANCE.
——————————————————————————————————————————————————-Disconnect ABS actuator and electric unit
connector and check whether brake is
effective.

Yes
.

CHECK WARNING LAMP ACTIVATE.
——————————————————————————————————————————————————-Ensure warning lamp remains off while
driving.
.

CHECK WHEEL SENSOR.
SBR186E ——————————————————————————————————————————————————-1. Check wheel sensor connector for terminal damage or loose connection.
2. Perform wheel sensor mechanical
check.
Refer to Diagnostic Procedure 1,
BR-57.
.

CHECK HARNESS CONNECTOR.
——————————————————————————————————————————————————-Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.

Diagnostic Procedure 9 (Long stopping
distance)
No
CHECK ABS PERFORMANCE.
in Diagnostic
Go to
c
——————————————————————————————————————————————————-Procedure 8, BR-67.
Disconnect ABS actuator and electric unit
connector and check whether stopping
distance is still long.
Yes
.

Perform Preliminary Check and air bleeding.

Note: Stopping distance may be larger than vehicles without
ABS when road condition is slippery.

BR-67

TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 10 (ABS does not work.)
CHECK WARNING LAMP ACTIVATE.
——————————————————————————————————————————————————-Does the ABS warning lamp activate?

Yes
c

Carry out self-diagnosis.
Refer to BR-47, 51.

No
.

Go to
BR-67.

in Diagnostic Procedure 8,

Note: ABS does not work when vehicle speed is under 10 km/h
(6 MPH).

Diagnostic Procedure 11 (Pedal vibration and
noise)
INSPECTION START
——————————————————————————————————————————————————-1. Apply brake.
2. Start engine.
3. Does the symptom appear only when
engine is started?

Yes
c

Carry out self-diagnosis.
Refer to BR-47, 51.

Go to
in Diagnostic
Procedure 8, BR-67.

No
.
SAT797A

CHECK IF SYMPTOM APPEARS.
——————————————————————————————————————————————————-Does the symptom appear when electrical
equipment switches (such as headlamp)
are operated?

Yes
.

CHECK WHEEL SENSOR.
——————————————————————————————————————————————————-Check wheel sensor shield ground. For
location of shield ground, refer to wiring
diagram and ‘‘HARNESS LAYOUT’’ in EL
section.
OK
.

CHECK HARNESS CONNECTOR.
——————————————————————————————————————————————————-Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.

BR-68

NG
c

Repair wheel sensor.

TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 11 (Pedal vibration and
noise) (Cont’d)
Note: ABS may operate and cause vibration under any of the
following conditions.
+ Applying brake gradually when shifting or operating
clutch.
+ Low friction (slippery) road.
+ High speed cornering.
+ Driving over bumps and pot holes.
+ Engine speed is over 5,000 rpm with vehicle stopped.

Diagnostic Procedure 12 (Warning lamp does
not come on when ignition switch is turned
ON.)
NG
CHECK FUSE.
Replace fuse.
c
——————————————————————————————————————————————————-Check 10A fuse 28 . For fuse layout, refer
to POWER SUPPLY ROUTING in EL section.
SBR205E

OK
.

Yes
CHECK WARNING LAMP ACTIVATE.
A (Go to next page.)
c j
——————————————————————————————————————————————————-Disconnect ABS actuator and electric unit
connector.
Does the warning lamp activate?
No

SBR186E

NG
CHECK HARNESS FOR SHORT.
Repair harness or connecc
——————————————————————————————————————————————————-tor.
1. Disconnect ABS actuator and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector E18 (body
side) terminal j
21 and ground.
Battery voltage should not exist.
OK
.

SBR144EB

CHECK COMBINATION METER.
——————————————————————————————————————————————————-Check combination meter. Refer to
WARNING LAMPS in EL section.

BR-69

TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 12 (Warning lamp does
not come on when ignition switch is turned
ON.) (Cont’d)
j
A
.

CHECK HARNESS CONNECTOR.
——————————————————————————————————————————————————-Check ABS actuator and electric unit pin
terminals for damage or connection of
ABS actuator and electric unit harness
connector. Reconnect ABS actuator and
electric unit harness connector. Then
retest.
NG
.

REPLACE.
——————————————————————————————————————————————————-Replace ABS actuator and electric unit.

BR-70

OK
c

Inspection end

TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 13 (Warning lamp stays
on when ignition switch is turned ON.)
NG
CHECK WARNING LAMP.
Repair combination meter.
c
——————————————————————————————————————————————————-Check the following.
1. Disconnect ABS actuator and electric
+ Harness connector E18
unit connector.
+ Harness for open or
2. Connect suitable wire between ABS
short between ABS
actuator and electric unit connector
actuator and electric unit
SBR206E
and fuse
E18 (body side) terminal j
21 and
If NG, repair harness or
ground.
connector.
Warning lamp should not activate.
OK
.

OK
Inspection end
CHECK HARNESS CONNECTOR.
c
——————————————————————————————————————————————————-Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector. Reconnect ABS actuator and
electric unit harness connector. Then
SBR146EA
retest.
NG
.

NG
CHECK ABS MOTOR GROUND.
Check the following.
c
——————————————————————————————————————————————————-+ Harness connector E18
1. Turn ignition switch ‘‘OFF’’.
+ Harness for open or
2. Disconnect ABS actuator and electric
short between ABS
unit connector.
actuator and electric unit
3. Check continuity between ABS actuator
and ground
and electric unit connector E18 (body
If NG, repair harness or
SBR147E
connector.
side) terminal j
16 and ground.
Continuity should exist.
OK
.

REPLACE.
——————————————————————————————————————————————————-Replace ABS actuator and electric unit.

BR-71

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Europe, Australia and
Middle East

Except for Europe, Australia and Middle East
Applied model
Standard

Option

All

Front brake
Type

CL36VE disc brake

Cylinder bore diameter

mm (in)

Pad dimension
Length x width x thickness

mm (in)

48.1 (1.894) x 2
147 x 56.5 x 12 (5.79 x 2.224 x 0.47)

Rotor outer diameter x thickness

306 x 32 (12.05 x 1.26)

mm (in)
Rear brake
Type

LT30 drum brake

CL18VF disc brake

Cylinder bore diameter

mm (in)

25.4 (1.00)

48.1 (1.894)

Lining or pad dimension
Length x width x thickness

mm (in)

296 x 50 x 6.1
(11.65 x 1.97 x 0.240)

111 x 41.8 x 10
(4.37 x 1.646 x 0.39)

Drum inner diameter

mm (in)

295 (11.61)

—

316 x 18 (12.44 x 0.71)

Rotor outer diameter x thickness
mm (in)

Except for 4-door rear disc
brake

Applied model

4-door rear disc brake

Brake booster
Model

235T

Diaphragm diameter

mm (in)

Primary: 252
Secondary: 230

Master cylinder bore diameter

mm (in)

25.4 (1.00)

Control valve
Type
Split point x reducing ratio
kPa (bar, kg/cm2, psi)

LSV
(Variable) x 0.15

Recommended brake fluid

(Variable) x 0.3
DOT 3

BR-72

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment
DISC BRAKE

BRAKE PEDAL
Unit: mm (in)

Brake model

CL36VE

CL18VF

Applied model

Pad wear limit

Free height ‘‘H’’*

Minimum thickness

2.0 (0.079)

Rotor repair limit
Minimum thickness

30.0 (1.181)

16.0 (0.630)

PARKING CENTER BRAKE
Unit: mm (in)
Brake model

Unit: mm (in)

DS20HB

Depressed height ‘‘D’’
[under force of 490 N (50
kg, 110 lb) with engine running]

More than
80 (3.15)

Clearance ‘‘C’’ between
pedal stopper and threaded
end of stop lamp switch or
ASCD switch

0.3 — 1.0 (0.012 — 0.039)

Pedal free play

Lining wear limit
Minimum thickness

1.5 (0.059)

Drum repair limit
Maximum inner diameter

M/T
184 — 194
(7.24 — 7.64)

At clevis

1.0 — 3.0 (0.039 — 0.118)

At pedal pad

3.0 — 11.0 (0.118 — 0.433)

*: Measured from surface of melt sheet to pedal pad.
204.5 (8.05)

PARKING CENTER BRAKE CONTROL
Control type
Lever stroke
[under force of 196 N (20 kg, 44 lb)]
Lever stroke when warning switch comes on

BR-73

Center lever
7-9
2

BODY & TRIM
SECTION

CONTENTS
PRECAUTIONS ………………………………………………………1
Service Notice……………………………………………………..1
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’……………1
GENERAL SERVICING ……………………………………………2
Clip and Fastener ………………………………………………..2
BODY END …………………………………………………………….4
Body Front End……………………………………………………4
Body Rear End and Opener………………………………….6
DOOR…………………………………………………………………….9
Front Door…………………………………………………………..9
Rear Door …………………………………………………………10
INSTRUMENT PANEL……………………………………………11
INTERIOR TRIM ……………………………………………………14
Side and Floor Trim ……………………………………………14
Door Trim ………………………………………………………….18
Roof Trim ………………………………………………………….20
Back Door Trim………………………………………………….24

EXTERIOR ……………………………………………………………26
SEAT ……………………………………………………………………32
Front Seat …………………………………………………………32
Heated Seat………………………………………………………34
Rear Seat………………………………………………………….35
3rd Seat ……………………………………………………………37
SUNROOF…………………………………………………………….39
WINDSHIELD AND WINDOWS ………………………………42
Windshield ………………………………………………………..43
Rear Side Window……………………………………………..44
Back Door Window …………………………………………….45
MIRROR ……………………………………………………………….46
Door Mirror………………………………………………………..46
CAB BODY …………………………………………………………..47
Body Mounting…………………………………………………..48
BODY ALIGNMENT……………………………………………….49
Engine Compartment………………………………………….49
Underbody ………………………………………………………..51

. For seat belt, refer to MA and RS section.
. For wiring diagrams of body electrical systems, refer to EL section.

PRECAUTIONS
Service Notice
+
+
+
+
+

When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil
or damage them.
Apply sealing compound where necessary when installing parts.
When applying sealing compound, be careful that the sealing compound does not protrude from parts.
When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust prevention measures.

Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’
The Supplemental Restraint System such as ‘‘AIR BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’ used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The composition varies according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.

BT-1

GENERAL SERVICING
Clip and Fastener
+
+

Clips and fasteners in BT section correspond to the following numbers and symbols.
Replace any clips and/or fasteners which are damaged during removal or installation.
Symbol
No.

Shapes

Removal & Installation

j
C101

SBF302H
SBF367BA

j
C103

SBF303H
SBF423H

j
C203

SBF258G

SBF708E

MBT080A

SBF638C

j
C205

BT-2

GENERAL SERVICING
Clip and Fastener (Cont’d)
Symbol
No.

Shapes

Removal & Installation

j
CE103

SBF104B
SBF147B

j
CF109

SBF651B
SBF652B

j
CR103

SBF768B

SBF770B

j
CS101

SBF078B
SBF992G

BT-3

BODY END
Body Front End
+
+
+
+
+

When removing or installing hood, place a cloth or other padding on front fender panel and cowl top. This
prevents vehicle body from being scratched.
Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
Hood adjustment: Adjust at hinge portion.
Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood
locks engaging mechanism.
Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.

REMOVAL — Front bumper assembly
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V

Remove front guard bar. Refer to ‘‘EXTERIOR’’ for details, BT-26.
Remove left and right headlamp wipers (on models with headlamp wipers).
Remove clips securing front grille and remove the front grille.
Remove screws and bolts securing left and right front bumper side bracket.
Remove bolts securing bumper lower to engine under cover.
Remove bolts securing left and right front bumper stay upper (without winch).
Remove bolts securing left and right front bumper stay side.
Extract bumper assembly.

SBT518

BT-4

BODY END
Body Front End (Cont’d)

SBT519

BT-5

BODY END
Body Rear End and Opener
Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
Back door lock system adjustment: Adjust lock & striker so that they are in the center.
After adjustment, check back door lock operation.
+ Back door hatch lock system adjustment: Adjust lock & striker so that they are in the center.
After adjustment, check back door hatch lock operation.
+ Opener cable: Do not attempt to bend cable using excessive force.
+ After installation, make sure that back door and fuel filler lid open smoothly.
WARNING:
+ Be careful not to scratch back door stay and/or back door hatch stay when installing back door
and/or back door hatch. A scratched stay may cause gas leakage.
+ The contents of the back door stay and back door hatch stay are under pressure. Do not take apart,
puncture, apply heat or allow fire near them.
+
+

REMOVAL — Rear bumper assembly
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V
9
V

Remove screws securing left and right mudguard.
Remove bolts securing left and right rear side bumper to rear fender.
Remove screws and clips securing left and right rear side bumper to rear bumper side reinforcement.
Remove bolts securing left and right rear side bumper to rear center bumper.
Remove bolts securing left and right rear bumper side reinforcement to rear center bumper.
Remove bolts securing left and right rear bumper side reinforcement to frame assembly.
Remove bolts securing rear hook assembly.
Extract rear bumper assembly.
Remove bolts securing left and right rear bumper side reinforcement to rear center bumper.

SBT520

BT-6

BODY END
Body Rear End and Opener (Cont’d)

SBT521

BT-7

BODY END
Body Rear End and Opener (Cont’d)

SBT571

BT-8

DOOR
Front Door
+
+

For removal of door trim, refer to ‘‘Door Trim’’ in ‘‘INTERIOR TRIM’’ (BT-18).
After adjusting door or door lock, check door lock operation.

SBT522

BT-9

DOOR
Rear Door

SBT523

BT-10

INSTRUMENT PANEL
CAUTION:
+ Disconnect both battery cables in advance.
+ Disconnect air bag system line in advance.
+ Never tamper with or force air bag lid open, as this may adversely affect air bag performance.
+ Be careful not to scratch pad and other parts.

REMOVAL — Instrument panel assembly
Instrument panel assembly

Combination meter

Remove air bag module (driver) and steering wheel.
Refer to ‘‘SUPPLEMENTAL RESTRAINT SYSTEM’’ in RS section for details.
Remove dash side lower finishers.
Refer to ‘‘Side and Floor Trim’’ in ‘‘INTERIOR TRIM’’ for
details, BT-14.
1
V

Steering column cover and combination switch
+ Remove screws.

2
V

Lower instrument panel on driver side
+ Remove bolts and screws.

3
V

Cluster lid A
+ Remove screws then disconnect harness connectors.

4
V

Combination meter
+ Remove screws then disconnect harness connectors.

5
V

Cluster lid C
+ Pull out then disconnect harness connectors.
+ Remove screws then remove in-vehicle sensor.

6
V

Audio
+ Remove screws then disconnect harness connectors.

7
V

A/C control unit
+ Remove screws then disconnect harness connectors.

8
V

Console M/T or A/T finisher
+ Remove screws then disconnect harness connectors.

9
V

Console box assembly
+ Remove screws then disconnect harness connectors.

10
V

Instrument panel stay cover
+ Remove screws then disconnect harness connectors.

11
V

Glove box assembly and lower instrument panel on
passenger side
+ Remove screws.

12
V

Passenger air bag module
+ Refer to ‘‘SUPPLEMENTAL RESTRAINT SYSTEM’’ in RS section.

13
V

Mirror control switch
+ Disconnect harness connector.

Remove front pillar garnish.
Refer to ‘‘Side and Floor Trim’’ in ‘‘INTERIOR TRIM’’ for
details, BT-14.
14
V

Mask instrument LH/RH or sensors.
+ Disconnect harness connectors (models with
sensors).

15
V

Instrument panel and pads
+ Remove bolts and nuts then disconnect harness
connectors.

BT-11

Audio & A/C control

Console box

INSTRUMENT PANEL

SBT524

BT-12

INSTRUMENT PANEL

SBT525

BT-13

INTERIOR TRIM
Side and Floor Trim
CAUTION:
Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes.

REMOVAL — Body side trim (WAGON)
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V
9
V
10
V
11
V
12
V
13
V
14
V
15
V
16
V
17
V
18
V
19
V

Remove front, rear and 3rd seats. Refer to ‘‘SEAT’’ for details, BT-32.
Remove front, rear and 3rd seat belts. Refer to ‘‘SEAT BELTS’’ in RS section for details.
Remove front and rear kicking plates.
Remove front and rear body side welts.
Remove dash side lower finishers.
Remove assist grips.
Remove front pillar garnishes.
Remove center pillar lower garnishes.
Remove assist grips.
Remove center pillar upper garnishes.
Remove luggage floor retainer.
Remove back door welt.
Remove assist grips or clips.
Remove luggage side upper finishers.
Remove luggage side lower finishers. (On vehicles equipped with power supply sockets, remove connector from luggage side lower finisher LH.)
Remove console box assembly. Refer to ‘‘INSTRUMENT PANEL’’ for details, BT-11.
Remove clips and luggage floor rope hooks, then remove luggage floor trim.
Remove screws and clips, then remove rear floor trim.
Remove clips, footrest and accel stopper, then remove front floor trim.

SBT526

BT-14

INTERIOR TRIM
Side and Floor Trim (Cont’d)
WAGON

SBT527

BT-15

INTERIOR TRIM
Side and Floor Trim (Cont’d)
CAUTION:
Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes.

REMOVAL — Body side trim (HARDTOP)
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V
9
V
10
V
11
V
12
V
13
V
14
V
15
V
16
V
17
V
18
V
19
V
20
V

Remove tonneau cover.
Remove front and rear seats. Refer to ‘‘SEAT’’ for details, BT-32.
Remove kicking plates.
Remove body side welts.
Remove dash side lower finishers.
Remove assist grips.
Remove front pillar garnishes.
Remove luggage floor retainer.
Remove back door welt.
Remove assist grips.
Remove lap outer covers.
Remove anchor bolt of seat belts. Refer to ‘‘SEAT BELTS’’ in RS section for details.
Remove seat belt escutcheons.
Remove rear parcel shelf holders.
Remove luggage side upper finishers.
Remove clips securing luggage side lower finishers. (On vehicles equipped with power supply sockets,
remove connector from luggage side lower finisher LH.)
Remove console box assembly. Refer to ‘‘INSTRUMENT PANEL’’ for details, BT-11.
Remove clips and luggage floor rope hooks, then remove luggage floor trim.
Remove screws, then remove rear floor trim.
Remove clips, footrest and accel stopper, then remove front floor trim.

SBT528

BT-16

INTERIOR TRIM
Side and Floor Trim (Cont’d)
HARDTOP

SBT529

BT-17

INTERIOR TRIM
Door Trim
REMOVAL — Door trim
1
V
2
V
3
V
4
V
5
V
6
V

Remove inside handle escutcheon.
Remove door armrest.
Remove screw securing power window switches, then disconnect the connector.
Remove screw securing door trim.
Remove clips securing door trim.
Lift out door trim.

SBT530

BT-18

INTERIOR TRIM
Door Trim (Cont’d)

SBT566

BT-19

INTERIOR TRIM
Roof Trim
REMOVAL — Headlining (WAGON)
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V
9
V
10
V
11
V
12
V

Remove
Remove
Remove
Remove
Remove
Remove
Remove
Remove
Remove
Remove
Remove
Remove

front, rear and 3rd seats. Refer to ‘‘SEAT’’ for details, BT-32.
front, rear and 3rd seat belts. Refer to ‘‘SEAT BELTS’’ in RS section for details.
body side trim. Refer to ‘‘Side and Floor Trim’’ for details, BT-14.
roof console assembly, then disconnect connectors.
inside mirror assembly.
sun visors.
interior lamp assembly.
luggage room lamp assembly.
assist grips.
clips securing headlining.
rear headlining from vehicle through either back door.
front headlining from vehicle through either back door.

SBT531

BT-20

INTERIOR TRIM
Roof Trim (Cont’d)

SBT569

BT-21

INTERIOR TRIM
Roof Trim (Cont’d)
REMOVAL — Headlining (HARDTOP)
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V
9
V

Remove
Remove
Remove
Remove
Remove
Remove
Remove
Remove
Remove

front and rear seats. Refer to ‘‘SEAT’’ for details, BT-32.
front and rear seat belts. Refer to ‘‘SEAT BELTS’’ in RS section for details.
body side trim. Refer to ‘‘Side and Floor Trim’’ for details, BT-14.
roof console assembly, then disconnect connector.
inside mirror assembly.
sun visors.
interior lamp assembly.
assist grips.
clips securing headlining from vehicle through either back door.

SBT532

BT-22

INTERIOR TRIM
Roof Trim (Cont’d)

SBT569

BT-23

INTERIOR TRIM
Back Door Trim
REMOVAL — Back door trim
1
V
2
V
3
V
4
V
5
V
6
V
7
V

Remove bolts securing pull handle (LH only).
Remove inside handle escutcheon (LH only).
Remove clip securing high-mounted stop lamp cover (RH only).
Remove back door cover (RH only).
Remove clips securing back door upper garnish.
Remove clips securing back door trim.
Pull out back door trim.

SBT533

BT-24

INTERIOR TRIM
Back Door Trim (Cont’d)

SBT568

BT-25

EXTERIOR

SBT534

BT-26

EXTERIOR
1
V

Hood front seal

2
V

Cowl top seal and cowl top grille

SBT535

3 V
4
V

Front windshield molding

SBT536

5
V

Sunroof lid weatherstrip

+ Upper and side molding

SBT538

6
V

Body side welt

SBT537
SBT540

+ Lower molding
Mounted with screws.

BT-27

EXTERIOR
7
V

Drip molding

10
V

Side guard molding

SBT572

8
V

Drip weatherstrip

SBT544

SBT539

11
V

Rear combination lamp

Rear combination lamps are installed with bolts.
9
V

High-mounted stop lamp

12
V

SBT545

BT-28

Back door weatherstrip

SBT543

EXTERIOR
13
V

Over fender

SBT548

14
V

Door outside molding

SBT542

BT-29

EXTERIOR
15
V

Side step

SBT546

16
V

Front door parting seal

17
V

SBT570

BT-30

Door weatherstrip

SBT541

EXTERIOR
18
V

Front grille guard

SBT549

19
V

Air outlet grille

20
V

SBT547

BT-31

Roof rack

SBT574

SEAT
Front Seat
+

When removing or installing the seat trim, carefully handle it to keep dirt out and avoid damage.

MANUAL SEAT

SBT550

BT-32

SEAT
Front Seat (Cont’d)
+

When removing or installing the seat trim, carefully handle it to keep dirt out and avoid damage.

POWER SEAT

SBT567

BT-33

SEAT
Heated Seat
+
+
+

When handling seat, be extremely careful not to scratch heating unit.
To replace heating unit, seat trim and pad should be separated.
Do not use any organic solvent, such as thinner, benzene, alcohol, gasoline, etc. to clean trims.

Seatback heating unit removal & installation

SBF424H

. For Wiring Diagram, refer to ‘‘HEATED SEAT’’ in EL section.

BT-34

SEAT
Rear Seat
WAGON & HARDTOP (Type-I)

SBT551

BT-35

SEAT
Rear Seat (Cont’d)
HARDTOP (Type-II)

SBT552

BT-36

SEAT
3rd Seat
TYPE I

SBT553

BT-37

SEAT
3rd Seat (Cont’d)
TYPE II

SBT554

BT-38

SUNROOF
ADJUSTMENT
Install motor & limit SW assembly and sunroof rail assembly in the following sequence:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Arrange equal lengths of link and wire assemblies on both sides of sunroof opening.
Connect sunroof connector to sunroof switch and positive (+) power supply.
Set lid assembly to fully closed position
by operating OPEN switch and TILT switch.
Fit outer side of lid assembly to the surface of roof on body outer panel.
Remove motor, and keep OPEN switch pressed until motor pinion gear reaches the end of its rotating
range.
Install motor.
Check that motor drive gear fits properly in wires.
Press TILT-UP switch to check lid assembly for normal tilting.
Check sunroof lid assembly for normal operations (tilt-up, tilt-down, open, and close).

SBF920F

BT-39

SUNROOF
REMOVAL
+ After any adjustment, check sunroof operation and lid alignment.
+ Handle finisher plate and glass lid with care so as not to cause damage.
+ It is desirable for easy installation to mark each point before removal.
CAUTION:
Always work with a helper.
Shade assembly

Sunroof frame assembly

Wind deflector assembly

Tilt glass lid up.

1
V

Side trim

2
V

Sunroof lid mounting nuts

3
V

Lid assembly

4
V

Rear drain mounting screws

5
V

Rear drain assembly

Use the sunroof switch to tilt the glass lid downward and slide it about 300 mm
(11.81 in) backward.

6
V

Wind deflector holder

7
V

Wind deflector mounting screws

8
V

Wind deflector assembly

Sunroof switch/interior accessories/headlining
+ For details, refer to ‘‘Roof Trim’’ in ‘‘INTERIOR TRIM’’, BT-20.

9
V

Motor switch bracket

10
V

Motor assembly

11
V

Drain hoses

12
V

Sunroof unit bracket

13
V

Sunroof frame assembly

14
V

Shade stopper

15
V

Shade assembly

BT-40

Lid assembly

Motor assembly

SUNROOF
. For Wiring Diagram, refer to ‘‘ELECTRIC SUNROOF’’ in EL section.

SBT555

BT-41

WINDSHIELD AND WINDOWS
REMOVAL

SBF034B

After removing moldings, remove glass using piano wire or power
cutting tool and an inflatable pump bag.
WARNING:
When cutting the glass from the vehicle, always wear safety
glasses and heavy gloves to help prevent glass splinters from
entering your eyes or cutting your hands.
CAUTION:
+ Be careful not to scratch the glass when removing.
+ Do not set or stand the glass on its edge. Small chips may
develop into cracks.

INSTALLATION
Use a genuine Nissan Urethane Adhesive Kit or equivalent
and follow the instructions furnished with it.
+ While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced out by
passenger compartment air pressure when a door is
closed.
+ The molding must be installed securely so that it is in
position and leaves no gap.
+ Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely cured
(preferably 24 hours). Curing time varies with temperature
and humidity.
WARNING:
+ Keep heat and open flames away as primers and adhesive
are flammable.
+ The materials contained in the kit are harmful if swallowed,
and may irritate skin and eyes. Avoid contact with the skin
and eyes.
+ Use in an open, well ventilated location. Avoid breathing
the vapors. They can be harmful if inhaled. If affected by
vapor inhalation, immediately move to an area with fresh
air.
+ Driving the vehicle before the urethane adhesive has completely cured may affect the performance of the windshield
in case of an accident.
CAUTION:
+ Do not use an adhesive which is past its usable term. Shelf
life of this product is limited to six months after the date
of manufacture. Carefully adhere to the expiration or
manufacture date printed on the box.
+ Keep primers and adhesive in a cool, dry place. Ideally,
they should be stored in a refrigerator.
+ Do not leave primers or adhesive cartridge unattended
with their caps open or off.
+ The vehicle should not be driven for at least 24 hours or
until the urethane adhesive has completely cured. Curing
time varies depending on temperature and humidities. The
curing time will increase under higher temperatures and
lower humidities.
+

SBT472

SBT473

BT-42

WINDSHIELD AND WINDOWS
Windshield

SBT556

REPAIRING WATER LEAKS FOR WINDSHIELD
Leaks can be repaired without removing and reinstalling glass.
If water is leaking between caulking material and body or glass, determine the extent of leakage. This
can be determined by applying water while pushing glass outward.
To stop the leak, apply primer and then sealant to the leak point.

BT-43

WINDSHIELD AND WINDOWS
Rear Side Window

SBT557

BT-44

WINDSHIELD AND WINDOWS
Back Door Window

SBT558

BT-45

MIRROR
Door Mirror
CAUTION:
Be careful not to scratch door rearview mirror body.
. For Wiring Diagram, refer to ‘‘POWER DOOR MIRROR’’ in EL section.

REMOVAL — Door mirror
1
V
2
V
3
V
4
V
5
V

Remove door trim. Refer to ‘‘Door Trim’’ for details, BT-18.
Remove clip securing inner cover, then remove inner cover.
Roll back sealing screen and remove door mirror harness connector.
Remove door mirror harness clip.
Remove bolts securing door mirror, then remove door mirror assembly.

SBT559

BT-46

CAB BODY
CAB BODY
+
(1)
+
+
(1)
(2)
(3)

Remove following parts in engine room at least.
Main harness and other wiring harness
Disconnect brake and clutch line in engine compartment.
Remove following parts from underbody at least.
Transmission and transfer control levers
Parking brake control lever and cable
Main harness and other wiring harness

SBF025E

BT-47

CAB BODY
Body Mounting
When removing, be sure to replace bolts and nuts (sealant applied bolts or self-lock nuts are used for all
mounting).

SBT573

BT-48

BODY ALIGNMENT
+
+
+
+
+
+

All dimensions indicated in figures are actual ones.
When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge
itself to make sure there is no free play.
When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
Measurements should be taken at the center of the mounting holes.
An asterisk (*) following the value at the measuring point indicates that the measuring point on the other
side is symmetrically the same value.
The coordinates of the measurement points are the distances measured from the standard line of ‘‘X’’, ‘‘Y’’
and ‘‘Z’’.

SBF874GD

Engine Compartment
MEASUREMENT

SBT560

BT-49

BODY ALIGNMENT
Engine Compartment (Cont’d)
MEASUREMENT POINTS
Unit: mm

SBT561

BT-50

BODY ALIGNMENT
Underbody
MEASUREMENT
Wagon

SBT562

BT-51

BODY ALIGNMENT
Underbody (Cont’d)
MEASUREMENT POINTS
Wagon

SBT563

BT-52

BODY ALIGNMENT
Underbody (Cont’d)
MEASUREMENT
(Hardtop)

SBT564

BT-53

BODY ALIGNMENT
Underbody (Cont’d)
MEASUREMENT POINTS
(Hardtop)

SBT565

BT-54

CLUTCH
SECTION

HYDRAULIC CLUTCH CONTROL ……………………………7
Clutch Master Cylinder …………………………………………7
Clutch Operating Cylinder …………………………………….8
Clutch Booster …………………………………………………….9
CLUTCH RELEASE MECHANISM ………………………….11
CLUTCH DISC AND CLUTCH COVER ……………………13
Clutch Disc………………………………………………………..13
Clutch Cover and Flywheel …………………………………14
SERVICE DATA AND SPECIFICATIONS (SDS) ……….16
General Specifications………………………………………..16
Inspection and Adjustment ………………………………….16

PRECAUTIONS AND PREPARATION
Precautions
+
+
+
+
+
+

Recommended fluid is brake fluid ‘‘DOT 3’’.
Do not reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.
When removing and installing clutch piping, use Tool.
Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.

SBR820BA

WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.

Special Service Tools
Tool number
Tool name

Description

ST20050010
Base plate

Inspecting diaphragm spring of clutch cover

a: 357 mm (14.06 in) dia.
b: 43 mm (1.69 in)

NT403

ST20050100
Distance piece

Inspecting diaphragm spring of clutch cover

a: 25 mm (0.98 in) dia.
b: 7.8 mm (0.307 in)

NT402

GG94310000
Flare nut torque wrench

Removing and installing each clutch piping

a: 10 mm (0.39 in)
: 16.2 Nzm (1.65 kg-m, 11.9 ft-lb)

NT406

ST20630000
Clutch aligning bar

Installing clutch cover and clutch disc

a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45 mm (1.77 in)

NT405

ST20050240
Diaphragm spring
adjusting wrench

Adjusting unevenness of clutch cover diaphragm spring

a: 150 mm (5.91 in)
b: 25 mm (0.98 in)

NT404

CL-1

PRECAUTIONS AND PREPARATION
Commercial Service Tools
Tool name
1
V
2
V

Description

Flare nut crowfoot
Torque wrench

Removing and installing clutch piping

a: 10 mm (0.39 in)

NT684

Bearing puller

Removing release bearing

NT077

Wire

Installing clutch cover

Wire: 3.2 mm (0.126 in) dia.

NT727

Bearing drift

Installing release bearing

a: 52 mm (2.05 in) dia.
b: 45 mm (1.77 in) dia.

NT474

CL-2

Reference page (CL-

Symptom
Clutch grabs/chatters

Clutch pedal spongy
1
1

Clutch noisy

2
3

OPERATING CYLINDER PISTON CUP (Damaged)

13
13
13
13
13
13
13
14
14
14
14

CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)

Refer to EM section.

MASTER CYLINDER PISTON CUP (Damaged)

CLUTCH DISC (Runout is excessive)

1
CLUTCH DISC (Out of true)

Clutch does not disengage
2

1
2

RELEASE BEARING (Worn, dirty or damaged)

Clutch slips
2
ENGINE MOUNTING (Loose)

CLUTCH LINE (Air in line)

SUSPECTED PARTS
(Possible cause)
5

)

CLUTCH PEDAL (Free play out of adjustment)

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
If necessary, repair or replace these parts.

2
2
2

4
5

CL-3
5
5
5
2
2

5
2

5
6
6
7

CLUTCH SYSTEM

SCL768

CL-4

INSPECTION AND ADJUSTMENT
Adjusting Clutch Pedal
1. Adjust pedal height with pedal stopper.
Pedal height ‘‘H*’’:
195 — 205 mm (7.68 — 8.07 in)
*: Measured from surface of dash reinforcement panel to
pedal pad
2. Adjust pedal free play with master cylinder push rod or clutch
booster input rod. Then tighten lock nut.
Pedal free play ‘‘A’’:
1.0 — 3.0 mm (0.039 — 0.118 in)

SCL788

Pedal free play means the following total measured at position
of pedal pad:
+ Play due to clevis pin and clevis pin hole in clutch pedal.
+ Play due to piston and push rod.
+ Push or step on clutch pedal until resistance is felt, and check
the distance the pedal moves.

SCL702

CL-5

INSPECTION AND ADJUSTMENT

SCL769

Air Bleeding Procedure
1. Bleed air from clutch operating cylinder according to the following procedure.
Carefully monitor fluid level at master cylinder during bleeding
operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 second intervals.
d. Hold clutch pedal depressed, open bleeder valve to release air.
e. Close bleeder valve.
f. Release clutch pedal and wait at least 5 seconds.
g . Repeat steps c through e above until brake fluid flows from air
bleeder valve without air bubbles.
2. Repeat the above bleeding procedure 1 several times.

CL-6

HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder

SCL770

DISASSEMBLY AND ASSEMBLY
+

When removing and installing stopper ring. Pry out or in with
screwdriver while pushing stopper.

INSPECTION
+
+
+
+
+

Check cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
Check piston with piston cup for wear or damage. Replace if
necessary.
Check return spring for wear or damage. Replace if necessary.
Check reservoir for deformation or damage. Replace if necessary.
Check dust cover for cracks, deformation or damage. Replace
if necessary.

CL-7

HYDRAULIC CLUTCH CONTROL
Clutch Operating Cylinder

SCL786

INSPECTION
+
+
+
+

Check rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
Check piston with piston cup for wear or damage. Replace if
necessary.
Check dust cover for cracks, deformation or damage. Replace
if necessary.
Check piston spring for wear or damage. Replace if necessary.

CL-8

HYDRAULIC CLUTCH CONTROL
Clutch Booster

SCL772

INSPECTION
Hoses and connectors
+
+

Check condition of vacuum hoses and connections.
Check vacuum hoses and check valve for air tightness.

Vacuum hose check valve
1. Remove the vacuum hose.
2. Blow air through one end (booster side) of the vacuum hose
and make sure that air passage continuity exists.
3. Blow air through the other end (engine side) of the vacuum
hose and make sure that air passage continuity does not exist.

SCL782

Check valve
1. Remove the vacuum hose.
2. Check the condition of the check valve using a handy vacuum
pump.
1
V

Vacuum pump connected to the
engine side
No vacuum pressure is applied.
SCL783

CL-9

2
V

Vacuum pump connected to the booster
side
Vacuum drop is less than 1.3 kPa (13
mbar, 10 mmHg, 0.39 inHg) at a vacuum
pressure of −66.7 kPa (−667 mbar, −500
mmHg, −19.69 inHg).

HYDRAULIC CLUTCH CONTROL
Clutch Booster (Cont’d)
ADJUSTMENT
Output rod length:
Length ‘‘A’’
1.30 — 1.55 mm (0.0512 — 0.0610 in)

SCL135

If amount of adjustment required exceeds 0.5 mm (0.020 in),
reaction disc may have either been dislocated or fallen off.
Replace clutch booster assembly.

SCL140

Input rod length:
Length ‘‘B’’
130 mm (5.12 in)

SCL136

CL-10

CLUTCH RELEASE MECHANISM

SCL775

REMOVAL AND INSTALLATION
+

Install retainer spring and holder spring.

Remove release bearing.

Install release bearing with suitable drift.

SCL217

CL145

SCL705

CL-11

CLUTCH RELEASE MECHANISM
INSPECTION
+
+

Check release bearing to see that it rolls freely and is free from
noise, cracks, pitting or wear. Replace if necessary.
Check release sleeve and withdrawal lever rubbing surface for
wear, rust or damage. Replace if necessary.

SCL706

LUBRICATION
+
+

Apply recommended grease to contact surface and rubbing
surface.
Too much lubricant might damage clutch disc facing.

WATERPROOF
+

Apply recommended sealant to contact surface of transmission
case dust cover and withdrawal lever, then install dust cover
clip.
Recommended sealant:
Nissan genuine part (KP115-00100) or equivalent.

SCL697-A

CL-12

CLUTCH DISC AND CLUTCH COVER

SCL778

Clutch Disc
INSPECTION
Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)

SCL780

SCL779

Check clutch disc for backlash of spline and runout of facing.
Maximum backlash of spline (at outer edge of disc):
Model 240
1.0 mm (0.039 in)
Runout limit:
Model 240
0.7 mm (0.028 in)
Distance of runout check point (from hub center):
Model 240
115.0 mm (4.53 in)
Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary.

INSTALLATION
Apply recommended grease to contact surface of spline portion.
Too much lubricant might cause clutch disc facing damage.
+

CL-13

CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel
INSPECTION
+

+
+

Set Tool and check height and unevenness of diaphragm
spring.
Diaphragm spring height ‘‘A’’:
Model 240
37.5 — 39.5 mm (1.476 — 1.555 in)
Check thrust rings for wear or damage by shaking cover
assembly up and down to listen for chattering noise, or lightly
hammering on rivets for a slightly cracked noise. Replace
clutch cover assembly if necessary.
Check pressure plate and clutch disc contact surface for slight
burns or discoloration. Repair pressure plate with emery paper.
Check pressure plate and clutch disc contact surface for deformation or damage. Replace if necessary.

SCL219-C

Adjust unevenness of diaphragm spring with Tool.
Uneven limit:
0.7 mm (0.028 in)

Check flywheel and clutch disc contact surface for slight burns
or discoloration. Repair flywheel with emery paper.
Check flywheel runout.
Maximum allowable runout:
Refer to EM section (‘‘Inspection’’, ‘‘CYLINDER
BLOCK’’).

SCL466-A

SEM929A

CL-14

CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel (Cont’d)
INSTALLATION
Model 240
+
+
+

Insert Tool into clutch disc hub while installing clutch cover and
disc.
Be careful not to allow grease to contaminate clutch facing.
Tighten bolts in numerical order, in two steps.
First step:
: 10 — 20 Nzm (1.0 — 2.0 kg-m, 7 — 14 ft-lb)
Final step:
: 22 — 29 Nzm (2.2 — 3.0 kg-m, 16 — 22 ft-lb)

SCL787

CL-15

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch control

CLUTCH DISC

CLUTCH MASTER CYLINDER (with clutch
damper)
Unit: mm (in)
Inner diameter

Model

240

Engine

RD28ETi

Facing size
(Outer dia. x inner dia. x thickness)
mm (in)

240 x 160 x 3.5
(9.45 x 6.30 x 0.138)

Thickness of disc assembly with
load
mm (in)/N (kg, lb)

7.7 — 8.1 (0.303 — 0.319)/
8,336 (850, 1,874)

Hydraulic

17.46 (11/16)

CLUTCH OPERATING CYLINDER
Unit: mm (in)
Inner diameter

CLUTCH COVER

20.64 (13/16)

CLUTCH BOOSTER
Unit: mm (in)
Type
Diaphragm diameter
Check valve type

Model

240

Engine

RD28ETi

Destination

M45

—

Full load

114.3 (4.50)

N (kg, lb)

5,835 — 6,620
(595 — 675, 1,312 — 1,488)

Built-in hose type

Inspection and Adjustment
CLUTCH PEDAL

CLUTCH DISC
Unit: mm (in)

Pedal height ‘‘H*’’
Pedal free play ‘‘A’’
(at pedal pad)

Unit: mm (in)
Model

195 — 205
(7.68 — 8.07)
1.0 — 3.0 (0.039 — 0.118)

Wear limit of facing surface to rivet head

0.3 (0.012)

Runout limit of facing

0.7 (0.028)

*: Measured from surface of melt sheet to pedal pad

Distance of runout
check point (from
the hub center)

115.0 (4.53)

Maximum backlash of
spline (at outer edge of
disc)

1.0 (0.039)

CLUTCH BOOSTER
Unit: mm (in)
Output rod length ‘‘A’’
Input rod length ‘‘B’’

1.30 — 1.55 (0.0512 — 0.0610)
130 (5.12)

240

CLUTCH COVER
Unit: mm (in)
Model
Diaphragm spring height ‘‘A’’
Uneven limit of diaphragm
spring toe height

CL-16

240
37.5 — 39.5
(1.476 — 1.555)
0.7 (0.028)

ENGINE CONTROL SYSTEM
SECTION

CONTENTS
EC
DIAGNOSTIC TROUBLE CODE INDEX…………………….1
Alphabetical & Numerical Index for DTC ………………..1
PRECAUTIONS AND PREPARATION……………………….2
Special Service Tools …………………………………………..2
Commercial Service Tool………………………………………3
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’……………4
PRECAUTIONS AND PREPARATION……………………….5
Engine Fuel & Emission Control System ………………..5
Precautions …………………………………………………………6
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM…………………………………………………………………8
ECCS-D Component Parts Location ………………………8
Circuit Diagram ………………………………………………….11
System Diagram ………………………………………………..12
Vacuum Hose Drawing ……………………………………….13
System Chart …………………………………………………….14
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION ………………………………………..15
Fuel Injection System …………………………………………15
Fuel Injection Timing System ………………………………18
Air Conditioning Cut Control………………………………..19
Fuel Cut Control (at no load & high engine
speed) ………………………………………………………………20
CRANKCASE VENTILATION SYSTEM……………………21
Description ………………………………………………………..21
Inspection………………………………………………………….21
INJECTION NOZZLE……………………………………………..22
Removal and Installation …………………………………….22
Disassembly (No. 2 — 4 nozzles) ………………………….22
Inspection (No. 2 — 4 nozzles) ……………………………..23
Cleaning (No. 2 — 4 nozzles) ……………………………….23
Assembly (No. 2 — 4 nozzles) ………………………………24
Test and Adjustment …………………………………………..25
ELECTRONIC FUEL INJECTION PUMP………………….27
Removal……………………………………………………………27
Installation…………………………………………………………28
Disassembly and Assembly…………………………………29
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION ………………………………………………………30
DTC and MIL Detection Logic ……………………………..30
Diagnostic Trouble Code (DTC) …………………………..30

Malfunction Indicator Lamp (MIL)…………………………31
CONSULT …………………………………………………………36
TROUBLE DIAGNOSIS — Introduction………………….42
Introduction ……………………………………………………….42
Diagnostic Worksheet…………………………………………43
TROUBLE DIAGNOSIS — Work Flow ……………………44
Work Flow…………………………………………………………44
Description for Work Flow …………………………………..45
TROUBLE DIAGNOSIS — Basic Inspection …………..46
Basic Inspection…………………………………………………46
TROUBLE DIAGNOSIS — General Description ……..48
Symptom Matrix Chart………………………………………..48
CONSULT Reference Value in Data Monitor
Mode ………………………………………………………………..51
Major Sensor Reference Graph in Data Monitor
Mode ………………………………………………………………..53
ECM Terminals and Reference Value …………………..54
TROUBLE DIAGNOSIS FOR POWER SUPPLY……….63
Main Power Supply and Ground Circuit………………..63
TROUBLE DIAGNOSIS FOR ‘‘CAM POS SEN
(PUMP)’’ (DTC 11)…………………………………………………69
Camshaft Position Sensor (CMPS) (PUMP) ………….69
TROUBLE DIAGNOSIS FOR ‘‘MASS AIR FLOW
SEN’’ (DTC 12) ……………………………………………………..74
Mass Air Flow Sensor (MAFS) …………………………….74
TROUBLE DIAGNOSIS FOR ‘‘COOLANT TEMP
SEN’’ (DTC 13) ……………………………………………………..79
Engine Coolant Temperature (ECT) Sensor ………….79
TROUBLE DIAGNOSIS FOR ‘‘VEHICLE SPEED
SEN’’ (DTC 14) ……………………………………………………..83
Vehicle Speed Sensor (VSS) ………………………………83
TROUBLE DIAGNOSIS FOR ‘‘CONT SLEEV POS
SEN’’ (DTC 15) ……………………………………………………..87
Control Sleeve Position Sensor (CSPS) ……………….87
TROUBLE DIAGNOSIS FOR ‘‘ADJUST
RESISTOR’’ (DTC 17) ……………………………………………92
Adjustment Resistor……………………………………………92
TROUBLE DIAGNOSIS FOR ‘‘F/INJ F/B 2’’
(DTC 18), ‘‘F/INJ F/B’’ (DTC 22), ‘‘ELECTRIC
GOV’’ (DTC 25)……………………………………………………..96
Electric Governor ……………………………………………….96

TROUBLE DIAGNOSIS FOR ‘‘F/INJ TIMG F/B’’
(DTC 21)……………………………………………………………..101
Injection Timing Control Valve ……………………………101
TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SW
(F/C)’’ (DTC 23) …………………………………………………..106
Accelerator Switch (F/C)……………………………………106
TROUBLE DIAGNOSIS FOR ‘‘ECM 1’’ (DTC 27),
‘‘ECM 2’’ (DTC 31)……………………………………………….111
Engine Control Module (ECM)-ECCS-D Control
Module ……………………………………………………………111
TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’
(DTC 28)……………………………………………………………..113
Cooling Fan (Overheat) …………………………………….113
TROUBLE DIAGNOSIS FOR ‘‘I/C INT/A TEMP
SEN’’ (DTC 33) ……………………………………………………122
Charge Air Temperature Sensor…………………………122
TROUBLE DIAGNOSIS FOR ‘‘NEEDLE LIFT
SEN’’ (DTC 34) ……………………………………………………126
Needle Lift Sensor (NLS) ………………………………….126
TROUBLE DIAGNOSIS FOR ‘‘FUEL CUT S/V 1’’
(DTC 36), ‘‘FCV SHORT’’ (DTC 37), ‘‘FUEL CUT
S/V 2’’ (DTC 38)…………………………………………………..130
Fuel Cut Solenoid Valve ……………………………………130
TROUBLE DIAGNOSIS FOR ‘‘FUEL TEMP
SENSOR’’ (DTC 42) …………………………………………….135
Fuel Temperature Sensor (FTS)…………………………135

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS
SENSOR’’ (DTC 43) …………………………………………….139
Accelerator Position Sensor ………………………………139
TROUBLE DIAGNOSIS FOR ‘‘CRANK POS SEN
(TDC)’’ (DTC 47)………………………………………………….144
Crankshaft Position Sensor (TDC) ……………………..144
TROUBLE DIAGNOSIS FOR ‘‘GOV CUT
CIRCUIT’’ (DTC 48)……………………………………………..149
Governor Cut Circuit…………………………………………149
TROUBLE DIAGNOSES FOR NON-DETECTABLE
ITEMS…………………………………………………………………151
Glow Control System………………………………………..151
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve …………………………………………………156
Start Signal ……………………………………………………..163
Accelerator Position Switch ……………………………….165
Park/Neutral Position Switch ……………………………..170
A/T Control………………………………………………………175
Charge Air Cooler Fan Control…………………………..178
Heat Up Switch………………………………………………..183
Air Conditioner Control ……………………………………..187
MIL & Data Link Connectors ……………………………..188
SERVICE DATA AND SPECIFICATIONS (SDS) ……..189
General Specifications………………………………………189
Injection Nozzle ……………………………………………….189
Inspection and Adjustment ………………………………..189

When you read wiring diagrams:
+ Read GI section, ‘‘HOW TO READ WIRING DIAGRAMS’’.
+ See EL section, ‘‘POWER SUPPLY ROUTING’’ for power distribution circuit.
When you perform trouble diagnoses, read GI section, ‘‘HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES’’ and ‘‘HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENT’’.

DIAGNOSTIC TROUBLE CODE INDEX
Alphabetical & Numerical Index for DTC
ALPHABETICAL INDEX FOR DTC

NUMERICAL INDEX FOR DTC

X: Applicable
—: Not applicable
Items
(CONSULT screen terms)
ACCEL POS SENSOR

DTC

MIL
illumination

X: Applicable
—: Not applicable

Reference
page

DTC

MIL
illumination

Items
Reference
(CONSULT screen terms) page

EC-139

CAM POS SEN (PUMP)

EC-69

—

MAS AIR FLOW SEN

EC-74

ACCEL POS SW (F/C)

EC-106

ADJUST RESISTOR

—

EC-92

COOLANT TEMP SEN

EC-79

CAM POS SEN (PUMP)

EC-69

—

VEHICLE SPEED SEN

EC-83

CONT SLEEV POS SEN

EC-87

CONT SLEEV POS SEN

EC-87

COOLANT TEMP SEN

EC-79

—

ADJUST RESISTOR

EC-92

CRANK POS SEN (TDC)

EC-144

F/INJ F/B 2

EC-96

ECM 1

EC-111

—

F/INJ TIMG F/B

EC-101

ECM 2

EC-111

F/INJ F/B

EC-96

ELECTRIC GOV

EC-96

ACCEL POS SW (F/C)

EC-106

FCV SHORT

EC-130

ELECTRIC GOV

EC-96

FUEL CUT S/V 1

EC-130

ECM 1

EC-111

FUEL CUT S/V 2

EC-130

OVER HEAT

EC-113

FUEL TEMP SENSOR

—

EC-135

ECM 2

EC-111

F/INJ F/B

EC-96

33 *1

—

I/C INT/A TEMP SEN

EC-122

F/INJ F/B 2

EC-96

—

NEEDLE LIFT SEN

EC-126

F/INJ TIMG F/B

—

EC-101

FUEL CUT S/V 1

EC-130

GOV CUT CIRCUIT

EC-149

FCV SHORT

EC-130

I/C INT/A TEMP SEN

33 *1

—

EC-122

FUEL CUT S/V 2

EC-130

MAS AIR FLOW SEN

—

EC-74

—

FUEL TEMP SENSOR

EC-135

NATS MALFUNCTION

141 — 148

EL section*

ACCEL POS SENSOR

EC-139

NEEDLE LIFT SEN

—

EC-126

CRANK POS SEN (TDC) EC-144

NO SELF DIAGNOSTIC
FAILURE INDICATED

—

GOV CUT CIRCUIT

EC-149

OVER HEAT

EC-113

—

NO SELF DIAGNOSTIC
FAILURE INDICATED

—

VEHICLE SPEED SEN

—

EC-83

141 — 148

NATS MALFUNCTION

EL section*2

*1: When nothing is displayed or the meaningless symbol is displayed in the ‘‘Self-diag result’’ mode with CONSULT, perform ‘‘Diagnostic Test Mode II
(Self-diagnostic results)’’ with ECM. Refer to EC-32.
*2: Refer to ‘‘NATS (Nissan Anti-Theft System)’’ in EL section.

EC-1

PRECAUTIONS AND PREPARATION
Special Service Tools
FOR DIESEL ENGINE INJECTION PUMP
Tool number
Tool name

Description

KV11229352
Measuring device
1 KV11229350
V
Holder
2 KV11229360
V
Nut
3
V KV11229370
Pin
4
V KV11254410
Dial gauge

Measuring plunger lift

NT570

KV11102900
Pulley puller

Removing injection pump sprocket

NT647

FOR DIESEL ENGINE INJECTION NOZZLE
Tool number
Tool name

Description

KV11289004
Nozzle cleaning kit
1 KV11290012
V
Box
2 KV11290110
V
Brush
3 KV11290122
V
Nozzle oil sump scraper
4
V KV11290140
Nozzle needle tip
5
V KV11290150
Nozzle seat scraper
6 KV11290210
V
Nozzle holder
7 KV11290220
V
Nozzle hole cleaning
needle

NT296

EC-2

PRECAUTIONS AND PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name

Description

KV11292010
Nozzle centering device

NT293

KV11100300
Nozzle holder socket
(For No. 2 — 4 injection
nozzles)

NT563

KV119E0010
No. 1 injection nozzle
holder socket

NT648

Commercial Service Tool
Tool name

Description

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening
pressure

NT653

EC-3

PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’
The Supplemental Restraint System such as ‘‘AIR BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’ used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The composition varies according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.

EC-4

PRECAUTIONS AND PREPARATION
Engine Fuel & Emission Control System

SEF656V

EC-5

PRECAUTIONS AND PREPARATION
Precautions
+

Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned off.

When connecting ECM harness connector, tighten securing bolt until the gap between orange indicators disappears.
: 3.0 — 5.0 Nzm (0.3 — 0.5 kg-m, 26 — 43 in-lb)

When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.

Before replacing ECM, perform Terminals and Reference
Value inspection and make sure ECM functions properly.
Refer to EC-54.

If MIL illuminates or blinks irregularly when engine is
running, water may have accumulated in fuel filter. Drain
water from fuel filter. If this does not correct the problem,
perform specified trouble diagnostic procedures.
After performing each TROUBLE DIAGNOSIS, perform
‘‘OVERALL FUNCTION CHECK’’ or ‘‘DTC (Diagnostic
Trouble Code) CONFIRMATION PROCEDURE’’.
The DTC should not be displayed in the ‘‘DTC CONFIRMATION PROCEDURE” if the repair is completed. The ‘‘OVERALL FUNCTION CHECK’’ should be a good result if the
repair is completed.

SEF289H

SEF308Q

SEF291H

MEF040D

SEF051P

EC-6

PRECAUTIONS AND PREPARATION
Precautions (Cont’d)
+

When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.

SEF348N

EC-7

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
ECCS-D Component Parts Location

SEF657V

EC-8

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
ECCS-D Component Parts Location (Cont’d)

SEF658V

EC-9

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
ECCS-D Component Parts Location (Cont’d)

SEF659V

EC-10

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram

TEC420

EC-11

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
System Diagram

SEF660V

EC-12

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Vacuum Hose Drawing

SEF661V

1
V
2
V
3
V
4
V

Charge air cooler to vacuum gallery
Throttle control valve to throttle
control solenoid valve
Vacuum pump to 3-way connector
Vacuum gallery to wastegate valve
actuator

5
V
6
V
7
V

3-way connector to throttle control
solenoid valve
3-way connector to EGRC-solenoid valve A
3-way connector to EGRC-solenoid valve A

Refer to ‘‘System Diagram’’, EC-12 for vacuum control system.

EC-13

8
V
9
V

3-way connector to EGRC-solenoid valve B
EGR valve and 3-way connector

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
System Chart
Camshaft position sensor (PUMP)

Crankshaft position sensor (TDC)

Control sleeve position sensor

Fuel temperature sensor

Engine coolant temperature sensor

Needle lift sensor

Accelerator position sensor

Accelerator position switch

Accelerator switch (F/C)

Neutral position switch

Ignition switch

Battery voltage

Vehicle speed sensor

Air conditioner switch

Mass air flow sensor

Charge air temperature sensor

Heat up switch

ECM
(ECCS-D
control
module)

Fuel injection control

Electric governor

Fuel injection timing control

Injection timing control valve

Fuel cut control

Fuel cut solenoid valve

Glow control system

Glow relay & glow lamp

On board diagnostic system

Malfunction indicator lamp
(On the instrument panel)

EGR valve & throttle control
valve control

EGRC-solenoid valve A, B &
throttle control solenoid valve

Cooling fan control

Cooling fan relay

Air conditioning cut control

Air conditioner relay

Charge air cooler fan control

Charge air cooler fan relay

EC-14

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection System
SYSTEM DESCRIPTION
Three types of fuel injection control are provided to accommodate engine operating conditions; normal control,
idle control and start control. The ECM determines the appropriate fuel injection control. Under each control,
the amount of fuel injected is compensated to improve engine performance. The ECM performs duty control
on the electric governor (built into the fuel injection pump) according to sensor signals to compensate the
amount of fuel injected to the preset value.

START CONTROL
Input/output signal line
Engine coolant temperature sensor
Crankshaft position sensor (TDC)
Ignition switch
Control sleeve position sensor

Engine coolant temperature
c

Engine speed
c

Start signal

ECM

Electric
governor

Control sleeve position
c

When the ECM receives a start signal from the ignition switch, the
ECM adapts the fuel injection system for the start control. The
amount of fuel injected at engine starting is a preset program value
in the ECM. The program is determined by the engine speed and
engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches 400 rpm (for M/T models), 600 rpm (for A/T models) and
shifts the control to the normal or idle control.
SEF648S

EC-15

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection System (Cont’d)
IDLE CONTROL
Input/output signal line
Engine coolant temperature sensor
Crankshaft position sensor (TDC)
Neutral position switch
Battery
Control sleeve position sensor
Accelerator position switch
Vehicle speed sensor
Air conditioner switch
Heat up switch

Engine coolant temperature
c

Engine speed
c

Gear position
c

Battery voltage
c

ECM

Control sleeve position

Electric
governor

Idle position
c

Vehicle speed
c

Air conditioner signal
c

Heat up switch signal
c

When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine
to keep engine speed constant. The ECM also provides the system with a fast idle control in response to the
engine coolant temperature and heat up switch signal.

NORMAL CONTROL
Input/output signal line
Crankshaft position sensor (TDC)
Control sleeve position sensor

Engine speed
c

Control sleeve position
c

ECM
Accelerator position sensor
Vehicle speed sensor

Accelerator position

Electric
governor

Vehicle speed
c

The amount of fuel injected under normal driving conditions is
determined according to sensor signals. The crankshaft position
sensor (TDC) detects engine speed and the accelerator position
sensor detects accelerator position. These sensors send signals to
the ECM.
The fuel injection data, predetermined by correlation between various engine speeds and accelerator positions, are stored in the
ECM memory, forming a map. The ECM determines the optimal
amount of fuel to be injected using the sensor signals in comparison with the map.
SEF649S

EC-16

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection System (Cont’d)
FUEL TEMPERATURE COMPENSATION
Input/output signal line
Fuel temperature sensor

Crankshaft position sensor (TDC)

Control sleeve position sensor

Fuel temperature
c

Engine speed
c

ECM

Electric
governor

Control sleeve position
c

The amount of fuel leaking at or around high-pressure parts inside fuel injection pump varies with fuel temperature and engine speed. This will result in a difference between the target amount of fuel injected and the
actual amount. The ECM compensates for the actual amount depending on the signal from the fuel temperature sensor which detects fuel temperature.

DECELERATION CONTROL
Input/output signal line
Accelerator switch (F/C)

Accelerator position
c

ECM
Camshaft position sensor (PUMP)

Engine speed

Electric
governor

The ECM cuts power supply delivery to the electric governor during deceleration for better fuel efficiency. The
ECM determines the time of deceleration according to signals from the accelerator switch (F/C) and camshaft
position sensor (PUMP).

EC-17

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection Timing System
SYSTEM DESCRIPTION
The fuel injection timing system provides the optimal fuel injection timing for the target amount of fuel injected
according to engine speed. The timing is compensated when the vehicle is being driven or when starting
depending on the engine coolant temperature.
The ECM performs duty control on the timing control valve, allowing the valve to provide optimal fuel injection
timing. The ECM also performs feedback control on the timing control valve using the signal from the needle
lift sensor which detects the actual fuel injection timing.

BASIC CONTROL
Input/output signal line
Crankshaft position sensor (TDC)

Engine speed
c

ECM
Injection timing

Needle lift sensor

Injection
timing control valve

The optimal fuel injection timing data, predetermined in proportion
to engine speeds and amount of fuel injected, are stored in the
ECM memory. The ECM uses the data to control the fuel injection
timing.

SEF650S

ENGINE COOLANT TEMPERATURE COMPENSATION (When starting)
Input/output signal line
Crankshaft position sensor (TDC)
Engine coolant temperature sensor

Engine speed
c

Engine coolant temperature
c

ECM
c

Ignition timing

Needle lift sensor

Injection
timing control valve

Start signal

Ignition switch

Fuel injection
timing compensation

For better startability under cool engine conditions, the fuel injection timing is compensated according to the engine coolant temperature.
Engine coolant
temperature

Engine rpm
SEF651S

EC-18

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection Timing System (Cont’d)
ENGINE COOLANT TEMPERATURE COMPENSATION (During driving)
Input/output signal line
Engine speed
Crankshaft position sensor (TDC)

Engine coolant temperature
Engine coolant temperature sensor

ECM

Injection
timing control valve

Injection timing
Needle lift sensor

For better exhaust efficiency under cool engine conditions, the fuel
injection timing is controlled within a compensation range depending on the engine speed, engine coolant temperature and amount
of fuel injected.

SEF652S

Air Conditioning Cut Control
INPUT/OUTPUT SIGNAL LINE
Air conditioner switch

Accelerator position sensor

Air conditioner ‘‘ON’’ signal
c

Accelerator valve opening angle
c

ECM
Vehicle speed sensor

Engine coolant temperature sensor

Vehicle speed

Air
conditioner
relay

Engine coolant temperature
c

SYSTEM DESCRIPTION
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues
until the coolant temperature returns to normal.

EC-19

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Cut Control (at no load & high engine
speed)
INPUT/OUTPUT SIGNAL LINE
Vehicle speed sensor

Neutral position switch

Accelerator position switch or Accelerator
switch (F/C)

Engine coolant temperature sensor

Crankshaft position sensor (TDC)

Vehicle speed
c

Neutral position
c

Accelerator position
c

ECM

Electric
governor

Engine coolant temperature
c

Engine speed
c

If the engine speed is above 3,000 rpm with no load (for example,
in neutral and engine speed over 3,000 rpm) fuel will be cut off after
some time. The exact time when the fuel is cut off varies based on
engine speed.
Fuel cut will operate until the engine speed reaches 1,500 rpm,
then fuel cut is cancelled.
NOTE:
This function is different from deceleration control and fuel cut
solenoid valve control listed under ‘‘Fuel Injection System’’,
EC-15 and ‘‘TROUBLE DIAGNOSIS FOR DTC 36, 37, 38’’,
EC-130.

EC-20

CRANKCASE VENTILATION SYSTEM
Description
In this system, blow-by gas is sucked into the air inlet pipe through
the control valve after oil separation by oil separator in the rocker
cover.

SEF456HA

Inspection
Blow-by control valve

BLOW-BY CONTROL VALVE
Check control valve for clogging and abnormalities.

Intake
manifold
Rocker cover
SEC586B

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

SEC692

EC-21

INJECTION NOZZLE
CAUTION:
+ Do not disassemble No. 1 nozzle (with needle lift sensor
built-in). If NG, replace No. 1 injection nozzle.
+ Plug flare nut with a cap or rag so that no dust enters the
nozzle. Cover nozzle tip for protection of needle.

Nozzle side

Combustion
chamber side

SEF939S

Removal and Installation
1. Remove fuel injection tube and spill tube.
2. Remove injection nozzle assembly.
Also remove gasket from nozzle end.
3. Install injection nozzle in the reverse order of removal.
Injection nozzle to engine:
: 59 — 69 Nzm (6.0 — 7.0 kg-m, 43 — 51 ft-lb)
Injection nozzle to tube:
: 22 — 25 Nzm (2.2 — 2.5 kg-m, 16 — 18 ft-lb)
Spill tube:
: 39 — 49 Nzm (4.0 — 5.0 kg-m, 29 — 36 ft-lb)
a. Always clean the nozzle holes.
b. Always use new injection nozzle gasket.
c. Note that small washer should be installed in specified
direction.
d. Bleed air from fuel system.

SEF662V

Disassembly (No. 2 — 4 nozzles)
Do not disassemble No. 1 nozzle (with needle lift sensor).
1. Loosen nozzle nut while preventing nozzle top from turning.

SEF669A

2. Arrange all disassembled parts in the order shown at left.

Holder
Adjusting shim
Nozzle spring
Push rod
Distance piece

Nozzle needle
Nozzle body
Nozzle nut

SEF670A

EC-22

INJECTION NOZZLE
Inspection (No. 2 — 4 nozzles)
Thoroughly clean all disassembled parts with fresh kerosene or
solvent.
+ If nozzle needle is damaged or fused, replace nozzle assembly with a new one.
+ If end of nozzle needle is seized or excessively discolored,
replace nozzle assembly.
+ Check nozzle body and distance piece for proper contact. If
excessively worn or damaged, replace nozzle assembly or distance piece.
+ Check distance piece and nozzle holder for proper contact. If
excessively worn or damaged, replace distance piece or nozzle
holder.
+ Check nozzle spring for excessive wear or damage. If excessively worn or damaged, replace it with a new spring.

Cleaning (No. 2 — 4 nozzles)
a. Do not touch the nozzle mating surface with your fingers.
b. To wash the nozzles, use a wooden stick and brass brush
with clean diesel fuel.
1. Remove any carbon from exterior of nozzle body (except wrapping angle portion) by using Tool.

SEF830

2. Clean oil sump of nozzle body using Tool.

SEF831

3. Clean nozzle seat by using Tool.
This job should be performed with extra precautions, since
efficiency of nozzle depends greatly on a good nozzle seat.

SEF832

EC-23

INJECTION NOZZLE
Cleaning (No. 2 — 4 nozzles) (Cont’d)
4. Clean spray hole of nozzle body by using Tool.
To prevent spray hole from canting, always clean it by starting with inner side and working towards outside.

SEF833

5. Decarbonate nozzle needle tip by using Tool.

SEF834

6. Check needle sinking.
(1) Pull needle about halfway out from body and then release it.
(2) Needle should sink into body very smoothly from just its own
weight.
(3) Repeat this test and rotate needle slightly each time.
If needle fails to sink smoothly from any position, replace both
needle and body as a unit.

SEF835

Assembly (No. 2 — 4 nozzles)
Assemble in the reverse order of disassembly, observing the following.

SEF671A

If nozzle body is not installed properly, Tool cannot be
removed and nozzle body may be damaged.
Holder to nozzle nut:
: 78 — 98 Nzm (8.0 — 10.0 kg-m, 58 — 72 ft-lb)

EC-24

INJECTION NOZZLE
Test and Adjustment
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and make
sure your eyes are properly protected with goggles.

INJECTION PRESSURE TEST
1. Install nozzle to injection nozzle tester and bleed air from flare
nut.

EF791A

SEF672A

2. Pump the tester handle slowly (one time per second) and watch
the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Used
14,220 kPa (142.2 bar, 145 kg/cm2, 2,062 psi)
New
14,711 — 15,495 kPa (147.1 — 155.0 bar,
150 — 158 kg/cm2, 2,133 — 2,247 psi)
Always check initial injection pressure using a new nozzle.
4. To adjust injection pressure, change adjusting shims (No. 2 — 4
nozzles).
a. Increasing the thickness of adjusting shims increases initial injection pressure. Decreasing thickness reduces initial pressure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds
approximately to a difference of 471 kPa (4.71 bar, 4.8
kg/cm2, 68 psi) in initial injection pressure.
Refer to SDS for adjusting shim (EC-189).

Adjusting shim

SEF673A

LEAKAGE TEST
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or around the
body.

SEF674A

EC-25

INJECTION NOZZLE
Test and Adjustment (Cont’d)
3. If there is leakage, clean, overhaul or replace nozzle.

SPRAY PATTERN TEST
1. Check spray pattern by pumping tester handle one full stroke
per second.
+ If main spray angle is within 30 degrees as shown, injection nozzle is good.
+ It is still normal even if a thin stream of spray deviates from
the main spray (pattern B).
2. If the spray pattern is not correct, disassemble and clean
nozzle.
3. Test again and if spray pattern is not corrected, replace nozzle.
SEF079S

EC-26

ELECTRONIC FUEL INJECTION PUMP

SEF663V

Removal
1. Remove battery.
Disconnect electronic injection pump harness connectors.

2. Set No. 1 piston at TDC on its compression stroke.
TDC: Crankshaft pulley notch without painted mark
3. Remove fuel hoses (supply, return and spill) and injection
tubes.
4. Remove air duct and injection pump timing belt cover.
5. Remove injection pump timing belt.
Refer to EM section (‘‘Injection Pump Timing Belt’’).

SEF664V

6. Remove injection pump sprocket with Tool.
+ Remove key from injection pump shaft and store safely.

SEF665V

EC-27

ELECTRONIC FUEL INJECTION PUMP
Removal (Cont’d)
7. Remove injection pump assembly.

SEF666V

Installation
1. Install key on injection pump shaft, then install injection pump
sprocket.
+ Use alignment mark on sprocket.
2. Install injection pump timing belt.
Refer to EM section (‘‘Injection Pump Timing Belt’’).

SEF667V

3. Adjust injection timing.
Refer to ‘‘Basic Inspection’’, EC-46.
4. Install all parts removed.

EC-28

ELECTRONIC FUEL INJECTION PUMP

SEF668V

Disassembly and Assembly
CAUTION:
+ Do not disassemble the parts not shown in the illustration
above.
+ Before installing injection timing control valve, liberally
apply a coat of diesel fuel to O-ring and its mating area.
Insert injection timing control valve straight into bore in
fuel pump body. After properly positioning injection timing
control valve, visually check that fuel does not leak.
+ After assembling the parts, erase Diagnostic Trouble Code
(DTC), and perform DTC CONFIRMATION PROCEDURE (or
OVERALL FUNCTION CHECK).

EC-29

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
DTC and MIL Detection Logic
When a malfunction is detected for the first time, the malfunction (DTC) is stored in the ECM memory.
The MIL will light up each time the ECM detects malfunction. However, if the same malfunction is experienced
in two consecutive driving patterns and the engine is still running, the MIL will stay lit up. For diagnostic items
causing the MIL to light up, refer to ‘‘DIAGNOSTIC TROUBLE CODE INDEX’’, EC-1.

Diagnostic Trouble Code (DTC)
HOW TO READ DTC
The diagnostic trouble code can be read by the following methods.
1. The number of blinks of the malfunction indicator lamp in the Diagnostic Test Mode II (Self-Diagnostic
Results) Examples: 11, 13, 14, etc.
These DTCs are controlled by NISSAN.
2. CONSULT Examples: ‘‘CAM POS SEN (PUMP)’’, etc.
+ Output of the trouble code means that the indicated circuit has a malfunction. However, in the Mode
II it does not indicate whether the malfunction is still occurring or occurred in the past and returned
to normal.
CONSULT can identify them. Therefore, using CONSULT (if available) is recommended.

HOW TO ERASE DTC
The diagnostic trouble code can be erased by the following methods.
Selecting ‘‘ERASE’’ in the ‘‘SELF-DIAG RESULTS’’ mode with CONSULT.
+
+

Changing the diagnostic test mode from Diagnostic Test Mode II to Mode I. (Refer to EC-32.)
If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours.
When you erase the DTC, using CONSULT is easier and quicker than switching the diagnostic test
modes.

HOW TO ERASE DTC (With CONSULT)
1. If the ignition switch stays ‘‘ON’’ after repair work, be sure to turn ignition switch ‘‘OFF’’ once. Wait at least
5 seconds and then turn it ‘‘ON’’ (Engine stopped) again.
2. Turn CONSULT ‘‘ON’’ and touch ‘‘ENGINE’’.
3. Touch ‘‘SELF-DIAG RESULTS’’.
4. Touch ‘‘ERASE’’. (The DTC in the ECM will be erased.)

SEF691S

HOW TO ERASE DTC (No Tools)
1. If the ignition switch stays ‘‘ON’’ after repair work, be sure to turn ignition switch ‘‘OFF’’ once. Wait at least
5 seconds and then turn it ‘‘ON’’ again.
2. Change the diagnostic test mode from Mode II to Mode I. (Refer to EC-32.)

EC-30

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL)

SEF051P

1. The malfunction indicator lamp will light up when the ignition
switch is turned ON without the engine running. This is a bulb
check.
+ If the malfunction indicator lamp does not light up, refer to EL
section (‘‘WARNING LAMPS AND CHIME’’) or see EC-188.
2. When the engine is started, the malfunction indicator lamp
should go off.
If the lamp remains on, the on board diagnostic system has
detected an engine system malfunction.
If MIL illuminates or blinks irregularly after starting engine,
water may have accumulated in fuel filter. Drain water from
fuel filter.

ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following three functions.

1. BULB CHECK
2. MALFUNCTION
WARNING
3. SELF-DIAGNOSTIC
RESULTS

: This function checks the MIL bulb for damage (blown, open circuit,
etc.).
: This is a usual driving condition. When a malfunction is detected, the
MIL will light up to inform the driver that a malfunction has been
detected.
: This function allows diagnostic trouble codes to be read.

Refer to ‘‘HOW TO SWITCH DIAGNOSTIC TEST MODES’’ on next page.
Condition
Engine
stopped
Ignition switch
in ‘‘ON’’ position

EC-31

Engine
running

Diagnostic
Test Mode I

Diagnostic
Test Mode II

BULB CHECK

SELF-DIAGNOSTIC
RESULTS

MALFUNCTION
WARNING

—

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Cont’d)
HOW TO SWITCH DIAGNOSTIC TEST MODES
Turn ignition switch ‘‘ON’’.
(Do not start engine.)

NG
Diagnostic Test Mode I — BULB CHECK.
Refer to previous page.
MIL should come on.
c

Check MIL circuit.
(See EC-188.)

NG
c

Repair harness or
connectors.
OK

OK
.

Start engine.

Diagnostic Test
Mode I
— MALFUNCTION WARNING.
Refer to previous page.

NG
c

Check MIL circuit and data link connector for
CONSULT circuit. (See EC-188.)
OK
.

Data link connector for CONSULT
(Connect CHK and IGN terminals with a suitable
harness.)
MIL should go off.

Repair harness or
connectors.
OK

Wait at least 2 seconds.

Data link connector for CONSULT
(Disconnect the suitable harness between CHK
and IGN terminals.)
.

DIAGNOSTIC TEST MODE II
— SELF-DIAGNOSTIC RESULTS

j
B

j
A

EC-32

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Cont’d)
j
B

j
A

m
.

Data link connector for CONSULT
(Connect CHK and IGN terminals with a suitable harness.)

+ Switching the modes is not possible when the engine
is running.
+ When ignition switch is turned off during diagnosis,
power to ECM will drop after approx. 5 seconds.
The diagnosis will automatically return to Diagnostic
Test Mode I.

Wait at least 2 seconds.
.

Data link connector for CONSULT
(Disconnect the suitable harness between
CHK and IGN terminals.)
.

If the suitable harness is disconnected at this
time, the diagnostic trouble code will be
erased from the backup memory in the ECM.

EC-33

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Cont’d)
DIAGNOSTIC TEST MODE I—BULB CHECK
In this mode, the MALFUNCTION INDICATOR LAMP on the instrument panel should stay ON. If it remains
OFF, check the bulb. Refer to EL section (‘‘WARNING LAMPS AND CHIME’’) or see EC-188.

DIAGNOSTIC TEST MODE I—MALFUNCTION WARNING
MALFUNCTION
INDICATOR LAMP

Condition

When the malfunction is detected or the ECM’s CPU is malfunctioning. (Refer to ‘‘MIL Illumination’’ of the
‘‘DIAGNOSTIC TROUBLE CODE INDEX’’, EC-1.)

OFF

No malfunction.

These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC
RESULTS).

DIAGNOSTIC TEST MODE II—SELF-DIAGNOSTIC RESULTS
In this mode, a diagnostic trouble code is indicated by the number of blinks of the MALFUNCTION INDICATOR LAMP as shown below.

SEF212NA

Long (0.6 second) blinking indicates the number of ten digits, and short (0.3 second) blinking indicates the
number of single digits. For example, the malfunction indicator lamp blinks 4 times for 5 seconds (0.6 sec x
4 times) and then it blinks three times for about 1 second (0.3 sec x 3 times). This indicates the DTC ‘‘43’’
and refers to the malfunction of the accelerator position sensor circuit.
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The DTC
‘‘55’’ refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE INDEX, EC-1.)

HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnostic results)
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic test mode
is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to ‘‘HOW TO SWITCH DIAGNOSTIC TEST MODES’’ on previous page.)
+ If the battery terminal is disconnected, the diagnostic trouble code will be lost from the backup
memory within 24 hours.
+ Be careful not to erase the stored memory before starting trouble diagnoses.
+ If the MIL blinks or ‘‘NATS MALFUNCTION’’ is displayed on
‘‘SELF-DIAG RESULTS’’ screen, perform self-diagnostic
results mode with CONSULT using NATS program card
(NATS-E940). Refer to EL section.
+ Confirm no self-diagnostic results of NATS is displayed
before touching ‘‘ERASE’’ in ‘‘SELF-DIAG RESULTS’’ mode
with CONSULT.
+ When replacing ECM, initialisation of NATS V2.0 system
and registration of all NATS V2.0 ignition key IDs must be
carried out with CONSULT using NATS program card
(NATS-E940).
SEF288Q
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialisation and NATS
ignition key ID registration, refer to CONSULT operation
manual, NATS V2.0.

EC-34

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Cont’d)
RELATIONSHIP BETWEEN MIL, DTC, CONSULT AND DRIVING PATTERNS

This driving pattern does not satisfy
self-diagnostic condition.

NG Detection

This driving pattern satisfies
self-diagnostic condition.
Driving Pattern

Engine
(GN)

MIL

RUN (ON)
STOP (OFF)

ON
OFF

ECM

Diagnostic
trouble
code

DISPLAY
NO
DISPLAY

CONSULT
SELFDTC exists
DIAGNOSTIC
RESULTS
SCREEN
DTC does
&
not exist
DATA MONITOR
(AUTO TRIG) SCREEN
SELFDIAGNOSTIC
RESULTS
SCREEN

COUNTER

SEF659S

*1: When a malfunction is detected, MIL will light up.
*2: When the same malfunction is detected in two consecutive
driving patterns, MIL will stay lit up.
*3: MIL will go off after vehicle is driven three times without
any malfunctions.
*4: When a malfunction is detected for the first time, the DTC
will be stored in ECM.

*5: The DTC will not be displayed any longer after vehicle is
driven 40 times without the same malfunction.
(The DTC still remain in ECM.)
*6: Other screens except SELF-DIAGNOSTIC RESULTS &
DATA MONITOR (AUTO TRIG) cannot display the malfunction. DATA MONITOR (AUTO TRIG) can display the
malfunction at the moment it is detected.

EC-35

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT
CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect ‘‘CONSULT’’ to data link connector for CONSULT.
(Data link connector for CONSULT is located under the hood
opener.)

SEF669V

3.
4.
5.
6.

Turn on ignition switch.
Touch ‘‘START’’.
Touch ‘‘ENGINE’’.
Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT Operation Manual.

SEF895K

SEF660S

EC-36

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont’d)
ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
SELF-DIAGNOSTIC
RESULTS

DATA
MONITOR

Camshaft position sensor (PUMP)

Engine coolant temperature sensor

Control sleeve position sensor

Fuel temperature sensor

Vehicle speed sensor

Accelerator position sensor

Accelerator position switch

Accelerator switch (F/C)

Crankshaft position sensor (TDC)

Needle lift sensor

ECCS COMPONENT PARTS

Item

INPUT

Ignition switch (start signal)

Neutral position switch

Battery voltage

Air conditioner switch

Heat up switch

ACTIVE
TEST

Mass air flow sensor

Charge air temperature sensor

Injection timing control valve

Fuel cut solenoid valve

Glow relay

EGRC-solenoid valve A, B & throttle control solenoid valve

Cooling fan relay

Charge air cooler fan relay

OUTPUT

X: Applicable

EC-37

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont’d)
SELF-DIAGNOSTIC MODE
Regarding items detected in ‘‘SELF-DIAG RESULTS’’ mode, refer to ‘‘DIAGNOSTIC TROUBLE CODE
INDEX’’, EC-1.

DATA MONITOR MODE
Monitored item
[Unit]
CKPSzRPM
(TDC) [rpm]
CKPSzRPM
(REF) [rpm]

CMPSzRPM PUMP [rpm]

ECM
Main
input
signals
signals

FUEL TEMP SEN
[°C] or [°F]
ACCEL POS SEN [V]
FULL ACCEL SW
[ON/OFF]
ACCEL SW (FC)
[OPEN/CLOSE]
OFF ACCEL SW
[ON/OFF]
C/SLEEV POS/S [V]
BATTERY VOLT [V]
P/N POSI SW
[ON/OFF]
START SIGNAL
[ON/OFF]

Remarks

j j

+ The engine speed computed from the
crankshaft position sensor (TDC) signal
is displayed.

j j

+ The engine speed [determined by the
time between pulses from the crankshaft
position sensor (TDC) signal] is displayed.

j j

+ The engine speed computed from the
camshaft position sensor (PUMP) signal
is displayed.

j j

+ When the engine coolant temperature
+ The engine coolant temperature (detersensor is open or short-circuited, ECM
mined by the signal voltage of the engine
enters fail-safe mode. The engine coolcoolant temperature sensor) is displayed.
ant temperature determined by the ECM
is displayed.

COOLAN TEMP/S
[°C] or [°F]

VHCL SPEED SE
[km/h] or [mph]

Description

j
j
j
j
j
j
j
j
j
j

+ The vehicle speed computed from the
vehicle speed sensor signal is displayed.
+ The fuel temperature (determined by the
signal voltage of the fuel temperature
sensor) is displayed.
+ The accelerator position sensor signal
voltage is displayed.
+ Indicates [ON/OFF] condition from the
accelerator position switch signal.
+ Indicates [OPEN/CLOSE] condition from
the accelerator switch (FC) signal.
+ Indicates [ON/OFF] condition from the
accelerator position switch signal.
+ The control sleeve position sensor signal
voltage is displayed.
+ The power supply voltage of ECM is displayed.
+ Indicates [ON/OFF] condition from the
park/neutral position switch signal.
+ Indicates [ON/OFF] condition from the
starter signal.

+ After starting the engine, [OFF] is displayed regardless of the starter signal.

NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-38

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont’d)
Monitored item
[Unit]
AIR COND SIG
[ON/OFF]
IGN SW
[ON/OFF]
MAS AIR/FL SE [V]

ECM
Main
input
signals
signals

j j
j j
j j

ACT INJ TIMG [°]

j j
INJ TIMG C/V [%]
DECELER F/CUT
[ON/OFF]

Remarks

+ Indicates [ON/OFF] condition of the air
conditioner switch as determined by the
air conditioner signal.
+ Indicates [ON/OFF] condition from ignition switch signal.
+ The signal voltage of the mass air flow
sensor is displayed.

+ When the engine is stopped, a certain
value is indicated.

+ The actual injection timing angle determined by the ECM (an approximate
average angle between injection start
and end from TDC) is displayed.
+ Indicates the duty ratio of fuel injection
timing control valve.

+ Indicates [ON/OFF] condition from decel- + When the accelerator pedal is released
eration fuel cut signal.
quickly with engine speed at 3,000 rpm
or more, ‘‘ON’’ is displayed.

+ The control condition of the fuel cut sole- + When the fuel cut solenoid valve is not
operating, fuel is not supplied to injection
noid valve (determined by ECM accordnozzles.
ing to the input signal) is indicted.
+ OFF … Fuel cut solenoid valve is not
operating.
ON … Fuel cut solenoid valve is operating.

+ The glow relay control condition (determined by ECM according to the input
signal) is displayed.

+ Indicates the control condition of the
cooling fans (determined by ECM
according to the input signal).
+ LOW … Operates at low speed.
HI … Operates at high speed.
OFF … Stopped.

+ Indicates the control condition of the
charge air cooler fan (determined by
ECM according to the input signals).

FUEL CUT S/V
[ON/OFF]

GLOW RLY [ON/OFF]

COOLING FAN
[LOW/HI/OFF]

I/C FAN RLY
[ON/OFF]

Description

EGRC SOL/V A
[ON/OFF]

+ The control condition of the EGRC-solenoid valve A (determined by ECM
according to the input signal) is indicated.
+ OFF … EGRC-solenoid valve A is not
operating.
ON … EGRC-solenoid valve A is operating.

EGRC SOL/V B
[ON/OFF]

+ The control condition of the EGRC-solenoid valve B (determined by ECM
according to the input signal) is indicated.
+ OFF … EGRC-solenoid valve B is not
operating.
ON … EGRC-solenoid valve B is operating.

THROT RLY
[ON/OFF]

+ The control condition of the throttle control solenoid valve (determined by ECM
according to the input signal) is indicated.
+ OFF … Throttle control solenoid valve is
not operating.
ON … Throttle control solenoid valve is
operating.

EC-39

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont’d)
ACTIVE TEST MODE
TEST ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

COOLING FAN

+ Ignition switch: ON
+ Operate the cooling fan at
‘‘LOW’’, ‘‘HI’’ speed and turn
‘‘OFF’’ using CONSULT.

OFF ACCEL PO
SIG

+ Clears the self-learning fully closed accelerator position, detected by accelerator position sensor, from the
ECM.

FUEL CUT SOL/V

+ Ignition switch: ON
+ Turn solenoid valve ‘‘ON’’ and
‘‘OFF’’ with the CONSULT and
listen to operating sound.

Solenoid valve makes an operating
sound.

+ Harness and connector
+ Solenoid valve

EGRC SOL/V A

+ Ignition switch: ON
+ Turn solenoid valve ‘‘ON’’ and
‘‘OFF’’ with the CONSULT and
listen to operating sound.

Solenoid valve makes an operating
sound.

+ Harness and connector
+ Solenoid valve

EGRC SOL/V B

+ Ignition switch: ON
+ Turn solenoid valve ‘‘ON’’ and
‘‘OFF’’ with the CONSULT and
listen to operating sound.

Solenoid valve makes an operating
sound.

+ Harness and connector
+ Solenoid valve

THROT CONT
SOL/V

+ Ignition switch: ON
+ Turn solenoid valve ‘‘ON’’ and
‘‘OFF’’ with the CONSULT and
listen to operating sound.

Solenoid valve makes an operating
sound.

+ Harness and connector
+ Solenoid valve

GLOW RLY

+ Ignition switch: ON (Engine
stopped)
+ Turn the glow relay ‘‘ON’’ and
‘‘OFF’’ using CONSULT and
listen to operating sound.

Glow relay makes the operating
sound.

+ Harness and connector
+ Glow relay

INJ TIMING

+ Engine: Return to the original
trouble condition
+ Retard the injection timing using
CONSULT.

If trouble symptom disappears, see
CHECK ITEM.

+ Adjust initial injection timing

Cooling fan moves at ‘‘LOW’’, ‘‘HI’’
speed and stops.

EC-40

+ Harness and connector
+ Cooling fan motor

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont’d)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT has two kinds of triggers and they can be selected by touching ‘‘SETTING’’ in ‘‘DATA MONITOR’’
mode.
1. ‘‘AUTO TRIG’’ (Automatic trigger):
+ The malfunction will be identified on the CONSULT screen in real time.
In other words, the malfunction item will be displayed at the moment the malfunction is detected by
ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA
MONITOR cannot continue any longer after the malfunction detection.
2. ‘‘MANU TRIG’’ (Manual trigger):
+ The malfunction item will not be displayed automatically on CONSULT screen even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though a malfunction is detected.
Use these triggers as follows:
1. ‘‘AUTO TRIG’’
+ While trying to detect the DTC by performing the ‘‘DTC CONFIRMATION PROCEDURE’’, be sure to
select to ‘‘DATA MONITOR (AUTO TRIG)’’ mode. You can confirm the malfunction at the moment it is
detected.
+ While narrowing down the possible causes, CONSULT should be set in ‘‘DATA MONITOR (AUTO
TRIG)’’ mode, especially in case the incident is intermittent.
Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness in
the ‘‘DTC CONFIRMATION PROCEDURE’’. The moment a malfunction is found the malfunction item
will be displayed. (Refer to GI section, ‘‘Incident Simulation Tests’’ in ‘‘HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT’’.)
2. ‘‘MANU TRIG’’
+ If the malfunction is displayed as soon as ‘‘DATA MONITOR’’ is selected, reset CONSULT to ‘‘MANU
TRIG’’. By selecting ‘‘MANU TRIG’’ you can monitor and store the data. The data can be utilized for
further diagnosis, such as a comparison with the value for the normal operating condition.

SEF529Q

EC-41

TROUBLE DIAGNOSIS — Introduction
Introduction

SEF858S

SEF233G

The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control system,
etc. The ECM accepts input signals from sensors and instantly
drives electronic fuel injection pump. It is essential that both input
and output signals are proper and stable. At the same time, it is
important that there are no problems such as vacuum leaks, or
other problems with the engine.
It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT or a circuit tester connected should be performed. Follow the ‘‘Work Flow’’, EC-44.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The customer can supply good information about such problems, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A ‘‘Diagnostic Worksheet’’ like the
example on next page should be used.
Start your diagnosis by looking for ‘‘conventional’’ problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.

SEF234G

EC-42

TROUBLE DIAGNOSIS — Introduction
Diagnostic Worksheet
There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can make
troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
SEF907L

WORKSHEET SAMPLE
Customer name

MR/MS

Model & Year

VIN

Engine #

Trans.

Mileage

Incident Date

Manuf. Date

In Service Date

h Startability

Symptoms

h Impossible to start
h No combustion
h Partial combustion when engine is warm
h Partial combustion when engine is cool
h Possible but hard to start
h Others [

h Idling

h No fast idle
h Others [

h Unstable

h Driveability

h Stumble
h Others [

h Engine stall

h At the time of start
h While accelerating
h Just after stopping

h Surge

Incident occurrence

h Just after delivery
h In the morning

Frequency

h All the time

Weather conditions

h Not affected

Weather

h Fine

Temperature

h Hot

h While idling
h While decelerating
h While loading
h Recently
h At night
h In the daytime

h Snowing
h Cool

h During warm-up

h Sometimes

h Others [

h Cold

Engine speed

Road conditions

h In town

Driving conditions

h Not affected
h At starting
h While idling
h At racing
h While accelerating
h While cruising
h While decelerating
h While turning (RH/LH)

h In suburbs

Vehicle speed

h Turned on

h Not turned on

EC-43

h Humid

h After warm-up

Engine conditions

Malfunction indicator lamp

h Low idle

h Lack of power
]

h Under certain conditions

h Warm

]

h High idle
]
h Knock

h Raining

h Cold

h Partial combustion

h Highway

h Off road (up/down)

]
°F

TROUBLE DIAGNOSIS — Work Flow
Work Flow
CHECK IN
.

CHECK INCIDENT CONDITIONS.
Listen to customer complaints. (Get symptoms.)

…………………………………………. STEP I

Check and PRINT OUT (write down) Diagnostic Trouble Code (DTC).
Then clear. Also check related service bulletins for information.
Symptoms
collected.

……………………………………. STEP II

No symptoms, except MIL
lights up, or Malfunction
Code exists at STEP II.

Verify the symptom by driving in the condition the cus*1
…………………………………………………………………………………
STEP III
tomer described.
Normal Code
(at STEP II)

Malfunction Code
(at STEP II)
.

INCIDENT CONFIRMATION
Verify the DTC by performing the ‘‘DTC CONFIRMATION PROCEDURE’’.

*1
…………………………………….
STEP IV

.
c

…………………………………….
STEP V
*2

Choose the appropriate action.
Malfunction Code (at STEP II or IV)

Normal Code (at both STEP II and IV)
.

BASIC INSPECTION
SYMPTOM BASIS (at STEP I or III)
……………………………………………………….c
.

Perform inspections
according to Symptom
Matrix Chart.
.

STEP VI

TROUBLE DIAGNOSIS FOR DTC XX.
.

REPAIR/REPLACE
.

FINAL CHECK
Confirm that the incident is completely fixed by performing BASIC INSPECTION and
DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK). Then,
erase the unnecessary (already fixed) DTCs in ECM.

……………………………………. STEP VII

OK
.

CHECK OUT

*1: If the incident cannot be duplicated, refer to GI section (‘‘Incident Simulation Tests’’, ‘‘HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT’’).
*2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to
‘‘TROUBLE DIAGNOSIS FOR POWER SUPPLY’’, EC-63.

EC-44

TROUBLE DIAGNOSIS — Work Flow
Description for Work Flow
STEP

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using the
‘‘DIAGNOSTIC WORKSHEET’’ as shown on EC-43.

STEP II

Before confirming the concern, check and write down (print out using CONSULT) the Diagnostic Trouble Code
(DTC), then erase the code. Refer to EC-30.
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
‘‘Symptom Matrix Chart’’ will be useful. Refer to EC-48.)

STEP III

Try to confirm the symptom and under what conditions the incident occurs.
The ‘‘DIAGNOSTIC WORK SHEET’’ is useful to verify the incident. Connect CONSULT to the vehicle in DATA
MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
If the malfunction code is detected, skip STEP IV and perform STEP V.

STEP IV

Try to detect the Diagnostic Trouble Code (DTC) by driving in (or performing) the ‘‘DTC CONFIRMATION PROCEDURE’’. Check and read the DTC by using CONSULT.
During the DTC verification, be sure to connect CONSULT to the vehicle in DATA MONITOR (AUTO TRIG) mode
and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
In case the ‘‘DTC CONFIRMATION PROCEDURE’’ is not available, perform the ‘‘OVERALL FUNCTION CHECK’’
instead. The DTC cannot be displayed by this check, however, this simplified ‘‘check’’ is an effective alternative.
The ‘‘NG’’ result of the ‘‘OVERALL FUNCTION CHECK’’ is the same as the DTC detection.

STEP V

Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC XX.
If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-46. Then perform inspections
according to the Symptom Matrix Chart. Refer to EC-48.

STEP VI

Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect
the system for mechanical binding, loose connectors or wiring damage using (tracing) ‘‘Harness Layouts’’.
Gently shake the related connectors, components or wiring harness with CONSULT set in ‘‘DATA MONITOR
(AUTO TRIG)’’ mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT. Refer to EC-54.
The ‘‘DIAGNOSTIC PROCEDURE’’ in EC section contains a description based on open circuit inspection. A short
circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI
section (‘‘Circuit Inspection’’, ‘‘HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT’’).
Repair or replace the malfunction parts.

STEP VII

Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer’s initial complaint.
Perform the ‘‘DTC CONFIRMATION PROCEDURE’’ and confirm the normal code (Diagnostic trouble code No. 55)
is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the
previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM. (Refer
to EC-30.)

EC-45

TROUBLE DIAGNOSIS — Basic Inspection
Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
+ Headlamp switch is OFF,
+ Air conditioner switch is OFF,
+ Rear defogger switch is OFF,
+ Steering wheel is in the straight-ahead position, etc.

SEF142I

SEF670V

BEFORE STARTING
1. Check service records for any recent
repairs that may indicate a related
problem, or the current need for scheduled maintenance.
2. Open engine hood and check the following:
+ Harness connectors for improper connections
+ Vacuum hoses for splits, kinks, or
improper connections
+ Wiring for improper connections,
pinches, or cuts
3. Using priming pump, bleed air from fuel
system. Refer to ‘‘DRAINING WATER’’,
‘‘Checking and Replacing Fuel Filter
and Draining Water’’ of ‘‘ENGINE
MAINTENANCE’’ in MA section.

CONNECT CONSULT TO THE VEHICLE.
Connect ‘‘CONSULT’’ to the data link connector for CONSULT and select
‘‘ENGINE’’ from the menu. Refer to
EC-36.
SEF669V
.

DOES ENGINE START?
Yes

Run engine for 10 minutes.

CHECK IDLE SPEED.
SEF714V
——————————————————————————————————————————————————-Read engine idle speed in ‘‘DATA
MONITOR’’ mode with CONSULT.
——————————————————————- OR ——————————————————————Check idle speed using tachometer tester.
——————————————————————————————————————————————————-775±25 rpm
.
A on next page.)
(Go to j

SEF671V

EC-46

No
c

Turn ignition switch OFF,
wait 5 seconds and then
start engine. If engine fails
to start, check diagnostic
trouble code (DTC).

TROUBLE DIAGNOSIS — Basic Inspection
Basic Inspection (Cont’d)
j
A
.

SEF672V

CHECK INJECTION TIMING.
1. Set No. 1 piston at TDC on its compression stroke.
2. Remove injection tubes and air bleeder
on the back of injection pump.
3. Set dial gauge so its indicator points to
somewhere between 1.0 and 2.0 mm
(0.039 and 0.079 in) on the scale.
4. Turn crankshaft 1 turn clockwise and
check that dial gauge indicates the
same value again.
5. Turn crankshaft counterclockwise about
100 degrees, then turn crankshaft
clockwise slowly, and set dial gauge
indicator to 0 mm at the position it
stops.
6. Turn crankshaft clockwise and set the
injection timing mark on the crankshaft
pulley to the timing indicator.
7. Read plunger lift.
Plunger lift:
0.92±0.04 mm (0.0362±0.0016 in)
+ When repeating the checking, start
with step 5.

SEF664V

OK
c

+ Bleed air from fuel system.
+ After this inspection,
unnecessary diagnostic
trouble code No. might
be displayed.
Erase the stored
memory in ECM.
Refer to ‘‘ON BOARD
DIAGNOSTIC SYSTEM
DESCRIPTION’’ (EC-30)
and ‘‘HOW TO ERASE
DTC’’ (EC-30).
OK
.

INSPECTION END

SEF673V

SEF666V

ADJUSTING
1. If plunger lift is not within the specified
value, adjust by turning injection pump.
+ If indication is smaller than the specified value, turn pump body away
from engine.
+ If indication is larger than the specified value, turn pump body towards
engine.
2. Tighten injection pump securing bolts
and nuts.
Nut:
: 16 — 21 Nzm
(1.6 — 2.1 kg-m, 12 — 15 ft-lb)
Bolt:
: 22 — 29 Nzm
(2.2 — 3.0 kg-m, 16 — 22 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 22 — 25 Nzm
(2.2 — 2.5 kg-m, 16 — 18 ft-lb)
5. Bleed air from fuel system.
Refer to ‘‘DRAINING WATER’’, ‘‘Checking and Replacing Fuel Filter and
Draining Water’’ of ‘‘ENGINE MAINTENANCE’’ in MA section.

EC-47

Go to

TROUBLE DIAGNOSIS — General Description
Symptom Matrix Chart

+ +
+ +

Injection Advanced
timing
Retarded

j j

Electric injection pump
mainframe

+ + + +

Injection nozzle

j j j j j j j

Glow system

j j

+ +

j j

+ +

Engine body

j j

+
+

j j j j j

j j j

+
+

j j

+ +

j j j

Air cleaner and ducts

+ +

EC-48

Feature of symptom, Check point

EC-47

j j j

—

EC-22

+ +

; High Possibility Item
j ; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.

DEAD BATTERY (UNDER CHARGE)

ABNORMAL SMOKE COLOR

EGR system

WHITE SMOKE

+ +

Reference page

AG AH AJ AK AL AM

BLACK SMOKE

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

SLOW/NO RETURN TO IDLE

IDLING VIBRATION

ROUGH IDLE/HUNTING

LOW IDLE

HI IDLE

Fuel cut

j j j

POOR ACCELERATION

LACK OF POWER

KNOCK/DETONATION

AC AD

Can be detected by CONSULT?

HESITATION/SURGING/FLAT SPOT

WHEN DECELERATING

DURING DRIVING

AT IDLE

HARD TO START WHEN ENGINE IS HOT

HARD TO START WHEN ENGINE IS COLD

Malfunction indicator lamp illuminates.

Warranty symptom
code

NO START (without first firing)

NO START (with first firing)

SYSTEM
— Basic engine
control system

ENGINE STALL

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

EC-151

EM section

EC-156
j

MA section

SYSTEM
— ECCS system

ECCS

EC-49

open, short
open, short
noise

Crankshaft position sensor (TDC) circuit

Accelerator position sensor circuit

open, short

short

ground short
open, short
ground short
open, short
open, short
open, ground short

open, short

HARD TO START WHEN ENGINE IS HOT

Fuel temperature sensor circuit

Fuel cut solenoid valve circuit

Charge air temperature sensor circuit
Needle lift sensor circuit

Accelerator switch (FC) circuit

Malfunction
j

j
j
j

j j

HI IDLE

Injection timing control valve circuit

NO START (without first firing)
j

j
j
j

j
j

j
j
j

j
j
j
j
j

j
j
j
j

Fuel cut

Electric governor circuit

HARD TO START WHEN ENGINE IS COLD

AT IDLE

open, short
open, short
open, short
open, ground short
short

HARD/NO START/
RESTART (EXCP. HA)
DURING DRIVING

Vehicle speed sensor circuit
Control sleeve position sensor circuit
Adjustment resistor circuit

WHEN DECELERATING

HESITATION/SURGING/FLAT SPOT

KNOCK/DETONATION

open, short

LACK OF POWER
j

ROUGH IDLE/HUNTING

Engine coolant temperature sensor
circuit

ENGINE STALL
HA

Malfunction indicator lamp illuminates.

Mass air flow sensor circuit

IDLING VIBRATION
AP

Can be detected by CONSULT?

j
j
j

SLOW/NO RETURN TO IDLE

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

AG AH AJ AK AL AM

EC-144

EC-139

EC-135

EC-130

EC-122
EC-126

EC-106

EC-101

EC-96

EC-83
EC-87
EC-92

EC-79

EC-74

EC-69

Reference
page

LOW IDLE
AF

EXCESSIVE FUEL CONSUMPTION

POOR ACCELERATION

BLACK SMOKE

AC AD

EXCESSIVE OIL CONSUMPTION

WHITE SMOKE

ABNORMAL SMOKE COLOR

open, short
noise
open, ground short
short

Engine runs on after turning ignition switch OFF.
Compensation for amount of fuel
injected according to fuel temperature does not function.

Injection timing cannot be controlled.

Compensation according to
engine coolant temperature does
not function.

Tachometer malfunction

Feature of symptom
Check point

Camshaft position sensor (PUMP) circuit

DEAD BATTERY (UNDER CHARGE)

Warranty symptom code

SYMPTOM

TROUBLE DIAGNOSIS — General Description
Symptom Matrix Chart (Cont’d)

NO START (with first firing)

SYSTEM
— ECCS system

EC-50

ECCS

Air conditioner switch circuit

Air conditioner relay circuit

short

open, ground short

short

open, short
open

short
j

j j

HI IDLE

ECM, Connector circuit

ECCS relay (Self-shutoff) circuit

NO START (with first firing)

Glow relay circuit

Malfunction

EGRC-solenoid valve A, B circuit

NO START (without first firing)

Throttle control solenoid valve circuit

HARD TO START WHEN ENGINE IS COLD
j

j
j

Fuel cut

Power supply for ECM circuit

HARD TO START WHEN ENGINE IS HOT

AT IDLE

Ignition switch circuit

HARD/NO START/
RESTART (EXCP. HA)
DURING DRIVING

open
short
open
short
open, short
ground short
open, short
ground short
open
short
open

WHEN DECELERATING

open, short

HESITATION/SURGING/FLAT SPOT
j
j

Malfunction indicator lamp illuminates.

Accelerator position switch (Full) circuit

KNOCK/DETONATION

LACK OF POWER

ROUGH IDLE/HUNTING

ENGINE STALL
HA

Can be detected by CONSULT?

short

IDLING VIBRATION
AP

EC-187

EC-111

EC-63

EC-151

EC-156

EC-63

EC-165

EC-170

EC-163

Reference page

Accelerator position switch (Idle) circuit

SLOW/NO RETURN TO IDLE

AG AH AJ AK AL AM

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

LOW IDLE
AF

Air conditioner
Air conditioner
operating.
Air conditioner
operating.
Air conditioner

does not work.

does not stop

does not operate.
does not stop

Ground short makes engine
unable to stop.

Does not stop operating.
Glow lamp does not turn on.
Glow lamp does not turn off.

Does not operate.
Does not stop operating.

Engine does not stop.

Accelerator position sensor NG
signal is output.

Start control does not function.

Feature of symptom
Check point

Neutral position switch circuit

POOR ACCELERATION

EXCESSIVE FUEL CONSUMPTION

AC AD

BLACK SMOKE

EXCESSIVE OIL CONSUMPTION

WHITE SMOKE

AA
j

ABNORMAL SMOKE COLOR

open, short
open, short
ground short
open, ground short

DEAD BATTERY (UNDER CHARGE)

Warranty symptom code
Start signal circuit

SYMPTOM

TROUBLE DIAGNOSIS — General Description
Symptom Matrix Chart (Cont’d)

TROUBLE DIAGNOSIS — General Description
CONSULT Reference Value in Data Monitor
Mode
Remarks:
+ Specification data are reference values.
+ Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
MONITOR ITEM

CONDITION

SPECIFICATION

CKPSzRPM (TDC)
+ Tachometer: Connect
+ Run engine and compare tachometer indication with the CONSULT value.

Almost the same speed as the CONSULT value.

COOLAN TEMP/S

+ Engine: After warming up

More than 70°C (158°F)

VHCL SPEED SE

+ Turn drive wheels and compare speedometer indication with the CONSULT
value

Almost the same speed as
the CONSULT value

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104 °F)

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: released

0.40 — 0.60V

ACCEL POS SEN

Accelerator pedal: depressed

Approx. 4.0V

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: depressed

Except above

OFF

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: released

Accelerator pedal: slightly open

OPEN

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: released

Accelerator pedal: slightly open

OFF

CKPSzRPM (REF)
CMPSzRPM-PUMP

FULL ACCEL SW

ACCEL SW (FC)

OFF ACCEL SW
C/SLEEV POS/S

+ Engine: After warming up

1.0 — 3.5V

BATTERY VOLT

+ Ignition switch: ON (Engine stopped)

11 — 14V

P/N POSI SW

+ Ignition switch: ON

START SIGNAL

+ Ignition switch: ON → START → ON

AIR COND SIG

+ Engine: After warming up, idle the
engine

IGN SW
WARM UP SW

OFF
OFF → ON → OFF

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON
ON → OFF

Heat up switch: ON

Heat up switch: OFF

OFF

Idle

1.6 — 2.0V

Idle

−9.5 to −12.0°

2,000 rpm

−10.0 to −15.5°

+ Ignition switch: ON
+
+
+
+

Engine: After warming up
Air conditioner switch: OFF
Shift lever: ‘‘N’’
No-load

ACT INJ TIMG

+
+
+
+

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

DECELER F/CUT

Except above

+ Ignition switch: ON → OFF

MAS AIR/FL SE

INJ TIMG C/V

Shift lever: Neutral/Park

+ Engine: After warming up, idle the engine.

+ Engine: After warming up

FUEL CUT S/V

+ Ignition switch: ON → OFF

GLOW RLY

+ Refer to EC-151.

Approx. 50%

Idle

OFF

When accelerator pedal is released
quickly with engine speed at 3,000 rpm
or more.

ON
ON → OFF

EC-51

TROUBLE DIAGNOSIS — General Description
CONSULT Reference Value in Data Monitor
Mode (Cont’d)
MONITOR ITEM

CONDITION

SPECIFICATION

+ When cooling fan is stopped.

OFF

+ When cooling fan operates.

+ When charge air cooler fan is stopped.

OFF

+ When charge air cooler fan operates.

COOLING FAN

I/C FAN RLY

EGRC SOL/V A

EGRC SOL/V B

THROT RLY

+
+
+
+

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

Idle

Revving engine from idle to 3,750 rpm

OFF

+
+
+
+

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

Idle

Revving engine from idle to 2,600 rpm

OFF

+
+
+
+

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

Idle

Revving engine from idle to 2,500 rpm

OFF

EC-52

TROUBLE DIAGNOSIS — General Description
Major Sensor Reference Graph in Data Monitor
Mode
The following are the major sensor reference graphs in ‘‘DATA MONITOR’’ mode.
(Select ‘‘HI SPEED’’ in ‘‘DATA MONITOR’’ with CONSULT.)

ACCEL POS SEN, C/SLEEV POS/S, ACT INJ TIMG
Below is the data for ‘‘ACCEL POS SEN’’, ‘‘C/SLEEV POS/S’’ and ‘‘ACT INJ TIMG’’ when revving engine
quickly up to 3,000 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.

SEF663S

EC-53

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value
PREPARATION
1. ECM is located behind the instrument lower panel. For this
inspection, remove the driver’s side instrument lower cover.

SEF519V

2. Remove ECM harness protector.

AEC913

3. Perform all voltage measurements with the connector connected. Extend tester probe as shown to perform tests easily.
+ Open harness securing clip to make testing easier.
+ Use extreme care not to touch 2 pins at one time.
+ Data is for comparison and may not be exact.

SEF367I

Be sure ECM unit is properly grounded before checking.

SEF665S

EC-54

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value (Cont’d)
ECM HARNESS CONNECTOR TERMINAL LAYOUT

SEF064P

ECM INSPECTION TABLE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Engine is running. (Warm-up condition)
Approximately 0.4V
1

Throttle control solenoid
valve

Idle speed
Engine is running. (Warm-up condition)
Revving engine from idle to 2,500 rpm

BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘ON’’
Ignition switch ‘‘OFF’’
4

B/Y

ECCS relay (Self-shutoff)

0 — 1.5V

For a few seconds after turning ignition switch
‘‘OFF’’
Ignition switch ‘‘OFF’’
A few seconds passed after turning ignition
switch ‘‘OFF’’

BATTERY VOLTAGE
(11 — 14V)
Approximately 1.0 — 2.0V

Engine is running. (Warm-up condition)
Idle speed

SEF715V

Y/B

Tachometer
Approximately 1.0 — 2.0V

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF716V

EC-55

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Engine is running.
8

G/OR

Charge air cooler fan
relay

Charge air cooler fan is not operating.

DATA
(DC Voltage and Pulse
Signal)
BATTERY VOLTAGE
(11 — 14V)

Engine is running.
0 — 1V
Charge air cooler fan is operating.

Fuel temperature sensor

Engine is running.

Engine is running.
Cooling fan is not operating.
14

Approximately 0 — 4.8V
Output voltage varies with
fuel temperature.
BATTERY VOLTAGE
(11 — 14V)

Cooling fan relay
Engine is running.
0 — 1V
Cooling fan is operating.
Engine is running.
Air conditioner switch is ‘‘OFF’’.

Y/L

Air conditioner relay

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Both air conditioner switch and blower fan
switch are ‘‘ON’’.
(Compressor is operating.)

0 — 1V

Ignition switch ‘‘ON’’
0 — 1.5V
Glow lamp is ‘‘ON’’.
16

L/W

Glow lamp
Ignition switch ‘‘ON’’
Glow lamp is ‘‘OFF’’.

Malfunction indicator lamp

Ignition switch ‘‘ON’’

0 — 1.5V

Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Idle speed

LG/R

R/W

Engine coolant temperature sensor

Engine is running.

Approximately 0 — 4.8V
Output voltage varies with
engine coolant temperature.

Ignition switch ‘‘ON’’

Approximately 0V

Ignition switch ‘‘START’’

BATTERY VOLTAGE
(11 — 14V)

Start signal

Engine is running.
Air conditioner switch is ‘‘OFF’’.
21

LG/B

Air conditioner switch

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Both air conditioner switch and blower fan
switch are ‘‘ON’’.
(Compressor is operating.)

EC-56

Approximately 0V

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse
Signal)

Ignition switch ‘‘ON’’

P/B

Inhibitor switch/
Neutral position switch

Gear position is ‘‘N’’ or ‘‘P’’ (A/T models).
Gear position is ‘‘Neutral’’ (M/T models).
Ignition switch ‘‘ON’’
Except the above gear position

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘ON’’
0.4 — 0.6V
23

Accelerator position sensor

Accelerator pedal fully released
Ignition switch ‘‘ON’’
Approximately 4.3V
Accelerator pedal fully depressed
Engine is running.

PU/W

A/T signal No. 1

6 — 8V
Idle speed
0 — BATTERY VOLTAGE
(11 — 14V)
Engine is running.

L/OR

Vehicle speed sensor

Lift up the vehicle.
In 1st gear position
Vehicle speed is 40 km/h.

SEF717V

28
33

Camshaft position sensor
(PUMP) ground

Engine is running. (Warm-up condition)
Approximately 0V
Idle speed
Ignition switch ‘‘ON’’
Accelerator pedal fully released

R/L

BATTERY VOLTAGE
(11 — 14V)

Accelerator switch (F/C)
Ignition switch ‘‘ON’’
Approximately 0V
Accelerator pedal depressed
Engine is running.

A/T signal No. 3

Approximately 0V
Idle speed
Ignition switch ‘‘ON’’

R/L

Accelerator position switch
(Idle)

Accelerator pedal fully released

BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘ON’’
Approximately 0V
Accelerator pedal depressed
Ignition switch ‘‘ON’’
Approximately 0V

W/G

Accelerator position switch
(Full)

Accelerator pedal released
Ignition switch ‘‘ON’’
Accelerator pedal fully depressed

EC-57

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse
Signal)
Approximately 0V

Engine is running. (Warm-up condition)
Idle speed

SEF718V

Needle lift sensor
Approximately 0V

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF719V

Engine is running. (Warm-up condition)
35

Mass air flow sensor

1.6 — 2.0V
Idle speed

Charge air temperature
sensor

P/B

A/T signal No. 2

Engine is running.

Approximately 0 — 4.8V
Output voltage varies with
charge air temperature.

Engine is running.
6 — 8V
Idle speed

39
43

B/Y

Ignition switch ‘‘OFF’’

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Ignition switch

Engine is running.
B

ECCS ground
Idle speed

EC-58

Engine ground
(Probe this terminal with
@ tester probe when
measuring.)

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse
Signal)
Approximately 0V

Engine is running. (Warm-up condition)
Idle speed

40
44

SEF720V

Crankshaft position sensor
(TDC)

Approximately 0V

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF721V

Approximately 0V

Engine is running. (Warm-up condition)
Idle speed

41
45

SEF722V

Camshaft position sensor
(PUMP)

Approximately 0V

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF723V

L/G

Y/G

Y/R

Engine is running.
Data link connector for
CONSULT

Idle speed (CONSULT is connected and
turned on)

Approximately 0V
Approximately 0 — 12V
Approximately 0 — 9V
Approximately 0 — 4.6V
(Voltage varies with part
number of adjustment
resistor.)

Adjustment resistor

Ignition switch ‘‘ON’’

47
52

Crankshaft position sensor
(TDC) ground

Engine is running. (Warm-up condition)

B/W

G/R

Accelerator position sensor power supply

Ignition switch ‘‘ON’’

Approximately 5V

G/R

Sensor’s power signal to
TCM

Ignition switch ‘‘ON’’

Approximately 5V

Approximately 0V
Idle speed

EC-59

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse
Signal)

Engine is running. (Warm-up condition)
50

Sensors’ ground

Approximately 0V
Idle speed

L/W

Accelerator position sensor ground

Engine is running. (Warm-up condition)
Approximately 0V
Idle speed
Approximately 2.6V

53
57

Control sleeve position
sensor power supply

Engine is running.
Idle speed

SEF724V

56
61

Power supply for ECM

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘ON’’
0V
Heat up switch is ‘‘OFF’’.
59

BR/W

Heat up switch
Ignition switch ‘‘ON’’
Heat up switch is ‘‘ON’’.

BATTERY VOLTAGE
(11 — 14V)
Approximately 2.6V

62
66

Control sleeve position
sensor ground

Engine is running.
Idle speed

SEF725V

Approximately 2.6V

63
67

Control sleeve position
sensor

Engine is running.
Idle speed

SEF726V

Ignition switch ‘‘ON’’
0.4 — 0.6V
68

B/W

Accelerator position sensor signal to TCM

Accelerator pedal fully released
Ignition switch ‘‘ON’’
Approximately 4.3V
Accelerator pedal fully depressed

Power supply (Back-up)

101
107

R/B

Electric governor

Ignition switch ‘‘OFF’’
Engine is running.
Idle speed

EC-60

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse
Signal)
Approximately 10V

Engine is running.
Idle speed

102
108

SEF727V

G/Y

Electric governor ground
Approximately 10V

Engine is running.
Engine speed is 2,000 rpm.

SEF728V

Engine is running. (Warm-up condition)
0 — 1V
Idle speed
103

L/Y

EGRC-solenoid valve A
Engine is running. (Warm-up condition)
Engine is revving from idle up to 3,750 rpm.

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

Engine is running. (Warm-up condition)
Idle speed

104
110

L/W

SEF729V

Injection timing control
valve

BATTERY VOLTAGE
(11 — 14V)

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF730V

106
112
118

Engine is running.
B

ECCS ground

Approximately 0V
Idle speed
Engine is running. (Warm-up condition)
0 — 1V
Idle speed

109

BR/Y

EGRC-solenoid valve B
Engine is running. (Warm-up condition)
Engine is revving from idle up to 2,600 rpm.

EC-61

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS — General Description
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.
111

WIRE
COLOR
LG/B

113
115

R/W

116
117

ITEM

Glow relay

CONDITION

Refer to ‘‘Glow Control System’’, EC-151.
Ignition switch ‘‘OFF’’

Approximately 0V

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Fuel cut solenoid valve

Power supply for ECM

DATA
(DC Voltage and Pulse
Signal)

EC-62

TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Ignition switch ‘‘ON’’
Ignition switch ‘‘OFF’’
4

B/Y

ECCS relay (Self-shutoff)

0 — 1.5V

For a few seconds after turning ignition switch
‘‘OFF’’
Ignition switch ‘‘OFF’’
A few seconds passed after turning ignition
switch ‘‘OFF’’

B/Y

BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘OFF’’

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Ignition switch

Engine is running.

Engine ground
(Probe this terminal with
@ tester probe when
measuring.)

39
43

56
61

Power supply for ECM

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Power supply (Back-up)

Ignition switch ‘‘OFF’’

BATTERY VOLTAGE
(11 — 14V)

106
112
118

ECCS ground

116
117

ECCS ground
Idle speed

Engine is running.
Approximately 0V
Idle speed
Power supply for ECM

Ignition switch ‘‘ON’’

EC-63

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)

TEC421

EC-64

TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)

TEC422

EC-65

TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
INSPECTION START

Start engine.
Is engine running?

Yes

SEF065P

CHECK POWER SUPPLY-I.
1. Turn ignition switch
‘‘ON’’.
2. Check voltage between
ECM terminal V
38 and
ground with CONSULT
or tester.
Voltage: Battery voltage
If NG, check the following.
+ Harness connectors
M51 , F6
+ 10A fuse
+ Harness for open or
short between ECM and
fuse
If NG, repair harness or
connectors.
.

Go to
‘‘CHECK
GROUND CIRCUIT’’ on
EC-68.

SEF056R

CHECK POWER SUPPLY-II.
1. Stop engine.
2. Check voltage between ECM terminal
70 and ground with CONSULT or
V
tester.
Voltage: Battery voltage

NG
c

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M52 , F7
+ 7.5A fuse
+ Harness for open or
short between ECM and
battery
If NG, repair harness or
connectors.

‘‘CHECK
Go to
GROUND CIRCUIT’’ on
EC-68.

SEF566S

CHECK POWER SUPPLY-III.
1. Turn ignition switch ‘‘ON’’ and then
‘‘OFF’’.
2. Check voltage between ECM terminals
56 , V
61 , 116 , 117 and ground with
V
CONSULT or tester.
Voltage:
After turning ignition switch ‘‘OFF’’,
battery voltage will exist for a few
seconds, then drop to approximately
0V.

Case-1: Battery voltage does
not exist.
Case-2: Battery voltage exists
for more than a few
seconds.

NG
SEF567S

Case-2
Case-1
.

j
A

EC-66

‘‘CHECK ECCS
Go to
RELAY’’ on next page.

TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
j
A

SEF513V

CHECK HARNESS CONTINUITY
BETWEEN ECCS RELAY AND ECM.
1. Disconnect ECM harness connector.
2. Disconnect ECCS relay.
3. Check harness continuity between ECM
terminals V
56 , V
61 and relay terminal
7
,
and
ECM
terminals
116 , 117
V
and relay terminal V
5 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Harness connectors
M52 , F7
+ Harness connectors
M50 , F5
+ Harness for open or
short between ECM and
ECCS relay
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

SEF569S

CHECK VOLTAGE BETWEEN ECCS
RELAY AND GROUND.
Check voltage between relay terminals
1 , V
3 , V
6 and ground with CONSULT
V
or tester.
Voltage: Battery voltage

NG
c

Check the following.
+ Harness connectors
E127 , M21
+ 15A fuse
+ Harness for open or
short between ECCS
relay and battery
If NG, repair harness or
connectors.

SEF030S

CHECK OUTPUT SIGNAL CIRCUIT.
Check harness continuity between ECM
terminal V
4 and relay terminal V
2 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

Check the following.
+ Harness connectors
M52 , F7
+ Harness for open or
short between ECM and
ECCS relay
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

SEC202B

CHECK ECCS RELAY.
1. Apply 12V direct current between relay
terminals V
1 and V
2 .
2. Check continuity between relay terminals V
3 and V
5 , V
7 and V
6 .
12V (V
1 — V
2 ) applied:
Continuity exists.
No voltage applied:
No continuity
.

j
B

EC-67

NG
c

Replace ECCS relay.

TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
j
B

SEF570S

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM
terminals V
39 , V
43 , 106 , 112 , 118
and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector.
.

INSPECTION END

EC-68

NG
c

Check the following.
+ Joint connector F18
+ Harness for open or
short between ECM and
ground
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

TROUBLE DIAGNOSIS FOR ‘‘CAM POS SEN (PUMP)’’ (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)

SEF674V

The camshaft position sensor (PUMP) is located on the electronic
fuel injection pump.
The sensor consists of a permanent magnet, core and coil.
When engine is running, gap between sensor and drive shaft rotating plate will periodically change. Permeability near the sensor also
changes.
Due to the permeability change, the magnetic flux near the core is
changed. Therefore, the voltage signal generated in the coil is
changed.
The ECM receives the voltage signal (6 pulses/2 engine revolutions).
These signals are used for tachometer indication.

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
CKPSzRPM (REF)
CKPSzRPM-PUMP

CONDITION

SPECIFICATION

+ Tachometer: Connect
+ Run engine and compare tachometer indication with the CONSULT
value.

Almost the same speed as the
CONSULT value.

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.
28
33

WIRE
COLOR

ITEM

Camshaft position sensor
(PUMP) ground

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Engine is running. (Warm-up condition)
Approximately 0V
Idle speed
Approximately 0V

Engine is running. (Warm-up condition)
Idle speed

41
45

SEF722V

Camshaft position sensor
(PUMP)

Approximately 0V

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF723V

EC-69

TROUBLE DIAGNOSIS FOR ‘‘CAM POS SEN (PUMP)’’ (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
(Cont’d)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
11

Malfunction is detected when ….
+ An improper signal from the sensor is detected by
ECM during engine running.

Check Items
(Possible cause)
+ Harness or connectors
[The camshaft position sensor (PUMP) circuit is open
or shorted.]
+ Camshaft position sensor (PUMP)

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1)

SEF714V

Turn ignition switch ‘‘ON’’ and select ‘‘DATA MONITOR’’
mode with CONSULT.
2) Start engine and run it for at least 2 seconds at idle
speed.
(If engine does not run, turn ignition switch to ‘‘START’’
for at least 2 seconds.)
—————————————————————————————————————————- OR —————————————————————————————————————————1) Start engine and run it for at least 2 seconds at idle
speed.
(If engine does not run, turn ignition switch to ‘‘START’’
for at least 2 seconds.)
2) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then ‘‘ON’’.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-70

TROUBLE DIAGNOSIS FOR ‘‘CAM POS SEN (PUMP)’’ (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
(Cont’d)

TEC423

EC-71

TROUBLE DIAGNOSIS FOR ‘‘CAM POS SEN (PUMP)’’ (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
(Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF675V

CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect electronic fuel injection
pump harness connector and ECM harness connector.
3. Check harness continuity between terminal V
1 and ECM terminals V
41 , V
45 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
.

SEF731V

CHECK GROUND CIRCUIT-I.
1. Turn ignition switch ‘‘OFF’’.
2. Check harness continuity between terminal V
2 and ECM terminals V
28 , V
33 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
.

SEF732V

CHECK GROUND CIRCUIT-II.
1. Loosen and retighten engine ground
screws.
2. Check harness continuity between terminal V
3 and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Joint connector F19
+ Harness for open or
short between electronic
fuel injection pump and
engine ground
If NG, repair harness or
connectors.

OK
.

CHECK COMPONENT
[Camshaft position sensor (PUMP)].
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.
SEF676V

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage or
the connection of ECM harness connector.
Reconnect ECM harness connector and
retest.
.

INSPECTION END

SEF733V

EC-72

NG
c

Replace camshaft position
sensor (PUMP).

TROUBLE DIAGNOSIS FOR ‘‘CAM POS SEN (PUMP)’’ (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
(Cont’d)
COMPONENT INSPECTION
Camshaft position sensor (PUMP)
1.
2.
3.
4.

Disconnect electronic fuel injection pump harness connector.
Loosen the camshaft position sensor (PUMP).
Remove the sensor.
Visually check the sensor for chipping.

SEF573S

5. Check resistance between terminals V
1 and V
2 .
Resistance:
Approximately 1,360 — 1,840Ω [at 25°C (77°F)]
If NG, replace camshaft position sensor (PUMP).

SEF677V

EC-73

TROUBLE DIAGNOSIS FOR ‘‘MASS AIR FLOW SEN’’ (DTC 12)
Mass Air Flow Sensor (MAFS)
COMPONENT DESCRIPTION

SEF734V

The mass air flow sensor is placed in the stream of intake air. It
measures the intake air flow rate by measuring a part of the entire
intake air flow. It consists of a hot wire that is supplied with electric
current from the ECM. The temperature of the hot wire is controlled
by the ECM a certain amount. The heat generated by the hot wire
is reduced as the intake air flows around it. The more air, the
greater the heat loss.
Therefore, the ECM must supply more electric current to the hot
wire as air flow increases. This maintains the temperature of the hot
wire. The ECM detects the air flow by means of this current change.

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION
+
+
+
+

MAS AIR/FL SE

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

SPECIFICATION

Idle

1.6 — 2.0V

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values, and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

43
V

DATA
(DC voltage)

CONDITION
Engine is running. (Warm-up condition)

Mass air flow sensor

1.6 — 2.0V
Idle speed
Engine is running. (Warm-up condition)

Sensors’ ground

Approximately 0V
Idle speed

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble
Code No.
12

Check Items
(Possible Cause)

Malfunction is detected when …
+ An excessively high or low voltage from the sensor is
sent to ECM.

EC-74

(ECCS

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Mass air flow sensor

TROUBLE DIAGNOSIS FOR ‘‘MASS AIR FLOW SEN’’ (DTC 12)
Mass Air Flow Sensor (MAFS) (Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF735V

1) Turn ignition switch ‘‘ON’’, and wait at least 6 seconds.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT.
3) Start engine and wait at least 3 seconds.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Turn ignition switch ‘‘ON’’, and wait at least 6 seconds.
2) Start engine and wait at least 3 seconds.
3) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
4) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-75

TROUBLE DIAGNOSIS FOR ‘‘MASS AIR FLOW SEN’’ (DTC 12)
Mass Air Flow Sensor (MAFS) (Cont’d)

TEC424

EC-76

TROUBLE DIAGNOSIS FOR ‘‘MASS AIR FLOW SEN’’ (DTC 12)
Mass Air Flow Sensor (MAFS) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF713V

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect mass air flow sensor harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminal V
1
and ground with CONSULT or tester.
Voltage: Battery voltage

NG
c

SEF736V

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Loosen and retighten engine ground
screws.
3. Check harness continuity between terminal V
2 and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

SEF676V

CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between terminal V
3 and ECM terminal V
35 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Harness connectors
M52 , F7
+ Harness for open or
short between mass air
flow sensor and ECM
+ Harness for open or
short between mass air
flow sensor and ECCS
relay
If NG, repair harness or
connector.

Check the following.
+ Harness connectors
E106 , M88
+ Harness connectors
M51 , F6
+ Harness for open or
short between mass air
flow sensor and ECM
+ Harness for open or
short between mass air
flow sensor and TCM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
.

CHECK COMPONENT
(Mass air flow sensor).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
.
SEF737V

Disconnect and reconnect harness connectors in the circuits. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.
.

INSPECTION END

SEF738V

EC-77

NG
c

Replace mass air flow sensor.

TROUBLE DIAGNOSIS FOR ‘‘MASS AIR FLOW SEN’’ (DTC 12)
Mass Air Flow Sensor (MAFS) (Cont’d)
COMPONENT INSPECTION
Mass air flow sensor
1. Start engine and warm it up to normal operating temperature.
2. Check voltage between ECM terminal V
35 and ground under the
following condition.
Conditions

SEF739V

Voltage V

Ignition switch ‘‘ON’’ (Engine stopped.)

Less than 1.0

Idle (Engine is warmed-up sufficiently.)

1.0 — 1.7

2,500 rpm
Idle to about 4,000 rpm*

Approximately 2.1
1.0 — 1.7 to Approx. 4.0

*: Check for linear voltage rise in response to increase to about 4,000 rpm in engine
speed.

3. If NG, remove mass air flow sensor from air duct. Check hot
wire for damage and dust.

SEF740V

EC-78

TROUBLE DIAGNOSIS FOR ‘‘COOLANT TEMP SEN’’ (DTC 13)
Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor is used to detect the engine
coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the
thermistor decreases as temperature increases.

SEF594K

SEF012P

Diagnostic
Trouble Code
No.
13

Engine coolant temperature
°C (°F)

Voltage*
(V)

Resistance
(kΩ)

−10 (14)

4.4

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.3

0.68 — 1.00

90 (194)

1.0

0.236 — 0.260

*: These data are reference values and measured between ECM terminal V
19
(Engine coolant temperature sensor) and ECM terminal V
43 (ECCS ground).

Check Items
(Possible Cause)

Malfunction is detected when …
+ An excessively high or low voltage from the sensor is
entered to ECM.

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Engine coolant temperature sensor

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF741V

1) Turn ignition switch ‘‘ON’’.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT.
3) Wait at least 5 seconds.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Turn ignition switch ‘‘ON’’ and wait at least 5 seconds.
2) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-79

TROUBLE DIAGNOSIS FOR ‘‘COOLANT TEMP SEN’’ (DTC 13)
Engine Coolant Temperature (ECT) Sensor
(Cont’d)

TEC425

EC-80

TROUBLE DIAGNOSIS FOR ‘‘COOLANT TEMP SEN’’ (DTC 13)
Engine Coolant Temperature (ECT) Sensor
(Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF678V

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect engine coolant temperature
sensor harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminal V
2
and ground with CONSULT or tester.
Voltage:
Approximately 5V

NG
c

SEF541P

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Check harness continuity between terminal V
1 and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

SEF542P

CHECK COMPONENT
(Engine coolant temperature sensor).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.

INSPECTION END

EC-81

NG
c

Check the following.
+ Harness connectors
E202 , E69
+ Harness connectors
E127 , M21
+ Harness connectors
M51 , F6
+ Harness for open or
short between ECM and
engine coolant temperature sensor
If NG, repair harness or
connectors.

Check the following.
+ Harness connectors
E202 , E69
+ Harness connectors
E127 , M21
+ Harness connectors
M50 , F5
+ Harness connectors
F6 , M51
+ Harness connectors
M88 , E106
+ Harness for open or
short between ECM and
engine coolant temperature sensor
+ Harness for open or
short between TCM and
engine coolant temperature sensor
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Replace engine coolant
temperature sensor.

TROUBLE DIAGNOSIS FOR ‘‘COOLANT TEMP SEN’’ (DTC 13)
Engine Coolant Temperature (ECT) Sensor
(Cont’d)
COMPONENT INSPECTION
Engine coolant temperature sensor
Check resistance as shown in the figure.

SEF152P

Temperature °C (°F)

Resistance kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.0

90 (194)

0.236 — 0.260

If NG, replace engine coolant temperature sensor.

SEF012P

EC-82

TROUBLE DIAGNOSIS FOR ‘‘VEHICLE SPEED SEN’’ (DTC 14)
Vehicle Speed Sensor (VSS)
The vehicle speed sensor is installed in the transaxle. It contains a
pulse generator which provides a vehicle speed signal to the
speedometer. The speedometer then sends a signal to the ECM.

AEC110

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
0 — BATTERY VOLTAGE
(11 — 14V)

Engine is running.
26

L/OR

Vehicle speed sensor

Lift up the vehicle.
In 1st gear position
Vehicle speed is 40 km/h (25 MPH).

SEF717V

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
14

Malfunction is detected when ….

Check Items
(Possible Cause)

+ The almost 0 km/h (0 MPH) signal from vehicle speed + Harness or connector
(The vehicle speed sensor circuit is open or shorted.)
sensor is sent to ECM even when vehicle is being
+ Vehicle speed sensor
driven.

EC-83

TROUBLE DIAGNOSIS FOR ‘‘VEHICLE SPEED SEN’’ (DTC 14)
Vehicle Speed Sensor (VSS) (Cont’d)
OVERALL FUNCTION CHECK

SEF941N

Use this procedure to check the overall function of the vehicle
speed sensor circuit. During this check, a DTC might not be confirmed.
1) Jack up drive wheels.
2) Start engine.
3) Read vehicle speed sensor signal in ‘‘DATA MONITOR’’
mode with CONSULT.
The vehicle speed on CONSULT should be able to
exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Jack up drive wheels.
2) Start engine.
3) Rotate drive wheel by hand.
4) Check voltage between ECM terminal V
26 and ground
with tester.
Voltage should vary between 0V — battery voltage.

SEF811R

EC-84

TROUBLE DIAGNOSIS FOR ‘‘VEHICLE SPEED SEN’’ (DTC 14)
Vehicle Speed Sensor (VSS) (Cont’d)

TEC426

EC-85

TROUBLE DIAGNOSIS FOR ‘‘VEHICLE SPEED SEN’’ (DTC 14)
Vehicle Speed Sensor (VSS) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF742V

CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector
and combination meter harness connector.
3. Check harness continuity between ECM
terminal V
26 and meter terminal V
26 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Harness connectors
M52 , F7
+ Joint connector M79
+ Harness for open or
short between ECM and
combination meter
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK SPEEDOMETER FUNCTION.
Make sure that speedometer functions
properly.
OK

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.

INSPECTION END

EC-86

NG
c

Check the following.
+ Harness connectors
M86 , E104 (LHD models)
+ Harness connectors
M21 , E127 (RHD models)
+ Harness connectors
E70 , E201
+ Harness for open or
short between combination meter and vehicle
speed sensor
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.
Check vehicle speed sensor and its circuit.
Refer to EL section.

TROUBLE DIAGNOSIS FOR ‘‘CONT SLEEV POS SEN’’ (DTC 15)
Control Sleeve Position Sensor (CSPS)
The control sleeve position sensor is installed on the electric governor. It senses the position of control sleeve (rotor angle) while the
control sleeve is being driven by the electric governor, and feeds it
back to the ECM.

SEF743V

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
C/SLEEV POS/S

CONDITION

SPECIFICATION

+ Engine: After warming up

1.0 — 3.5V

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
Approximately 2.6V

53
57

Control sleeve position
sensor power supply

Engine is running.
Idle speed

SEF724V

Approximately 2.6V

62
66

Control sleeve position
sensor ground

Engine is running.
Idle speed

SEF725V

Approximately 2.6V

63
67

Control sleeve position
sensor

Engine is running.
Idle speed

SEF726V

EC-87

TROUBLE DIAGNOSIS FOR ‘‘CONT SLEEV POS SEN’’ (DTC 15)
Control Sleeve Position Sensor (CSPS) (Cont’d)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
15

Malfunction is detected when ….

Check Items
(Possible cause)

+ An excessively high or low voltage from the sensor is + Harness or connectors
(The control sleeve position sensor circuit is open or
detected by ECM.
shorted.)
……………………………………………………………………………….
+ Control sleeve position sensor
+ An improper voltage signal from the sensor is
detected by ECM during engine running.

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1)

SEF714V

Turn ignition switch ‘‘ON’’ and select ‘‘DATA MONITOR’’
mode with CONSULT.
2) Start engine and run it for at least 2 seconds at idle
speed.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Start engine and run it for at least 2 seconds at idle
speed.
2) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then ‘‘ON’’.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-88

TROUBLE DIAGNOSIS FOR ‘‘CONT SLEEV POS SEN’’ (DTC 15)
Control Sleeve Position Sensor (CSPS) (Cont’d)

TEC427

EC-89

TROUBLE DIAGNOSIS FOR ‘‘CONT SLEEV POS SEN’’ (DTC 15)
Control Sleeve Position Sensor (CSPS) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF679V

CHECK POWER SUPPLY CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector
and electronic fuel injection pump harness connector.
3. Check harness continuity between terminal V
2 and ECM terminals V
53 , V
57 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
.

SEF744V

CHECK INPUT SIGNAL CIRCUIT.
Check harness continuity between sensor
terminal V
3 and ECM terminals V
63 , V
67 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
.

CHECK GROUND CIRCUIT-I.
Check harness continuity between sensor
terminal V
6 and ECM terminals V
62 , V
66 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

SEF745V
.

CHECK GROUND CIRCUIT-II.
1. Loosen and retighten engine ground
screws.
2. Check harness continuity between terminal V
4 and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
SEF746V

j
A

SEF676V

EC-90

NG
c

Check the following.
+ Joint connector F19
+ Harness for open or
short between control
sleeve position sensor
and engine ground
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

TROUBLE DIAGNOSIS FOR ‘‘CONT SLEEV POS SEN’’ (DTC 15)
Control Sleeve Position Sensor (CSPS) (Cont’d)
j
A
.

CHECK COMPONENT
(Control sleeve position sensor).
Refer to ‘‘COMPONENT INSPECTION’’
below.

NG
c

Take proper action.

OK
.
SEF747V

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END

COMPONENT INSPECTION
Control sleeve position sensor
1. Disconnect electronic fuel injection pump harness connector.
2. Check continuity between terminals V
2 and V
3 , V
2 and V
6 .
Resistance: Approximately 5.9Ω [at 23°C (73°F)]
If NG, take proper action.

SEF680V

EC-91

TROUBLE DIAGNOSIS FOR ‘‘ADJUST RESISTOR’’ (DTC 17)
Adjustment Resistor
The adjustment resistor is used to achieve uniform pump characteristics.

SEF681V

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

Adjustment resistor

Sensors’ ground

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
Approximately 0 — 4.6V
(Voltage varies with part
number of adjustment
resistor.)

Ignition switch ‘‘ON’’

Engine is running. (Warm-up condition)
Approximately 0V
Idle speed

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
17

Check Items
(Possible Cause)

Malfunction is detected when …
+ An excessively high or low voltage from the resistor is
detected by ECM.

+ Harness or connectors
(The adjustment resistor circuit is open or shorted.)
+ Adjustment resistor

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF748V

EC-92

TROUBLE DIAGNOSIS FOR ‘‘ADJUST RESISTOR’’ (DTC 17)
Adjustment Resistor (Cont’d)

TEC428

EC-93

TROUBLE DIAGNOSIS FOR ‘‘ADJUST RESISTOR’’ (DTC 17)
Adjustment Resistor (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF682V

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect electronic fuel injection
pump harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminal V
2
and ground.
Voltage:
Approximately 5V

NG
c

Repair harness or connectors.

OK
.

SEF749V

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Check harness continuity between terminal V
6 and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Harness connectors
F6 , M51
+ Harness connectors
M88 , E106
+ Harness for open or
short between ECM and
adjustment resistor
+ Harness for open or
short between TCM and
adjustment resistor
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

.
SEF750V

CHECK COMPONENT
(Adjustment resistor).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector.
Reconnect ECM harness connector and
retest.
.

INSPECTION END

EC-94

NG
c

Replace adjustment resistor.

TROUBLE DIAGNOSIS FOR ‘‘ADJUST RESISTOR’’ (DTC 17)
Adjustment Resistor (Cont’d)
COMPONENT INSPECTION
Adjustment resistor
Check resistance between terminals V
2 and V
6 .
Resistance: Approximately 0.2 — 15.0 kΩ [at 25°C
(77°F)]
Resistance value varies with adjustment sensor numbers.
If NG, replace adjustment resistor.
Always replace adjustment resistor with a new one which has same
number on label.
SEF683V

EC-95

TROUBLE DIAGNOSIS FOR ‘‘F/INJ F/B 2’’ (DTC 18),
‘‘F/INJ F/B’’ (DTC 22), ‘‘ELECTRIC GOV’’ (DTC 25)
Electric Governor
The electric governor is built into the electronic fuel injection pump.
It moves the control sleeve to increase or decrease the amount of
fuel injected.
When current flows through the coil, a magnetic force is produced,
rotating the rotor. The rotor shaft is installed to the control sleeve
via a ball pin which is eccentrically situated in relation to the rotor
shaft. With this arrangement, the control sleeve can be moved in
relation to rotor rotation.
The rotor’s rotating angle is determined by a balanced condition of
magnetic force (generated by current flow regulated by means of
the ECM) and tension of return spring (installed to rotor). The larger
the current flow through the coil, the greater the rotor’s rotating
angle. This means that the control sleeve moves to the right,
increasing the amount of fuel injected.
The ECM regulates the current flow through the coil by changing
the duty ratio which controls the ON-OFF operation of the electric
governor grounding circuit.

SEF632S

SEF633S

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Ignition switch ‘‘ON’’
Ignition switch ‘‘OFF’’
4

B/Y

ECCS relay (Self-shutoff)

0 — 1.5V

For a few seconds after turning ignition switch
‘‘OFF’’
Ignition switch ‘‘OFF’’
A few seconds passed after turning ignition
switch ‘‘OFF’’

101
107

Engine is running.
R/B

Electric governor
Idle speed

EC-96

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS FOR ‘‘F/INJ F/B 2’’ (DTC 18),
‘‘F/INJ F/B’’ (DTC 22), ‘‘ELECTRIC GOV’’ (DTC 25)
Electric Governor (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse
Signal)
Approximately 10V

Engine is running.
Idle speed

102
108

SEF727V

G/Y

Electric governor ground
Approximately 10V

Engine is running.
Engine speed is 2,000 rpm.

SEF728V

116
117

Power supply for ECM

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
18, 22, 25

Malfunction is detected when ….

Check Items
(Possible cause)

+ Fuel injection feedback system does not operate prop- + Main power supply circuit (ECM terminals 116 , 117 )
erly. (This system consists essentially of ECM, electric
and fuse
governor and control sleeve position sensor.)
+ Harness or connectors
(Electric governor and control sleeve position sensor
circuit)
+ Electric governor
+ Electronic fuel injection pump
+ ECM

EC-97

TROUBLE DIAGNOSIS FOR ‘‘F/INJ F/B 2’’ (DTC 18),
‘‘F/INJ F/B’’ (DTC 22), ‘‘ELECTRIC GOV’’ (DTC 25)
Electric Governor (Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF751V

Note: If DTC 18, 22, 25 and DTC 15 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 15. (See EC-87.)
1) Turn ignition switch ‘‘ON’’ and select ‘‘DATA MONITOR’’
mode with CONSULT.
2) Start engine and warm it up to normal operating temperature.
3) Run engine for 2 seconds at 3,000 rpm. Return engine
speed to idle, then increase to 3,000 rpm under no load.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Start engine and warm it up to normal operating temperature.
2) Run engine for 2 seconds at 3,000 rpm. Return engine
speed to idle, then increase to 3,000 rpm under no load.
3) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
4) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.
Note: If a malfunction occurs intermittently, conduct suitable
driving pattern for 10 minutes. This makes it possible to
determine DTC.

EC-98

TROUBLE DIAGNOSIS FOR ‘‘F/INJ F/B 2’’ (DTC 18),
‘‘F/INJ F/B’’ (DTC 22), ‘‘ELECTRIC GOV’’ (DTC 25)
Electric Governor (Cont’d)

TEC429

EC-99

TROUBLE DIAGNOSIS FOR ‘‘F/INJ F/B 2’’ (DTC 18),
‘‘F/INJ F/B’’ (DTC 22), ‘‘ELECTRIC GOV’’ (DTC 25)
Electric Governor (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.

CHECK POWER SUPPLY.
Refer to EC-63.

.
SEF679VA

CHECK POWER SUPPLY CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector
and electronic fuel injection pump harness connector.
3. Check harness continuity between terminal V
1 and ECM terminals 101 ,
107 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
.
SEF752V

CHECK GROUND CIRCUIT.
Check harness continuity between terminal V
5 and ECM terminals 102 , 108 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
.

CHECK COMPONENT
(Electric governor).
Refer to ‘‘COMPONENT INSPECTION’’
below.
SEF753V

NG
c

Take proper action.

OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END

COMPONENT INSPECTION
Electric governor
1. Disconnect electronic fuel injection pump harness connector.
1 and V
5 .
2. Check continuity between terminals V
Resistance: Approximately 0.68Ω [at 23°C (73°F)]
If NG, take proper action.

SEF684V

EC-100

TROUBLE DIAGNOSIS FOR ‘‘F/INJ TIMG F/B’’ (DTC 21)
Injection Timing Control Valve

SEF638S

The injection timing control valve is built into the electronic fuel
injection pump. It controls the timer piston to change the fuel injection timing.
The timing control valve is a solenoid valve located in the line
between high-pressure chamber and low-pressure chamber. It
changes fuel pressure in the high-pressure chamber.
When current flows through the solenoid (the solenoid turns ON),
the timing control valve opens, advancing fuel injection timing.
When current does not flow through it, the timing control valve
closes, retarding injection timing.
The ECM emits an ON-OFF duty signal. The longer the OFFduration, the greater the advance angle. The longer the
ON-duration, the greater the retard angle. This means that changing the ON-OFF duty ratio makes it possible to achieve an optimal
advance angle and accurately control fuel injection timing.

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM

ACT INJ TIMG

INJ TIMG C/V

CONDITION
+
+
+
+

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

SPECIFICATION

Idle

−9.5 to −12.0°

2,000 rpm

−10.0 to −15.5°

+ Engine: After warming up, idle the engine.

Approx. 50%

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
BATTERY VOLTAGE
(11 — 14V)

Engine is running. (Warm-up condition)
Idle speed

104
110

L/W

SEF729V

Injection timing control
valve

BATTERY VOLTAGE
(11 — 14V)

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF730V

EC-101

TROUBLE DIAGNOSIS FOR ‘‘F/INJ TIMG F/B’’ (DTC 21)
Injection Timing Control Valve (Cont’d)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
21

Malfunction is detected when ….
+ Injection timing feedback system does not operate
properly. (This system consists essentially of ECM,
injection timing control valve and needle lift sensor.)

Check Items
(Possible cause)
+ Harness or connectors
[Injection timing control valve, needle lift sensor,
crankshaft position sensor (TDC) circuits]
+ Injection timing control valve
+ Needle lift sensor
+ Crankshaft position sensor (TDC)
+ Air in fuel line

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF751V

Note: If both DTC 21 and 34 or 47 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 34 or 47. (See EC-126
or EC-144.)
1) Turn ignition switch ‘‘ON’’ and select ‘‘DATA MONITOR’’
mode with CONSULT.
2) Start engine and warm it up to normal operating temperature.
3) Run engine for 2 seconds at 3,000 rpm. Return engine
speed to idle, then increase to 3,000 rpm under no load.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Start engine and warm it up to normal operating temperature.
2) Run engine for 2 seconds at 3,000 rpm. Return engine
speed to idle, then increase to 3,000 rpm under no load.
3) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
4) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.
Note: If a malfunction occurs intermittently, conduct suitable
driving pattern for 10 minutes. This makes it possible to
determine DTC.

EC-102

TROUBLE DIAGNOSIS FOR ‘‘F/INJ TIMG F/B’’ (DTC 21)
Injection Timing Control Valve (Cont’d)

TEC430

EC-103

TROUBLE DIAGNOSIS FOR ‘‘F/INJ TIMG F/B’’ (DTC 21)
Injection Timing Control Valve (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF670V

CHECK FOR AIR IN FUEL FILTER.
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform ‘‘DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCEDURE’’.

OK
c

INSPECTION END

NG
.

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect injection timing control valve
harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check harness continuity between terminal V
2 and ground with CONSULT or
tester.
Voltage: Battery voltage
SEF685V

CHECK OUTPUT SIGNAL CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector.
3. Check harness continuity between terminal V
1 and ECM terminals 104 ,
110 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

.
SEF755V

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END

EC-104

Check the following.
+ Electronic fuel injection
pump harness connector
F3

+ Harness for open or
short between injection
timing control valve and
ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK COMPONENT
(Injection timing control valve).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.

Check the following.
+ Harness connectors
M51 , F6
+ Electronic fuel injection
pump harness connector
+ 10A fuse
+ Harness for open or
short between injection
timing control valve and
fuse
If NG, repair harness or
connectors.

SEF754V

NG
c

Replace injection timing
control valve.

TROUBLE DIAGNOSIS FOR ‘‘F/INJ TIMG F/B’’ (DTC 21)
Injection Timing Control Valve (Cont’d)
COMPONENT INSPECTION
Injection timing control valve
1. Reconnect injection timing control valve harness connector.
2. Disconnect electronic fuel injection pump harness connector.
3. Check resistance between terminals V
3 and V
7 .
Resistance: Approximately 11Ω [at 20°C (68°F)]
If NG, replace injection timing control valve.

SEF686V

EC-105

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SW (F/C)’’ (DTC 23)
Accelerator Switch (F/C)
The accelerator switch is installed to the accelerator pedal assembly. The switch senses accelerator position and sends an ON-OFF
signal to the ECM. The ECM uses the signal to control the fuel cut
operation at deceleration for better fuel efficiency.

SEF687V

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
ACCEL SW (FC)

DECELER F/CUT

CONDITION
+ Ignition switch: ON
(Engine stopped)

+ Engine: After warming up

SPECIFICATION

Accelerator pedal: released

Accelerator pedal: slightly open

OPEN

Idle

OFF

When accelerator pedal is
released quickly with engine
speed at 3,000 rpm or more.

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Ignition switch ‘‘ON’’
Accelerator pedal fully released
29

R/L

43
V

DATA
(DC Voltage and Pulse
Signal)
BATTERY VOLTAGE
(11 — 14V)

Accelerator switch (F/C)
Ignition switch ‘‘ON’’
Approximately 0V
Accelerator pedal depressed

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
23

Malfunction is detected when ….
+ The OFF signal (short) is sent to the ECM for a certain period of time even when the accelerator pedal is
not being depressed.

EC-106

(ECCS

Check Items
(Possible cause)
+ Harness or connectors
(The switch circuit is shorted.)
+ Accelerator switch (F/C)

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SW (F/C)’’ (DTC 23)
Accelerator Switch (F/C) (Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1)

SEF756V

Turn ignition switch ‘‘ON’’ and select ‘‘DATA MONITOR’’
mode with CONSULT.
2) Depress and release accelerator pedal once for 15 seconds.
3) Repeat step 2 for 26 times.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Turn ignition switch ‘‘ON’’.
2) Depress and release accelerator pedal once for 15 seconds.
3) Repeat step 2 for 26 times.
4) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
5) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-107

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SW (F/C)’’ (DTC 23)
Accelerator Switch (F/C) (Cont’d)

TEC431

EC-108

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SW (F/C)’’ (DTC 23)
Accelerator Switch (F/C) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.

CHECK OVERALL FUNCTION.
1. Turn ignition switch ‘‘ON’’.
2. Check ‘‘ACCEL SW (F/C)’’ in
‘‘DATA MONITOR’’ mode with
CONSULT.
Accelerator pedal released:
OFF
Accelerator pedal depressed:
SEF688V
ON
——————————————————————- OR ——————————————————————1. Turn ignition switch ‘‘ON’’.
2. Check voltage between ECM
terminal V
29 and ground.
Voltage:
Accelerator pedal released
Battery voltage
Accelerator pedal depressed
Approximately 0V

OK
c

INSPECTION END

NG
.
SEF589S

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Loosen and retighten engine ground
screws.
3. Disconnect accelerator switch (F/C) harness connector.
4. Check harness continuity between terminal V
3 and engine ground.
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

OK
.
SEF590S

CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal V
29 and terminal V
1 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

CHECK COMPONENT
[Accelerator switch (F/C)].
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
SEF591S
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END
SEF592S

EC-109

NG
c

Check the following.
+ Harness connectors
M51 , F6 (RHD models)
+ Joint connector F18
+ Harness for open or
short between accelerator switch (F/C) and
engine ground
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Check the following.
+ Harness connectors
F6 , M51 (RHD models)
+ Harness for open or short
between ECM and accelerator switch (F/C)
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.
Replace accelerator pedal
assembly.

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SW (F/C)’’ (DTC 23)
Accelerator Switch (F/C) (Cont’d)
COMPONENT INSPECTION
Accelerator switch (F/C)
1. Disconnect accelerator switch (F/C) harness connector.
2. Check continuity between terminals V
1 and V
3 .
Conditions

Continuity

Accelerator pedal released

Accelerator pedal depressed

Yes

If NG, replace accelerator pedal assembly.
SEF689V

EC-110

TROUBLE DIAGNOSIS FOR ‘‘ECM 1’’ (DTC 27), ‘‘ECM 2’’ (DTC 31)
Engine Control Module (ECM)-ECCS-D Control
Module
The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the engine.

SEC220B

Diagnostic
Trouble Code
No.
27, 31

Malfunction is detected when ….
+ ECM calculation function is malfunctioning.

Check Item
(Possible Cause)
+ ECM
(ECCS-D control module)

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF748V

1) Turn ignition switch ‘‘ON’’.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT.
3) Wait at least 2 seconds.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Turn ignition switch ‘‘ON’’.
2) Wait at least 2 seconds.
3) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
4) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-111

TROUBLE DIAGNOSIS FOR ‘‘ECM 1’’ (DTC 27), ‘‘ECM 2’’ (DTC 31)
Engine Control Module (ECM)-ECCS-D Control
Module (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

1) Turn ignition switch ‘‘ON’’.
2) Select ‘‘SELF DIAG RESULTS’’
mode with CONSULT.
3) Touch ‘‘ERASE’’.
——————————————————————- OR ——————————————————————1) Turn ignition switch ‘‘ON’’.
2) Erase the Diagnostic Test Mode
II (Self-diagnostic results)
memory.

PERFORM SELF-DIAGNOSIS.
Select ‘‘SELF DIAG RESULTS’’
mode with CONSULT.
——————————————————————- OR ——————————————————————PERFORM ‘‘Diagnostic Test Mode
II’’ (SELF-DIAGNOSTIC
RESULTS).

Is the DTC 27, 31 displayed again?
No
.

INSPECTION END

EC-112

Yes
c

Replace ECM.

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat)
SYSTEM DESCRIPTION
Vehicle speed

Vehicle speed sensor

Engine coolant temperature sensor

Engine coolant temperature

ECM
(ECCS-D
control
c
module)

Cooling fan
relay

Air conditioner ‘‘ON’’ signal

Air conditioner switch

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air conditioner system pressure and air conditioner ON signal. The control system has 2-step control [ON/OFF].

Operation

SEF757V

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
AIR COND SIG

COOLING FAN

CONDITION
+ Engine: After warming up, idle
the engine

SPECIFICATION

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

+ When cooling fan is stopped.

OFF

+ When cooling fan operates.

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Engine is running.
Cooling fan is not operating.
14

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
0 — 1V

EC-113

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Cooling fan relay
Cooling fan is operating.

43
V

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat) (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

DATA
(DC Voltage and Pulse
Signal)

CONDITION

Engine is running.
Air conditioner switch is ‘‘OFF’’.
15

Y/L

Air conditioner relay

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Both air conditioner switch and blower fan
switch are ‘‘ON’’.
(Compressor is operating.)

0 — 1V

ON BOARD DIAGNOSIS LOGIC
This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Diagnostic Trouble
Code No.
28

Malfunction is detected when …
+ Cooling fan does not operate properly (Overheat).
+ Cooling fan system does not operate properly (Overheat).
+ Engine coolant was not added to the system using
the proper filling method.

Check Items
(Possible Cause)
+ Harness or connectors
(The cooling fan circuit is open or shorted.)
+ Cooling fan
+ Radiator hose
+ Radiator
+ Radiator cap
+ Water pump
+ Thermostat
+ Fan belt
+ Engine coolant temperature sensor
For more information, refer to ‘‘MAIN 12
CAUSES OF OVERHEATING’’, EC-120.

CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (‘‘Changing Engine Coolant’’, ‘‘ENGINE MAINTENANCE’’). Also, replace the engine oil.
a. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA section (‘‘Anti-freeze Coolant Mixture Ratio’’,
‘‘RECOMMENDED FLUIDS AND LUBRICANTS’’).
b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.

EC-114

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat) (Cont’d)
OVERALL FUNCTION CHECK

AEC640

SEF758V

Use this procedure to check the overall function of the cooling fan.
During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ‘‘DIAGNOSTIC PROCEDURE’’, EC-117.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ‘‘DIAGNOSTIC PROCEDURE’’, EC-117.
3) Turn ignition switch ‘‘ON’’.
4) Perform ‘‘COOLING FAN’’ in ‘‘ACTIVE TEST’’ mode with
CONSULT and make sure that cooling fan operates
when touching ‘‘ON’’.
—————————————————————————————————————————- OR —————————————————————————————————————————3) Disconnect engine coolant temperature sensor harness
connector.
4) Connect 150Ω resistor to engine coolant temperature
sensor harness connector.
5) Start engine and make sure that cooling fan operates.
Be careful not to overheat engine.

SEF979S

EC-115

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat) (Cont’d)

TEC432

EC-116

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

OK Go to
CHECK COOLING FAN OPERATION.
‘‘CHECK COOLc
1. Turn ignition switch ‘‘OFF’’.
ING SYSTEM FOR LEAK’’,
EC-119.
2. Turn ignition switch ‘‘ON’’.
3. Perform ‘‘COOLING FAN’’ in
‘‘ACTIVE TEST’’ mode with
CONSULT and make sure that
SEF758V
cooling fan operates when touching ‘‘ON’’.
——————————————————————- OR ——————————————————————2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Ω resistor to engine
coolant temperature sensor harness connector.
4. Start engine and make sure that
cooling fan operates.
SEF979S

NG
.

SEF690V

NG Check the following.
CHECK POWER SUPPLY.
c
+ 10A fuse
1. Turn ignition switch ‘‘OFF’’.
+ 30A fusible link
2. Disconnect cooling fan relay-1.
+ Harness for open or short
3. Turn ignition switch ‘‘ON’’.
between cooling fan
4. Check voltage between terminals V
2 ,
relay-1 and fuse
5 and ground with CONSULT or tester.
V
+ Harness for open or short
Voltage: Battery voltage
between cooling fan
OK
relay-1 and battery
If NG, repair harness or
connectors.
.

SEF759V

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect cooling fan motor harness
connector.
3. Check harness continuity between
relay terminal V
3 and motor terminals V
1 , V
3 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
4. Check harness continuity between
motor terminals V
2 , V
4 and body
ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.
.

j
A

SEF691V

EC-117

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat) (Cont’d)
j
A

SEF760V

CHECK OUTPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal V
14 and terminal V
1 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M52 , F7
+ Harness for open or short
between cooling fan
relay-1 and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK COMPONENT
(Cooling fan relay-1).
Refer to ‘‘COMPONENT INSPECTION’’,
EC-121.

Replace cooling fan relay.
c

OK
SEF761V

CHECK COMPONENT
(Cooling fan motor-1).
Refer to ‘‘COMPONENT INSPECTION’’,
EC-121.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.
SEF762V

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END

EC-118

Replace cooling fan motor.
c

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat) (Cont’d)
CHECK COOLING SYSTEM FOR LEAK.
Apply pressure to the cooling system with
a tester, and check if the pressure drops.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
Pressure should not drop.
CAUTION:
Higher than the specified pressure may
cause radiator damage.

NG
c

Check the following for
leak.
+ Hose
+ Radiator
+ Water pump
Refer to LC section (‘‘Water
Pump’’).

SLC754AA
.

CHECK RADIATOR CAP.
Apply pressure to cap with a tester.
Radiator cap relief pressure:
78 — 98 kPa (0.78 — 0.98 bar, 0.8 — 1.0
kg/cm2, 11 — 14 psi)

NG
c

Replace radiator cap.

OK
.

SLC755AB

CHECK THERMOSTAT.
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
2. Check valve opening temperature and
valve lift.
Valve opening temperature:
82°C (180°F) [standard]
Maximum valve lift:
More than 10 mm/95°C
(0.39 in/203°F)
3. Check if valve is closed at 5°C (9°F)
below valve opening temperature.
For details, refer to LC section (‘‘Thermostat’’).
.

SLC343

Replace thermostat.

Check engine coolant temperature sensor.
Refer to ‘‘COMPONENT INSPECTION’’,
EC-82.
.

NG
c

Replace engine coolant
temperature sensor.

If the cause cannot be isolated, go to
‘‘MAIN 12 CAUSES OF OVERHEATING’’
on next page.
.

INSPECTION END

Perform FINAL CHECK by the following procedure after repair
is completed.
1. Warm up engine. Run the vehicle for at least 20 minutes. Pay
attention to engine coolant temperature gauge on the instrument
panel. If the reading shows an abnormally high temperature,
another part may be malfunctioning.
2. Stop vehicle and let engine idle. Check the intake and exhaust
systems for leaks by listening for noise or visually inspecting the
components.
3. Allow engine to cool and visually check for oil and coolant leaks.
Then, perform ‘‘OVERALL FUNCTION CHECK’’.

EC-119

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat) (Cont’d)
MAIN 12 CAUSES OF OVERHEATING
Engine

Step

Inspection item

Equipment

Condition

OFF

+ Blocked radiator
+ Blocked radiator grille
+ Blocked bumper

+ Visual

No blocking

+ Coolant mixture

+ Coolant tester

50 — 50% coolant mixture

See ‘‘RECOMMENDED
FLUIDS AND LUBRICANTS’’ in MA section.

+ Coolant level

+ Visual

Coolant up to MAX level
in reservoir tank and
radiator filler neck

See ‘‘Changing Engine
Coolant’’, ‘‘ENGINE
MAINTENANCE’’ in MA
section.

+ Radiator cap

+ Pressure tester

78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0
kg/cm2, 11 — 14 psi)

See ‘‘System Check’’
‘‘ENGINE COOLING
SYSTEM’’ in LC section.

ON*2

+ Coolant leaks

+ Visual

No leaks

See ‘‘System Check’’
‘‘ENGINE COOLING
SYSTEM’’ in LC section.

ON*2

+ Thermostat

+ Touch the upper and
lower radiator hoses

Both hoses should be hot See ‘‘Thermostat’’ and
‘‘Radiator’’, ‘‘ENGINE
COOLING SYSTEM’’ in
LC section.

ON*1

+ Cooling fan

+ CONSULT

Operating

OFF

+ Combustion gas leak

+ Color checker chemical Negative
tester 4 Gas analyzer

—

ON*3

+ Coolant temperature
gauge

+ Visual

—

Gauge less than 3/4
when driving

Reference page
—

See ‘‘TROUBLE DIAGNOSIS FOR DTC 28’’,
EC-113.

+ Coolant overflow to res- + Visual
ervoir tank

No overflow during driving See ‘‘Changing Engine
and idling
Coolant’’, ‘‘ENGINE
MAINTENANCE’’ in MA
section.

OFF*4

+ Coolant return from res- + Visual
ervoir tank to radiator

Should be initial level in
reservoir tank

See ‘‘ENGINE MAINTENANCE’’ in MA section.

OFF

+ Cylinder head

+ Straight gauge feeler
gauge

0.1mm (0.004 in) Maximum distortion (warping)

See ‘‘Inspection’’, ‘‘CYLINDER HEAD’’ in EM
section.

+ Cylinder block and pistons

+ Visual

No scuffing on cylinder
walls or piston

See ‘‘Inspection’’, ‘‘CYLINDER BLOCK’’ in EM
section.

*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to ‘‘OVERHEATING CAUSE ANALYSIS’’ in LC section.

EC-120

TROUBLE DIAGNOSIS FOR ‘‘OVER HEAT’’ (DTC 28)
Cooling Fan (Overheat) (Cont’d)
COMPONENT INSPECTION
Cooling fan relay-1
Check continuity between terminals

3
V

and

Conditions

SEF511P

5 .
V

Continuity

12V direct current supply between
terminals V
1 and V
2

Yes

No current supply

If NG, replace relay.

Cooling fan motor-1
1. Disconnect cooling fan motor harness connector.
2. Supply cooling fan motor terminals with battery voltage and
check operation.
Terminals

Cooling fan motor
SEF763V

Cooling fan motor should operate.
If NG, replace cooling fan motor.

EC-121

(⊕)

(@)

1 , V
3
V

2 , V
4
V

TROUBLE DIAGNOSIS FOR ‘‘I/C INT/A TEMP SEN’’ (DTC 33)
Charge Air Temperature Sensor
The charge air temperature sensor is used to detect the charge air
temperature. The sensor modifies a voltage signal from the ECM.
The modified signal returns to the ECM as the charge air temperature input. The sensor uses a thermistor which is sensitive to the
change in temperature. The electrical resistance of the thermistor
decreases as temperature increases.
The ECM uses this signal for the charge air cooler control.

SEF594K

Charge air temperature
°C (°F)

Voltage
(V)

Resistance
(kΩ)

−10 (14)

4.4

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.3

0.68 — 1.00

90 (194)

1.0

0.236 — 0.260

110 (230)

0.64

0.143 — 0.153

150 (302)

0.30

0.050 — 0.065

SEF012P

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

Charge air temperature
sensor

Sensors’ ground

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
Approximately 0 — 4.8V
Output voltage varies with
charge air temperature.

Engine is running.

Engine is running. (Warm-up condition)
Approximately 0V
Idle speed

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
33 *1

Check Items
(Possible Cause)

Malfunction is detected when …
+ An excessively high or low voltage from the sensor is
entered to ECM.

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Charge air temperature sensor

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1)
2)
3)

Turn ignition switch ‘‘ON’’ and wait at least 5 seconds.
Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-122

TROUBLE DIAGNOSIS FOR ‘‘I/C INT/A TEMP SEN’’ (DTC 33)
Charge Air Temperature Sensor (Cont’d)

TEC438

EC-123

TROUBLE DIAGNOSIS FOR ‘‘I/C INT/A TEMP SEN’’ (DTC 33)
Charge Air Temperature Sensor (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF710V

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect charge air temperature sensor harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminal V
2
and ground with CONSULT or tester.
Voltage:
Approximately 5V

NG
c

Repair harness or connectors.

OK
.

SEF764V

NG
c

.
SEF765V

CHECK COMPONENT
(Charge air temperature sensor).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.

INSPECTION END

EC-124

NG
c

Check the following.
+ Harness connectors
F6 , M51
+ Harness connectors
M88 , E106
+ Harness for open or
short between ECM and
charge air temperature
sensor
+ Harness for open or
short between TCM and
charge air temperature
sensor
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Replace charge air temperature sensor.

TROUBLE DIAGNOSIS FOR ‘‘I/C INT/A TEMP SEN’’ (DTC 33)
Charge Air Temperature Sensor (Cont’d)
COMPONENT INSPECTION
Charge air temperature sensor
Check resistance as shown in the figure.
Temperature °C (°F)

Resistance kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.0

90 (194)

0.236 — 0.260

SEF152P

If NG, replace charge air temperature sensor.

SEF012P

EC-125

TROUBLE DIAGNOSIS FOR ‘‘NEEDLE LIFT SEN’’ (DTC 34)
Needle Lift Sensor (NLS)

Terminal

The needle lift sensor is built into the No. 1 injection nozzle. Its
piezoelectric element senses changes in fuel injection timing
caused by fuel temperature, etc. This change of fuel injection timing is sent as a pulse signal to the ECM.

Piezoelectric element
SEF604S

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
Approximately 0V

Engine is running. (Warm-up condition)
Idle speed

SEF718V

Needle lift sensor
Approximately 0V

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF719V

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
34

Malfunction is detected when ….
+ An improper signal from the sensor is sent to ECM.

EC-126

Check Items
(Possible Cause)
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Needle lift sensor
+ Air in fuel line
+ Clogging No. 1 injection nozzle

TROUBLE DIAGNOSIS FOR ‘‘NEEDLE LIFT SEN’’ (DTC 34)
Needle Lift Sensor (NLS) (Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1)

SEF714V

Turn ignition switch ‘‘ON’’ and select ‘‘DATA MONITOR’’
mode with CONSULT.
2) Start engine and run it for at least 10 seconds at idle
speed.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Start engine and run it for at least 10 seconds at idle
speed.
2) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-127

TROUBLE DIAGNOSIS FOR ‘‘NEEDLE LIFT SEN’’ (DTC 34)
Needle Lift Sensor (NLS) (Cont’d)

TEC433

EC-128

TROUBLE DIAGNOSIS FOR ‘‘NEEDLE LIFT SEN’’ (DTC 34)
Needle Lift Sensor (NLS) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

OK
CHECK FOR AIR IN FUEL FILTER.
INSPECTION END
c
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform ‘‘DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCEDURE’’.
SEF670V

NG
.

Loosen and retighten engine ground
screws.

SEF676V

CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector and
needle lift sensor harness connector.
3. Check harness continuity between terminal V
1 and ECM terminal V
34 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
.

NG
CHECK GROUND CIRCUIT.
Repair open circuit or short
c
2 and
Check resistance between terminal V
to ground or short to power
engine ground.
in harness or connectors.
Continuity should exist.
If OK, check harness for short to ground
and short to power.
SEF692V

OK
.

CHECK NO. 1 INJECTION NOZZLE FOR
CLOGGING.
Refer to ‘‘SPRAY PATTERN TEST’’, ‘‘Test
and Adjustment’’, ‘‘INJECTION NOZZLE’’,
EC-26.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.
SEF766V

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END

SEF767V

EC-129

NG
c

Replace No. 1 injection
nozzle.

TROUBLE DIAGNOSIS FOR ‘‘FUEL CUT S/V 1’’ (DTC 36),
‘‘FCV SHORT’’ (DTC 37), ‘‘FUEL CUT S/V 2’’ (DTC 38)
Fuel Cut Solenoid Valve
When the ignition switch is OFF, the ECM turns the fuel cut solenoid valve OFF (under this condition, no current flows through the
fuel cut solenoid valve), shutting off fuel supply.
When the engine is not operating due to trouble, the fuel cut solenoid valve may or may not be OFF even when the ignition switch
is ON.

SEF667S

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM

DECELER F/CUT

FUEL CUT S/V

CONDITION

+ Engine: After warming up

SPECIFICATION

Idle

OFF

When accelerator pedal is released
quickly with engine speed at 3,000
rpm or more.

+ Ignition switch: ON → OFF

ON → OFF

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Ignition switch ‘‘ON’’
Ignition switch ‘‘OFF’’
4

B/Y

ECCS relay (Self-shutoff)

0 — 1.5V

For a few seconds after turning ignition switch
‘‘OFF’’
Ignition switch ‘‘OFF’’
A few seconds passed after turning ignition
switch ‘‘OFF’’

56
61

113
115

R/W

116
117

Power supply for ECM

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘OFF’’

Approximately 0V

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘ON’’

BATTERY VOLTAGE
(11 — 14V)

Fuel cut solenoid valve

Power supply for ECM

BATTERY VOLTAGE
(11 — 14V)

EC-130

TROUBLE DIAGNOSIS FOR ‘‘FUEL CUT S/V 1’’ (DTC 36),
‘‘FCV SHORT’’ (DTC 37), ‘‘FUEL CUT S/V 2’’ (DTC 38)
Fuel Cut Solenoid Valve (Cont’d)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble
Code No.
36, 37, 38

Malfunction is detected when …
+ Fuel cut solenoid valve circuit is malfunctioning.

Check Items
(Possible Cause)
+ Main power supply circuit (ECM terminals 116 ,
and fuse
+ Harness or connectors
(The solenoid valve circuit is open or shorted.)
+ Fuel cut solenoid valve
+ ECM

117

)

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1)
2)
3)
4)

SEF748V

Turn ignition switch ‘‘ON’’.
Select ‘‘DATA MONITOR’’ mode with CONSULT.
Start engine.
Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Start engine.
2) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-131

TROUBLE DIAGNOSIS FOR ‘‘FUEL CUT S/V 1’’ (DTC 36),
‘‘FCV SHORT’’ (DTC 37), ‘‘FUEL CUT S/V 2’’ (DTC 38)
Fuel Cut Solenoid Valve (Cont’d)

TEC434

EC-132

TROUBLE DIAGNOSIS FOR ‘‘FUEL CUT S/V 1’’ (DTC 36),
‘‘FCV SHORT’’ (DTC 37), ‘‘FUEL CUT S/V 2’’ (DTC 38)
Fuel Cut Solenoid Valve (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.

CHECK POWER SUPPLY FOR ECM.
Check power supply circuit. Refer to
EC-63.
OK
SEF860S

NG
CHECK OUTPUT SIGNAL CIRCUIT.
Repair open circuit or short
c
to ground or short to power
1. Turn ignition switch ‘‘ON’’.
in harness or connectors.
2. Select ‘‘FUEL CUT SOL/V’’ in
‘‘ACTIVE TEST’’ mode with
CONSULT.
3. Touch ‘‘ON’’ and ‘‘OFF’’ alternately.
4. Check that operating sound is
emitted.
——————————————————————- OR ——————————————————————1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness conSEF682VA
nector and electronic fuel injection pump harness connector.
3. Check harness continuity
between terminal V
4 and ECM
terminals 113 , 115 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.

SEF768V

CHECK COMPONENT
(Fuel cut solenoid valve).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.
.

INSPECTION END

EC-133

NG
c

Replace fuel cut solenoid
valve.

TROUBLE DIAGNOSIS FOR ‘‘FUEL CUT S/V 1’’ (DTC 36),
‘‘FCV SHORT’’ (DTC 37), ‘‘FUEL CUT S/V 2’’ (DTC 38)
Fuel Cut Solenoid Valve (Cont’d)
COMPONENT INSPECTION
Fuel cut solenoid valve

Fuse

Shaft

1. Remove fuel cut solenoid valve.
2. Check shaft to see if it is lifted when applying 12V direct current to terminals.
If NG, replace fuel cut solenoid valve.

SEF859S

EC-134

TROUBLE DIAGNOSIS FOR ‘‘FUEL TEMP SENSOR’’ (DTC 42)
Fuel Temperature Sensor (FTS)
The fuel temperature sensor is used to detect the fuel temperature
in the injection pump. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the fuel temperature input. The sensor uses a thermistor which is sensitive to the
change in temperature. The electrical resistance of the thermistor
decreases as temperature increases.

SEF666S

Engine coolant temperature
°C (°F)

Voltage
(V)

Resistance
(kΩ)

−20 (−4)

4.6

13.67 — 16.37

20 (68)

3.5

2.306 — 2.568

60 (140)

1.8

0.538 — 0.624

80 (176)

1.2

0.289 — 0.344

SEF012P

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Fuel temperature sensor

Sensors’ ground

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
Approximately 0 — 4.8V
Output voltage varies with
fuel temperature.

Engine is running.

Engine is running. (Warm-up condition)
Approximately 0V
Idle speed

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
42

Malfunction is detected when …
+ An excessively high or low voltage from the sensor is
detected by ECM.

Check Items
(Possible Cause)
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Fuel temperature sensor

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF748V

EC-135

TROUBLE DIAGNOSIS FOR ‘‘FUEL TEMP SENSOR’’ (DTC 42)
Fuel Temperature Sensor (FTS) (Cont’d)

TEC435

EC-136

TROUBLE DIAGNOSIS FOR ‘‘FUEL TEMP SENSOR’’ (DTC 42)
Fuel Temperature Sensor (FTS) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF682VB

NG
c

Repair harness or connectors.

OK
.

SEF769V

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Check harness continuity between terminal V
5 and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Harness connectors
F6 , M51
+ Harness connectors
M88 , E106
+ Harness for open or
short between ECM and
electronic fuel injection
pump
+ Harness for open or
short between TCM and
electronic fuel injection
pump
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

SEF770V
.

CHECK COMPONENT
(Fuel temperature sensor).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.

Disconnect and reconnect harness connectors in the circuits. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.

INSPECTION END

EC-137

NG
c

Take proper action.

TROUBLE DIAGNOSIS FOR ‘‘FUEL TEMP SENSOR’’ (DTC 42)
Fuel Temperature Sensor (FTS) (Cont’d)
COMPONENT INSPECTION
Fuel temperature sensor
Wait until fuel temperature sensor reaches room temperature.
Check resistance as shown in the figure.

SEF693V

Temperature °C (°F)

Resistance kΩ

20 (68)

2.306 — 2.568

60 (140)

0.538 — 0.624

80 (176)

0.289 — 0.344

If NG, take proper action.

SEF012P

EC-138

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SENSOR’’ (DTC 43)
Accelerator Position Sensor
The accelerator position sensor is installed on the upper end of the
accelerator pedal assembly. The sensor detects the accelerator
position and sends a signal to the ECM. The ECM uses the signal
to determine the amount of fuel to be injected.

SEF861SA

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
ACCEL POS SEN

CONDITION
+ Ignition switch: ON
(Engine stopped)

SPECIFICATION

Accelerator pedal: released

0.40 — 0.60V

Accelerator pedal: depressed

Approx. 4.0V

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Ignition switch ‘‘ON’’
0.4 — 0.6V
23

Accelerator position sensor

Accelerator pedal fully released
Ignition switch ‘‘ON’’
Approximately 4.3V
Accelerator pedal fully depressed

G/R

Accelerator position sensor power supply

L/W

Accelerator position sensor ground

Ignition switch ‘‘ON’’

Approximately 5V

Engine is running. (Warm-up condition)
Approximately 0V
Idle speed

EC-139

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SENSOR’’ (DTC 43)
Accelerator Position Sensor (Cont’d)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble
Code No.
43

Malfunction is detected when …
+ An excessively low or high voltage from the sensor is
detected by the ECM.

Check Items
(Possible Cause)
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Accelerator position sensor
+ Accelerator position switch
+ Accelerator switch (F/C)

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF748V

1) Turn ignition switch ‘‘ON’’.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT.
3) Wait at least 2 seconds.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Turn ignition switch ‘‘ON’’ and wait at least 2 seconds.
2) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-140

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SENSOR’’ (DTC 43)
Accelerator Position Sensor (Cont’d)

TEC436

EC-141

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SENSOR’’ (DTC 43)
Accelerator Position Sensor (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF694V

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect accelerator position sensor
harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminal V
1
and ground with CONSULT or tester.
Voltage: Approximately 5V

NG
c

OK
.

SEF771V

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Loosen and retighten engine ground
screw.
3. Check harness continuity between terminal V
3 and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal V
23 and terminal V
2 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
SEF676V

CHECK COMPONENT
(Accelerator position sensor).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.
SEF772V

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.
.

INSPECTION END

SEF773V

EC-142

NG
c

Check the following.
+ Harness connectors
F7 , M52 (RHD models)
+ Harness for open or
short between ECM and
accelerator position sensor
If NG, repair harness or
connectors.

Check the following.
+ Harness connectors
F7 , M52 (RHD models)
+ Harness for open or
short between ECM and
accelerator position sensor
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

TROUBLE DIAGNOSIS FOR ‘‘ACCEL POS SENSOR’’ (DTC 43)
Accelerator Position Sensor (Cont’d)
COMPONENT INSPECTION
Accelerator position sensor
1. Disconnect accelerator position sensor harness connector.
2
and
2. Make sure that resistance between terminals V
changes when depressing accelerator pedal manually.
Accelerator pedal conditions
Completely released
Partially depressed
SEF695V

Completely depressed

3
V

Resistance [at 25°C (77°F)]
Approximately 0.5 kΩ
0.5 — 4 kΩ
Approximately 4 kΩ

If NG, replace accelerator pedal assembly.
CAUTION:
If accelerator position sensor or ECM connector is
disconnected, perform the following procedures:
Select ‘‘OFF ACCEL PO SIG’’ in ‘‘ACTIVE TEST’’ mode.
Touch CLEAR.
—————————————————————————————————————————- OR —————————————————————————————————————————Start and warm up engine. After engine has warmed up,
idle for 10 minutes.

EC-143

TROUBLE DIAGNOSIS FOR ‘‘CRANK POS SEN (TDC)’’ (DTC 47)
Crankshaft Position Sensor (TDC)
The crankshaft position sensor (TDC) monitors engine speed by
means of signals from the sensing plate (with two protrusions)
installed to the crankshaft pulley. The datum signal output is
detected at ATDC 70° and sent to the ECM. The sensor signal is
used for fuel injection control and fuel injection timing control.

SEF615S

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
CKPSzRPM (TDC)

CONDITION

SPECIFICATION

+ Tachometer: Connect
+ Run engine and compare tachometer indication with the CONSULT
value.

Almost the same speed as the
CONSULT value.

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
Approximately 0V

Engine is running. (Warm-up condition)
Idle speed

40
44

SEF720V

Crankshaft position sensor
(TDC)

Approximately 0V

Engine is running. (Warm-up condition)
Engine speed is 2,000 rpm.

SEF721V

47
52

B/W

Crankshaft position sensor
(TDC) ground

Engine is running. (Warm-up condition)
Approximately 0V
Idle speed

ON BOARD DIAGNOSIS LOGIC
Diagnostic
Trouble Code
No.
47

Malfunction is detected when ….
+ An improper signal from the sensor is detected by
ECM during engine running and cranking.

EC-144

Check Items
(Possible Cause)
+ Harness or connectors
(The sensor circuit is open.)
+ Crankshaft position sensor (TDC)

TROUBLE DIAGNOSIS FOR ‘‘CRANK POS SEN (TDC)’’ (DTC 47)
Crankshaft Position Sensor (TDC) (Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE

SEF714V

Before performing the following procedure, confirm that battery voltage is more than 10V.
1) Turn ignition switch ‘‘ON’’ and select ‘‘DATA MONITOR’’
mode with CONSULT.
2) Crank engine for at least 1 second.
3) Start engine and run it for at least 2 seconds at idle
speed.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Crank engine for at least 1 second.
2) Start engine and run it for at least 2 seconds at idle
speed.
3) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
4) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’ with ECM.

EC-145

TROUBLE DIAGNOSIS FOR ‘‘CRANK POS SEN (TDC)’’ (DTC 47)
Crankshaft Position Sensor (TDC) (Cont’d)

TEC437

EC-146

TROUBLE DIAGNOSIS FOR ‘‘CRANK POS SEN (TDC)’’ (DTC 47)
Crankshaft Position Sensor (TDC) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF696V

CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect crankshaft position sensor
(TDC) harness connector and ECM harness connector.
3. Check harness continuity between ECM
terminals V
40 , V
44 and terminal V
1 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

OK
.

SEF774V

CHECK GROUND CIRCUIT-I.
Check harness continuity between terminal V
2 and ECM terminals V
47 , V
52 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

SEF775V

CHECK GROUND CIRCUIT-II.
1. Loosen and retighten engine ground
screws.
2. Disconnect harness connectors F13 ,
EC4 .
3. Check harness continuity between ter3 and engine ground.
minal V
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Harness connectors
F13 , EC4
+ Harness for open or
short between ECM and
crankshaft position sensor (TDC)
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Check the following.
+ Harness connectors
F13 , EC4
+ Harness for open or
short between crankshaft
position sensor (TDC)
and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Check the following.
+ Joint connector F19
+ Harness for open or
short between harness
connector F13 and
engine ground
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

OK
.

CHECK COMPONENT
[Crankshaft position sensor (TDC)].
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
SEF676V

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END
SEF776V

EC-147

NG
c

Replace crankshaft position sensor (TDC).

TROUBLE DIAGNOSIS FOR ‘‘CRANK POS SEN (TDC)’’ (DTC 47)
Crankshaft Position Sensor (TDC) (Cont’d)
COMPONENT INSPECTION
Crankshaft position sensor (TDC)
1. Disconnect crankshaft position sensor (TDC) harness connector.
2. Loosen the fixing bolt of the sensor.
3. Remove the sensor.
4. Visually check the sensor for chipping.

SEF620S

5. Check resistance between terminals V
1 and V
2 .
Resistance: Approximately 0.8 — 1.2 kΩ
[at 25°C (77°F)]
If NG, replace crankshaft position sensor (TDC).

SEF697V

EC-148

TROUBLE DIAGNOSIS FOR ‘‘GOV CUT CIRCUIT’’ (DTC 48)
Governor Cut Circuit
ON BOARD DIAGNOSIS LOGIC
This diagnostic procedure checks whether or not fuel cut is being performed during deceleration.
Signals from the accelerator switch and camshaft position sensor (PUMP) are sent to the ECM. The ECM uses
these signals to control the electric governor operation.
Accelerator position

Accelerator switch (F/C)

ECM
Camshaft position sensor (PUMP)

Diagnostic
Trouble Code
No.
48

Engine speed

Electric
governor

Malfunction is detected when ….
+ Accelerator switch circuit is shorted.
+ Crankshaft position sensor (PUMP) or ECM is malfunctioning.

Check Item
(Possible Cause)
+ Harness or connectors
[Accelerator switch (F/C) and camshaft position sensor (PUMP) circuits]
+ Accelerator switch (F/C)
+ Camshaft position sensor (PUMP)
+ ECM

DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
Note: If both DTC 48 and 11 or 23 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 11 or 23 (See EC-69 or
106).
1) Turn ignition switch ‘‘ON’’.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT.
3) Start engine and run it to 3,000 rpm, then quickly release
accelerator pedal.
—————————————————————————————————————————- OR —————————————————————————————————————————1) Start engine and run it to 3,000 rpm, then quickly release
accelerator pedal.
2) Turn ignition switch ‘‘OFF’’, wait at least 5 seconds and
then turn ‘‘ON’’.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’.

EC-149

TROUBLE DIAGNOSIS FOR ‘‘GOV CUT CIRCUIT’’ (DTC 48)
Governor Cut Circuit (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.

1) Turn ignition switch ‘‘ON’’.
2) Select ‘‘SELF DIAG RESULTS’’
mode with CONSULT.
3) Touch ‘‘ERASE’’.
——————————————————————- OR ——————————————————————1) Turn ignition switch ‘‘ON’’.
2) Erase the diagnostic test mode
II (Self-diagnostic results)
memory.
.

PERFORM DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCEDURE.
See previous page.
.

Is the DTC 48 displayed again?
No
.

INSPECTION END

EC-150

Yes
c

Replace ECM.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System
SYSTEM DESCRIPTION
Crankshaft position sensor (TDC)

Engine speed
c

Glow relay

Glow plugs

ECM
Engine coolant temperature sensor

Engine coolant temperature
c

Glow lamp

When engine coolant temperature is more than 90°C (194°F), the glow relay turns off, inactivating the quickglow control until coolant temperature drops below 70°C (158°F).
When coolant temperature is lower than 90°C (194°F):
+ Ignition switch ON
After ignition switch has turned to ON, the glow relay turns ON for a certain period of time in relation to
engine coolant temperature, allowing current to flow through glow plug.
+ Cranking
The glow relay turns ON, allowing current to flow through glow plug.
+ Starting
After engine has started, current continues to flow through glow plug (after-glow mode) for a certain period
in relation to engine coolant temperature.
When engine speed exceeds 2,400 rpm, current flow through glow plug is interrupted.
The glow lamp turns ON for a certain period of time in relation to engine coolant temperature at the time glow
relay is turned ON.

COMPONENT DESCRIPTION
Glow plug
The glow plug is provided with a ceramic heating element to obtain
a high-temperature resistance. It glows in response to a signal sent
from the ECM, allowing current to flow through the glow plug via the
glow relay.

SEF857S

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Ignition switch ‘‘ON’’
0 — 1.5V
Glow lamp is ‘‘ON’’.
16

L/W

Glow lamp
Ignition switch ‘‘ON’’
Glow lamp is ‘‘OFF’’.

111

LG/B

Glow relay

Refer to ‘‘SYSTEM DESCRIPTION’’.

EC-151

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Cont’d)

TEC441

EC-152

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.

Check fuel level, fuel supplying system,
starter motor, etc.

NG
c

Correct.

OK
.
SEF698V

Check that all glow plug connecting plate
nuts are installed properly.

NG
c

Install properly.

OK
.

CHECK OVERALL FUNCTION.
Check entire glow control system. (Refer
to ‘‘System Operation Check’’ on next
page.)

OK
c

CHECK COMPONENT
(Glow plug).
See page EC-155.

NG
.

SEF699V

CHECK VOLTAGE BETWEEN GLOW
RELAY AND GROUND.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect glow relay.
3. Check voltage between terminals V
1 ,
3 and ground with CONSULT or
V
tester.
Voltage: Battery voltage

NG
c

Check the following.
+ 100A fusible link
+ Harness for open or
short between glow
relay and battery
If NG, repair harness or
connectors.

OK
.

SEF777V

CHECK OUTPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal 111 and terminal V
2 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

SEF778V

CHECK HARNESS CONTINUITY
BETWEEN GLOW RELAY AND GLOW
PLUG.
1. Disconnect glow plug harness connector.
2. Check harness continuity between glow
relay terminal V
5 and glow plug harness connector.
Continuity should exist.
If OK, check harness for short to
ground and short to power.
.

j
A
SEF779V

EC-153

NG
c

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M51 , F6
+ Harness for open or
short between glow
relay and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Check the following.
+ Harness connectors
E65 , E204
+ Harness for open or
short between glow
relay and glow plug
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Cont’d)
j
A
.

CHECK COMPONENTS
(Glow relay, Glow plug).
Refer to ‘‘COMPONENT INSPECTION’’,
EC-155.

NG
c

Replace malfunctioning
component(s).

OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END

SYSTEM OPERATION CHECK
Set voltmeter between glow plug and engine body.

SEF700V

SEF780V

1. Quick-glow (Pre-glow) system
a. Turn ignition switch ‘‘ON’’.
b. Read voltage.
Voltage:
Battery voltage for about 20* seconds
* Engine coolant temperature is lower than 90°C
(194°F). [It is lower than 70°C (158°F) after
warm-up.]
* Repeating ignition switch ‘‘ON’’ and ‘‘OFF’’ may
change the time.
2. Quick-glow (Cranking) system
a. Disconnect ‘‘S’’ terminal for starter motor to prevent engine
from cranking.
b. Read voltage when ignition switch is turned to ‘‘START’’.
Voltage:
Battery voltage*
* For about 20 seconds after returning ignition
switch to ‘‘ON’’.

EC-154

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Cont’d)
3. After-glow system
a. Connect ‘‘S’’ terminal to starter motor.
b. Start engine and read voltage.
Voltage:
Battery voltage for 5* minutes
* Engine coolant temperature is lower than 50°C
(122°F).

SEF781V

COMPONENT INSPECTION
Glow relay
1. Check relay for coil continuity.
Continuity should exist.
2. Check relay for proper operation.
Coil voltage

Continuity

Contact point

OFF

12V

Yes

SEC564B

Glow plug
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:
Approximately 0.8Ω [at 25°C (77°F)]
+ If NG, replace glow plug.

SEF701V

3. Install glow plug connecting plate securely.
+ Do not bump glow plug heating element. If it is bumped,
replace glow plug with new one. (If glow plug is dropped
from a height of 10 cm (3.94 in), replace with new one.)
+ If glow plug installation hole is contaminated with carbon,
remove using a reamer or suitable tool.
+ Hand-tighten glow plug by turning it two to three times,
then tighten using a tool to specified torque.
: 15 — 20 Nzm (1.5 — 2.0 kg-m, 11 — 14 ft-lb)
SEC565B

EC-155

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve
SYSTEM DESCRIPTION
Camshaft position sensor (TDC)

Accelerator position sensor

Engine coolant temperature sensor

Engine speed
c

Accelerator position

Engine coolant temperature

ECM
(ECCS-D
c control
module)

EGRC-solenoid valve A

EGRC-solenoid valve B

Throttle control solenoid valve

Start signal

Ignition switch

Amount of intake air

Mass air flow sensor

The ECM receives signals sent from the engine coolant temperature sensor, crankshaft position sensor (TDC), ignition switch, mass
air flow sensor and accelerator position sensor to determine engine
speed and operating conditions. Based on these signals, the ECM
controls EGR control solenoid valve (A and B) operation and
throttle control solenoid valve operation.
Engine coolant
temperature
°C (°F)
Below 70 (158)

EGRC-solenoid valve
B

Throttle control
solenoid valve

EGR valve

Throttle control
valve

Amount of EGR
gas

Any

OFF
(Closed)

Fully closed

Fully open

—

Low load

ON
(Open)

Fully open

Closed

Large

Medium load-1

ON
(Open)

OFF
(Closed)

Fully open

Medium

Medium load-2

ON
(Open)

OFF
(Closed)

Half open

Fully open

Small

High load

OFF
(Closed)

Fully closed

Fully open

—

Load

Above 70 (158)

COMPONENT DESCRIPTION
The EGRC-solenoid valves A and B control vacuum pressure acting on the EGR valve. The EGR control valve will then be fully
opened, half-opened or fully closed, as required.
The throttle control solenoid valve controls vacuum pressure acting
on the throttle chamber. Thus, intake air passages are opened or
closed in relation to exhaust gas and intake air. Utilizing the relationship between exhaust gas pressure and intake air pressure
control, the amount of EGR (exhaust gas recirculated) is regulated
in three stages — large, medium, small.
SEF784V

EC-156

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Cont’d)
CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM

EGRC SOL/V A

EGRC SOL/V B

THROT RLY

CONDITION

SPECIFICATION

+
+
+
+

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

Idle

Revving engine from idle to 3,750
rpm

OFF

+
+
+
+

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

Idle

Revving engine from idle to 2,600
rpm

OFF

+
+
+
+

Engine: After warming up
Air conditioner switch: ‘‘OFF’’
Shift lever: ‘‘N’’
No-load

Idle

Revving engine from idle to 2,500
rpm

OFF

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Engine is running. (Warm-up condition)
Approximately 0.4V
1

Throttle control solenoid
valve

Idle speed
Engine is running. (Warm-up condition)
Revving engine from idle to 2,500 rpm

BATTERY VOLTAGE
(11 — 14V)

Engine is running. (Warm-up condition)
0 — 1V
Idle speed
103

L/Y

EGRC-solenoid valve A
Engine is running. (Warm-up condition)
Revving engine from idle up to 3,750 rpm.

BATTERY VOLTAGE
(11 — 14V)

Engine is running. (Warm-up condition)
0 — 1V
Idle speed
109

BR/Y

EGRC-solenoid valve B
Engine is running. (Warm-up condition)
Revving engine from idle up to 2,600 rpm.

EC-157

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Cont’d)

TEC442

EC-158

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF702V

SEF703V

CHECK OVERALL FUNCTION.
1. Start engine and warm it up to normal
operating temperature.
2. Perform diagnostic test mode II (Selfdiagnostic results).
Make sure that diagnostic trouble code
No. 55 is displayed.
3. Make sure that EGR valve spring
moves up and down (Use your finger)
under the following conditions.
At idle:
Spring moves up and down.
Revving engine from idle to 3,800
rpm:
Spring does not move.
4. Make sure that throttle control valve rod
moves up and down under the following
conditions.
At idle:
Rod moves up and down.
Revving engine from idle to 2,500
rpm:
Rod does not move.

OK
c

INSPECTION END

NG
.
SEF704V

SEF705V

CHECK VACUUM SOURCES TO EGR
VALVE AND THROTTLE CONTROL
VALVE.
1. Disconnect vacuum hose to EGR valve.
2. Make sure that vacuum exists under
the following conditions.
At idle:
Vacuum should exist.
Revving engine from idle to 3,800
rpm:
Vacuum should not exist.
3. Disconnect vacuum hose to throttle
control valve.
4. Make sure that vacuum exists under
the following conditions.
At idle:
Vacuum should exist.
Revving engine from idle to 2,500
rpm:
Vacuum should not exist.
NG
.

j
A

EC-159

OK
c

CHECK COMPONENTS
(EGR valve and throttle
control valve).
(See page EC-162.)
NG

Replace malfunctioning
component(s).

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Cont’d)
j
A

OK
CHECK VACUUM HOSE.
CHECK CONTROL FUNCTION.
c
Check vacuum hose for
1. Stop engine.
clogging, cracks or
2. Turn ignition switch ‘‘ON’’.
improper connection.
3. Turn EGRC-solenoid valve A, B
and throttle control solenoid
valve ‘‘ON’’ and ‘‘OFF’’ in
SEF682S
‘‘ACTIVE TEST’’ mode with
CONSULT and check operating
sound.
——————————————————————- OR ——————————————————————1. Check voltage between ECM
terminal 103 and ground under
the following conditions.
Voltage:
At idle
0 — 1V
Revving engine from idle to
3,800 rpm
SEF683S
Battery voltage
2. Check voltage between ECM
terminal 109 and ground under
the following conditions.
Voltage:
At idle
0 — 1V
Revving engine from idle to
2,600 rpm
Battery voltage
3. Check voltage between ECM
terminal V
1 and ground under
SEF816F
the following conditions.
Voltage:
At idle
0 — 1V
Revving engine from idle to
2,500 rpm
Battery voltage
NG
.

j
B

EC-160

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Cont’d)
j
B

SEF706V

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect EGRC-solenoid valve A, B
and throttle control solenoid valve harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminal V
1
and ground with CONSULT or tester.
Voltage: Battery voltage

NG
c

Check the following.
+ Harness connectors
M21 , E127
+ 10A fuse
+ Harness for open or
short between EGRCsolenoid valve A, B and
fuse
+ Harness for open or
short between throttle
control solenoid valve
and fuse
If NG, repair harness or
connectors.

.
SEF782V

CHECK OUTPUT SIGNAL CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector.
3. Check harness continuity between
ECM terminal V
1 and terminal V
2 ,
ECM terminal 103 and terminal V
2 ,
ECM terminal 109 and terminal V
2 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

SEF783V

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M50 , F5
+ Harness for open or
short between EGRCsolenoid valve A, B and
ECM
+ Harness for open or
short between throttle
control solenoid valve
and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK COMPONENTS
(EGRC-solenoid valve A, B and throttle
control solenoid valve).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage or
the connection of ECM harness connector.
Reconnect ECM harness connector and
retest.
.

INSPECTION END

EC-161

NG
c

Replace malfunctioning
component(s).

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Cont’d)
COMPONENT INSPECTION
EGR valve
Apply vacuum to EGR vacuum port with a hand vacuum pump.
EGR valve spring should lift.
If NG, replace EGR valve.

MEF137D

Throttle control valve
Apply vacuum to throttle control valve vacuum port with a hand
vacuum pump.
Throttle control valve should close.
If NG, replace throttle control valve.

SEF707V

EGRC-solenoid valve A, B and throttle control solenoid
valve
Check air passage continuity.

MEC488B

Condition

Air passage
continuity
A and j
B
between j

Air passage
continuity
A and j
C
between j

12V direct current supply
between terminals V
1
and V
2

Yes

No supply

Yes

If NG, replace solenoid valve(s).

EC-162

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Start Signal

TEC443

EC-163

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Start Signal (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK OVERALL FUNCTION.
1. Turn ignition switch ‘‘ON’’.
2. Check ‘‘START SIGNAL’’ in
‘‘DATA MONITOR’’ mode with
CONSULT.
SEF625S

IGN ‘‘ON’’

OFF

IGN ‘‘START’’

OK
c

INSPECTION END

——————————————————————- OR ——————————————————————1. Turn ignition switch to ‘‘START’’.
2. Check voltage between ECM
terminal V
20 and ground.
Voltage:
Ignition switch ‘‘START’’
Battery voltage
Except above
Approximately 0V
NG

SEF109P
.

CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector and
ignition switch harness connector.
3. Check harness continuity between ECM
terminal V
20 and terminal V
6 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.
OK
SEF785V
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END

EC-164

NG
c

Check the following.
+ Harness connectors
M52 , F7
+ 7.5A fuse
+ Fuse block M3 , E112
+ Harness for open or short
between ECM and ignition switch
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch
The accelerator position switch detects OFF-accelerator switch signal and Full-accelerator switch signal and send these signals to the
ECM. The ECM will then determine engine idle conditions. These
signals are also used for diagnosing the accelerator position sensor.

SEF708V

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
FULL ACCEL SW

OFF ACCEL SW

CONDITION

SPECIFICATION

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: depressed

Except above

OFF

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: released

Accelerator pedal: slightly open

OFF

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Ignition switch ‘‘ON’’
31

R/L

Accelerator position switch
(Idle)

Accelerator pedal fully released

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)
BATTERY VOLTAGE
(11 — 14V)

Ignition switch ‘‘ON’’
Approximately 0V
Accelerator pedal depressed
Ignition switch ‘‘ON’’
Approximately 0V

W/G

Accelerator position switch
(Full)

Accelerator pedal released
Ignition switch ‘‘ON’’
Accelerator pedal fully depressed

EC-165

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch (Cont’d)

TEC444

EC-166

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK OVERALL FUNCTION.
1. Turn ignition switch ‘‘ON’’.
2. Select ‘‘FULL ACCEL SW’’ and
‘‘OFF ACCEL SW’’ in ‘‘DATA
MONITOR’’ mode with CONSEF626S
SULT.
3. Check ‘‘FULL ACCEL SW’’ and
‘‘OFF ACCEL SW’’ signal under
the following conditions.
OFF ACCEL SW:
Accelerator pedal released
ON
Accelerator pedal
depressed OFF
FULL ACCEL SW:
Accelerator pedal released
OFF
Accelerator pedal fully
depressed ON
SEF627S
——————————————————————- OR ——————————————————————1. Turn ignition switch ‘‘ON’’.
2. Check voltage between ECM
terminal V
31 and ground under
the following conditions.
Voltage:
Accelerator pedal released
Battery voltage
Accelerator pedal
depressed
Approximately 0V
3. Check voltage between ECM
terminal V
32 and ground under
SEF708V
the following conditions.
Voltage:
Accelerator pedal released
Approximately 0V
Accelerator pedal fully
depressed
Battery voltage

OK
c

INSPECTION END

NG
.

SEF786V

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect accelerator position switch
harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminal V
5
and ground with CONSULT or tester.
Voltage: Battery voltage
OK

j
A

EC-167

NG
c

Check the following.
+ Harness connectors
M52 , F7 (LHD models)
+ Harness for open or
short between accelerator position switch and
ECCS relay
+ Harness for open or
short between accelerator position switch and
ECM
If NG, repair harness or
connectors.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch (Cont’d)
j
A

SEF787V

CHECK INPUT SIGNAL CIRCUIT-I.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector.
3. Check harness continuity between terminal V
6 and ECM terminal V
31 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Harness connectors
M52 , F7 (RHD models)
+ Harness for open or
short between ECM and
accelerator position
switch
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

SEF788V

CHECK INPUT SIGNAL CIRCUIT-II.
Check harness continuity between terminal V
4 and ECM terminal V
32 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

CHECK COMPONENT
(Accelerator position switch).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.

Disconnect and reconnect harness connectors in the circuits. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.
.

INSPECTION END

EC-168

NG
c

Replace accelerator pedal
assembly.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch (Cont’d)
COMPONENT INSPECTION
Accelerator position switch
1. Disconnect accelerator position switch harness connector.
2. Check continuity between terminals V
5 and V
6 .
Conditions

SEF709V

Continuity

Accelerator pedal released

Yes

Accelerator pedal depressed

3. Check continuity between terminals

4
V

Conditions

and

5 .
V

Continuity

Accelerator pedal released

Accelerator pedal fully depressed

Yes

EC-169

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch

TEC445

EC-170

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch (Cont’d)
When the gear position is in ‘‘N’’, neutral position switch is ‘‘ON’’.
The ECM detects the position because the continuity of the line (the
‘‘ON’’ signal) exists.

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
P/N POSI SW

+ Ignition switch: ON

CONDITION
Shift lever: Neutral/Park
Except above

SPECIFICATION
ON
OFF

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Ignition switch ‘‘ON’’

P/B

Inhibitor switch/
Neutral position switch

Gear position is ‘‘N’’ or ‘‘P’’ (A/T models).
Gear position is ‘‘Neutral’’ (M/T models).
Ignition switch ‘‘ON’’
Except the above gear position

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

DIAGNOSTIC PROCEDURE
M/T models
INSPECTION START

OK
CHECK OVERALL FUNCTION.
c
1. Turn ignition switch ‘‘ON’’.
2. Select ‘‘P/N POSI SW’’ in
SEF963N
‘‘DATA MONITOR’’ mode with
CONSULT.
3. Check ‘‘P/N POSI SW’’ signal
under the following conditions.
Neutral position: ON
Except neutral position: OFF
——————————————————————- OR ——————————————————————2. Check voltage between ECM
terminal V
22 and ground under
the following conditions.
Voltage:
Neutral position
SEF622S
Approximately 0V
Except neutral position
Battery voltage
NG
.

j
A

SEF789V

EC-171

INSPECTION END

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch (Cont’d)
j
A

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect neutral position switch harness connector.
3. Check harness continuity between terminal V
2 and body ground.
AEC750

NG
c

Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK

Check the following.
+ Harness connectors
E202 , E69
+ Harness for open or short
between neutral position
switch and body ground
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal V
22 and terminal V
1 .

SEF624S

NG
c

Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK

Check the following.
+ Harness connectors
F7 , M52
+ Harness connectors
M21 , E127
+ Harness connectors
E70 , E201
+ Harness for open or short
between ECM and neutral position switch
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK COMPONENT
(Neutral position switch).
Refer to MT section.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness connector. Reconnect ECM harness connector
and retest.
.

INSPECTION END

EC-172

NG
c

Replace neutral position
switch.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch (Cont’d)
A/T models
INSPECTION START

OK
CHECK OVERALL FUNCTION.
c
1. Turn ignition switch ‘‘ON’’.
2. Select ‘‘P/N POSI SW’’ in
‘‘DATA MONITOR’’ mode with
SEF963N
CONSULT.
3. Check ‘‘P/N POSI SW’’ signal
under the following conditions.
‘‘P’’ or ‘‘N’’ position: ON
Except above positions: OFF
——————————————————————- OR ——————————————————————2. Check voltage between ECM
terminal V
22 and ground under
the following conditions.
Voltage:
‘‘P’’ or ‘‘N’’ position
Approximately 0V
SEF622S
Except above positions
Battery voltage

INSPECTION END

NG
.

SEF790V

CHECK POWER SUPPLY.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect inhibitor switch harness connector.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminal V
3 and
ground with CONSULT or tester.
Voltage: Battery voltage
OK
.

j
A

SEF791V

SEF792V

EC-173

NG
c

Check the following.
+ 7.5A fuse
+ Harness for open or short
between inhibitor switch
and fuse
If NG, repair harness or
connectors.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch (Cont’d)
j
A

SEF793V

CHECK INPUT SIGNAL CIRCUIT-I.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect TCM harness connector.
3. Check harness continuity between TCM
terminal V
36 and terminals V
7 , V
9 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.

NG
c

Check the following.
+ Diode E103
+ Harness continuity
between inhibitor switch
and TCM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT-II.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal V
22 and TCM terminal V
14 .
Continuity should exist.
If OK, check harness for short to ground
and short to power.
SEF794V

NG
c

Check the following.
+ Harness connectors
F7 , M52
+ Harness connectors
M21 , E127
+ Harness for open or short
between ECM and TCM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK COMPONENT
(Inhibitor switch).
Refer to AT section.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
.

Trouble is not fixed.

Check ECM pin terminals for damage or
the connection of ECM harness connector.
Reconnect ECM harness connector and
retest.
.

INSPECTION END

EC-174

Replace inhibitor switch.
c

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
A/T Control
These circuit lines are used to control the smooth shifting up and
down of A/T during the hard acceleration/deceleration.
Voltage signals are exchanged between ECM and TCM.

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

PU/W

ITEM

CONDITION

43
V

DATA
(DC Voltage and Pulse
Signal)

Engine is running.
A/T signal No. 1

6 — 8V
Idle speed
Engine is running.

A/T signal No. 3

Approximately 0V
Idle speed
Engine is running.

P/B

A/T signal No. 2

6 — 8V
Idle speed

EC-175

(ECCS

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
A/T Control (Cont’d)

TEC440

EC-176

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
A/T Control (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF792V

CHECK OVERALL FUNCTION.
1. Start engine and let it idle.
2. Check voltage between ECM terminals
24 , V
30 , V
37 and ground with CONV
SULT or tester.
Terminal
24

V
30
V
37
V

OK
c

INSPECTION END

Voltage

and ground

6 — 8V

and ground

Approximately 0V

and ground

6 — 8V

NG
.

SEF795V

CHECK INPUT SIGNAL CIRCUIT-I.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector
and TCM harness connector.
3. Check harness continuity between
ECM terminal V
24 and terminal V
5 ,
ECM terminal V
30 and terminal V
7 ,
ECM terminal V
37 and terminal V
6 .
Continuity should exist.

NG
c

Check the following.
+ Harness connectors
M51 , F6
+ Harness connectors
E106 , M88
+ Harness continuity
between ECM and TCM
If NG, repair harness or
connectors.

OK
.

SEF796V

CHECK INPUT SIGNAL CIRCUIT-II.
Check harness continuity between ECM
terminal V
24 and ground, ECM terminal
30 and ground, ECM terminal V
37 and
V
ground.
Continuity should not exist.
If OK, check harness for short to power.
OK

Disconnect and reconnect harness connectors in the circuit. Then retest.
SEF797V

Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.

INSPECTION END

EC-177

NG
c

Check the following.
+ Harness connectors
E106 , M88
+ Harness connectors
M51 , F6
+ Harness for short
between ECM and TCM
If NG, repair short to
ground or short to power in
harness or connectors.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control
SYSTEM DESCRIPTION
Crankshaft position sensor (TDC)

Engine speed

Charge air temperature sensor

Charge air temperature

Ignition switch

Start signal

ECM

Charge air cooler fan relay

The ECM controls the charge air cooler fan operation corresponding to the engine speed, the charge air temperature and the start signal. The control system has 2-step control [ON/OFF]. The ECM does not directly drive
the charge air cooler fan. It controls the ON/OFF charge air cooler fan relay, which in turn controls the charge
air cooler fan.
When the charge air temperature is above 67°C (153°F) and engine speed is more than 1,600 rpm, the charge
air cooler fan operates.

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
I/C FAN RLY

CONDITION

SPECIFICATION

+ When charge air cooler fan is stopped.

OFF

+ When charge air cooler fan operates.

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Engine is running.
8

G/OR

Charge air cooler fan
relay

Charge air cooler fan is not operating.

BATTERY VOLTAGE
(11 — 14V)

0 — 1V

EC-178

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Engine is running.
Charge air cooler fan is operating.

43
V

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Cont’d)

TEC439

EC-179

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

SEF710V

CHECK OVERALL FUNCTION.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect charge air temperature sensor harness connector.
3. Connect 150Ω resistor to charge air
temperature sensor harness connector.
4. Start engine and keep engine speed at
2,000 rpm.
5. Make sure that charge air cooler fan
operates.

OK
c

INSPECTION END

NG
.

SEF798V

CHECK POWER SUPPLY.
1. Stop engine.
2. Disconnect charge air cooler fan relay.
3. Turn ignition switch ‘‘ON’’.
4. Check voltage between terminals V
2 ,
5
and
ground
with
CONSULT
or
V
tester.
Voltage: Battery voltage

NG
c

Check the following.
+ Harness connectors
M21 , E127
+ 10A fuse
+ 15A fuse
+ Fuse block M2
+ Harness for open or
short between charge air
cooler fan relay and
fuses
If NG, repair harness or
connectors.

.
SEF712V

CHECK GROUND CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect charge air cooler fan motor
harness connector.
3. Check harness continuity between relay
terminal V
3 and motor terminal V
1 ,
motor terminal V
2 and engine ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK

SEF799V

j
A

SEF711V

EC-180

NG
c

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M50 , F5
+ Harness for open or
short between charge air
cooler fan relay and
charge air cooler fan
motor
+ Harness for open or
short between charge air
cooler fan motor and
engine ground
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Cont’d)
j
A

SEF800V

CHECK OUTPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal V
8 and relay terminal V
1 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.

NG
c

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M52 , F7
+ Harness for open or
short between ECM and
charge air cooler fan
relay
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

CHECK COMPONENT
(Charge air cooler fan relay).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
SEF801V

NG
c

Replace charge air cooler
fan relay.

Replace charge air cooler
fan motor.

OK
.

CHECK COMPONENT
(Charge air cooler fan motor).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness connector and retest.

INSPECTION END

EC-181

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Cont’d)
COMPONENT INSPECTION
Charge air cooler fan relay
Check continuity between terminals
Conditions

SEF511P

3
V

and

5 .
V

Continuity

12V direct current supply between
terminals V
1 and V
2

Yes

No current supply

If NG, replace relay.

Charge air cooler fan motor
1. Disconnect charge air cooler fan motor harness connector.
2. Supply charge air cooler fan motor terminals with battery voltage and check operation.
Charge air cooler fan motor should operate.
If NG, replace charge air cooler fan motor.

SEF802V

EC-182

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch
The heat up switch is located on the lower side of the instrument
panel. This switch is used to speed up the heater’s operation when
the engine is cold.
When the ECM received the heat up switch ‘‘ON’’ signal, the ECM
increases the engine idle speed to 1,100 — 1,200 rpm to warm up
engine quickly.
This system works when all conditions listed below are met.
Heat up switch
SEF803V

Engine coolant temperature

Below 70°C (158°F)

Shift lever

‘‘P’’ or ‘‘N’’

Accelerator pedal

Fully released

Vehicle speed

Below 4 km/h (2 MPH)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM
WARM UP SW

CONDITION
+ Ignition switch: ON

SPECIFICATION

Heat up switch: ON

Heat up switch: OFF

OFF

ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and
ground) with a voltmeter.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

43
V

(ECCS

DATA
(DC Voltage and Pulse
Signal)

Ignition switch ‘‘ON’’
0V
Heat up switch is ‘‘OFF’’.
59

BR/W

Heat up switch
Ignition switch ‘‘ON’’
Heat up switch is ‘‘ON’’.

EC-183

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch (Cont’d)

TEC447

EC-184

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START

OK
CHECK OVERALL FUNCTION.
c
1. Turn ignition switch ‘‘ON’’.
2. Check ‘‘WARM UP SW’’ signal
in ‘‘DATA MONITOR’’ mode with
CONSULT.
SEF804V
Heat up switch is ‘‘ON’’: ON
Heat up switch is ‘‘OFF’’: OFF
——————————————————————- OR ——————————————————————2. Check voltage between ECM
terminal V
59 and ground under
the following condition.
Voltage:
Heat up switch is ‘‘ON’’
Battery voltage
Heat up switch is ‘‘OFF’’
Approximately 0V

INSPECTION END

SEF805V
.

CHECK POWER SUPPLY.
1. Turn heat up switch ‘‘OFF’’.
2. Turn ignition switch ‘‘OFF’’.
3. Disconnect heat up switch harness connector.
4. Turn ignition switch ‘‘ON’’.
5. Check voltage between terminal V
6
and ground with CONSULT or tester.
Voltage: Battery voltage
SEF806V

NG
c

Check the following.
+ Fuse block M3
+ 10A fuse
+ Harness for open or
short between heat up
switch and fuse
If NG, repair harness or
connectors.

OK
.

CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM
terminal V
59 and terminal V
5 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK

SEF807V
.

j
A

EC-185

NG
c

Check the following.
+ Harness connectors
M51 , F6
+ Harness for open or
short between heat up
switch and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch (Cont’d)
j
A
.

CHECK COMPONENT
(Heat up switch).
Refer to ‘‘COMPONENT INSPECTION’’
below.

NG
c

Replace heat up switch.

OK
.

Disconnect and reconnect harness connectors in the circuit. Then retest.
Trouble is not fixed.
.

Check ECM pin terminals for damage or
the connection of ECM harness connector.
Reconnect ECM harness connector and
retest.

INSPECTION END

COMPONENT INSPECTION
Heat up switch
1. Disconnect heat up switch harness connector.
2. Check continuity between terminals V
5 and V
6 .
Condition

SEF808V

Continuity

Heat up switch ‘‘ON’’

Yes

Heat up switch ‘‘OFF’’

If NG, replace heat up switch.

EC-186

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Air Conditioner Control

TEC446

EC-187

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
MIL & Data Link Connectors

TEC448

EC-188

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Unit: rpm
Engine

RD28ETi

Idle speed

775±25

Maximum engine speed

5,400

Injection pump numbers
Engine

Part number

Pump assembly
number

RD28ETi

16700 VB300

104721-2000

Injection Nozzle
INSPECTION AND ADJUSTMENT

Adjusting shims

Injection nozzle assembly
2

Unit: kPa (bar, kg/cm , psi)
Initial injection pressure

Thickness mm (in)

Parts No.

0.50 (0.0197)

16613-V0700

0.54 (0.0213)

16613-V0702

Used

14,220 (142.2, 145, 2,062)

0.58 (0.0228)

16613-V0704

New

14,711 — 15,495 (147.1 — 155.0,
150 — 158, 2,133 — 2,247)

0.62 (0.0244)

16613-V0706

0.66 (0.0260)

16613-V0708

0.70 (0.0276)

16613-V0710

0.74 (0.0291)

16613-V0712

0.78 (0.0307)

16613-V0714

0.82 (0.0323)

16613-V0716

0.86 (0.0339)

16613-V0718

0.90 (0.0354)

16613-V0720

0.94 (0.0370)

16613-V0722

0.98 (0.0386)

16613-V0724

1.00 (0.0394)

16613-V0760

Inspection and Adjustment
Plunger lift

0.92±0.04 (0.0362±0.0016)
(at 9.75° ATDC)

mm (in)

ENGINE COOLANT TEMPERATURE
SENSOR

CAMSHAFT POSITION SENSOR (PUMP)
Resistance [at 25°C (77°F)]

Ω

1,360 — 1,840

Temperature °C (°F)

Resistance kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.00

90 (194)

0.236 — 0.260

CONTROL SLEEVE POSITION SENSOR
Resistance [at 23°C (73°F)]

EC-189

Ω

5.9

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
ADJUSTMENT RESISTOR
Resistance [at 25°C (77°F)]

kΩ

ACCELERATOR POSITION SENSOR
0.2 — 15.0

Throttle valve conditions
Completely closed

INJECTION TIMING CONTROL VALVE
Resistance [at 20°C (68°F)]

Ω

Approximately 11

Ω

Completely open

0.68

CRANKSHAFT POSITION SENSOR (TDC)
Resistance [at 25°C (77°F)]

kΩ

Approximately 0.8 — 1.2

Ω

0.8

GLOW PLUG
Resistance [at 25°C (77°F)]

Approximately 0.5
0.5 — 4
Approximately 4

FUEL TEMPERATURE SENSOR

ELECTRIC GOVERNOR
Resistance [at 23°C (73°F)]

Partially open

Resistance kΩ
[at 25°C (77°F)]

EC-190

Temperature °C (°F)

Resistance kΩ

−20 (−4)

13.67 — 16.37

20 (68)

2.306 — 2.568

60 (140)

0.538 — 0.624

80 (176)

0.289 — 0.344

ELECTRICAL SYSTEM
SECTION

When you read wiring diagrams:
+ Read GI section, ‘‘HOW TO READ WIRING DIAGRAMS’’.
When you perform trouble diagnoses, read GI section, ‘‘HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES’’ and ‘‘HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT’’.
+ Check for any service bulletins before servicing the vehicle.

CONTENTS
PRECAUTIONS ………………………………………………………1
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’……………1
HARNESS CONNECTOR…………………………………………2
Description ………………………………………………………….2
STANDARDIZED RELAY …………………………………………3
Description ………………………………………………………….3
POWER SUPPLY ROUTING …………………………………….5
Schematic …………………………………………………………..5
Wiring Diagram — POWER —………………………………6
Fuse …………………………………………………………………14
Fusible Link……………………………………………………….14
Circuit Breaker Inspection …………………………………..14
GROUND DISTRIBUTION/LHD MODELS………………..15
Engine Room Harness ……………………………………….15
Main Harness…………………………………………………….19
Body Harness ……………………………………………………22
Body No. 2 Harness …………………………………………..23
Back Door and Rear Window Defogger Harness …..24
Room Lamp Harness………………………………………….25
GROUND DISTRIBUTION/RHD MODELS ……………….26
Engine Room Harness ……………………………………….26
Main Harness…………………………………………………….30
Body Harness ……………………………………………………33
Body No. 2 Harness …………………………………………..34
Back Door and Rear Window Defogger Harness …..35
Room Lamp Harness………………………………………….36
BATTERY ……………………………………………………………..37
How to Handle Battery ……………………………………….37
Battery Test and Charging Chart………………………….40
Service Data and Specifications (SDS)…………………44
STARTING SYSTEM ……………………………………………..45
Wiring Diagram — START —………………………………45

Trouble Diagnoses……………………………………………..46
Construction………………………………………………………47
Removal and Installation …………………………………….47
Inspection………………………………………………………….47
Assembly ………………………………………………………….50
Service Data and Specifications (SDS)…………………51
CHARGING SYSTEM …………………………………………….52
Wiring Diagram — CHARGE —…………………………..52
Trouble Diagnoses……………………………………………..53
Construction………………………………………………………54
Removal and Installation …………………………………….54
Disassembly………………………………………………………54
Inspection………………………………………………………….55
Assembly ………………………………………………………….56
Service Data and Specifications (SDS)…………………56
COMBINATION SWITCH………………………………………..57
Check……………………………………………………………….57
Replacement……………………………………………………..58
STEERING SWITCH………………………………………………59
Check……………………………………………………………….59
HEADLAMP — Conventional Type — ……………………61
Wiring Diagram — H/LAMP —…………………………….61
Trouble Diagnoses……………………………………………..62
Bulb Replacement ……………………………………………..63
Aiming Adjustment ……………………………………………..63
HEADLAMP — Daytime Light System — ………………65
System Description…………………………………………….65
Wiring Diagram — DTRL — ………………………………..67
Trouble Diagnoses……………………………………………..69
Bulb Replacement ……………………………………………..69
Aiming Adjustment ……………………………………………..69
HEADLAMP — Headlamp Aiming Control — …………70
System Description…………………………………………….70

Wiring Diagram — H/AIM — ……………………………….71
PARKING, LICENSE AND TAIL LAMPS………………….73
Wiring Diagram — TAIL/L —/Type A…………………….73
Wiring Diagram — TAIL/L —/Type B…………………….75
STOP LAMP …………………………………………………………77
Wiring Diagram — STOP/L —/Type A ………………….77
BACK-UP LAMP……………………………………………………78
Wiring Diagram — BACK/L —/LHD Models…………..78
Wiring Diagram — BACK/L —/RHD Models ………….79
REAR FOG LAMP …………………………………………………80
Wiring Diagram — R/FOG —………………………………80
TURN SIGNAL AND HAZARD WARNING LAMPS …..81
Wiring Diagram — TURN —/Type A …………………….81
Wiring Diagram — TURN —/Type B…………………….83
Trouble Diagnoses……………………………………………..85
Electrical Components Inspection ………………………..85
ILLUMINATION ……………………………………………………..86
Schematic …………………………………………………………86
Wiring Diagram — ILL — ……………………………………87
INTERIOR ROOM LAMP — With Timer — ……………..93
System Description…………………………………………….93
Schematic …………………………………………………………94
Wiring Diagram — ROOM/L —/LHD Models …………95
Wiring Diagram — ROOM/L —/RHD Models…………98
Trouble Diagnoses……………………………………………100
MAP AND VANITY MIRROR LAMPS …………………….101
Wiring Diagram — INT/L —……………………………….101
METER AND GAUGES ………………………………………..102
System Description…………………………………………..102
Combination Meter …………………………………………..103
Wiring Diagram — METER —/LHD Models…………104
Wiring Diagram — METER —/RHD Models ………..106
Meter/Gauge Operation and Odo/Trip Meter
Segment Check in Diagnosis Mode ……………………108
Flexible Print Circuit (FPC)………………………………..109
Trouble Diagnoses……………………………………………110
Electrical Components Inspection ………………………114
COMPASS AND THERMOMETER ………………………..116
System Description…………………………………………..116
Wiring Diagram — COMPAS —…………………………117
Trouble Diagnoses……………………………………………118
Calibration Procedure For Compass …………………..119
WARNING LAMPS ………………………………………………121
Schematic ……………………………………………………….121
Wiring Diagram — WARN — …………………………….123
Electrical Components Inspection ………………………134
WARNING CHIME ……………………………………………….135
System Description…………………………………………..135
Wiring Diagram — CHIME —/LHD Models………….136
Wiring Diagram — CHIME —/RHD Models …………137
Trouble Diagnoses……………………………………………138
Electrical Components Inspection ………………………140

FRONT WIPER AND WASHER …………………………….141
System Description…………………………………………..141
Wiring Diagram — WIPER —/With Intermittent
Wiper………………………………………………………………142
Removal and Installation …………………………………..143
Washer Nozzle Adjustment ……………………………….144
Washer Tube Layout ………………………………………..144
REAR WIPER AND WASHER ………………………………145
System Description…………………………………………..145
Wiring Diagram — WIP/R —/LHD Models…………..146
Wiring Diagram — WIP/R —/RHD Models ………….148
Trouble Diagnoses……………………………………………150
Removal and Installation …………………………………..151
Washer Nozzle Adjustment ……………………………….151
Washer Tube Layout ………………………………………..152
Check Valve…………………………………………………….152
HEADLAMP WIPER AND WASHER ……………………..153
Wiring Diagram — HLC — ………………………………..153
Electrical Components Inspection ………………………154
Removal and Installation …………………………………..154
Washer Tube Layout ………………………………………..154
Check Valve…………………………………………………….154
HORN …………………………………………………………………155
Wiring Diagram — HORN —……………………………..155
CIGARETTE LIGHTER…………………………………………156
Wiring Diagram — CIGAR —…………………………….156
CLOCK……………………………………………………………….157
Wiring Diagram — CLOCK —……………………………157
REAR WINDOW DEFOGGER……………………………….158
System Description…………………………………………..158
Wiring Diagram — DEF —/LHD Models ……………..159
Wiring Diagram — DEF —/RHD Models …………….161
Trouble Diagnoses……………………………………………163
Electrical Components Inspection ………………………164
Filament Check………………………………………………..164
Filament Repair ……………………………………………….165
WIPER DEICER …………………………………………………..166
System Description…………………………………………..166
Wiring Diagram — DEICER —…………………………..167
AUDIO ………………………………………………………………..168
Wiring Diagram — AUDIO —/LHD Models ………….168
Wiring Diagram — AUDIO —/RHD Models …………170
Trouble Diagnoses……………………………………………172
CATS (Code) System/RHD ……………………………….173
NATS Audio Link/LHD ………………………………………174
AUDIO — CD AUTO CHANGER — ………………………176
Wiring Diagram — CD/CHG —/LHD Wagon ……….176
Wiring Diagram — CD/CHG —/LHD Hardtop………177
Wiring Diagram — CD/CHG —/RHD Wagon……….178
Wiring Diagram — CD/CHG —/RHD Hardtop ……..179
Trouble Diagnoses……………………………………………180
AUDIO ANTENNA ……………………………………………….181

Wiring Diagram — P/ANT —/LHD Models…………..181
Wiring Diagram — P/ANT —/RHD Models ………….182
Trouble Diagnoses……………………………………………183
Location of Antenna………………………………………….183
Antenna Rod Replacement ……………………………….183
Window Antenna Repair ……………………………………184
ELECTRIC SUNROOF …………………………………………186
Wiring Diagram — SROOF — …………………………..186
POWER DOOR MIRROR ……………………………………..188
Wiring Diagram — MIRROR —/LHD Models……….188
Wiring Diagram — MIRROR —/RHD Models ………189
POWER SEAT …………………………………………………….190
Wiring Diagram — SEAT —/LHD Models ……………190
Wiring Diagram — SEAT —/RHD Models……………192
HEATED SEAT ……………………………………………………194
Wiring Diagram — HSEAT —…………………………….194
POWER WINDOW ……………………………………………….196
System Description…………………………………………..196
Schematic ……………………………………………………….197
Wiring Diagram — WINDOW — ………………………..198
Trouble Diagnoses……………………………………………203
POWER DOOR LOCK………………………………………….204
System Description…………………………………………..204
Wiring Diagram — D/LOCK —…………………………..205
Trouble Diagnosis …………………………………………….207
POWER DOOR LOCK — Super Lock — ………………211
Component Parts and Harness Connector
Location ………………………………………………………….211
System Description…………………………………………..212
Schematic ……………………………………………………….214
Wiring Diagram — S/LOCK —/LHD Models ………..215
Wiring Diagram — S/LOCK —/RHD Models ……….219
Trouble Diagnoses……………………………………………223
MULTI-REMOTE CONTROL SYSTEM …………………..234
System Description…………………………………………..234
Wiring Diagram — MULTI —/LHD Models…………..235
Trouble Diagnoses……………………………………………237
ID Code Entry Procedure ………………………………….239
NATS (Nissan Anti-Theft System)/LHD MODELS….240

System Description…………………………………………..240
System Composition…………………………………………240
Wiring Diagram — NATS —………………………………241
CONSULT ……………………………………………………….242
Trouble Diagnoses……………………………………………244
How to Replace NATS IMMU…………………………….253
NATS (Nissan Anti-Theft System)/RHD MODELS …254
Component Parts and Harness Connector
Location ………………………………………………………….254
System Description…………………………………………..255
System Composition…………………………………………255
Wiring Diagram — NATS —………………………………256
CONSULT ……………………………………………………….257
Trouble Diagnoses……………………………………………259
LOCATION OF ELECTRICAL UNITS…………………….269
Engine Compartment………………………………………..269
Passenger Compartment — LHD Models……………270
Passenger Compartment — RHD Models …………..272
HARNESS LAYOUT …………………………………………….275
How to Read Harness Layout ……………………………275
Outline/LHD Models………………………………………….276
Outline/RHD Models …………………………………………277
Main Harness/LHD Models………………………………..278
Main Harness/RHD Models ……………………………….282
Engine Room Harness/LHD Models …………………..286
Engine Room Harness/RHD Models…………………..290
Engine Harness ……………………………………………….294
Engine Control Harness and Alternator Harness ….295
Body Harness/LHD Models ……………………………….296
Body Harness/RHD Models……………………………….300
Body No. 2 Harness/LHD Models ………………………304
Body No. 2 Harness/RHD Models………………………306
Chassis Harness………………………………………………308
Room Lamp Harness………………………………………..309
Front Door Harness (Driver side) ……………………….310
Front Door Harness (Passenger side) ………………..311
Rear Door Harness…………………………………………..312
Back Door Harness and Rear Window Defogger
Harness…………………………………………………………..313

BULB SPECIFICATIONS ……………………………………..314
Headlamp………………………………………………………..314
Exterior Lamp ………………………………………………….314
Interior Lamp……………………………………………………314
WIRING DIAGRAM CODES (CELL CODES)………….315

WIRING DIAGRAM REFERENCE CHART
ECCS, IGNITION SYSTEM ………………………………………………………………………………. EC SECTION
ANTI-LOCK BRAKE SYSTEM ………………………………………………………………………….. BR SECTION
SRS ‘‘AIR BAG’’ ……………………………………………………………………………………………… RS SECTION
HEATER AND AIR CONDITIONER …………………………………………………………………… HA SECTION
DIFFERENTIAL CARRIER ……………………………………………………………………………….. PD SECTION
REAR SUSPENSION ……………………………………………………………………………………….. RA SECTION
FUEL SYSTEM ………………………………………………………………………………………………… FE SECTION

PRECAUTIONS
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’
The Supplemental Restraint System such as ‘‘AIR BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’ used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The composition varies according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.

EL-1

HARNESS CONNECTOR
Description
HARNESS CONNECTOR
+ All harness connectors have been modified to prevent accidental looseness or disconnection.
+ The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector.
[Example]

SEL769D

EL-2

STANDARDIZED RELAY
Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.

SEL881H

TYPE OF STANDARDIZED RELAYS
1M

……………….. 1 Make

……………….. 2 Make

……………….. 1 Transfer

1Mz1B ……………….. 1 Make 1 Break

SEL882H

EL-3

STANDARDIZED RELAY
Description (Cont’d)

SEL661TA

EL-4

POWER SUPPLY ROUTING
Schematic

TEL478A

EL-5

POWER SUPPLY ROUTING
Wiring Diagram — POWER —
BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

TEL479A

EL-6

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL480A

EL-7

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL481A

EL-8

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL482A

EL-9

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)
ACCESSORY POWER SUPPLY — IGNITION SW. IN ‘‘ACC’’ OR ‘‘ON’’

TEL483A

EL-10

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)
IGNITION POWER SUPPLY — IGNITION SW. IN ‘‘ON’’ AND/OR ‘‘START’’

TEL484A

EL-11

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL485A

EL-12

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL486A

EL-13

POWER SUPPLY ROUTING
Fuse
a. If fuse is blown, be sure to eliminate cause of problem
before installing new fuse.
b. Use fuse of specified rating. Never use fuse of more than
specified rating.
c. Do not partially install fuse; always insert it into fuse
holder properly.
d. Remove fuse for ‘‘ELECTRICAL PARTS (BAT)’’ if vehicle is
not used for a long period of time.
CEL083

Fusible Link

MEL944F

A melted fusible link can be detected either by visual inspection or
by feeling with finger tip. If its condition is questionable, use circuit
tester or test lamp.
CAUTION:
+ If fusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of
problem.
+ Never wrap outside of fusible link with vinyl tape. Important: Never let fusible link touch any other wiring harness,
vinyl or rubber parts.

Circuit Breaker Inspection
For example, when current is 30A, the circuit is broken within 8 to
20 seconds.

SBF284E

EL-14

GROUND DISTRIBUTION/LHD MODELS
Engine Room Harness

CEL723

EL-15

GROUND DISTRIBUTION/LHD MODELS
Engine Room Harness (Cont’d)

CEL724

EL-16

GROUND DISTRIBUTION/LHD MODELS
Engine Room Harness (Cont’d)

CEL725

EL-17

GROUND DISTRIBUTION/LHD MODELS
Engine Room Harness (Cont’d)
RD ENGINE

CEL795

EL-18

GROUND DISTRIBUTION/LHD MODELS
Main Harness

CEL720

EL-19

GROUND DISTRIBUTION/LHD MODELS
Main Harness (Cont’d)

CEL721

EL-20

GROUND DISTRIBUTION/LHD MODELS
Main Harness (Cont’d)

CEL722

EL-21

GROUND DISTRIBUTION/LHD MODELS
Body Harness

CEL729

EL-22

GROUND DISTRIBUTION/LHD MODELS
Body No. 2 Harness

CEL730

EL-23

GROUND DISTRIBUTION/LHD MODELS
Back Door and Rear Window Defogger Harness

CEL731

EL-24

GROUND DISTRIBUTION/LHD MODELS
Room Lamp Harness

CEL734

EL-25

GROUND DISTRIBUTION/RHD MODELS
Engine Room Harness

CEL796

EL-26

GROUND DISTRIBUTION/RHD MODELS
Engine Room Harness (Cont’d)

CEL797

EL-27

GROUND DISTRIBUTION/RHD MODELS
Engine Room Harness (Cont’d)

CEL798

EL-28

GROUND DISTRIBUTION/RHD MODELS
Engine Room Harness (Cont’d)
RD ENGINE

CEL802

EL-29

GROUND DISTRIBUTION/RHD MODELS
Main Harness

CEL803

EL-30

GROUND DISTRIBUTION/RHD MODELS
Main Harness (Cont’d)

CEL804

EL-31

GROUND DISTRIBUTION/RHD MODELS
Main Harness (Cont’d)

CEL805

EL-32

GROUND DISTRIBUTION/RHD MODELS
Body Harness

CEL806

EL-33

GROUND DISTRIBUTION/RHD MODELS
Body No. 2 Harness

CEL807

EL-34

GROUND DISTRIBUTION/RHD MODELS
Back Door and Rear Window Defogger Harness

CEL791

EL-35

GROUND DISTRIBUTION/RHD MODELS
Room Lamp Harness

CEL799

EL-36

BATTERY
CAUTION:
If it becomes necessary to start the engine with a booster battery and jumper cables,
a. Use a 12-volt booster battery.
b. After connecting battery cables, ensure that they are
tightly clamped to battery terminals for good contact.
c. Never add distilled water through the hole used to check
specific gravity.

How to Handle Battery
METHODS OF PREVENTING OVER-DISCHARGE

MEL040F

The following precautions must be taken to prevent over-discharging a battery.
+ The battery surface (particularly its top) should always be kept
clean and dry.
+ The terminal connections should be clean and tight.
+ At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as ‘‘low maintenance’’
and ‘‘maintenance-free’’.
+

When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal.

Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte. Keep
a close check on charge condition to prevent over-discharge.

MEL041F

MEL042F

CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If acid contacts eyes, skin or clothing, immediately
flush with water for 15 minutes and seek medical attention.

EL-37

BATTERY
How to Handle Battery (Cont’d)
+
+

Remove the cell plug using a suitable tool.
Add distilled water up to the MAX level.

MEL043F

SULPHATION
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates.
To determine if a battery has been ‘‘sulphated’’, note its voltage and current when charging it. As shown in the figure, less
current and higher voltage are observed in the initial stage of
charging sulphated batteries.
A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.
SEL709E

SPECIFIC GRAVITY CHECK
1. Read hydrometer and thermometer indications at eye level.

MEL042FA

EL-38

BATTERY
How to Handle Battery (Cont’d)
2. Convert into specific gravity at 20°C (68°F).
Example:
+ When electrolyte temperature is 35°C (95°F) and specific gravity of electrolyte is 1.230, converted specific gravity at 20°C
(68°F) is 1.240.
+ When electrolyte temperature is 0°C (32°F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20°C
(68°F) is 1.196.

SEL007Z

EL-39

BATTERY
Battery Test and Charging Chart
Chart I

VISUAL INSPECTION
+ Check battery case for cracks or bends.
+ Check battery terminals for damage.
+ If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in), it is OK.
OK

Replace
battery.

CHECKING SPECIFIC GRAVITY
Refer to ‘‘Specific Gravity Check’’.

Below 1.100

SLOW CHARGE
Refer to ‘‘A: Slow
Charge’’.

1.100 — 1.220

Above 1.220

QUICK CHARGE
Refer to ‘‘C: Quick Charge’’.

STANDARD CHARGE
Refer to ‘‘B: Standard
Charge’’.

CAPACITY TEST
Refer to ‘‘Chart II’’.

Ready for use
+ Mount battery again and
check loose terminals.
Also check other related
circuits.

CAPACITY TEST
Refer to ‘‘Chart II’’.

Replace
battery.

Ready for use

CHECKING SPECIFIC
GRAVITY
Refer to ‘‘Specific Gravity
Check’’.

QUICK CHARGE
Refer to ‘‘C: Quick Charge’’.
+ Time required: 45 min.

RECHARGE
Refer to ‘‘C: Quick Charge’’.
+ If battery temperature rises above 60°C (140°F), stop
charging. Always charge battery when its temperature
is below 60°C (140°F).

Ready for use

CAPACITY TEST
Refer to ‘‘Chart II’’.
OK

CAPACITY TEST
Refer to ‘‘Chart II’’.

CAPACITY TEST
Refer to ‘‘Chart II’’.
OK

Ready for
use

.
.

Ready for Replace
use
battery.
* ‘‘STANDARD CHARGE’’ is recommended if the vehicle is in storage after charging.

EL-40

Replace
battery.

BATTERY
Battery Test and Charging Chart (Cont’d)
+ Check battery type and determine the specified current
using the following table.
Fig. 1 DISCHARGING CURRENT
(Load Tester)

Chart II

CAPACITY TEST

Test using battery checker.

Test using load tester.

Ready for use

Current (A)

28B19R(L)

34B19R(L)

46B24R(L)

135

55B24R(L)

135

50D23R(L)

150

55D23R(L)

180

65D26R(L)

195

80D26R(L)

195

75D31R(L)

210

95D31R(L)

240

115D31R(L)

240

95E41R(L)

300

130E41R(L)

330

Follow manufacturer’s instructions to check and determine
if battery is serviceable.

Type

Read load tester voltage
when specified discharging
current (Refer to Fig. 1.) flows
through battery for 15 seconds.

Go to next
step.
.

Above 9.6
volts

Below 9.6
volts

OK
.

Ready for use

NG
.

Go to next
step.

SEL008Z

EL-41

BATTERY
Battery Test and Charging Chart (Cont’d)
A: SLOW CHARGE

Determine initial charging current from specific gravity referring to Fig. 2.
Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)

Below
1.100
.

Below 12 volts or above 15
volts

12 to 15 volts
OK

4.0
(A)

5.0
(A)

7.0
(A)

8.0
(A)

9.0
(A)

10.0
(A)

130E41R(L)

95E41R(L)

115D31R(L)

95D31R(L)

75D31R(L)

80D26R(L)

65D26R(L)

50D23R(L)

55B24R(L)

46B24R(L)

34B19R(L)

28B19R(L)

CONVERTED
SPECIFIC
GRAVITY

55D23R(L)

BATTERY TYPE

+ Charge battery.
+ Check charging voltage 30 minutes after starting the battery charge.

14.0
(A)

+ Check battery type and determine the specified current using the table
shown above.
+ After starting charging, adjustment of charging current is not necessary.

Fig. 3 ADDITIONAL CHARGE (Slow charge)

Continue to charge for 12
hours.

Replace battery.

Below 1.150

CHECKING SPECIFIC GRAVITY
Refer to ‘‘Specific Gravity Check’’.

Charge for 5
hours at initial charging
current setting.

1.150 — 1.200

1.200 — 1.240

Above 1.240

Charge for 4
hours at initial charging
current setting.

Charge for 2
hours at initial charging
current setting.

Conduct additional charge as per Fig. 3, if necessary.
.

Go to ‘‘CAPACITY TEST’’.
.

Go to ‘‘CAPACITY TEST’’.

CAUTION:
+ Set charging current to value specified in Fig. 2. If charger
is not capable of producing specified current value, set its
charging current as close to that value as possible.
+ Keep battery away from open flame while it is being
charged.
+ When connecting charger, connect leads first, then turn on
charger. Do not turn on charger first, as this may cause a
spark.
+ If battery temperature rises above 60°C (140°F), stop
charging. Always charge battery when its temperature is
below 60°C (140°F).

EL-42

BATTERY
Battery Test and Charging Chart (Cont’d)
B: STANDARD CHARGE

Fig. 4 INITIAL CHARGING CURRENT SETTING
(Standard charge)

Determine initial charging current from
specific gravity, referring to Fig. 4.

CONVERTED
SPECIFIC
GRAVITY

CHECKING SPECIFIC GRAVITY
Refer to ‘‘Specific Gravity Check’’.

130E41R(L)

115D31R(L)

7.0 (A)

8.0
(A)

9.0 (A)

13.0
(A)

1.130 — 1.160

3.0 (A)

4.0 (A)

5.0 (A)

6.0 (A)

7.0
(A)

8.0 (A)

11.0
(A)

1.160 — 1.190

2.0 (A)

3.0 (A)

4.0 (A)

5.0 (A)

6.0
(A)

7.0 (A)

9.0
(A)

1.190 — 1.220

2.0 (A)

3.0 (A)

4.0 (A)

5.0
(A)

5.0 (A)

7.0
(A)

95E41R(L)

95D31R(L)

65D26R(L)

55D23R(L)

6.0 (A)

55B24R(L)

5.0 (A)

46B24R(L)

4.0 (A)

34B19R(L)

1.100 — 1.130

28B19R(L)

75D31R(L)

80D26R(L)

Charge battery for 8 hours.

50D23R(L)

BATTERY TYPE

+ Check battery type and determine the specified current using the table shown above.
+ After starting charging, adjustment of charging current is not necessary.
Fig. 5 ADDITIONAL CHARGE (Standard charge)

Below 1.150

1.150 — 1.200

1.200 — 1.240

Above 1.240

Conduct additional charge as per Fig. 5, if
necessary.

.
.

Go to ‘‘CAPACITY TEST’’.

Charge for 3.5
hours at initial
charging current
setting.

Charge for 2.5
hours at initial
charging current
setting.

Charge for 1.5
hours at initial
charging current
setting.

Go to ‘‘CAPACITY TEST’’.

CAUTION:
+ Do not use standard charge method on a battery whose specific gravity is less than 1.100.
+ Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
+ Keep battery away from open flame while it is being charged.
+ When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
+ If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).

EL-43

BATTERY
Battery Test and Charging Chart (Cont’d)

CONVERTED SPECIFIC GRAVITY

Charge battery.

Go to ‘‘CAPACITY TEST’’.

15 (A)

20 (A)

30 (A)

1.100 — 1.130

2.5 hours

1.130 — 1.160

2.0 hours

1.160 — 1.190

1.5 hours

1.190 — 1.220

1.0 hours

Above 1.220

0.75 hours (45 min.)

130E41R(L)

95E41R(L)

115D31R(L)

95D31R(L)

75D31R(L)

80D26R(L)

65D26R(L)

55D23R(L)

50D23R(L)

55B24R(L)

10 (A)

46B24R(L)

CURRENT [A]

Determine initial charging current setting and charging time from specific gravity, referring to Fig. 6.

34B19R(L)

BATTERY TYPE

28B19R(L)

Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick
charge)

C: QUICK CHARGE

40
(A)

+ Check battery type and determine the specified current using the table shown
above.
+ After starting charging, adjustment of charging current is not necessary.

CAUTION:
+ Do not use quick charge method on a battery whose specific gravity is less than 1.100.
+ Set initial charging current to value specified in Fig. 6. If charger is not capable of producing
specified current value, set its charging current as close to that value as possible.
+ Keep battery away from open flame while it is being charged.
+ When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
+ Be careful of a rise in battery temperature because a large current flow is required during quickcharge operation.
If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).
+ Do not exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.

Service Data and Specifications (SDS)
RD28

Applied
model

Standard

Cold areas for Europe

Type

95D31L

115D31L

12-80

Capacity
V-AH

EL-44

STARTING SYSTEM
Wiring Diagram — START —

TEL400A

EL-45

STARTING SYSTEM
Trouble Diagnoses
If any abnormality is found, immediately disconnect battery negative terminal.
Starter does not stop.

Replace magnetic switch.

Engine does not start.
.

Does engine turn by cranking?

Yes
c

Yes

Does engine turn normally?

Check ignition/fuel system.

No (Turns slowly.)
.

Check battery as follows:
+ Charging condition
+ Terminal connections
+ Terminal corrosion
.

Repair starter motor.

j
A
.

Does starter motor turn?

Yes
c

Yes

Does gear shaft turn?

Check pinion clutch.

No
.

Check reduction gear, armature
and gear shaft.
.

Check fuse and fusible link.

NG
c

Replace.

OK
.

Check battery as follows:
+ Charging condition
+ Terminal connections
+ Terminal corrosion

A
j

OK
.

Check starting system wiring.

.
c + Charge battery.
+ Repair connections and corrosion of battery terminals.

NG
c

Repair.

OK
.

Does magnetic switch operation
sound occur?

No
c

Replace magnetic switch.

Yes
.

Check condition of pinion and ring
gear mesh.

OK
c

Does starter turn under no load by
connecting wires as follows?

Yes
c

Replace magnetic switch.

NG
.

+ Adjust pinion movement.
+ Check pinion moving mechanism.
+ Check ring gear.

SEL009Z

EL-46

Repair starter motor.

STARTING SYSTEM
Construction

MEL996DB

Removal and Installation

MEL609I

Inspection
MAGNETIC SWITCH CHECK
+
+
1.
+

Before starting to check, disconnect battery ground cable.
Disconnect ‘‘M’’ terminal of starter motor.
Continuity test (between ‘‘S’’ terminal and switch body).
No continuity … Replace.

SEL036H

EL-47

STARTING SYSTEM
Inspection (Cont’d)
2. Continuity test (between ‘‘S’’ terminal and ‘‘M’’ terminal).
+ No continuity … Replace.

SEL038H

PINION/CLUTCH CHECK

SEL630BA

1. Inspect pinion teeth.
+ Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
+ Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
+ If it locks or rotates in both directions, or unusual resistance is
evident. … Replace.

BRUSH CHECK
Brush
Check wear of brush.
Wear limit length:
Refer to SDS (EL-51).
+ Excessive wear … Replace.

SEL014Z

Brush spring pressure
Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
Refer to SDS (EL-51).
+ Not within the specified values … Replace.

SEL015Z

Brush holder
1. Perform insulation test between brush holder (positive side)
and its base (negative side).
+ Continuity exists. … Replace.
2. Check brush to see if it moves smoothly.
+ If brush holder is bent, replace it; if sliding surface is dirty, clean.

SEL568B

EL-48

STARTING SYSTEM
Inspection (Cont’d)
YOKE CHECK
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.

SEL305H

ARMATURE CHECK
1.
+
2.
+

Continuity test (between two segments side by side).
No continuity … Replace.
Insulation test (between each commutator bar and shaft).
Continuity exists. … Replace.

SEL019Z

3. Check commutator surface.
+ Rough … Sand lightly with No. 500 — 600 emery paper.

SEL020Z

4. Check diameter of commutator.
Commutator minimum diameter:
Refer to SDS (EL-51).
+ Less than specified value … Replace.

SEL021Z

EL-49

STARTING SYSTEM
Inspection (Cont’d)
5. Check depth of insulating mold from commutator surface.
+ Less than 0.2 mm (0.008 in) … Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)

SEL022Z

Assembly
Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.

PINION PROTRUSION LENGTH ADJUSTMENT
Clearance ‘‘!’’
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance ‘‘!’’ between the front edge
of the pinion and the pinion stopper.
Clearance ‘‘!’’:
Refer to SDS (EL-51).

SEL026Z

Movement ‘‘!’’
Compare movement ‘‘!’’ in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement ‘‘!’’:
Refer to SDS (EL-51).

SEL497D

EL-50

STARTING SYSTEM
Assembly (Cont’d)
+

Not in the specified value … Adjust by adjusting plate.

SEL633BA

Service Data and Specifications (SDS)
STARTER
S13-502
Type

HITACHI make
Reduction gear type

Applied model
System voltage

RD28
V

No-load
Terminal voltage

Current

Less than 125

Revolution

rpm

4,000

Minimum diameter of commutator
mm (in)

35.5 (1.398)

Minimum length of brush mm (in)

11 (0.43)

Brush spring tension
N (kg, lb)

28.4 — 34.3
(2.9 — 3.5,
6.4 — 7.7)

Clearance between bearing metal
and armature shaft
mm (in)

—

Clearance ‘‘!’’ between pinion
front edge and pinion stopper
mm (in)

—

Movement ‘‘!’’ in height of pinion
assembly
mm (in)

0.3 — 2.0
(0.012 — 0.079)

EL-51

CHARGING SYSTEM
Wiring Diagram — CHARGE —

YEL782A

EL-52

CHARGING SYSTEM
Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test. The alternator can be checked easily by referring to the Inspection Table.
+ Before starting, inspect the fusible link.
+ Use fully charged battery.

WITH IC REGULATOR

Ignition switch
‘‘ON’’

Warning lamp
‘‘OFF’’

Disconnect connector (S, L) and
ground L harness side.

Check the following:
+ Warning
lamp bulb
+ Fuse for
warning lamp

Warning lamp
‘‘OFF’’

Warning lamp
‘‘ON’’

Damaged IC
regulator.
Replace.

Warning lamp
‘‘ON’’

Engine start.
Engine speed:
1,500 rpm

Warning lamp
‘‘ON’’

Warning lamp
‘‘OFF’’

Check the following:
+ Drive belt
+ Fuse for S terminal
+ Connector (S, L terminal) connection

Engine idling

Warning lamp
‘‘OFF’’

More than
15.5V

Damaged IC
regulator.
Replace.

No generation

Field circuit is
open.

Warning lamp
‘‘ON’’
Engine speed:
1,500 rpm
(Measure B
terminal voltage)

Warning lamp: ‘‘CHARGE’’ warning lamp in combination meter

Note:
+ If the inspection result is OK even though the charging system is malfunctioning, check the B terminal connection. (Check the tightening torque.)
+ When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.

MALFUNCTION INDICATOR
The IC regulator warning function activates to illuminate ‘‘CHARGE’’ warning lamp, if any of the following
symptoms occur while alternator is operating:
+ Excessive voltage is produced.
+ No voltage is produced.

EL-53

CHARGING SYSTEM
Construction

YEL783A

Removal and Installation
CAUTION:
+ Start service operation after removing the negative terminal from the battery.
+ Also remove the undercover, if equipped, before servicing.

MEL610I

Disassembly
REAR COVER
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
SEL032Z

EL-54

CHARGING SYSTEM
Disassembly (Cont’d)
REAR BEARING
CAUTION:
+ Do not reuse rear bearing after removal. Replace with a
new one.
+ Do not lubricate rear bearing outer race.

Inspection
ROTOR CHECK

SEL033Z

1. Resistance test
Resistance: Refer to SDS (EL-56).
+ Not within the specified values … Replace rotor.
2. Insulator test
+ Continuity exists … Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to SDS (EL-56).
+ Not within the specified values … Replace rotor.

BRUSH CHECK
1.
+
2.
+

Check smooth movement of brush.
Not smooth … Check brush holder and clean.
Check brush for wear.
Replace brush if it is worn down to the limit line.

SEL631DA

STATOR CHECK
1. Continuity test
+ No continuity … Replace stator.

SEL108E

2. Ground test
+ Continuity exists … Replace stator.

SEL109E

EL-55

CHARGING SYSTEM
Assembly
RING FITTING IN REAR BEARING
Fix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
+

SEL044Z

REAR COVER INSTALLATION
1. Fit brush assembly, diode assembly, regulator assembly and
stator.
2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.

SEL048Z

SEL049Z

Service Data and Specifications (SDS)
ALTERNATOR
A3TA4399
Type
MITSUBISHI
Applied model

RD28

Nominal rating

V-A

Ground polarity

12-100
Negative

Minimum revolution under no-load
(When 13.5V is applied)
rpm
Hot output current
(When 13.5V is applied)
A/rpm

Less than 1,300
More than 35/1,300
More than 72/2,500

Regulated output voltage

Minimum length of brush

mm (in)

5 (0.20)

N (g, oz)

4.6 — 5.8
(470 — 590, 16.58 — 20.81)

Brush spring pressure
Slip ring minimum outer diameter
mm (in)
Rotor (Field coil) resistance

EL-56

Ω

14.1 — 14.7

22.1 (0.870)
2.1 — 2.5

COMBINATION SWITCH
Check
RHD MODELS AND LHD MODELS

CEL781

EL-57

COMBINATION SWITCH
Replacement
For removal and installation of spiral cable, refer to RS section
[‘‘Installation — Air Bag Module and Spiral Cable’’, ‘‘SUPPLEMENTAL RESTRAINT SYSTEM (SRS)’’].
+ Each switch can be replaced without removing combination
switch base.

MEL304D

To remove combination switch base, remove base attaching
screw.

Before installing the steering wheel, align the steering wheel
guide pins with the screws which secure the combination switch
as shown in the left figure.

MEL326G

SEL151V

EL-58

STEERING SWITCH
Check
WITH ASCD

CEL782

EL-59

STEERING SWITCH
Check (Cont’d)
WITHOUT ASCD

CEL783

EL-60

HEADLAMP — Conventional Type —
Wiring Diagram — H/LAMP —

TEL403A

EL-61

HEADLAMP — Conventional Type —
Trouble Diagnoses
Symptom
LH headlamps do not operate.

Possible cause
1. Bulb
2. Grounds
3. 15A fuse

E25

and

E40

1. Bulb
2. Grounds
3. 15A fuse

E25

1. Check bulb.
2. Check grounds E25 and E40 .
3. Check 15A fuse (No. 51 , located in fuse and fusible

link box). Verify battery positive voltage is present at
terminal j
8 of lighting switch.
4. Check lighting switch.

4. Lighting switch
RH headlamps do not operate.

Repair order

and

E40

1. Check bulb.
2. Check grounds E25 and E40 .
3. Check 15A fuse (No. 52 , located in fuse and fusible

link box). Verify battery positive voltage is present at
5 of lighting switch.
terminal j
4. Check lighting switch.

4. Lighting switch
LH high beams do not operate, but 1. Bulbs
LH low beam operates.
2. Open in LH high beams circuit
3. Lighting switch
LH low beam does not operate, but 1. Bulb
LH high beam operates.
2. Open in LH low beam circuit
3. Lighting switch
RH high beams do not operate, but 1. Bulbs
RH low beam operates.
2. Open in RH high beams circuit
3. Lighting switch
RH low beam does not operate, but 1. Bulb
RH high beam operates.
2. Open in RH low beam circuit
3. Lighting switch
High beam indicator does not work. 1. Bulb
2. Grounds M30 and M98
3. Open in high beam circuit

EL-62

1. Check bulbs.
2. Check R/L wire between lighting switch and LH headlamps for an open circuit.
3. Check lighting switch.
1. Check bulb.
2. Check R/G wire between lighting switch and LH headlamp for an open circuit.
3. Check lighting switch.
1. Check bulbs.
2. Check R/Y wire between lighting switch and RH headlamps for an open circuit.
3. Check lighting switch.
1. Check bulb.
2. Check R/B wire between lighting switch and RH headlamp for an open circuit.
3. Check lighting switch.
1. Check bulb in combination meter.
2. Check grounds M30 and M98 .
3. Check R/L wire between lighting switch and combination meter for an open circuit.

HEADLAMP — Conventional Type —
Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replaceable halogen bulb. The bulb can be replaced from the engine compartment side without removing the headlamp body.
+ Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
2. Turn the bulb retaining ring counterclockwise until it is free from
the headlamp reflector, and then remove it.
3. Disconnect the harness connector from the back side of the
bulb.
4. Remove the headlamp bulb carefully. Do not shake or rotate
the bulb when removing it.
5. Install in the reverse order of removal.
CAUTION:
Do not leave headlamp reflector without bulb for a long period
of time. Dust, moisture, smoke, etc. entering headlamp body
may affect the performance of the headlamp. Remove headlamp bulb from the headlamp reflector just before a replacement bulb is installed.

SEL995K

Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers should be
in good repair, calibrated and operated in accordance with respective operation manuals.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is no-load in vehicle (coolant, engine oil
filled up to correct level and full fuel tank) other than the
driver (or equivalent weight placed in driver’s position).

CAUTION:
Be sure aiming switch is set to ‘‘0’’ when performing aiming
adjustment on vehicles equipped with headlamp aiming control.

SEL466V

EL-63

HEADLAMP — Conventional Type —
Aiming Adjustment (Cont’d)
LOW BEAM
1. Turn headlamp low beam on.
2. Use adjusting screws to perform aiming adjustment.
+ First tighten the adjusting screw all the way and then make
adjustment by loosening the screw.

CEL735

Adjust headlamps so that main axis of light is parallel to
center line of body and is aligned with point P shown in
illustration.
+ Figure to the left shows headlamp aiming pattern for driving on right side of road; for driving on left side of road,
aiming pattern is reversed.
+ Dotted lines in illustration show center of headlamp.
‘‘H’’:
Horizontal center line of headlamps
‘‘WL’’: Distance between each headlamp center
‘‘L’’:
5,000 mm (196.85 in)
‘‘C’’:
63 mm (2.48 in)
+

SEL254I

EL-64

HEADLAMP — Daytime Light System —
System Description
OPERATION
Headlamp system on vehicles for North Europe contains a daytime light system. The unit operates to illuminate headlamps low beam, parking, tail, license lamps and illuminations automatically in the following conditions.
+ The engine is running with lighting switch in OFF position.
When the any of following conditions exists, the daytime light operation will be canceled.
+ Ignition switch is in any position other than ON
+ Engine is stopped
+ Lighting switch is turned to 1st or 2nd position.
If the daytime light system is canceled, lighting switch operations are the same as for conventional light system.

DAYTIME LIGHT IS OPERATING
(With engine running and lighting switch in OFF position)

SEL490V

With engine running, power is supplied
+ from alternator terminal L
+ through daytime light control unit terminal j
8
+ to base of transistor-2 in the daytime light control unit.
The transistor-2 supplies ground path to all relays. Then the relays energize to illuminate lamps.

EL-65

HEADLAMP — Daytime Light System —
System Description (Cont’d)
DAYTIME LIGHT IS CALCELED
(Lighting switch in 1st or 2nd position or ignition switch in START position)

SEL491V

+ Ignition switch is in START position
+ Lighting switch is in 1st or 2nd position.
When one of the above conditions exists, power is supplied
+ to base of the transistor-1 in daytime light control unit
+ through daytime light control unit terminal j
11 or j
6 .
And then, power supply path to the base transistor-2 is interrupted to cancel daytime light operation.

EL-66

HEADLAMP — Daytime Light System —
Wiring Diagram — DTRL —

TEL635A

EL-67

HEADLAMP — Daytime Light System —
Wiring Diagram — DTRL — (Cont’d)

TEL636A

EL-68

HEADLAMP — Daytime Light System —
Trouble Diagnoses
DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE
Terminal No.

Connections

INPUT (I)/
OUTPUT (O)

Operated condition

Voltage (V)
(Approximate
values)

Power source for illumination & tail lamp

—

Power source for headlamp LH

—

Power source for headlamp RH

—

ON (daytime light operating*)

Headlamp RH

O
OFF

ON (daytime light operating*)

OFF

Headlamp LH

Start signal

Power source

Alternator ‘‘L’’ terminal

—

Ground

—

Illumination & tail lamp

Lighting switch

ON, ACC or OFF

ON or START

ACC or OFF

Running

Stopped

Ignition switch

START
Ignition switch

Engine
—

—

ON (daytime light operating*)

OFF

1STz2ND position

OFF

*: Daytime light operating: Lighting switch in ‘‘OFF’’ position with engine running.

Bulb Replacement
Refer to ‘‘HEADLAMP’’ (EL-63).

Aiming Adjustment
Refer to ‘‘HEADLAMP’’ (EL-63).

EL-69

HEADLAMP — Headlamp Aiming Control —
System Description
CIRCUIT OPERATION
[Example]
Aiming switch ‘‘0’’
+

When the aiming switch is set to ‘‘0’’, the motor will not start.
This is because the power terminals are positioned at the nonconductive section of the sensor’s rotary unit.

SEL465M

Aiming switch ‘‘0’’ → ‘‘1’’
+

+
+

When the aiming switch is moved from ‘‘0’’ to ‘‘1’’, the sensor’s
conductive section activates the relay. Power is supplied
through the relay to the motor. The headlamps will then move
in the ‘‘DOWN’’ direction.
The motor continues to rotate while the rotary unit of the sensor moves from point A to point B.
The power terminals will then be positioned at the nonconductive section, disconnecting the power to the motor. The motor
will then stop.

SEL364P

Aiming switch ‘‘1’’ → ‘‘0’’
+

When the aiming switch is moved from ‘‘1’’ to ‘‘0’’, the sensor’s
conductive section activates the relay. Power is supplied
through the relay to the motor. The motor will rotate to move the
headlamps in the ‘‘UP’’ direction.
When the rotary unit of the sensor moves from point B to point
A, the motor will stop.

SEL365P

EL-70

HEADLAMP — Headlamp Aiming Control —
Wiring Diagram — H/AIM —

TEL406A

EL-71

HEADLAMP — Headlamp Aiming Control —
Wiring Diagram — H/AIM — (Cont’d)

TEL407A

EL-72

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type A
LHD MODELS
Rear combination lamps are located on rear bumper.

YEL784A

EL-73

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type A (Cont’d)

YEL785A

EL-74

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type B
RHD MODELS
Rear combination lamps are located on rear bumper.

YEL786A

EL-75

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type B (Cont’d)

YEL787A

EL-76

Stop Lamp
Wiring Diagram — STOP/L —/Type A
Rear combination lamps are located on rear bumper.

YEL788A

EL-77

BACK-UP LAMP
Wiring Diagram — BACK/L —/LHD Models

TEL411A

EL-78

BACK-UP LAMP
Wiring Diagram — BACK/L —/RHD Models

TEL640A

EL-79

REAR FOG LAMP
Wiring Diagram — R/FOG —

TEL641A

EL-80

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type A
LHD MODELS
Rear combination lamps are located on rear bumper.

YEL789A

EL-81

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type A (Cont’d)

YEL790A

EL-82

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type B
RHD MODELS
Rear combination lamps are located on rear bumper.

YEL791A

EL-83

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type B (Cont’d)

YEL792A

EL-84

TURN SIGNAL AND HAZARD WARNING LAMPS
Trouble Diagnoses
Symptom

Possible cause

Repair order

Turn signal and hazard warning
lamps do not operate.

1. Hazard switch
1. Check hazard switch.
2. Combination flasher unit
2. Refer to combination flasher unit check.
3. Open in combination flasher unit 3. Check wiring to combination flasher unit for open circircuit
cuit.

Turn signal lamps do not operate
but hazard warning lamps operate.

1. 7.5A fuse

1. Check 7.5A fuse [No. 11 , located in fuse block
(J/B)]. Turn ignition switch ON and verify battery
positive voltage is present at terminal j
2 of hazard
switch.
2. Hazard switch
2. Check hazard switch.
3. Turn signal switch
3. Check turn signal switch.
4. Open in turn signal switch circuit 4. Check harness between combination flasher unit and
turn signal switch for open circuit.

Hazard warning lamps do not oper- 1. 15A fuse
ate but turn signal lamps operate.
2. Hazard switch
3. Open in hazard switch circuit
Front turn signal lamp LH or RH
does not operate.

1. Bulb
2. Grounds

and

E40

Rear turn signal lamp LH or RH
does not operate.

1. Bulb
2. Grounds B23 and
B112 and D106

D83

LH and RH turn indicators do not
operate.
LH or RH turn indicator does not
operate.

1. Check 10A fuse (No. 48 , located in fuse and fusible
link box). Verify battery positive voltage is present at
terminal j
3 of hazard switch.
2. Check hazard switch.
3. Check harness between combination flasher unit and
hazard switch for open circuit.
1. Check bulb.
2. Check grounds

E25

and

E40

1. Check bulb.
2. Check grounds

B23

and

D83

1. Ground

1. Check grounds

M30

and

M98

1. Bulb

1. Check bulb in combination meter.

E25

.
or B112 and D106 .
.

Electrical Components Inspection
COMBINATION FLASHER UNIT CHECK
+
+

Before checking, ensure that bulbs meet specifications.
Connect a battery and test lamp to the combination flasher unit,
as shown. Combination flasher unit is properly functioning if it
blinks when power is supplied to the circuit.

SEL122E

EL-85

ILLUMINATION
Schematic

TEL417A

EL-86

ILLUMINATION
Wiring Diagram — ILL —

TEL418A

EL-87

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL419A

EL-88

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL420A

EL-89

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL421A

EL-90

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL422A

EL-91

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL423A

EL-92

INTERIOR ROOM LAMP — With Timer —
System Description
Front interior room lamp timer is controlled by smart entrance control unit while interior room lamp switch is
in the ‘‘DOOR’’ position.
Smart entrance control unit does not control rear interior room lamp.

TIMER OPERATION
Interior room lamp timer keeps interior room lamp illuminated for about 15 seconds when:
+ driver’s door is unlocked while key is out of ignition key cylinder,
+ key is withdrawn from ignition key cylinder while driver’s door is closed, and
+ driver’s door is opened and then closed while ignition switch is not in the ‘‘ON’’ position.
The timer is cancelled, and interior room lamp turns off when:
+ driver’s door is locked, or
+ ignition switch is turned ‘‘ON’’.

ON-OFF CONTROL
When the front driver side door, front passenger side door, rear LH door, rear RH door or back door is opened,
interior room lamp turns on.
When driver side door is opened and then closed while ignition switch is not in the ON position, interior room
lamp timer operates. (Timer does not operate when doors other than the driver side door is opened and
closed.)

EL-93

INTERIOR ROOM LAMP — With Timer —
Schematic

TEL611A

EL-94

INTERIOR ROOM LAMP — With Timer —
Wiring Diagram — ROOM/L —/LHD Models

TEL607A

EL-95

INTERIOR ROOM LAMP — With Timer —
Wiring Diagram — ROOM/L —/LHD Models
(Cont’d)

TEL608A

EL-96

INTERIOR ROOM LAMP — With Timer —
Wiring Diagram — ROOM/L —/LHD Models
(Cont’d)

TEL609A

EL-97

INTERIOR ROOM LAMP — With Timer —
Wiring Diagram — ROOM/L —/RHD Models

TEL646A

EL-98

INTERIOR ROOM LAMP — With Timer —
Wiring Diagram — ROOM/L —/RHD Models
(Cont’d)

TEL647A

EL-99

INTERIOR ROOM LAMP — With Timer —
Trouble Diagnoses
DIAGNOSTIC PROCEDURE
SYMPTOM: Front interior room lamp does not turn on when
any door is opened, or timer does not operate
properly.
Does room lamp turn on when room lamp
switch is in ‘‘ON’’ position?

No
c

Check the following.
+ Bulb
+ 10A fuse [No. 20 ,
located in the fuse block
(J/B)]
+ Harness for open or
short between fuse and
room lamp
+ Room lamp ground condition

Yes
SEL152VA

Does key warning chime operate properly?

No
c

Yes
SEL153VA

Check ‘‘WARNING
CHIME’’ system.
(Refer to EL-135.)

Does power door lock operate using driver
side knob lock switch?

No
c

Yes

Check ‘‘POWER DOOR
LOCK’’ system.
(Refer to EL-204.)

CHECK ROOM LAMP OUTPUT SIGNAL.
1. Turn room lamp switch to ‘‘DOOR’’
position.
2. Disconnect control unit connector.
3. Check voltage between control unit terminal j
17 and ground.
Battery voltage should exist.

NG
c

Check harness for open or
short between room lamp
and control unit.

OK
.

CHECK DOOR SWITCH INPUT SIGNAL.
1. Connect control unit connector.
2. Check voltage between control unit terminal j
10 and ground.
Condition

Voltage [V]

At least one door is
opened.

All doors are closed.

Approx. 12

OK
.

Replace control unit.

EL-100

NG
c

Check the following.
+ Door switch
+ Door switch ground condition
+ Harness for open or
short between control
unit and door switch

MAP AND VANITY MIRROR LAMPS
Wiring Diagram — INT/L —

TEL424A

EL-101

METER AND GAUGES
System Description
UNIFIED CONTROL METER
Speedometer, odo/trip meter, tachometer, fuel gauge and water temperature gauge are controlled totally
by control unit combined with speedometer.
+ Digital meter is adopted for odo/trip meter.*
*The record of the odo meter is kept even if the battery cable is disconnected. The record of the trip meter
is erased when the battery cable is disconnected.
+ Odo/trip meter segment can be checked in diagnosis mode.
+ Meter/gauge can be checked in diagnosis mode.
Note: Sub fuel gauge is not controlled by the control unit.
+

HOW TO CHANGE THE DISPLAY FOR ODO/TRIP METER

SEL253V

Note: Turn ignition switch to the ‘‘ON’’ position to operate odo/trip meter.

EL-102

METER AND GAUGES
Combination Meter

CEL785

EL-103

METER AND GAUGES
Wiring Diagram — METER —/LHD Models

TEL426A

EL-104

METER AND GAUGES
Wiring Diagram — METER —/LHD Models
(Cont’d)

TEL427A

EL-105

METER AND GAUGES
Wiring Diagram — METER —/RHD Models

TEL650A

EL-106

METER AND GAUGES
Wiring Diagram — METER —/RHD Models
(Cont’d)

TEL651A

EL-107

METER AND GAUGES
Meter/Gauge Operation and Odo/Trip Meter
Segment Check in Diagnosis Mode
DIAGNOSIS FUNCTION
+
+

Odo/trip meter segment can be checked in diagnosis mode.
Meters/gauges (except for sub fuel gauge) can be checked in
diagnosis mode.

HOW TO ALTERNATE DIAGNOSIS MODE
1. Turn ignition switch to ON and change odo/trip meter to ‘‘TRIP
A’’ or ‘‘TRIP B’’.
2. Turn ignition switch to OFF.
3. Turn ignition switch to ON when pushing odo/trip meter switch.
4. Confirm that trip meter indicates ‘‘000.0’’.
5. Push odo/trip meter switch more than three times within 5 seconds.

6. All odo/trip meter segments should be turned on.
NOTE: If some segments are not turned on, speedometer (unified meter control unit) with odo/trip meter should be
replaced.
At this point, the unified control meter is turned to diagnosis
mode.

SEL110V

7. Push odo/trip meter switch. Indication of each meter/gauge
should be as shown left during pushing odo/trip meter switch if
it is no malfunctioning.
NOTE: It takes about 1 minute for indication of fuel gauge to
become stable.

SEL111V

EL-108

METER AND GAUGES
Flexible Print Circuit (FPC)
Tachometer, fuel gauge and water temperature gauge are connected with unified meter control unit (speedometer) by Flexible
Print Circuit (FPC) connector. When replace or remove and install
unified control unit (speedometer), disconnect and connect FPC
connector according to the following steps.

DISCONNECT
1. Open connector cover.
2. Release connector lock by holding both ends of it and pulling it
up.
3. Disconnect FPC by pulling it up.

SEL109V

CONNECT
1. Insert FPC into connector and lock connector pushing FPC
downward.
2. Check secure connection of FPC.
3. Check continuity of check land terminal for secure connection
of FPC.
Resistance: 0Ω
4. Close connector cover.

SEL114V

EL-109

METER AND GAUGES
Trouble Diagnoses
PRELIMINARY CHECK
CHECK-IN

Can Diagnosis mode
be activated? Refer to
‘‘Meter/Gauge Operation and Odo/Trip Meter
Segment Check in
Diagnosis Mode’’,
EL-108.

No
c

Do meter warning
lamps operate?

Yes
c

Check the screws
securing speedometer
and FPC.
(The screws are
located behind the
combination meter. For
details refer to EL-114.)

Can Diagnosis mode
be activated?
m

Yes

Yes
.

Check power supply
and ground circuit.
Refer to ‘‘POWER
SUPPLY AND
GROUND CIRCUIT
CHECK’’, EL-111.
.

Check meter/gauge
operation in Diagnosis
mode.

Malfunction is indicated
in Diagnosis mode.

No malfunction is indicated in Diagnosis
mode.

Check the following:
+ FPC connector connection
Refer to ‘‘Flexible
Print Circuit (FPC)’’,
EL-109.
+ Screws securing the
malfunctioning
meter/gauge
(The screws are
located behind the
combination meter.
For details refer to
EL-114.)

SYMPTOM CHART 2
Refer to EL-111.

OK
.

SYMPTOM CHART 1
Refer to EL-111.

Reconnect FPC connector and check continuity between
check land terminals and/or repair malfunctioning part.
Refer to ‘‘Flexible Print Circuit (FPC)’’, EL-109.

EL-110

Replace speedometer
(unified meter control
unit).

METER AND GAUGES
Trouble Diagnoses (Cont’d)
SYMPTOM CHART
Symptom chart 1 (Malfunction is indicated in Diagnosis mode)
Symptom
Speedometer and/or odo/trip
meter indicate(s) malfunction
in Diagnosis mode.

Possible causes

Repair order

+ Speedometer (Unified meter control unit)

+ Replace speedometer (unified meter control unit).

+ Meter/Gauge
+ Speedometer (Unified meter control unit)

1. Check resistance of meter/gauge indicating malfunction. If
the resistance is NG, replace the meter/gauge. Refer to
‘‘METER/GAUGE RESISTANCE CHECK’’, EL-114.
2. If the resistance is OK, replace speedometer (unified meter
control unit).

Multiple meter/gauge indicate
malfunction in Diagnosis
mode.
One of tachometer/fuel gauge/
water temp. gauge indicates
malfunction in Diagnosis
mode.

Symptom chart 2 (No malfunction is indicated in Diagnosis mode)
Symptom
Speedometer and odo/trip
meter are malfunctioning.

Possible causes

Repair order

1. Sensor
— Speedometer, Odo/Trip meter
2. FPC connector

1. Check vehicle speed sensor.
INSPECTION/VEHICLE SPEED SENSOR (Refer to EL-112.)
2. Check FPC connector. Refer to ‘‘Flexible Print Circuit
(FPC)’’, EL-109.
3. Replace speedometer (unified meter control unit).

3. Speedometer (Unified meter control unit)
Multiple meter/gauge are malfunctioning. (except
speedometer, odo/trip meter)

1. FPC connector

One of tachometer/fuel gauge/
water temp. gauge is malfunctioning.

1. Sensor/Engine revolution signal
— Tachometer

1. Check FPC connector. Refer to ‘‘Flexible Print Circuit
(FPC)’’, EL-109.
2. Replace speedometer (unified meter control unit).

2. Speedometer (Unified meter control unit)

1. Check the sensor for malfunctioning meter/gauge.
INSPECTION/ENGINE REVOLUTION SIGNAL (Refer to
EL-113.)
INSPECTION/FUEL TANK GAUGE (Refer to EL-113.)
INSPECTION/THERMAL TRANSMITTER (Refer to EL-114.)
2. Check FPC connector. Refer to ‘‘Flexible Print Circuit
(FPC)’’, EL-109.
3. Replace speedometer (unified meter control unit).

— Fuel gauge
— Water temp. gauge
2. FPC connector
3. Speedometer (Unified meter control unit)

Before starting trouble diagnoses above, perform PRELIMINARY CHECK, EL-110.

POWER SUPPLY AND GROUND CIRCUIT CHECK
Power supply circuit check
Terminals

Ignition switch position

⊕

OFF

ACC

j
33

Ground

Battery
voltage

j
9

Ground

Battery
voltage

If NG, check the following.
+ 7.5A fuse [No. 24 , located in fuse block (J/B)]
+ 10A fuse [No. 28 , located in fuse block (J/B)]
+ Harness for open or short between fuse and combination meter

SEL419V

EL-111

METER AND GAUGES
Trouble Diagnoses (Cont’d)
Ground circuit check
Terminals

Continuity

j
5 — Ground

Yes

SEL420V

INSPECTION/VEHICLE SPEED SENSOR
CHECK VEHICLE SPEED SENSOR
OUTPUT.
1. Remove vehicle speed sensor from
transmission.
2. Check voltage between combination
meter terminals j
43 and j
45 while quickly
turning speed sensor pinion.
Voltage: Approx. 0.5V

OK
c

Vehicle speed sensor is
OK.

Replace vehicle speed
sensor.

NG
.

CHECK VEHICLE SPEED SENSOR.
Check resistance between vehicle speed
sensor terminals j
1 and j
2 .
Resistance: Approx. 250Ω
OK
.

SEL421V

Check harness for open or short between
speedometer and vehicle speed sensor.

SEL422V

EL-112

METER AND GAUGES
Trouble Diagnoses (Cont’d)
INSPECTION/ENGINE REVOLUTION SIGNAL
Terminals
Engine

RD28 (Injection)

Check item

DC voltage

⊕

j
44

Explanation
@
Higher rpm = Higher voltage
Lower rpm = Lower voltGround
age
Voltage should change
with rpm.

SEL423V

Engine
TB45E, RD28
(Injection)

Check item
+ Harness for open or short and connection

SEL461V

INSPECTION/FUEL TANK GAUGE (MAIN)
CHECK GROUND CIRCUIT FOR FUEL
TANK GAUGE UNIT.
Check harness continuity between fuel
tank gauge unit terminal j
2 and ground.
Continuity should exist.

NG
c

Repair harness or connector.

Repair or replace.
Refer to FE section.

Repair harness or connector.

OK
.
SEL424V

CHECK GAUGE UNITS.
Refer to ‘‘FUEL TANK GAUGE UNIT
CHECK’’ (EL-115).

SEL425V

CHECK HARNESS FOR OPEN OR
SHORT.
1. Disconnect combination connector and
fuel tank gauge unit connector.
2. Check continuity between combination
meter terminal j
46 and fuel tank gauge
unit terminal j
1 .
Continuity should exist.
3. Check continuity between combination
meter terminal j
46 and ground.
Continuity should not exist.
OK
.

Fuel tank gauge is OK.

EL-113

METER AND GAUGES
Trouble Diagnoses (Cont’d)
INSPECTION/THERMAL TRANSMITTER
NG

CHECK THERMAL TRANSMITTER.
Refer to ‘‘THERMAL TRANSMITTER
CHECK’’ (EL-115).

Repair or replace.

OK
.

SEL426V

CHECK HARNESS FOR OPEN OR
SHORT.
1. Disconnect combination connector and
thermal transmitter connector.
2. Check continuity between combination
meter terminal j
47 and thermal transmitter terminal j
1 .
Continuity should exist.
3. Check continuity between combination
meter terminal j
47 and ground.
Continuity should not exist.

NG
c

Repair harness or connector.

OK
.

Thermal transmitter is OK.

Electrical Components Inspection
METER/GAUGE RESISTANCE CHECK
1. Disconnect FPC connector. Refer to ‘‘Flexible Print Circuit
(FPC)’’ (EL-109).
2. Check resistance between installation screws of meter/gauge.
Screws
Tachometer

Fuel/Temp.
gauge

Sub fuel gauge

Resistance
Ω

A-C

—

Approx. 104 (±5)

B-D

B-C

—

Approx. 134 (±5)

—

A-C

Approx. 174 (±5)

—

B-C

Approx. 100 (±5)

CEL736

EL-114

METER AND GAUGES
Electrical Components Inspection (Cont’d)
FUEL TANK GAUGE UNIT CHECK
+ For removal, refer to FE section.
Check the resistance between terminals j
1 and j
2 .
Ohmmeter
(+)

Float position
mm (in)

(−)
*1

j
1

j
2

Full

Resistance value
(Ω)
60 (2.36)

Approx. 4 — 6

1/2

179 (7.05)

32 — 33

Empty

270 (10.63)

80 — 83

*1 and *3: When float rod is in contact *with stopper.

CEL737

THERMAL TRANSMITTER CHECK
Check the resistance between the terminals of thermal transmitter
and body ground.
Water temperature

Resistance (Ω)

60°C (140°F)

Approx. 170 — 210

100°C (212°F)

Approx. 47 — 53

MEL424F

VEHICLE SPEED SENSOR CHECK
1. Remove vehicle speed sensor from transmission.
2. Turn vehicle speed sensor pinion quickly and measure voltage
between terminals j
2 and j
1 .

CEL739

EL-115

COMPASS AND THERMOMETER
System Description

SEL713U

This unit displays the following items:
+ Earth magnetism and heading direction of vehicle.
+ Outside air temperature.
+ Caution for frozen road surfaces.

OUTSIDE TEMPERATURE DISPLAY
Push the switch when the ignition key is in the ‘‘ACC’’ or ‘‘ON’’ position. The outside temperature will be displayed in ‘‘°F’’.
+ Selecting the indication range
Push the switch to change from ‘‘°F’’ to ‘‘°C’’.
+ When the outside temperature drops below freezing point, ICE is displayed on the unit.
+ When the outside temperature is between 55°C (130°F) and 70°C (158°F), the display shows 55°C
(130°F).
+ When the outside temperature is lower than −30°C (−20°F) or higher than 70°C (158°F), the display shows
only ‘‘- — -’’ though it is operating. This is not a problem.
+ The indicated temperature on the thermometer is not readily affected by engine heat. It changes only when
one of the following conditions is present.
a) The temperature detected by the ambient air temperature sensor is lower than the indicated temperature
on the thermometer.
b) The difference in temperature detected during a period of 40 seconds is less than 1°C (1.8°F) when vehicle
speed has been greater than 24 km/h (15 MPH) for more than 100 seconds.
(This is to prevent the indicated temperature from being affected by engine heat or cooling fan operation
during low-speed driving.)
c) The ignition key has been turned to the ‘‘OFF’’ position for more than 4 hours. (The engine is cold.)

DIRECTION DISPLAY
Push the switch when the ignition key is in the ‘‘ACC’’ or ‘‘ON’’ position. The direction will be displayed.

EL-116

COMPASS AND THERMOMETER
Wiring Diagram — COMPAS —

TEL428A

EL-117

COMPASS AND THERMOMETER
Trouble Diagnoses
PRELIMINARY CHECK FOR THERMOMETER
Turn the ignition key switch to the ‘‘ACC’’
position.
.

Cool down the ambient air temperature
sensor with water or ice, so that the indicated temperature falls.
.

Does the indicated temperature fall?
.

No
c

The system is malfunctioning..1

Yes

Leave the vehicle for 10 minutes, so that
the indicated temperature rises.
.

With the ignition key in the ‘‘ACC’’
position, disconnect and reconnect the
ambient air temperature sensor connector.
.

Does the indicated temperature rise?
.

Yes

The system is OK.

.1: Check the system following ‘‘INSPECTION/COMPASS AND THERMOMETER’’.

INSPECTION/COMPASS AND THERMOMETER
Symptom
No display at all

Possible causes

Repair order

1. 7.5A fuse

2. Ground circuit
3. Compass and thermometer

1. Check 7.5A fuse [No. 9 , located in fuse block (J/B)].
Turn the ignition switch ON and verify that battery positive
voltage is at terminal j
2 of compass and thermometer.
2. Check ground circuit for compass and thermometer.
3. Replace compass and thermometer.

Forward direction indication
slips off the mark or incorrect.

1. Drive the vehicle and turn at an angle of 90°.
1. In manual correction mode
(Bar and display vanish.)
2. Zone variation change is not 2. Perform the zone variation change.
done.

Compass reading remains
unchanged.

1. Vehicle speed sensor is not
entered.
2. Compass and thermometer

1. Check harness for open or short between combination meter
terminal j
26 and compass and thermometer terminal j
8 .
2. Replace compass and thermometer.

Displays wrong temperature
when ambient temperature is
between −30°C (−20°F) and
55°C (130°F). (See NOTE)

1. Check operation
2. Ambient air temperature
sensor circuit
3. Vehicle speed sensor is not
entered.
4. Ambient air temperature
sensor
5. Compass and thermometer

1. Perform preliminary check shown below.
2. Check harness for open or short between ambient air temperature sensor and compass and thermometer.
3. Check harness for open or short between combination meter
terminal j
26 and compass and thermometer terminal j
8 .
4. Replace ambient air temperature sensor.
5. Replace compass and thermometer.

NOTE:
+ When the outside temperature is between 55°C (130°F) and 70°C (158°F), the display shows 55°C
(130°F). When the outside temperature is lower than −30°C (−20°F) or higher than 70°C (158°F), the
display shows only ‘‘- — -’’.
+ The indicated temperature on the thermometer is not readily affected by engine heat. It changes
only when one of the following conditions (shown on next page) is present.

EL-118

COMPASS AND THERMOMETER
Trouble Diagnoses (Cont’d)
a) The temperature detected by the ambient air temperature sensor is lower than the indicated temperature on the thermometer.
b) The difference in temperature detected during a period of 40 seconds is less than 1°C (1.8°F) when
vehicle speed has been greater than 24 km/h (15 MPH) for more than 100 seconds.
(This is to prevent the indicated temperature from being affected by engine heat or cooling fan
operation during low-speed driving.)
c) The ignition key has been turned to the ‘‘OFF’’ position for more than 4 hours. (The engine is cold.)

Calibration Procedure For Compass
The difference between magnetic North and geographical North
can sometimes be great enough to cause false compass readings.
In order for the compass to operate accurately in a particular zone,
it must be calibrated using the following procedure.
1. Determine your location on the worldwide magnetic variation
map on next page. Record your zone number.
2. Turn the ignition switch to ACC or ON position.
3. Push the ‘‘Mode’’ switch continuously for five seconds until the
current zone entry number is displayed.
4. Press the ‘‘Mode’’ switch repeatedly until the desired zone number is displayed.
Once the desired zone number is displayed, stop pressing the
‘‘Mode’’ switch and the display will show compass direction after a
few seconds.

CORRECTION FUNCTIONS OF COMPASS
The direction display is equipped with automatic correction function. If the direction is not shown correctly, carry out initial correction.

INITIAL CORRECTION PROCEDURE FOR COMPASS

SEL065V

1. Pushing the ‘‘Mode’’ switch for about 10 seconds will enter the
initial correction mode. The direction bar starts blinking.
2. Turn the vehicle slowly in an open, safe place. The initial correction is completed in one or two turns.
NOTE:
In places where the terrestrial magnetism is extremely
disturbed, the initial correction may start automatically.

EL-119

COMPASS AND THERMOMETER
Calibration Procedure For Compass (Cont’d)

SEL427V

EL-120

WARNING LAMPS
Schematic

TEL697A

EL-121

WARNING LAMPS
Schematic (Cont’d)

TEL698A

EL-122

WARNING LAMPS
Wiring Diagram — WARN —

TEL699A

EL-123

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL700A

EL-124

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL701A

EL-125

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL702A

EL-126

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL703A

EL-127

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL704A

EL-128

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL705A

EL-129

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL706A

EL-130

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL707A

EL-131

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)
LHD MODELS

TEL708A

EL-132

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)
RHD MODELS

TEL709A

EL-133

WARNING LAMPS
Electrical Components Inspection
FUEL WARNING LAMP SENSOR CHECK
+ It will take a short time for the bulb to light.
NOTE: Inspection for sub fuel warning lamp sensor is the
same as for fuel warning lamp sensor.

MEL828F

OIL PRESSURE SWITCH CHECK
Oil pressure
kPa (bar, kg/cm2, psi)

Continuity

Engine start

More than 10 — 20
(0.10 — 0.20, 0.1 — 0.2, 1 — 3)

Engine stop

Less than 10 — 20
(0.10 — 0.20, 0.1 — 0.2, 1 — 3)

YES

Check the continuity between the terminals of oil pressure switch
and body ground.
MEL425F

DIODE CHECK
Check continuity using an ohmmeter.
Diode is functioning properly if test results are as shown in the
figure at left.
NOTE: Specification may vary depending on the type of tester.
Before performing this inspection, be sure to refer to
the instruction manual for the tester to be used.
+
+

CEL520

Diodes for warning lamps are built into the combination meter
printed circuit.

CEL740

EL-134

WARNING CHIME
System Description
The warning chime is combined with the smart entrance control unit.
Both the ignition key and light warning chime will not sound, when ignition switch in the ON or START position. (When power supply exists at smart entrance control unit terminal j
12 .)

IGNITION KEY WARNING CHIME
With the key in the ignition key cylinder, the ignition switch in the OFF or ACC position, and the driver’s door
open, the warning chime will sound. A battery positive voltage is supplied
+ from key switch terminal j
1
+ to smart entrance control unit terminal j
1 .
Ground is supplied
+ through driver side door switch
+ to smart entrance control unit terminal j
7 .

LIGHT WARNING CHIME
With ignition switch in the OFF or ACC position, driver’s door open, and lighting switch in 1ST or 2ND position,
warning chime will sound. A battery positive voltage is supplied
+ from lighting switch terminal j
12 or daytime light control unit
14 .
+ to smart entrance control unit terminal j
Ground is supplied
+ through driver side door switch
+ to smart entrance control unit terminal j
7 .

EL-135

WARNING CHIME
Wiring Diagram — CHIME —/LHD Models

TEL441A

EL-136

WARNING CHIME
Wiring Diagram — CHIME —/RHD Models

TEL654A

EL-137

WARNING CHIME
Trouble Diagnoses

Light warning chime does not activate.

EL-139

DIAGNOSTIC PROCEDURE 3

SYMPTOM

EL-138

DIAGNOSTIC PROCEDURE 2
(Key switch input signal check)

REFERENCE PAGE

DIAGNOSTIC PROCEDURE 1
(Lighting switch input signal check)

SYMPTOM CHART

Ignition key warning chime does not
activate.

All warning chimes do not activate.

DIAGNOSTIC PROCEDURE 1
(Lighting switch input signal check)
CHECK LIGHTING SWITCH INPUT SIGNAL.
Check voltage between control unit terminal j
14 and ground.

SEL851UB

Condition of lighting
switch

Voltage [V]

1ST or 2ND

Approx. 12

OFF

OK
.

Go to DIAGNOSTIC PROCEDURE 3.

EL-138

NG
c

Check the following.
+ 7.5A fuse (No. 42 ,
located in the fuse and
fusible link box) for LHD
models
+ Harness for open or
short between control
unit and lighting switch/
daytime light control unit

WARNING CHIME
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 2
(Key switch input signal check)
CHECK KEY SWITCH INPUT SIGNAL.
Check voltage between control unit terminal j
1 and ground.
Condition of key switch

Voltage [V]

Key is inserted.

Approx. 12

Key is withdrawn.

SEL852UB

NG
c

Check the following.
+ Key switch
Refer to ‘‘Electrical Components Inspection’’ (EL140).
+ 7.5A fuse [No. 24 ,
located in fuse block
(J/B)]
+ Harness for open or
short between key
switch and fuse
+ Harness for open or
short between control
unit and key switch

Go to DIAGNOSTIC PROCEDURE 3.

DIAGNOSTIC PROCEDURE 3
CHECK POWER SUPPLY CIRCUIT FOR
CONTROL UNIT.
Check voltage between control unit terminals j
11 , j
12 and ground.
Terminals

⊕

ACC

j
11
Ground
SEL853UB

j
12
Ground

Ignition switch position
OFF

Check the following.
+ M92 circuit breaker
+ 7.5A fuse [No. 8 ,
located in the fuse block
(J/B)]
+ Harness for open or
short

Approx. 12V
0V

Approx. 12V

OK
.

CHECK GROUND CIRCUIT FOR CONTROL UNIT.
Check continuity between control unit terminal j
18 and ground.
Continuity should exist.

NG
c

Repair harness or connectors.

OK
.
SEL854UB

CHECK DOOR SWITCH INPUT SIGNAL.
Check voltage between control unit terminal j
7 and ground.
Condition of driver’s door
Driver side door is closed.
Driver side door is open.

OK
.

Replace control unit.
SEL855UB

EL-139

Voltage [V]
Approx. 12
0

NG
c

Check the following.
+ Driver side door switch
Refer to ‘‘Electrical Components Inspection’’ (EL140).
+ Door switch ground circuit
+ Harness for open or
short between control
unit and door switch

WARNING CHIME
Electrical Components Inspection
KEY SWITCH (insert)
Check continuity between terminals when key is inserted in ignition
key cylinder and key is removed from ignition key cylinder.
Terminal No.
j
1 -j
2

Condition
Key is inserted.
Key is removed.

Continuity
Yes
No

SEL462V

DRIVER SIDE DOOR SWITCH
Check continuity between terminals when door switch is pushed
and released.
Terminal No.
j
1 -j
3

SEL463V

EL-140

Condition
Door switch is pushed.
Door switch is released.

Continuity
No
Yes

FRONT WIPER AND WASHER
System Description
WIPER OPERATION
The wiper switch is controlled by a lever built into the combination switch.
There are three wiper switch positions:
+ LO speed
+ HI speed
+ INT (Intermittent)
With the ignition switch in the ACC or ON position, power is supplied
+ through 20A fuse [No.
, located in the fuse block (J/B)]
4 .
+ to wiper motor terminal j
Low and high speed wiper operation
Ground is supplied to wiper switch terminal j
17 through body grounds.
When the wiper switch is placed in the LO position, ground is supplied
+ through terminal j
14 of the wiper switch
+ to wiper motor terminal j
2 .
With power and ground supplied, the wiper motor operates at low speed.
When the wiper switch is placed in the HI position, ground is supplied
+ through terminal j
16 of the wiper switch
3 .
+ to wiper motor terminal j
With power and ground supplied, the wiper motor operates at high speed.
Auto stop operation
With wiper switch turned OFF, wiper motor will continue to operate until wiper arms reach windshield base.
When wiper arms are not located at base of windshield with wiper switch OFF, ground is provided
+ from terminal j
14 of the wiper switch
2 , in order to continue wiper motor operation at low speed.
+ to wiper motor terminal j
+ through wiper amplifier (OUTPUT) combined with wiper switch and (with intermittent wiper)
+ through terminal j
13 of wiper switch
5
+ to wiper motor terminal j
+ through terminal j
6 of the wiper motor, and
+ through body grounds.
When wiper arms reach base of windshield, wiper motor terminals j
4 and j
5 are connected instead of terminals j
5 and j
6 . Wiper motor will then stop wiper arms at the PARK position.
Intermittent operation
The wiper motor operates the wiper arms one time at low speed at a set interval of approximately 3 to 13
seconds. This feature is controlled by the wiper amplifier (INT SW) combined with wiper switch.
When the wiper switch is placed in the INT position, ground is supplied to wiper amplifier.
The desired interval time is input to wiper amplifier (INT VR) from wiper volume switch combined with wiper
switch.
Then intermittent ground is supplied
+ to wiper motor terminal j
2
+ from terminal j
14 of wiper switch
+ through wiper amplifier (OUTPUT).
The wiper motor operates at low speed at the desired interval.

WASHER OPERATION
With the ignition switch in the ACC or ON position, power is supplied
+ through 20A fuse [No.
, located in the fuse block (J/B)]
+ to washer motor terminal j
2 .
When the lever is pulled to the WASH position, ground is supplied through wiper switch
+ to washer motor terminal j
1 , and
+ to wiper amplifier (WASH SW) combined with wiper switch.
With power and ground supplied, the washer motor operates.
When the lever is pulled to the WASH position for one second or more, the wiper motor operates at low speed
for approximately 3 seconds to clean windshield. This feature is controlled by the wiper amplifier in the same
manner as the intermittent operation.

EL-141

FRONT WIPER AND WASHER
Wiring Diagram — WIPER —/With Intermittent
Wiper

TEL442A

EL-142

FRONT WIPER AND WASHER
Removal and Installation
WIPER ARMS

SEL543TA

1. Prior to wiper arm installation, turn on wiper switch to operate
wiper motor and then turn it ‘‘OFF’’ (Auto Stop).
2. Lift the blade up and then set it down onto glass surface to set
the blade center to clearance ‘‘L1’’ & ‘‘L2’’ immediately before
tightening nut.
3. Eject washer fluid. Turn on wiper switch to operate wiper motor
and then turn it ‘‘OFF’’.
4. Ensure that wiper blades stop within clearance ‘‘L1’’ & ‘‘L2’’.
Clearance ‘‘L1’’: 25 mm (0.98 in)
Clearance ‘‘L2’’: 23 mm (0.91 in)
+ Tighten wiper arm nuts to specified torque.
Front wiper: 21 — 26 Nzm (2.1 — 2.7 kg-m, 15 — 20 ft-lb)

Before reinstalling wiper arm, clean up the pivot area as
illustrated. This will reduce possibility of wiper arm looseness.

SEL024J

WIPER LINKAGE

CEL741

EL-143

FRONT WIPER AND WASHER
Removal and Installation (Cont’d)
Removal
1.
2.
3.
Be

Remove 4 bolts that secure wiper motor.
Detach wiper motor from wiper linkage at ball joint.
Remove wiper linkage.
careful not to break ball joint rubber boot.

Installation
+ Grease ball joint portion before installation.
1. Installation is the reverse order of removal.

Washer Nozzle Adjustment
+

Adjust washer nozzle with suitable tool as shown in the figure
at left.
Adjustable range: ±10°

SEL241P

Unit: mm (in)
*1

180 (7.09)

70 (2.76)

170 (6.69)

40 (1.57)

290 (11.42)

370 (14.57)

200 (7.87)

470 (18.50)

*: The diameters of these circles are less than 100 mm (3.94 in).
SEL544T

Washer Tube Layout

CEL742

EL-144

REAR WIPER AND WASHER
System Description
WIPER OPERATION
The rear wiper switch is controlled by a ring built into the combination switch.
There are two wiper switch positions:
+ ON (LO speed)
+ INT (Intermittent)
With the ignition switch in the ON position, power is supplied
+ through 10A fuse (No. 18 , located in the fuse block)
+ to rear wiper motor terminal j
4 , and
5 .
+ to rear wiper amplifier terminal j

Low speed wiper operation
Ground is supplied to rear wiper switch terminal j
24 through body grounds.
When the rear wiper is placed in the ON position, ground is supplied
+ through rear wiper switch terminal j
22
+ to rear wiper relay terminal j
6 .
Then ground is supplied
+ to rear wiper motor terminal j
1
+ through rear wiper amplifier terminals j
2 and j
3 .
With power and ground supplied, the wiper motor operates.

Auto stop operation
With the rear wiper switch turned OFF, rear wiper motor will continue to operate until wiper arm reaches rear
window base.
When wiper arm is not located at base of rear window with rear wiper switch OFF, ground is supplied
+ to rear wiper motor terminal j
1
+ through rear wiper amplifier terminals j
2 ,j
7 and
3 , in order to continue rear wiper motor operation at low speed.
+ through rear wiper motor terminal j
Ground is also supplied
+ to rear wiper motor terminal j
2
+ through body grounds.
When wiper arm reaches base of rear window, rear wiper motor terminals j
3 and j
4 are connected instead
of terminals j
2 and j
3 . Rear wiper motor will then stop wiper arm at the PARK position.

Intermittent operation
The rear wiper motor operates the wiper arm one time at low speed at an interval of approximately 7 seconds.
When the rear wiper switch is placed in the INT position, ground is supplied
+ to rear wiper amplifier terminal j
1
+ through rear wiper switch terminal j
21 .
Then the rear wiper motor operates intermittently in the same manner as the low speed wiper operation.

WASHER OPERATION
With the ignition switch in the ACC or ON position, power is supplied
+ through 10A fuse (No. 18 , located in the fuse block)
2 .
+ to rear washer motor terminal j
When the ring is turned WASH position, ground is supplied
+ to rear washer motor terminal j
1 , and
4
+ to rear wiper amplifier terminal j
+ through terminal j
23 of rear wiper switch.
With power and ground is supplied, the rear washer motor operates.
The rear wiper motor operates when the ring is turned to WASH position for one second or more and for
approximately 3 seconds after the ring is released. This feature is controlled by the rear wiper amplifier in the
same manner as the low speed wiper operation.

EL-145

REAR WIPER AND WASHER
Wiring Diagram — WIP/R —/LHD Models

TEL444A

EL-146

REAR WIPER AND WASHER
Wiring Diagram — WIP/R —/LHD Models
(Cont’d)

TEL445A

EL-147

REAR WIPER AND WASHER
Wiring Diagram — WIP/R —/RHD Models

TEL655A

EL-148

REAR WIPER AND WASHER
Wiring Diagram — WIP/R —/RHD Models
(Cont’d)

TEL656A

EL-149

REAR WIPER AND WASHER
Trouble Diagnoses
REAR WIPER AMP. INSPECTION TABLE
(Data are reference values.)
Terminal No.

Item

Intermittent switch

Ground

Washer switch

Power supply

Wiper on switch

INT

Less than 1V

OFF, ON or WASH

Approx. 10V

Less than 1V

OFF

Approx. 12V

Rear wiper switch

Wiper motor
(Ground)

Voltage
(Approximate value)

Condition

Rear wiper switch
—

—
WASH

Less than 1V

OFF

Approx. 12V

Rear wiper switch

—

Approx. 12V
ON or WASH

Less than 1V

OFF or INT

Approx. 12V

Wiper is moving

Less than 1V

Wiper stop

Approx. 12V

Rear wiper switch
Rear wiper switch
should be placed in
‘‘WASH’’ or ‘‘INT’’ to
inspect the value for
wiper movement.

Wiper amp. output

SEL428V

EL-150

REAR WIPER AND WASHER
Removal and Installation
WIPER ARM

CEL779

1. Prior to wiper arm installation, turn on wiper switch to operate
wiper motor and then turn it ‘‘OFF’’ (Auto Stop).
2. Lift the blade up and then set it down onto glass surface. Set
the blade center to clearance ‘‘E’’ immediately before tightening nut.
3. Eject washer fluid. Turn on wiper switch to operate wiper motor
and then turn it ‘‘OFF’’.
4. Ensure that wiper blades stop within clearance ‘‘E’’.
Clearance ‘‘E’’: 20 mm (0.79 in)
+ Tighten windshield wiper arm nuts to specified torque.
: 13 — 18 Nzm (1.3 — 1.8 kg-m, 9 — 13 ft-lb)

Before reinstalling wiper arm, clean up the pivot area as
illustrated. This will reduce possibility of wiper arm looseness.

SEL024J

Washer Nozzle Adjustment
+

Adjust washer nozzle with suitable tool as shown in the figure
at left.
Adjustable range: ±10° (In any direction)

SEL241P

Unit: mm (in)
*1

30 (1.18)

40 (1.57)

30 (1.18)

20 (0.79)

CEL780

EL-151

REAR WIPER AND WASHER
Washer Tube Layout

CEL743

Check Valve
+

A check valve is provided in the washer fluid line. Be careful not
to connect check valve to washer tube in the wrong direction.

SEL411H

EL-152

HEADLAMP WIPER AND WASHER
Wiring Diagram — HLC —

TEL694A

EL-153

HEADLAMP WIPER AND WASHER
Electrical Components Inspection
HEADLAMP WIPER MOTOR CHECK
When wiper motor is locked, a protective circuit built into
wiper motor activates to stop wiper motor. If wiper motor will
not restart even after cause of problems has been eliminated,
turn ignition switch OFF and leave it off for approx. 1 to 3
minutes.
1. Turn headlamp wiper switch OFF.
2. Connect ohmmeter and check continuity.
Headlamp
wiper motor

Ohmmeter probe
Continuity
(+)

(−)

j
1

j
4

Yes

j
1

j
2

Yes

j
1

j
3

Yes

j
3

j
5

Stop position

CEL813

Removal and Installation
WIPER ARM
Tighten nut to secure wiper arm with wiper blade held below lower
stopper.
After installing wiper arm, position wiper blade on stopper upper
surface.
+ Tighten headlamp wiper arm nut to the specified torque.
: 2.3 — 3.0 Nzm (0.23 — 0.31 kg-m, 20.0 — 26.9 in-lb)
CEL814

Washer Tube Layout

CEL815

Check Valve
+

A check valve is provided in the washer fluid line. Be careful not
to connect check valve to washer tube in the wrong direction.

SEL411H

EL-154

HORN
Wiring Diagram — HORN —

TEL446A

EL-155

CIGARETTE LIGHTER
Wiring Diagram — CIGAR —

TEL447A

EL-156

CLOCK
Wiring Diagram — CLOCK —

TEL448A

EL-157

REAR WINDOW DEFOGGER
System Description
The rear window defogger system is controlled by the smart entrance control unit. The rear window defogger
operates only for approximately 15 minutes.
Power is supplied at all times
+ to rear window defogger relay terminal j
3
+ through 15A fuse (No. 43 , located in the fuse and fusible link box) and
6
+ to rear window defogger relay terminal j
+ through 20A fuse (No. 44 , located in the fuse and fusible link box).
With the ignition switch in the ON or START position, power is supplied
+ to the rear window defogger relay terminal j
1 and
+ to smart entrance control unit terminal j
12
+ through 7.5A fuse [No. 8 , located in the fuse block (J/B)].
Ground is supplied to terminal j
2 of the rear window defogger switch through body grounds.
When the rear window defogger switch is turned ON, ground is supplied
+ through terminal j
1 of the rear window defogger switch
+ to smart entrance control unit terminal j
8 .
Terminal j
9 of the smart entrance control unit then supplies ground to the rear window defogger relay termi2 .
nal j
With power and ground supplied, the rear window defogger relay is energized.
Power is supplied
+ through terminals j
5 and j
7 of the rear window defogger relay
+ to the rear window defogger.
The rear window defogger has an independent ground.
With power and ground supplied, the rear window defogger filaments heat and defog the rear window.
When the system is activated, the rear window defogger indicator illuminates in the rear window defogger
switch.
Power is supplied
+ to terminal j
3 of the rear window defogger switch
5 of the rear window defogger relay.
+ from terminal j
Terminal j
4 of the rear window defogger switch is grounded through body grounds.

EL-158

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/LHD Models

TEL449A

EL-159

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/LHD Models (Cont’d)

TEL450A

EL-160

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/RHD Models

TEL657A

EL-161

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/RHD Models (Cont’d)

TEL658A

EL-162

REAR WINDOW DEFOGGER
Trouble Diagnoses
SYMPTOM: Rear window defogger does not activate, or does
not go off after activating.
CHECK REAR WINDOW DEFOGGER
OUTPUT SIGNAL.
1. Turn ignition switch to ON position.
2. Check voltage between control unit harness terminals j
9 and ground.
Condition

SEL856UA

OK
c

Check the following.
+ Rear window defogger
relay
(Refer to EL-164.)
+ Rear window defogger
circuit
+ Rear window defogger
filament
(Refer to EL-164.)

Check the following.
+ 7.5A fuse [No. 8 ,
located in the fuse block
(J/B)]
+ Rear window defogger
relay
+ Harness for open or
short between control
unit and fuse

Check the following.
+ Rear window defogger
switch
(Refer to EL-164.)
+ Harness for open or
short between control
unit and rear window
defogger switch
+ Rear window defogger
switch ground circuit

Check the following.
+ 7.5A fuse [No. 8
located in the fuse block
(J/B)]
+ Harness for open or
short between control
unit and fuse

Repair harness or connectors.

Voltage [V]

Rear window defogger
switch is released.

Approx. 12

Rear window defogger
switch is pushed.

NG
.

1. Disconnect control unit connector.
2. Turn ignition switch to ON position.
3. Check voltage between control unit terminal j
9 and ground.
Battery voltage should exist.

OK
SEL857UA
.

CHECK REAR WINDOW DEFOGGER
SWITCH INPUT SIGNAL.
Check continuity between control unit terminal j
8 and ground.
Condition of
defogger switch

Continuity

Rear window defogger
switch is pushed.

Yes

Rear window defogger
switch is released.

SEL858UA

OK
.

CHECK IGNITION INPUT SIGNAL.
Check voltage between control unit terminal j
12 and ground.
Condition

Voltage [V]

Ignition switch is ‘‘ON’’.

Approx. 12

Ignition switch is ‘‘OFF’’.

OK
.

SEL859UA

CHECK CONTROL UNIT GROUND CIRCUIT.
Check continuity between control unit terminal j
18 and ground.
Continuity should exist.
OK
.

Replace control unit.

SEL854UC

EL-163

REAR WINDOW DEFOGGER
Electrical Components Inspection
REAR WINDOW DEFOGGER RELAY
Check continuity between terminals j
3 and j
5 ,j
6 and j
7 .
Condition

Continuity

12V direct current supply between
terminals j
1 and j
2

Yes

No current supply

SEC202B

REAR WINDOW DEFOGGER SWITCH
Check continuity between terminals when rear window defogger
switch is pushed and released.
Terminals

Condition

Continuity

Rear window defogger
switch is pushed

Yes

Rear window defogger
switch is released

j
1 -j
2

SEL430TC

Filament Check
1. Attach probe circuit tester (in volt range) to middle portion of
each filament.

SEL263

When measuring voltage, wrap tin foil around the top of
the negative probe. Then press the foil against the wire
with your finger.

SEL122R

2. To locate burned out point, move probe to left and right along
filament. Test needle will swing abruptly when probe passes the
point.
+ If a filament is burned out, circuit tester registers 0 or 12
volts.

SEL266

EL-164

REAR WINDOW DEFOGGER
Filament Repair
REPAIR EQUIPMENT
1.
2.
3.
4.
5.
6.

Conductive silver composition (Dupont No. 4817 or equivalent)
Ruler 30 cm (11.8 in) long
Drawing pen
Heat gun
Alcohol
Cloth

REPAIRING PROCEDURE
1. Wipe broken heat wire and its surrounding area clean with a
cloth dampened in alcohol.
2. Apply a small amount of conductive silver composition to tip of
drawing pen.
Shake silver composition container before use.
3. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap
existing heat wire on both sides [preferably 5 mm (0.20 in)] of
the break.
BE540

4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver
composition is deposited.
Do not touch repaired area while test is being conducted.

SEL012D

5. Apply a constant stream of hot air directly to the repaired area
for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area
and hot air outlet. If a heat gun is not available, let the repaired
area dry for 24 hours.

SEL013D

EL-165

WIPER DEICER
System Description

SEL505V

+
+
+

A heat line has been added to the lower portion of the windshield.
During cold weather, water can freeze between the wiper
blades and windshield. Turning the wiper deicer switch ON
melts the ice between the blades and windshield.
During snowfall, packed snow can accumulate around the
windshield lower surface and surrounding areas. Turning the
wiper deicer switch ON melts the snow to allow the wiper
blades to more easily remove it.
The wiper deicer operates only for approximately 15 minutes
while ignition switch is in ON position. The timer is combined
with wiper deicer switch.

EL-166

WIPER DEICER
Wiring Diagram — DEICER —

TEL712A

EL-167

AUDIO
Wiring Diagram — AUDIO —/LHD Models

TEL659A

EL-168

AUDIO
Wiring Diagram — AUDIO —/LHD Models
(Cont’d)

TEL660A

EL-169

AUDIO
Wiring Diagram — AUDIO —/RHD Models

TEL661A

EL-170

AUDIO
Wiring Diagram — AUDIO —/RHD Models
(Cont’d)

TEL662A

EL-171

AUDIO
Trouble Diagnoses
RADIO
Symptom
Radio inoperative (no digital
display and no sound from
speakers).
See NOTE.

Possible causes

Repair order

10 , located in fuse block (J/B)].
Turn ignition switch ON and verify battery positive voltage is present at terminal j
10 of radio.
2. Check radio case ground.
3. Remove radio for repair.

1. 10A fuse

1. Check 10A fuse [No.

2. Poor radio case ground
3. Radio

Radio controls are operational, 1. Radio output
but no sound is heard from
2. Radio
any speaker.

1. Check radio output voltages.
2. Remove radio for repair.

Radio presets are lost when
ignition switch is turned OFF.

2. Radio

1. Check 10A fuse (No. 56 , located in fuse and fusible link
box) and verify battery positive voltage is present at terminal
j
6 of radio.
2. Remove radio for repair.

Individual speaker is noisy or
inoperative.

1.
2.
3.
4.

Radio stations are weak or
noisy.

1. Antenna
2. Poor radio ground
3. Radio

1. Check antenna.
2. Check radio ground.
3. Remove radio for repair.

FM stations are weak or noisy
but AM stations are OK. (with
window antenna)

1. Window antenna
2. Radio

1. Check window antenna.
2. Remove radio for repair.

Radio generates noise in AM
and FM modes with engine
running.

1. Poor radio ground
2. Loose or missing ground bonding straps
3. Ignition condenser or rear window defogger
noise suppressor condenser
4. Alternator
5. Ignition coil or secondary wiring
6. Radio

1. Check radio ground.
2. Check ground bonding straps.
3. Replace ignition condenser or rear window defogger noise
suppressor condenser.
4. Check alternator.
5. Check ignition coil and secondary wiring.
6. Remove radio for repair.

Radio generates noise in AM
and FM modes with accessories on (switch pops and motor
noise).

1.
2.
3.
4.

1. 10A fuse

Speaker
Radio output
Speaker circuit
Radio

Poor radio ground
Antenna
Accessory ground
Faulty accessory

Check speaker.
Check radio output voltages.
Check wires for open or short between radio and speaker.
Remove radio for repair.

Check radio ground.
Check antenna.
Check accessory ground.
Replace accessory.

NOTE:
If the radio has anti-theft function, check the anti-theft function of the radio before circuit inspection.
(Radios which have anti-theft function are equipped with a code indicator. For details, refer to EL-173.)

Speaker inspection
1.
2.
+
3.
+

Disconnect speaker harness connector.
Measure the resistance between speaker terminals j
1 and j
2 .
The resistance should be 2 — 4Ω.
Using jumper wires, momentarily connect a 9V battery between speaker terminals j
1 and j
2 .
A momentary hum or pop should be heard.

Antenna inspection
Using a jumper wire, clip an auxiliary ground between antenna and body.
+ If reception improves, check antenna ground (at body surface).
+ If reception does not improve, check main feeder cable for short circuit or open circuit.

Radio inspection
All
+
+
+

voltage inspections are made with:
Ignition switch ON or ACC
Radio ON
Radio connected (If removed for inspection, supply a ground to the case using a jumper wire.)

EL-172

AUDIO
CATS (Code) System/RHD
NOTE:
+ This system is used for code indicator-equipped radios on all models except the Europe LHD
model.
+ The Europe LHD model has a NATS-linked anti-theft function that renders the code system inoperable.

DESCRIPTION
By using a personal 4-digit code known only to the vehicle owner, the possibility of the audio unit being stolen is effectively reduced, because without the code the unit can not be activated. When in normal use, the
unit is unlocked and accessible in the usual way.
If however, someone attempts to remove the unit or the battery cable is disconnected, the anti-theft system
activates and the unit ‘‘locks’’. The only way it can be unlocked is by entering a personal code number known
only by the owner.

UNLOCKING THE UNIT (How to enter a personal code number)
+
1.
2.
3.
4.
5.

If the battery supply to the vehicle is interrupted by accident for some reason, the unit will lock.
To unlock the unit, proceed as follows:
Press the power/volume control knob to turn the unit on.
‘‘CODE IN’’ is displayed.
Input your personal code by pressing the preset buttons (1 to 4).
Press the
button.
If the entered code number is correct, the radio turns on.

When the code is incorrect
1. If the entered code is incorrect, the unit becomes inoperable for 10 seconds for the first three attempts,
then the code input mode is automatically set (‘‘CODE IN’’ is displayed).
2. If the code is incorrect the fourth time, the unit becomes inoperable for 60 minutes and ‘‘
’’ is displayed.
After 60 minutes, the code input mode is automatically set (‘‘CODE IN’’ is displayed).
NOTE:
If the above is repeated 17 times, the unit will lock and ‘‘LOCKED’’ is displayed.
3. After ‘‘LOCKED’’ is displayed, radio can be returned to the code input mode only within three attempts as
follows. (Only three attempts are allowed to unlock the unit.)
a. Press the power/volume control knob while pushing both the MOD and TA switches.
b. The unit then returns to the code input mode.
CAUTION:
If the third attempt is unsuccessful, the unit will lock permanently.

EL-173

AUDIO
NATS Audio Link/LHD
DESCRIPTION
The link with the NATS IMMU implies that the radio can basically only be operated if connected to the matching NATS IMMU to which the radio was initially fitted on the production line.
Since radio operation is impossible after the link with the NATS is disrupted theft of the radio unit is basically
useless since special equipment is required to reset the radio.

Initialisation process for radios that are linked to the NATS IMMU
New radios will be delivered to the factories in the ‘‘NEW’’ state, i.e. ready to be linked with the vehicle’s NATS.
When the radio in ‘‘NEW’’ state is first switched on at the factory, it will start up communication with the vehicle’s immobiliser control unit (IMMU) and send a code (the ‘‘Radio Code’’) to the IMMU. The IMMU will then
store this code, which is unique to each radio, in its (permanent) memory.
Upon receipt of the code by the IMMU, the NATS will confirm correct receipt of the radio code to the radio.
Hereafter, the radio will operate as normal.
During the initialisation process, ‘‘NEW’’ is displayed on the radio display. Normally though, communication
between Radio and IMMU takes such a short time (300 ms) that the radio seems to switch on directly without showing ‘‘NEW’’ on its display.

Normal operation
Each time the radio is switched on afterwards, the radio code will be verified between the radio unit and the
NATS before the radio becomes operational. During the code verification process, ‘‘WAIT’’ is shown on the
radio display. Again, the communication takes such a short time (300 ms) that the radio seems to switch on
directly without showing ‘‘WAIT’’ on its display.

When the radio is locked
In case of a radio being linked with the vehicle’s NATS (immobiliser system), disconnection of the link between
the radio and the IMMU will cause the radio to switch into the lock (‘‘SECURE’’) mode in which the radio unit
is fully inoperative. Hence, repair of the radio is basically impossible, unless the radio is reset to the ‘‘NEW’’
state for which special decoding equipment is required.
Both Blaupunkt and Clarion have provided their authorized service representatives with so called ‘‘decoder
boxes’’ which can bring the radio unit back to the ‘‘NEW’’ state, enabling the radio to be switched on after which
repair can be carried out. Subsequently, when the repaired radio is delivered to the final user again, it will be
in the ‘‘NEW’’ state as to enable re-linking the radio to the vehicle’s immobiliser system. As a result of the
above, repair of the radio can only be done by an authorized Blaupunkt or Clarion representative.
Note:
Radio manufacturer of Nissan Y61 models for Europe is ‘‘Clarion’’.

SERVICE PROCEDURE
Item

Service procedure

Description

Battery disconnection

No additional action required.

—

Radio needs repair

Repair needs to be done by authorized representative of radio manufacturer since radio cannot
be operated unless it is reset to NEW state,
using special decoding equipment.

—

Replacement of radio by new No additional action required.
part
Transferring radio to another
vehicle/replacement of radio
by an ‘‘old’’ part

Radio needs to be reset to NEW state by authorized representative of radio manufacturer.

Replacement of IMMU by
new part

No additional action required.

EL-174

Radio is delivered in NEW state.
—

The new IMMU will be recognized by the radio
since a ‘blank’ code is stored in the memory of
the IMMU. In case the radio recognizes this
‘blank’ code, it will request for input of the correct
CATS code after which the radio will switch back
to the initialisation process.

AUDIO
NATS Audio Link/LHD (Cont’d)
Item

Service procedure

Description

Replacement of IMMU by old Radio needs to be reset to NEW state by authopart
rized representative of radio manufacturer.

If a radio code has already been stored in
memory of the IMMU, the radio cannot be linked
to it. After switching on the radio, it will display
‘‘SECURE’’ after 1 minute.

No communication from
IMMU to radio

After switching on the radio, the radio will display
‘‘SECURE’’ after 1 minute. Further use of radios
impossible until communication is established
again, or after radio is reset by authorized representative of (radio) manufacturer.

1. If NATS is malfunctioning, check NATS system.
2. After NATS is repaired, reset radio to NEW
state by authorized representative of radio
manufacture.

NOTE: Authorized radio manufacturer representatives in Europe are listed in the technical bulletin
TB-EL 96-001 issued by Nissan Europe N.V.

EL-175

AUDIO — CD AUTO CHANGER —
Wiring Diagram — CD/CHG —/LHD Wagon

TEL663A

EL-176

AUDIO — CD AUTO CHANGER —
Wiring Diagram — CD/CHG —/LHD Hardtop

TEL664A

EL-177

AUDIO — CD AUTO CHANGER —
Wiring Diagram — CD/CHG —/RHD Wagon

TEL665A

EL-178

AUDIO — CD AUTO CHANGER —
Wiring Diagram — CD/CHG —/RHD Hardtop

TEL710A

EL-179

AUDIO — CD AUTO CHANGER —
Trouble Diagnoses
CD AUTOCHANGER
Symptom

Possible causes

Repair order

No play of the CD after CD play button
is pushed.
There is no error code shown on
the radio.

Error code [ERR] is shown on the
radio.

1. Radio
(The radio is not working.)
2. Harness connection
(Magazine does not eject.)
3. Changer

1. Remove the radio for repair.

1. Discs

1. Inspect discs.
(Refer to testing magazines and discs.)
2. Reset the changer.
(Disconnect harness connector at the changer and reconnect
after 30 sec.)
3. Remove the changer for repair.

2. Magazine does not eject or a
disc remains in CD player.
3. Changer
CD skipping.

1. Rough road driving
2. Discs

3. Remove the changer for repair.

1. System is not malfunctioning.
2. Inspect discs.
(Refer to testing magazines and discs.)
3. Check and repair bracket and installation of changer.
4. Remove the changer for repair.

3. Bracket
4. Changer
Error code [NO DISC] is shown on the
radio after CD play button is pressed.

2. Check harness connection.

1. Magazine setting
2. Magazine

1. Confirm the magazine is pushed completely.
2. Inspect magazine.
(Refer to testing magazines and discs.)
3. Remove the changer for repair.

3. Changer

Testing magazines and discs
1. Confirm discs are installed correctly into the magazine (not upside down).
2. Visually inspect/compare the customer’s discs with each other and other discs.
Identify any of the following conditions:
+ Discs with a large outside diameter. [Normal size is 120 mm (4.72 in).]
+ Discs with rough or lipped edges.
+ Discs with excessive thickness [Normal size is 1.2 mm (0.047 in).]
+ Discs with scratches, abrasions, or pits on the surface.
+ Discs with grease/oil, fingerprints, foreign material.
+ Discs are warped due to excessive heat exposure.
3. Slide/place the discs in and out of the various magazine positions.
Identify any discs and/or positions that require additional force for placement/ejection. If interference
(sticking, excessive tensions) is found, replace the magazine or the discs.
Note:
+ Discs which are marginally out of specification (ex. dirty, scratched and so on) may play correctly
on a home stereo.
However, when used in the automotive environment skipping may occur due to the added vehicle
movement and/or vibration due to road conditions. Autochangers should not be replaced when
discs are at fault.
+ Use a soft damp cloth to wipe the discs starting from the center outward in radial direction. Never
use chemical cleaning solutions to clean the discs.

EL-180

AUDIO ANTENNA
Wiring Diagram — P/ANT —/LHD Models

TEL457A

EL-181

AUDIO ANTENNA
Wiring Diagram — P/ANT —/RHD Models

TEL666A

EL-182

AUDIO ANTENNA
Trouble Diagnoses
POWER ANTENNA
Symptom
Power antenna does not operate.

Possible causes

Repair order
1. Check 10A fuse (No. 56 , located in fuse and fusible link
box). Verify that battery positive voltage is present at terminal j
1 : LHD, j
2 : RHD of power antenna.
2. Turn ignition switch and radio ON. Verify that battery positive
voltage is present at terminal j
3 : LHD, j
1 : RHD of power
antenna.
3. Check grounds E25 and E40 .

1. 10A fuse

2. Radio signal

3. Grounds E25

and E40

Location of Antenna

CEL744

Antenna Rod Replacement
REMOVAL
1. Remove antenna nut and antenna base.

CEL745

2. Withdraw antenna rod while raising it by operating antenna
motor.

CEL746

EL-183

AUDIO ANTENNA
Antenna Rod Replacement (Cont’d)
INSTALLATION
1. Lower antenna rod by operating antenna motor.
2. Insert gear section of antenna rope into place with it facing
toward antenna motor.
3. As soon as antenna rope is wound on antenna motor, stop
antenna motor. Insert antenna rod lower end into antenna
motor pipe.
4. Retract antenna rod completely by operating antenna motor.
5. Install antenna nut and base.

CEL747

Window Antenna Repair
ELEMENT CHECK
1. Attach probe circuit tester (in ohm range) to antenna terminal
on each side.

SEL250I

2. If an element is broken, no continuity will exist.

SEL252I

EL-184

AUDIO ANTENNA
Window Antenna Repair (Cont’d)
3. To locate broken point, move probe along element. Tester
needle will swing abruptly when probe passes the point.

SEL253I

ELEMENT REPAIR
Refer to ‘‘Filament Repair’’, ‘‘REAR WINDOW DEFOGGER’’ (EL165).

EL-185

ELECTRIC SUNROOF
Wiring Diagram — SROOF —

TEL458A

EL-186

ELECTRIC SUNROOF
Wiring Diagram — SROOF — (Cont’d)

TEL459A

EL-187

POWER DOOR MIRROR
Wiring Diagram — MIRROR —/LHD Models

TEL460A

EL-188

POWER DOOR MIRROR
Wiring Diagram — MIRROR —/RHD Models

TEL667A

EL-189

POWER SEAT
Wiring Diagram — SEAT —/LHD Models

TEL461A

EL-190

POWER SEAT
Wiring Diagram — SEAT —/LHD Models
(Cont’d)

TEL462A

EL-191

POWER SEAT
Wiring Diagram — SEAT —/RHD Models

TEL668A

EL-192

POWER SEAT
Wiring Diagram — SEAT —/RHD Models
(Cont’d)

TEL669A

EL-193

HEATED SEAT
Wiring Diagram — HSEAT —

TEL670A

EL-194

HEATED SEAT
Wiring Diagram — HSEAT — (Cont’d)

TEL671A

EL-195

POWER WINDOW
System Description
With ignition switch in ON or START position, power is supplied
+ through 7.5A fuse [No. 8 , located in the fuse block (J/B)]
1 .
+ to power window relay terminal j
The power window relay is energized and power is supplied
+ through power window relay terminal j
5
+ to power window main switch terminal j
1 ,
+ to power window sub switch terminal j
5 .

MANUAL OPERATION
NOTE:
Numbers in parentheses are terminal numbers, when power window switch is pressed in the UP and DOWN
positions respectively.

Driver side
When the driver side switch in the power window main switch is pressed in the up position, power is supplied
2 ,j
1 )
+ to driver side power window regulator terminal (j
+ through power window main switch terminal (j
9 ,j
8 ).
Ground is supplied
+ to driver side power window regulator terminal (j
1 ,j
2 )
+ through power window main switch terminal (j
8 ,j
9 ).
Then, the motor raises or lowers the window until the switch is released.

Passenger side
MAIN SWITCH OPERATION
Power is supplied
+ through power window main switch (j
5 ,j
6 )
+ to front power window sub-switch (j
3 ,j
4 ).
The subsequent operation is the same as the sub-switch operation.
SUB-SWITCH OPERATION
Power is supplied
+ through front power window sub-switch (j
1 ,j
2 )
2 ,j
1 ).
+ to passenger side power window regulator (j
Ground is supplied
+ to passenger side power window regulator (j
1 ,j
2 )
2 ,j
1 )
+ through front power window sub-switch (j
+ to front power window sub-switch (j
4 ,j
3 )
6 ,j
5 ).
+ through power window main switch (j
Then, the motor raises or lowers the window until the switch is released.

Rear door
Rear door windows will raise and lower in the same manner as passenger side door window.

AUTO OPERATION
The power window AUTO feature enables the driver to open or close the driver’s window without holding the
window switch in the respective position.
When the AUTO switch in the main switch is pressed and released, the driver’s window will travel to the fully
open or closed position.

POWER WINDOW LOCK
The power window lock is designed to lock operation of all windows except for driver’s door window.
When the lock switch is pressed to lock position, ground of the sub-switches in the power window main switch
is disconnected. This prevents the power window motors from operating.

EL-196

POWER WINDOW
Schematic

TEL468A

EL-197

POWER WINDOW
Wiring Diagram — WINDOW —

TEL672A

EL-198

POWER WINDOW
Wiring Diagram — WINDOW — (Cont’d)

TEL673A

EL-199

POWER WINDOW
Wiring Diagram — WINDOW — (Cont’d)

TEL674A

EL-200

POWER WINDOW
Wiring Diagram — WINDOW — (Cont’d)
LHD MODELS

TEL675A

EL-201

POWER WINDOW
Wiring Diagram — WINDOW — (Cont’d)
RHD MODELS

TEL676A

EL-202

POWER WINDOW
Trouble Diagnoses
Symptom

Possible cause

None of the power windows can be 1. 7.5A fuse, 40A fusible link and
operated using any switch.
M92 circuit breaker

2. Grounds M30 and M19 or M98
3. Power window relay
4. Open/short in power window
main switch circuit

Repair order
1. Check 7.5A fuse [No. 8 , located in fuse block (J/B)],
40A fusible link (letter e , located in fuse and fusible
link box) and M92 circuit breaker. Turn ignition switch
‘‘ON’’ and verify battery positive voltage is present at
terminal j
1 of power window main switch and terminal
j
5 of sub-switch.
2. Check grounds M30 and M19 or M98 .
3. Check power window relay.
4. Check W wire between power window relay and power
window main switch for open/short circuit.

Driver side power window cannot be 1. Driver side power window regula- 1. Check harness between power window main switch
and power window regulator for open or short circuit.
tor circuit
operated but other windows can be
2. Driver side power window regula- 2. Check driver side power window regulator.
operated.
tor
Passenger power window cannot be 1. Power window sub-switches
operated.
2. Passenger side power window
regulators
3. Power window main switch
4. Power window circuit

1. Check power window sub-switch.
2. Check passenger side power window regulator.

Passenger power window cannot be 1. Power window main switch
operated using power window main
switch but can be operated by power
window sub-switch.

1. Check power window main switch.

Driver side power window auto func- 1. Power window main switch
tion cannot be operated using power
window main switch.

1. Check power window main switch.

EL-203

3. Check power window main switch.
4-1. Check harnesses between power window main
switch and power window sub-switch for open/
short circuit.
4-2. Check harnesses between power window subswitch and power window regulator for open/
short circuit.

POWER DOOR LOCK
System Description
Power is supplied at all times
+ through 40A fusible link (Letter e , located in the fuse and fusible link box)
1
+ to circuit breaker terminal j
+ through circuit breaker terminal j
2
+ to smart entrance control unit terminal j
11 .
18 through body grounds.
Ground is supplied to smart entrance control unit terminal j

INPUT
When the door lock & unlock switch (power window main switch) is in LOCKED position, ground signal is
supplied
+ to smart entrance control unit terminal j
4
+ through door lock & unlock switch terminal j
14 .
When the door lock & unlock switch (power window main switch) is in UNLOCKED position, ground signal is
supplied
+ to smart entrance control unit terminal j
5
+ through door lock & unlock switch terminal j
7 .
Driver side door key cylinder and driver side lock knob are connected to driver side door lock switch with a
rod. When driver side door lock switch is in UNLOCKED position, ground signal is supplied
+ to smart entrance control unit terminal j
2
+ through driver side door lock switch terminal j
1 (without multi-remote control system) or
+ through driver side door lock actuator terminal j
2 (with multi-remote control system).
When driver side door lock switch is in LOCKED position, ground signal is interrupted.
Door lock operates according to the conditions of the door lock & unlock switch (power window main switch)
and driver side door lock switch.

OUTPUT
Unlock
Ground is supplied
+ to passenger side door lock actuator, rear door lock
+ through smart entrance control unit terminal j
15 .
Power is supplied
+ to passenger side door lock actuator, rear door lock
+ through smart entrance control unit terminal j
16 .
Then, the doors are unlocked.
Lock
Ground is supplied
+ to passenger side door lock actuator, rear door lock
+ through smart entrance control unit terminal j
16 .
Power is supplied
+ to passenger side door lock actuator, rear door lock
+ through smart entrance control unit terminal j
15 .
Then, the doors are locked.

actuator LH and RH terminal j
3
actuator LH and RH terminal j
1

1
actuator LH and RH terminal j

actuator LH and RH terminal j
3

EL-204

POWER DOOR LOCK
Wiring Diagram — D/LOCK —

TEL473A

EL-205

POWER DOOR LOCK
Wiring Diagram — D/LOCK — (Cont’d)

TEL474A

EL-206

POWER DOOR LOCK
Trouble Diagnosis

None of the doors lock/unlock when operating any switch.

EL-208

EL-209

EL-210

DIAGNOSTIC PROCEDURE 2
(Door lock actuator check)

DIAGNOSTIC PROCEDURE 3
(Driver side door lock switch check)

SYMPTOM

EL-207

DIAGNOSTIC PROCEDURE 1
(Door lock/unlock switch check)

REFERENCE PAGE

MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK

SYMPTOM CHART

One or more doors are not locked and/or
unlocked.

Door lock/unlock switch does not operate.

Door knob lock switch/key cylinder on driver’s door does not operate.

Driver side door does not lock/unlock when
operating remote controller. (With multi-remote control system)

POWER SUPPLY AND GROUND CIRCUIT CHECK
Power supply circuit check
Terminal

Ignition switch

⊕

OFF

ACC

j
11

Ground

Battery
voltage

SEL860UB

Ground circuit check
Terminals

Continuity

j
18 — Ground

Yes

SEL854UD

EL-207

POWER DOOR LOCK
Trouble Diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 1
(Door lock/unlock switch check)
CHECK DOOR LOCK/UNLOCK SWITCH
INPUT SIGNAL.
1. Disconnect control unit connector.
2. Check continuity between control unit
terminal j
4 or j
5 and ground.
SEL147VA

Terminals

j
4 — Ground
j
5 — Ground

Door lock/
unlock switch
(LH or RH)
condition
Lock
N and Unlock
Unlock
N and Lock

OK
c

Door lock/unlock switch is
OK.

Replace door lock/unlock
switch.

Continuity
Yes
No
Yes
No

NG
.
SEL432V

CHECK DOOR LOCK/UNLOCK SWITCH.
1. Disconnect door lock/unlock switch connector.
2. Check continuity between power window main switch (Door lock/unlock
switch) terminals.
Condition
Unlock
N
Lock

Terminals
7
j
No continuity

3
j
j

SEL433V
.

Check the following.
+ Ground circuit for door lock/unlock
switch
+ Harness for open or short between door
lock/unlock switch and control unit connector

EL-208

POWER DOOR LOCK
Trouble Diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 2
(Door lock actuator check)
CHECK DOOR LOCK ACTUATOR CIRCUIT.
Check voltage for door lock actuator.

SEL863UB

Door lock/unlock
switch condition
Lock
Unlock

Terminals
@
j
15
ground
j
16
ground

⊕

NG
c

Replace control unit.
(Before replacing control
unit, perform DIAGNOSTIC
PROCEDURE 1.)

Voltage
(V)
Battery
voltage

OK
.

CHECK DOOR LOCK ACTUATOR.
1. Disconnect door lock actuator connector.
2. Apply 12V direct current to door lock
actuator and check operation.
SEL434V

Door lock actuator operation
Unlocked → Locked
Locked → Unlocked

Terminals
⊕ @
j
j
3
1
j
j
1
3

OK
.

Repair harness between control unit connector and door lock actuator.

EL-209

NG
c

Replace door lock actuator.

POWER DOOR LOCK
Trouble Diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 3
(Driver side door lock switch check)
CHECK DOOR LOCK SWITCH INPUT
SIGNAL.
Check voltage between control unit terminal j
2 and ground.

SEL861UB

Driver side door lock
switch condition
Lock
Unlock

OK
c

Driver side door lock
switch is OK.

Voltage
(V)
Approx. 12
0

NG
.

SEL435V

CHECK DOOR LOCK SWITCH.
1. Disconnect driver side door lock switch
or door lock actuator connector.
2. Check continuity between door lock
switch terminals.
Without multi-remote control system
Terminals
j
1 -j
2

Condition
Locked
Unlocked

Continuity
No
Yes

With multi-remote control system
Terminals
j
2 -j
4

Condition
Locked
Unlocked

Continuity
No
Yes

SEL436V

OK
.

Check the following.
+ Ground circuit for door lock switch
+ Harness for open or short between door
lock switch and control unit

EL-210

NG
c

Replace door lock switch.

POWER DOOR LOCK — Super Lock —
Component Parts and Harness Connector
Location

SEL548V

EL-211

POWER DOOR LOCK — Super Lock —
System Description
OUTLINE
Power door lock system with super lock and key reminder is controlled by super lock control unit. Super lock
has a higher anti-theft performance than conventional power door lock systems.
When super lock is in released condition, lock knob operation locks or unlocks door.
When super lock is in set condition, lock knob operation cannot lock nor unlock door.
NOTE: Super lock function is not applied to back door. (Power door lock only)

SEL831U

OPERATION
Power door lock/unlock and super lock set/release operation by door key cylinder
+
+

With the key inserted into front door key cylinder, turning it to LOCK will lock all doors and set super lock
while all doors are closed or one or more door is open. (Super lock will not be set while key is inserted
in the ignition key cylinder.)
With the key inserted into front door key cylinder, turning it to UNLOCK will unlock all doors and release
super lock.

Power door lock/unlock and super lock set/release operation by multi-remote controller
+
+

Pressing multi-remote controller LOCK button will lock all doors and set super lock while all doors are
closed and key is not inserted in the ignition key cylinder.
Pressing multi-remote controller UNLOCK button will unlock all doors and release super lock with key not
inserted in the ignition key cylinder.

Power door lock and super lock release operation (by NATS IMMU signal)
+

When the super lock is set, turning ignition key switch to ON will release super lock and unlock all doors.

EL-212

POWER DOOR LOCK — Super Lock —
System Description (Cont’d)
Power door lock/unlock operation by lock knob
With lock knob on driver or passenger door setting to LOCK while all doors are closed will lock all doors.
When one or more door is opened, with lock knob on passenger door setting to LOCK will lock
passenger door only. (Power door lock system will not operate.)
+ With lock knob on driver or passenger door setting to UNLOCK while all doors are closed will unlock all
doors.
Lock knob operation cannot control super lock.
+

Key reminder system
+

If the ignition key is in the ignition key cylinder and any door is open, setting lock/unlock switch or lock
knob on driver or passenger door to ‘‘LOCK’’ locks the door once but then immediately unlocks all doors.

System initialisation
+

System initialisation is required when battery cables are reconnected. Conduct one of the followings to
release super lock once;
— insert the key into ignition key cylinder and turn it to ON.
— LOCK/UNLOCK operation using door key cylinder.

EL-213

POWER DOOR LOCK — Super Lock —
Schematic

TEL677A

EL-214

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models

TEL678A

EL-215

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL679A

EL-216

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL680A

EL-217

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL681A

EL-218

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models

TEL682A

EL-219

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL683A

EL-220

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL684A

EL-221

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL711A

EL-222

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses
PRELIMINARY CHECK
CHECK-IN
.

Open all windows and remove
key from ignition key cylinder.
.

No (All doors)

Does power door lock operate
properly?

Power door lock does not operate by using;
— any switch.
…………………………………………………………………
— driver side lock knob switch and/or key cylinder.
…………………………………………………………………
— passenger side lock knob switch and/or key
cylinder..

Yes

SYMPTOM 1

SYMPTOM 2

SYMPTOM 3

SYMPTOM 4

SYMPTOM 5

SYMPTOM 6

SYMPTOM 9

SYMPTOM 7

SYMPTOM 8

SYMPTOM 9

No (Specific door)
.

No (All doors)

Does super lock set by using
door key cylinder?

Super lock does not set by using;
— both door key cylinders.
…………………………………………………………………
— one of door key cylinders.

Yes
No (Specific door)
.

Does super lock release by using
door key cylinder or IGN key
switch?

No (All doors)
c

Super lock does not release by using;
— one or both door key cylinders.
…………………………………………………………………
— IGN key switch.
(Signal from NATS IMMU)

Yes

No (Specific door)
.

Does super lock set/release by
using multi-remote controller?
(If equipped)

No
c

Does multi-remote control system operate
properly?

Yes
c

No
c

Yes

SYMPTOM 11
Check ‘‘MULTIREMOTE
CONTROL’’
system.

Insert key to ignition key cylinder,
open any door and lock the door
using driver or passenger side
knob lock switch.
.

Does key reminder system operate properly?
.

No
c

SYMPTOM 10

Yes

INSPECTION END

After performing preliminary check, go to symptom chart on the next page.
. When one or more doors are opened, with lock knob on passenger door setting to LOCK, will lock passenger door only. (Power door lock system will not operate.)

EL-223

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
Before starting trouble diagnoses below, perform preliminary check, EL-223.
Symptom numbers in the symptom chart correspond with those of Preliminary check.

SYMPTOM CHART

Power door lock does not operate
with any switch of passenger side.

Specific door lock actuator does not
operate.

Super lock cannot be set by both
door key cylinders.

Super lock cannot be set by one of
door key cylinders.

*Super lock cannot be released by
one or both door key cylinders.

*Super lock cannot be released by
ignition key switch. (Signal from
NATS IMMU)

Specific super lock actuator does not
operate.

*Key reminder system does not
operate.

Super lock cannot be set/released
by using multi-remote controller.

Procedure 9
(Remote controller signal check)

Procedure 6
(NATS release signal check)

Procedure 5
(Door switch check)

Procedure 8
(Ignition switch ‘‘ON’’ circuit check)

Power door lock does not operate
with any switch of driver side.

Procedure 7
(Key switch check)

Procedure 4
(Super lock actuator check)

Power door lock does not operate
using any switch.

Procedure 3
(Door lock actuator check)

Procedure 2
(Door key cylinder switch check)

Procedure 1
(Door unlock sensor check)

SYMPTOM

EL-225 EL-226 EL-227 EL-228 EL-229 EL-230 EL-231 EL-232 EL-232 EL-233
Power supply and ground circuit check

REFERENCE PAGE

X
X

X: Applicable
*: Make sure the power door lock system operates properly.

EL-224

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
POWER SUPPLY AND GROUND CIRCUIT CHECK
Main power supply circuit check
Terminals

Ignition switch position

⊕

OFF

ACC

j
11

Ground

Battery
voltage

SEL811UB

Ground circuit check
Terminals

Continuity

j
16 — Ground

Yes

SEL812UB

EL-225

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 1
(Door unlock sensor check)
CHECK DOOR UNLOCK SENSOR
INPUT SIGNAL.
Check voltage between control unit termi4 or j
5 and ground.
nals j
Terminals

Condition

⊕

Driver
side

j
4

Ground

Passenger
side

j
5

SEL813UB

Locked
Unlocked
Locked

Ground

Unlocked

OK
c

Door unlock sensor is OK.

Voltage
[V]
Approx.
5
0
Approx.
5
0

Refer to wiring diagram in EL-215 (LHD),
EL-219 (RHD).
NG
SEL814UB

CHECK DOOR UNLOCK SENSOR.
1. Disconnect door unlock sensor connector.
2. Check continuity between door unlock
sensor terminals.
Terminals
j
2 -j
5

Condition
Locked
Unlocked

Continuity
No
Yes

OK
.

Check the following.
+ Door unlock sensor ground circuit
+ Harness for open or short between control unit and door unlock sensor

EL-226

NG
c

Replace door lock actuator
assembly.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 2
(Door key cylinder switch check)
CHECK DOOR KEY CYLINDER SWITCH
INPUT SIGNAL (LOCK SIGNAL).
Check voltage between control unit termi1 and ground.
nal j
Key cylinder switch operation
Between neutral and lock
Unlock/neutral

OK
c

Door key cylinder switch is
OK.

Replace key cylinder
switch.

Voltage [V]
0
Approx. 5

Refer to wiring diagram in EL-215 (LHD),
EL-219 (RHD).
NG
.

SEL815UB

CHECK DOOR KEY CYLINDER SWITCH.
1. Disconnect door key cylinder switch
connector.
2. Check continuity between door key cylinder switch terminals.
Terminals
j
1 -j
2
(LH side)
j
2 -j
3
(RH side)

Key position
Neutral
Between
neutral and
lock
Unlock/
neutral

Continuity
No
Yes
No

OK
.
SEL492V

Check the following.
+ Door key cylinder switch ground circuit
+ Harness for open or short between control unit and door key cylinder

EL-227

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 3
(Door lock actuator check)
NG

CHECK OUTPUT SIGNAL FOR DOOR
LOCK ACTUATOR.
Check voltage for door lock actuator.

SEL817UB

Terminals

Knob lock switch
condition

⊕

Unlock → Lock

j
15

Lock → Unlock

j
14

Door lock actuator is OK.

Voltage
(V)

Ground Approx. 12
(Approx. 5
Ground seconds)

Before operating passenger side knob
lock switch, close all doors.
Refer to wiring diagram in EL-215 (LHD),
EL-219 (RHD).
OK
.

SEL818UB

CHECK DOOR LOCK ACTUATOR.
1. Disconnect door lock actuator connector.
2. Apply 12V direct current to door lock
actuator and check operation.
Door lock actuator operation
Door lock actuator operation
Unlocked → Locked
Locked → Unlocked

Terminals

⊕ @
j
6
j
3

j
3
j
6

Back door lock actuator operation

Back door lock actuator operation
SEL827UB

Unlocked → Locked
Locked → Unlocked

Terminals

⊕ @
j
3
j
1

NG
.

Replace door lock actuator assembly.

SEL434VA

EL-228

j
1
j
3

OK
c

Check harness between
control unit and door lock
actuator.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 4
[Super lock actuator (in door lock actuator assembly)
check]
CHECK OUTPUT SIGNAL FOR SUPER
LOCK ACTUATOR.
Check voltage for super lock actuator.

SEL819UB

Door key cylinder
switch condition
Lock (Set)
Unlock
(Released)

Terminals

NG
c

Super lock actuator is OK.

Voltage
(V)

⊕

j
18

Ground

j
13

Ground

Approx. 12

Put the system in set condition before
checking release signal.
Refer to wiring diagram in EL-215 (LHD),
EL-219 (RHD).
OK
.

CHECK SUPER LOCK ACTUATOR.
1. Disconnect door lock actuator assembly
connector.
2. Set lever A in Lock position.
3. Apply 12V direct current to door lock
actuator assembly and check operation.
Super lock actua- Terminals Connection from
tor operation
⊕ @ lever B to lever A
Released → Set
Set → Released

j
1
j
4

SEL820UB

j
4
j
1

Disconnect
Connect

NG
.

Replace door lock actuator assembly.

EL-229

OK
c

Check harness between
control unit and door lock
actuator assembly.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 5
(Door switch check)

CHECK DOOR SWITCH INPUT SIGNAL.
Check voltage between control unit terminal j
8 and ground.

SEL821UB

Condition
Any door is opened.
All doors are closed.

OK
c

Door switch is OK.

Voltage [V]
0
Approx. 12

Refer to wiring diagram in EL-215 (LHD),
EL-219 (RHD).
NG
.

CHECK DOOR SWITCH.
1. Disconnect door switch connector.
2. Check continuity between door switch
terminals.

Driver side
door
switch
Other door
switches

Terminals

Condition

Continuity

j
2 ground

Closed

Open

Yes

j
1 ground

Closed
Open

No
Yes

OK
.

SEL822UC

Check the following.
+ Door switch ground condition
+ Harness for open or short between control unit and door switch

EL-230

NG
c

Replace door switch.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 6
(NATS release signal check)
No

Does engine start properly?

Check NATS system.

Yes
.

SEL493V

CHECK NATS SIGNAL CIRCUIT.
1. Disconnect control unit connector and
NATS IMMU connector.
2. Check continuity between control unit
terminal j
9 and NATS IMMU terminal
j
3 (LHD models), j
7 (RHD models).
Continuity should exist.
3. Check continuity between control unit
terminal j
9 and ground.
Continuity should not exist.
Refer to wiring diagram in EL-215
(LHD), EL-219 (RHD).

NG
c

Repair harness.

OK
SEL494V

CHECK NATS RELEASE SIGNAL.
1. Connect control unit connector and
NATS IMMU connector.
2. Check voltage between control unit terminal j
9 and ground.
Ignition switch condition
OFF
More than 10 seconds after ignition
switch turned ON
For 10 seconds after ignition switch
turned ON

OK
.

Replace super lock control unit.

SEL495V

EL-231

Voltage
[V]
5

Pulse

NG
c

Check NATS system.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 7
(Key switch check)
CHECK KEY SWITCH INPUT SIGNAL.
Check voltage between control unit termi7 and ground.
nal j

SEL883UB

Condition of key switch

Voltage [V]

Key is inserted.

Approx. 12

Key is withdrawn.

OK
c

Key switch is OK.

Refer to wiring diagram in EL-215 (LHD),
EL-219 (RHD).
NG
.

SEL496V

CHECK KEY SWITCH POWER SUPPLY.
1. Disconnect key switch connector.
2. Check voltage between key switch harness terminal j
2 and ground.
Battery voltage should exist.

NG
c

Check the following.
+ 7.5A fuse [No. 24 ,
located in fuse block
(J/B)]
+ Harness for open or
short between key
switch and fuse

CHECK KEY SWITCH.
Check continuity between key switch terminals.
Terminals

SEL462V

j
1 -j
2

Condition

Continuity

Key is inserted.

Yes

Key is withdrawn.

NG
c

Replace key switch.

OK
.

Check harness for open or short between
control unit and key switch.

DIAGNOSTIC PROCEDURE 8
(Ignition switch ‘‘ON’’ circuit check)
Terminals

SEL829UB

Ignition switch position

⊕

OFF

ACC

j
6

Ground

Battery
voltage

If NG, check the following.
+ 10A fuse [No. 25 , located in the fuse block (J/B)]
+ Harness for open or short

EL-232

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 9
(Remote controller signal check)

SEL051VA

CHECK REMOTE CONTROLLER INPUT
SIGNAL.
1. Withdraw key from ignition key cylinder.
2. Check voltage between control unit terminal j
2 or j
3 and ground.
NOTE: The multi-remote control system
does not activate with key inserted
in ignition key cylinder or if one of
the doors is opened.
Terminals
⊕

j
2

j
3

Condition of
remote controller
button

Voltage
[V]

LOCK button is
pressed

0 (Approx.
0.5 seconds)

LOCK button is
released

UNLOCK button
is pressed

0 (Approx.
0.5 seconds)

UNLOCK button
is released

Ground

Refer to Wiring Diagram in EL-216.
NG
.

Check harness for open or short between
super lock control unit and multi-remote
control unit.

EL-233

OK
c

Replace super lock control
unit.

MULTI-REMOTE CONTROL SYSTEM
System Description
FUNCTION
Multi-remote control system has the following function.
+ Door lock (and set super lock)
+ Door unlock (and release super lock)
+ Hazard reminder

LOCK OPERATION
To lock door by multi-remote controller, the following two signals must be received.
+ Key switch OFF (when ignition key is not in ignition key cylinder.)
+ All door switches CLOSED
When the LOCK signal is input to multi-remote control unit (the antenna of the system is combined with multiremote control unit), ground is supplied
+ through multi-remote control unit terminal j
10
+ to super lock control unit terminal j
2 .
Then super lock control unit operates to lock doors and set super lock.

UNLOCK OPERATION
To unlock door by multi-remote controller, the following signal must be received.
+ Key switch OFF (when ignition key is not in ignition key cylinder)
When the UNLOCK signal is input to multi-remote control unit (the antenna of the system is combined with
multi-remote control unit), ground is supplied
+ through multi-remote control unit terminal j
11
+ to super lock control unit terminal j
3 .
Then super lock control unit operates to unlock doors and release super lock.

HAZARD REMINDER
When the doors are locked or unlocked by multi-remote controller, ground is supplied
+ to terminal j
1 of multi-remote control relay-1 and 2
+ through multi-remote control unit terminal j
12 .
Then the relays are energized and hazard warning lamp flashes as follows
+ Lock operation: Flash once
+ Unlock operation: Flash twice

MULTI-REMOTE CONTROLLER ID CODE ENTRY
A maximum of four remote controllers can be entered. Any attempt to enter a remote controller will erase all
ID codes previously entered. Therefore, be sure to receive all remote controllers from the vehicle owner when
any ID code entry is performed.
To enter ID code entry, the following signals must be input to the multi-remote control unit.
+ Driver side LOCKED signal (from driver side door unlock sensor)
+ Door switch CLOSED signal
+ Key switch signal (INSERTED/WITHDRAWN)
+ Accessory power supply
+ Signal from remote controller
For detailed procedure, refer to ‘‘ID Code Entry Procedure’’ in EL-239.

EL-234

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/LHD Models

TEL688A

EL-235

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/LHD Models
(Cont’d)

TEL689A

EL-236

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses
SYMPTOM CHART
Symptom

Possible cause

Diagnoses/service order

1. Check remote controller battery. Refer to EL-238.
2. Check key switch (insert) signal at terminal j
7 of
multi-remote control unit.
3. Check door switch signal at terminals j
1 and
j
2 of multi-remote control unit.
4. Power supply circuit for multi- 4. Make sure battery voltage is present at
remote control unit
terminal j
3 of multi-remote control unit.
5. Ground circuit for multi-remote 5. Check continuity between terminal j
5 of multi-recontrol unit
mote control unit and ground.
6. Remote controller
6. Replace remote controller. Refer to EL-239.

1. Remote controller battery
No doors can be Hazard reminder
locked or unlocked also does not oper- 2. Key switch (insert)
by remote control ate either.
3. Door switch
operation.

Hazard reminder
operates properly.

1. Super lock system

1. Check that power door lock operates properly. If
NG, check super lock, EL-211.
2. Lock/unlock signal to super 2. Check lock/unlock signal to super lock control unit
at terminals j
lock control unit
10 and j
11 of multi-remote control unit.
(See NOTE.)

Hazard reminder does not operate properly. 1. 10A fuse
2. Multi-remote control
and 2
3. Hazard reminder circuit
The new ID of remote controller
cannot be entered.

1. Check 10A fuse (No. 48 , located in the fuse and
fusible link box).
relay-1 2. Check multi-remote control relay-1 and 2.
3. Check harness for open or short between relays
and multi-remote control unit terminal j
12 .

1. Remote controller battery
2. Key switch (insert)
3.
4.
5.

1. Check remote controller battery. Refer to EL-238.
2. Check key switch (insert) signal at terminal j
7 of
multi-remote control unit.
Door switch
3. Check door switch signal at terminals j
1 and j
2
of multi-remote control unit.
Driver’s door unlock sensor
4. Check driver’s door unlock sensor signal at terminal j
6 of multi-remote control unit.
Accessory power supply circuit 5. Make sure battery voltage is present at terminal
j
for multi-remote control unit
8 of multi-remote control unit while ignition
switch is in ACC position.
Remote controller
6. Replace remote controller. Refer to EL-239.

Refer to ‘‘MULTI-REMOTE CONTROL UNIT INSPECTION TABLE’’ on next page to check the control unit
signals.
NOTE:
+ The unlock operation of multi-remote control system does not activate with key inserted in the ignition key
cylinder.
+ The lock operation of multi-remote controller does not activate with the key inserted ignition key cylinder
or if one of the door is opened.

EL-237

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses (Cont’d)
MULTI-REMOTE CONTROL UNIT INSPECTION TABLE
Terminal
No.

Connections

Voltage (V)
(approximate
values)

Condition

Driver side door switch

Opened

Closed

Driver side door
One of doors is opened

All doors are closed

Door switch (all doors)

Power source (BAT)

—

Ground

—

Driver side door unlock sensor

Locked

Unlocked

Driver side door
Key is in ignition key cylinder

Key is not in ignition key cylinder

Key switch (insert)

Accessory power supply

OFF

ACC or ON

Ignition switch

Lock signal (to super lock control
unit)

Unlock signal (to super lock control
unit)

Multi-remote control relay-1, 2

Remote controller LOCK button is pushed
(All doors are closed and key is not in ignition key cylinder.)

Other than above condition

Remote controller UNLOCK button is pushed
(Key is not in ignition key cylinder.)

Other than above condition

Remote controller LOCK/UNLOCK button is pushed
(All doors are closed and key is not in ignition key cylinder.)

Other than above condition

SEL439V

REMOTE CONTROLLER BATTERY CHECK
Remove battery and measure voltage across battery positive and
negative terminals, ⊕ and @.
Measuring terminal

SEL672U

Standard value

⊕

Battery positive terminal
⊕

Battery negative terminal
@

2.5 — 3.0V

Note:
Remote controller does not function if battery is not set correctly.

EL-238

MULTI-REMOTE CONTROL SYSTEM
ID Code Entry Procedure
Note:
A maximum of four remote controllers can be entered. Any attempt to enter a remote controller will
erase all ID codes previously entered. Therefore, be sure to receive all remote controllers from the
vehicle owner when any ID code entry is performed.
Enter the identity (ID) code manually when:
+ remote controller or control unit is replaced.
+ an additional remote controller is activated.
To enter the ID code, follow the procedures below.

PROCEDURE
Close all doors and lock driver side door.

Insert and remove the key from the ignition more than six times within 10 seconds.

Turn ignition key switch to ‘‘ACC’’ position. (The hazard warning lamps will then
flash twice.

Push any button on the new remote controller once. (The hazard warning lamps will
then flash twice.)
At this time, the new ID code is entered and all previous ID memory is completely erased.

Do you want to enter any additional remote controller ID codes?
A maximum four ID codes may be entered. Any attempt to enter more will be
ignored.
No

Yes
.

ADDITIONAL ID CODE ENTRY
Release the door lock, then lock again
with driver side knob lock switch.
.

Open driver side door or turn the ignition key switch to ‘‘OFF’’ position.

END.
After entering the identity (ID) code, check the operation of multi-remote control system.

NOTE:
+ If you need to activate more than two additional new remote controllers, repeat the procedure
‘‘Additional ID code entry’’ for each new remote controller.
+ If the same ID code that exists in the memory is input, the entry will be ignored.
+ Entry of maximum four ID codes is allowed and any attempt to enter more will be ignored.
+ Any ID codes cannot be entered after termination of the ‘‘setting mode’’.

EL-239

NATS (Nissan Anti-Theft System)/LHD MODELS
System Description
NATS has the following immobiliser functions:
+ Since only NATS ignition keys, whose ID nos. have been registered into the ECM and IMMU of NATS,
allow the engine to run, operation of a stolen vehicle without a NATS registered key is prevented by NATS.
That is to say, NATS will immobilize the engine if someone tries to start it without the registered key of
NATS.
+ Both of the originally supplied ignition key IDs have been NATS registered.
If requested by the vehicle owner, a maximum of four key IDs can be registered into the NATS components.
+ The NATS security indicator (NATS security ind.) blinks when the ignition switch is in ‘‘OFF’’ or ‘‘ACC’’
position. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.
+ When NATS detects trouble, the malfunction indicator lamp (MIL) blinks.
+ NATS trouble diagnoses, system initialisation and additional registration of other NATS ignition key IDs
must be carried out using CONSULT hardware and CONSULT NATS software.
When NATS initialisation has been completed, the ID of the inserted ignition key is automatically NATS
registered. Then, if necessary, additional registration of other NATS ignition key IDs can be carried out.
Regarding the procedures of NATS initialisation and NATS ignition key ID registration, refer to CONSULT
operation manual, NATS.
+ When servicing a malfunction of the NATS (indicated by flashing of Malfunction Indicator Lamp)
or registering another NATS ignition key ID no., it may be necessary to re-register original key
identification. Therefore, be sure to receive all keys from vehicle owner.

System Composition
The immobiliser function of the NATS consists of the following:
+ NATS ignition key
+ NATS immobiliser control unit (NATS IMMU) located in the ignition key cylinder
+ Engine control module (ECM)
+ NATS security indicator
+ Malfunction indicator lamp (MIL)

SEL402V

EL-240

NATS (Nissan Anti-Theft System)/LHD MODELS
Wiring Diagram — NATS —

TEL691A

EL-241

NATS (Nissan Anti-Theft System)/LHD MODELS
CONSULT
CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect ‘‘CONSULT’’ to Data link connector for CONSULT.

SEF532V

3. Insert NATS program card into CONSULT.
: Program card
NATS-E940
4. Turn on ignition switch.
5. Touch ‘‘START’’.

SEL327U

6. Touch ‘‘V.2.0 (GASOLINE)’’.
NOTE: ‘‘V.2.0 (GASOLINE)’’ should be selected for electrically
controlled diesel and gasoline engines.

SEL328U

7. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT Operation Manual,
NATS V2.0 (GASOLINE).

SEL329U

EL-242

NATS (Nissan Anti-Theft System)/LHD MODELS
CONSULT (Cont’d)
CONSULT DIAGNOSTIC TEST MODE FUNCTION
CONSULT DIAGNOSTIC TEST
MODE

Description

C/U INITIALIZATION

When replacing any of the following three components, C/U initialization is necessary.
[NATS ignition key/IMMU/ECM]

SELF-FUNCTION CHECK

ECM checks its own NATS communication interface by itself.

SELF-DIAGNOSTIC RESULTS

Detected items (screen terms) are as shown in the chart below.

NOTE:
When any initialisation is performed, all ID previously registered will be erased. So all NATS ignition
keys must be registered again.
The engine cannot be started with an unregistered key. In this case, the system may show ‘‘DIFFERENCE OF KEY’’ or ‘‘LOCK MODE’’ as a self-diagnostic result on the CONSULT screen.

HOW TO READ SELF-DIAGNOSTIC RESULTS

SEL332UE

NOTE:
+ If trip number is more than 1, MIL does not blink.
+ Time data is not indicated for TB45E engine models.

SELF-DIAGNOSTIC RESULTS ITEM CHART
Detected items (Screen terms)

Description

Reference page

IMMU

ECM received the signal from IMMU that IMMU is malfunctioning.

EL-246

ECM

ECM is malfunctioning.

EL-246

CHAIN OF ECM-IMMU

Communication impossible between ECM and IMMU.

EL-247

DIFFERENCE OF KEY

IMMU can receive the key ID signal but the result of ID verification
between key ID and IMMU is NG.

EL-249

CHAIN OF IMMU-KEY

IMMU cannot receive the key ID signal.

EL-250

ID DISCORD, IMM-ECM

The result of ID verification between IMMU and ECM is NG. System initialisation is required.

EL-250

MINGLE NOISE

Noise (interference) mingled into NATS communication lines during communicating.

EL-251

DON’T ERASE BEFORE CHECKING ENG DIAG

Engine trouble data and NATS trouble data have been detected in ECM.

EL-244

LOCK MODE

When an unregistered ignition key is used, or if the starting operation is
carried out two or more times consecutively with the ignition key, IMMU
or ECM malfunctioning, NATS will shift the mode to one which prevents
the engine from being started.

EL-252

EL-243

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses
WORK FLOW
*Lighting-up mode of MIL (Malfunction Indicator Lamp)
For single malfunction of NATS: Blinking
For dual malfunctions of NATS and an engine-related part:
Stays ON
For single malfunction of an engine-related part: Stays ON

CHECK IN
.

Listen to customer complaints or request. (Get symptoms)

KEY SERVICE REQUEST (Additional key ID registration)

TROUBLE
.

Verify the MIL*.

INITIALISATION
(Refer to CONSULT operation
manual NATS V2.0.)

Using the CONSULT program card for NATS check the ‘‘SELF-

c DIAG RESULTS’’ with CONSULT.

Self-diagnostic results referring to NATS, but no information
about engine self-diagnostic results is displayed on CONSULT.
.

Self-diagnostic results referring to NATS and ‘‘DON’T ERASE
BEFORE CHECKING ENG DIAG’’ are displayed on CONSULT.
(This means that engine trouble data has been detected in
ECM.)

Turn ignition switch ‘‘OFF’’.
.

Repair NATS.
(If necessary, carry out ‘‘SELF-FUNCTION CHECK’’ or ‘‘C/U INITIALISATION’’ with CONSULT.)

Turn ignition switch ‘‘OFF’’.

Turn ignition switch ‘‘ON’’.

Repair NATS.
(If necessary, carry out ‘‘SELF-FUNCTION CHECK’’ or ‘‘C/U INITIALISATION’’ with CONSULT.)
.

Erase the NATS ‘‘SELF-DIAG RESULTS’’ by using CONSULT.
(Touch ‘‘ERASE’’.)

Do not erase the NATS ‘‘SELF-DIAG RESULTS’’ by using
CONSULT.
.

Start the engine.
.

Start the engine.

Check the NATS ‘‘SELF-DIAG RESULTS’’ by using CONSULT.

OK
NG

Verify no blinking of MIL*.

Turn ignition switch ‘‘OFF’’.
OK
.

CHECK OUT

Check the engine ‘‘SELF-DIAG RESULTS’’ with CONSULT by
using the CONSULT generic program card.
(Engine diagnostic software included)
.

Perform running test with CONSULT in engine ‘‘SELF-DIAG
RESULTS’’ mode.

Repair ECCS. (Refer to EC section.)

NG Verify ‘‘NO FAILURE’’ displayed on the CONSULT screen.

Turn ignition switch ‘‘ON’’.

OK
.

CHECK OUT

Erase the engine ‘‘SELF-DIAG RESULTS’’ by using CONSULT.
(Touch ‘‘ERASE’’.)
.

Start the engine.

EL-244

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)
SYMPTOM CHART
SYMPTOM

Displayed ‘‘SELF-DIAG RESULTS’’
on CONSULT screen.

DIAGNOSTIC PROCEDURE
(Reference page)

SYSTEM
(Malfunctioning part or mode)

IMMU

PROCEDURE 1
(EL-246)

IMMU

ECM

PROCEDURE 2
(EL-246)

ECM

+ MIL blinking
+ Engine will start

Open circuit in battery voltage line
of IMMU circuit
Open circuit in ignition line of IMMU
circuit
PROCEDURE 3
(EL-247)

CHAIN OF ECM-IMMU

Open circuit in ground line of IMMU
circuit
Open or short circuit in communication line between IMMU and ECM
ECM
IMMU

+ MIL blinking
+ Engine does not start

DIFFERENCE OF KEY

CHAIN OF IMMU-KEY

PROCEDURE 4
(EL-249)

Unregistered key

PROCEDURE 5
(EL-250)

Malfunction of key ID chip

PROCEDURE 6
(EL-250)

ID DISCORD, IMM-ECM

IMMU

IMMU
System initialisation has not yet
been completed.
ECM
IMMU

+ MIL staying ON

+ Security indicator does not operate properly.
+ Engine starts properly.

MINGLE NOISE

PROCEDURE 7
(EL-251)

Noise interference in communication line

LOCK MODE

PROCEDURE 8
(EL-252)

LOCK MODE

DON’T ERASE BEFORE CHECKING ENG DIAG

WORK FLOW
(EL-244)

Engine trouble data and NATS
trouble data have been detected in
ECM.
Security indicator circuit

PROCEDURE 9
(EL-253)

—

Security indicator
Continuation of initialisation mode

*Lighting-up mode of MIL (Malfunction Indicator Lamp)
For single malfunction of NATS: Blinking
For dual malfunctions of NATS and an engine-related part: Stays ON
For single malfunction of an engine-related part: Stays ON

EL-245

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 1
Self-diagnostic results:
‘‘IMMU’’ displayed on CONSULT screen

Confirm SELF-DIAGNOSTIC RESULTS ‘‘IMMU’’ displayed on CONSULT screen.

.
SEL330U

+ IMMU is malfunctioning.
1. Replace IMMU.
2. Perform initialisation with CONSULT.
For the initialisation procedure, refer to ‘‘CONSULT operation manual NATS
V2.0 (GASOLINE)’’.

DIAGNOSTIC PROCEDURE 2
Self-diagnostic results:
‘‘ECM’’ displayed on CONSULT screen

Confirm SELF-DIAGNOSTIC RESULTS ‘‘ECM’’ displayed on CONSULT
screen.

.
SEL331U

+ ECM is malfunctioning.
1. Replace ECM.
2. Perform initialisation with CONSULT.
For the initialisation procedure, refer to ‘‘CONSULT operation manual NATS
V2.0 (GASOLINE)’’.

EL-246

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 3
Self-diagnostic results:
‘‘CHAIN OF ECM-IMMU’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC
RESULTS ‘‘CHAIN OF ECMIMMU’’ displayed on CONSULT
screen.
OK
SEL333U
.

CHECK POWER SUPPLY CIRCUIT FOR
IMMU.
Check voltage between IMMU terminal j
8
and ground.
Battery voltage should exist.

NG
c

.
SEL395VA

CHECK IGN SW. ON SIGNAL.
Check voltage between IMMU terminal j
7
and ground while ignition switch is ‘‘ON’’
position.
Battery voltage should exist.

NG
c

CHECK GROUND CIRCUIT FOR IMMU.
Check continuity between IMMU terminal
j
4 and ground.
Continuity should exist.

NG
c

Check the following.
+ 7.5A fuse (No. 50 : RD
engine, 49 : TB engine,
located in the fuse and
fusible link box)
+ Harness for open or
short between fuse and
IMMU connector

Check the following.
+ 10A fuse [No. 25 ,
located in the fuse block
(J/B)]
+ Harness for open or
short between fuse and
IMMU connector

Repair harness.

SEL396VA

OK
.

CHECK COMMUNICATION OPEN CIRCUIT.
Check continuity between IMMU terminal
j
1 and ECM terminal j
55 (RD engine), j
11
(TB engine).
Continuity should exist.
OK
.
SEL397VA

j
A

SEL497V

EL-247

NG
c

Repair harness.

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)
j
A

CHECK COMMUNICATION LINE SHORT
CIRCUIT.
1. Disconnect ECM connector and IMMU
connector.
2. Check continuity between IMMU terminal j
1 and ground.
Continuity should not exist.
3. Turn ignition switch to ON.
4. Check voltage between IMMU terminal
j
1 and ground.
No voltage should exist.

NG
c

Repair harness.

OK
.

SELF-FUNCTION CHECK
1. Connect ECM connector and
disconnect IMMU connector.
2. Turn ignition switch ‘‘ON’’.
3. Touch ‘‘SELF-FUNCTION
CHECK’’ on CONSULT
‘‘SELECT DIAG MODE’’
screen.
SEL399VA

Touch ‘‘START’’. ECM will then
check its communication interface
by itself.
OK

SEL340U

+ IMMU is malfunctioning.
1. Replace IMMU.
2. Perform initialisation with CONSULT.
For the initialisation procedure, refer to
‘‘CONSULT operation manual NATS
V2.0’’.

SEL341U

SEL342U

EL-248

NG
c

+ ECM is malfunctioning.
1. Replace ECM.
2. Perform initialisation
with CONSULT.
For the initialisation
procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)

SEL343U

DIAGNOSTIC PROCEDURE 4
Self-diagnostic results:
‘‘DIFFERENCE OF KEY’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC
RESULTS ‘‘DIFFERENCE OF
KEY’’ displayed on CONSULT
screen.
OK
SEL344U

PERFORM INITIALISATION.
Perform initialisation with CONSULT.
Re-register all NATS ignition key IDs.
For the initialisation procedure, refer to
‘‘CONSULT operation manual NATS
V2.0’’.
Can the system be initialized?
Note: If the initialisation is not completed
or fails, CONSULT shows
message on the screen.
Yes

SEL372U
.

END.
(The ignition key was unregistered.)

EL-249

No
c

+ IMMU is malfunctioning.
1. Replace IMMU.
2. Perform initialisation
with CONSULT.
For the initialisation
procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 5
Self-diagnostic results:
‘‘CHAIN OF IMMU-KEY’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC
RESULTS ‘‘CHAIN OF IMMUKEY’’ displayed on CONSULT
screen.
OK
SEL373U

CHECK NATS IGNITION KEY ID CHIP.
Can the engine start with another registered NATS ignition key?

Yes

+ Ignition key ID chip is
malfunctioning.
1. Replace the ignition
key.
2. Perform initialisation
with CONSULT.
For the initialisation
procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

+ IMMU is malfunctioning.
1. Replace IMMU.
2. Perform initialisation with CONSULT.
For the initialisation procedure, refer to
‘‘CONSULT operation manual NATS
V2.0’’.

DIAGNOSTIC PROCEDURE 6
Self-diagnostic results:
‘‘ID DISCORD, IMM-ECM’’ displayed on CONSULT screen
* ‘‘ID DISCORD, IMM-ECM’’:
Registered ID of IMMU is in
discord with that of ECM.

Confirm SELF-DIAGNOSTIC
RESULTS ‘‘ID DISCORD, IMMECM*’’ displayed on CONSULT
screen.
.
SEL383U

SEL372U

END.
(System initialisation was not completed.)

EL-250

No
c

+ ECM is malfunctioning.
1. Replace ECM.
2. Perform initialisation
with CONSULT.
For the initialisation
procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 7
Self-diagnostic results:
‘‘MINGLE NOISE’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC RESULTS ‘‘MINGLE NOISE’’ displayed on CONSULT screen.

Turn off or remove any possible noise sources.
SEL384U

Touch ‘‘ERASE’’ on CONSULT SELF-DIAGNOSTIC RESULTS
screen.

Can the engine start?
Yes
.

SEL385U

END

EL-251

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 8
Self-diagnostic results:
‘‘LOCK MODE’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC
RESULTS ‘‘LOCK MODE’’ is displayed on CONSULT screen.

.
SEL790U

1. Turn the ignition switch to OFF position.
2. Turn the ignition key switch to ON position with a registered key.
(Do not start engine.) Wait for 5 seconds.
3. Return the key to the OFF position.
4. Repeat steps 2 and 3 twice (total of
three cycles).
5. Start the engine.
Can the engine start?

Yes
c

System is OK.
(Now the system is
escaped from ‘‘LOCK
MODE’’.)

No
.
SEL038V

CHECK NATS IMMU INSTALLATION.
Refer to ‘‘How to Replace NATS IMMU’’ in
EL-253.

NG
c

Reinstall NATS IMMU correctly.

OK
.

PERFORM INITIALISATION.
Perform initialisation with CONSULT.
For the initialisation procedure, refer to
‘‘CONSULT operation manual NATS V2.0
(GASOLINE)’’.
Can the system be initialized?
Note: If the initialisation is incompleted or
failed, CONSULT shows
message on the screen.
No
.

Go to DIAGNOSTIC PROCEDURE 5,
EL-250 to check ‘‘CHAIN OF IMMU-KEY’’.

EL-252

Yes
c

System is OK.

NATS (Nissan Anti-Theft System)/LHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 9
Security indicator check
CHECK INDICATOR CIRCUIT.
1. Disconnect NATS IMMU connector.
2. Check voltage between NATS IMMU
terminal j
6 and ground.
Battery voltage should exist.

SEL400VA

Check the following.
+ 7.5A fuse [No. 24 ,
located in the fuse block
(J/B)]
+ Security indicator
+ Harness for open or
short between fuse and
security indicator
+ Harness for open or
short between NATS
IMMU and security indicator

PERFORM INITIALISATION.
Perform initialisation with CONSULT.
For the initialisation procedure, refer to
‘‘CONSULT operation manual NATS V2.0
(GASOLINE)’’.

How to Replace NATS IMMU
NOTE:
+ If NATS IMMU is not installed correctly, NATS system will
not operate properly and SELF-DIAG RESULTS on CONSULT screen will show ‘‘LOCK MODE’’ or ‘‘CHAIN OF
IMMU-KEY’’.

SEL498V

EL-253

NATS (Nissan Anti-Theft System)/RHD MODELS
Component Parts and Harness Connector
Location

SEL549V

EL-254

NATS (Nissan Anti-Theft System)/RHD MODELS
System Description
NATS has the following immobiliser functions:
+ Since only NATS ignition keys, whose ID nos. have been registered into the ECM and IMMU of NATS,
allow the engine to run, operation of a stolen vehicle without a NATS registered key is prevented by NATS.
That is to say, NATS will immobilize the engine if someone tries to start it without the registered key of
NATS.
+ Both of the originally supplied ignition key IDs have been NATS registered.
If requested by the vehicle owner, a maximum of four key IDs can be registered into the NATS components.
+ The NATS security indicator (NATS security ind.) blinks when the ignition switch is in ‘‘OFF’’ or ‘‘ACC’’
position. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.
+ When NATS detects trouble, the malfunction indicator lamp (MIL) blinks.
+ NATS trouble diagnoses, system initialisation and additional registration of other NATS ignition key IDs
must be carried out using CONSULT hardware and CONSULT NATS software.
When NATS initialisation has been completed, the ID of the inserted ignition key is automatically NATS
registered. Then, if necessary, additional registration of other NATS ignition key IDs can be carried out.
Regarding the procedures of NATS initialisation and NATS ignition key ID registration, refer to CONSULT
operation manual, NATS.
+ When servicing a malfunction of the NATS (indicated by flashing of Malfunction Indicator Lamp)
or registering another NATS ignition key ID no., it may be necessary to re-register original key
identification. Therefore, be sure to receive all keys from vehicle owner.

System Composition
The immobiliser function of the NATS consists of the following:
+ NATS ignition key
+ NATS antenna amp. located in the ignition key cylinder
+ NATS immobiliser control unit (NATS IMMU)
+ Engine control module (ECM)
+ NATS security indicator
+ Malfunction indicator lamp (MIL)

SEL304U

EL-255

NATS (Nissan Anti-Theft System)/RHD MODELS
Wiring Diagram — NATS —

TEL693A

EL-256

NATS (Nissan Anti-Theft System)/RHD MODELS
CONSULT
CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect ‘‘CONSULT’’ to Data link connector for CONSULT.
(Data link connector for CONSULT is located behind the fuse
box cover.)

SEF532V

3. Insert NATS program card into CONSULT.
: Program card
NATS-E940
4. Turn on ignition switch.
5. Touch ‘‘START’’.

SEL327U

6. Touch ‘‘V.2.0 (GASOLINE)’’.
NOTE: ‘‘V2.0 (GASOLINE)’’ should be selected for electrically
controlled diesel and gasoline engines.

SEL328U

7. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT Operation Manual,
NATS V2.0 (GASOLINE).

SEL329U

EL-257

NATS (Nissan Anti-Theft System)/RHD MODELS
CONSULT (Cont’d)
CONSULT DIAGNOSTIC TEST MODE FUNCTION
CONSULT DIAGNOSTIC TEST
MODE

Description

C/U INITIALIZATION

When replacing any of the following three components, C/U initialization is necessary.
[NATS ignition key/IMMU/ECM]

SELF-FUNCTION CHECK

ECM checks its own NATS communication interface by itself.

SELF-DIAGNOSTIC RESULTS

Detected items (screen terms) are as shown in the chart below.

HOW TO READ SELF-DIAGNOSTIC RESULTS

SEL332UC

* If trip number is more than 1, MIL does not blink.

SELF-DIAGNOSTIC RESULTS ITEM CHART
Detected items (Screen terms)

Description

Reference page

IMMU

ECM received the signal from IMMU that IMMU is malfunctioning.

EL-261

ECM

ECM is malfunctioning.

EL-261

CHAIN OF ECM-IMMU

Communication impossible between ECM and IMMU.

EL-262

DIFFERENCE OF KEY

IMMU can receive the key ID signal but the result of ID verification
between key ID and IMMU is NG.

EL-264

CHAIN OF IMMU-KEY

IMMU cannot receive the key ID signal.

EL-265

ID DISCORD, IMM-ECM

The result of ID verification between IMMU and ECM is NG. System initialisation is required.

EL-266

MINGLE NOISE

Noise (interference) mingled into NATS communication lines during communicating.

EL-267

DON’T ERASE BEFORE CHECKING ENG DIAG

Engine trouble data and NATS trouble data have been detected in ECM.

EL-259

LOCK MODE

EL-268

EL-258

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses
WORK FLOW
*Lighting-up mode of MIL (Malfunction Indicator Lamp)
For single malfunction of NATS: Blinking
For dual malfunctions of NATS and an engine-related part:
Stays ON
For single malfunction of an engine-related part: Stays ON

CHECK IN
.

Listen to customer complaints or request. (Get symptoms)
TROUBLE

KEY SERVICE REQUEST (Additional key ID registration)
.

Verify the MIL*.

INITIALISATION
(Refer to CONSULT operation
manual NATS V2.0.)

Using the CONSULT program card for NATS check the ‘‘SELF-

c DIAG RESULTS’’ with CONSULT.

Self-diagnostic results referring to NATS, but no information
about engine self-diagnostic results is displayed on CONSULT.
.

Self-diagnostic results referring to NATS and ‘‘DON’T ERASE
BEFORE CHECKING ENG DIAG’’ are displayed on CONSULT.
(This means that engine trouble data has been detected in
ECM.)

Turn ignition switch ‘‘OFF’’.
.

Repair NATS.
(If necessary, carry out ‘‘SELF-FUNCTION CHECK’’ or ‘‘C/U INITIALISATION’’ with CONSULT.)

Turn ignition switch ‘‘OFF’’.

Turn ignition switch ‘‘ON’’.

Repair NATS.
(If necessary, carry out ‘‘SELF-FUNCTION CHECK’’ or ‘‘C/U INITIALISATION’’ with CONSULT.)
.

Erase the NATS ‘‘SELF-DIAG RESULTS’’ by using CONSULT.
(Touch ‘‘ERASE’’.)

Do not erase the NATS ‘‘SELF-DIAG RESULTS’’ by using
CONSULT.
.

Start the engine.
.

Start the engine.

Check the NATS ‘‘SELF-DIAG RESULTS’’ by using CONSULT.

OK
NG

Verify no blinking of MIL*.

Turn ignition switch ‘‘OFF’’.
OK
.

CHECK OUT

Check the engine ‘‘SELF-DIAG RESULTS’’ with CONSULT by
using the CONSULT generic program card.
(Engine diagnostic software included)
.

Perform running test with CONSULT in engine ‘‘SELF-DIAG
RESULTS’’ mode.

Repair ECCS. (Refer to EC section.)

Verify ‘‘NO FAILURE’’ displayed on the CONSULT screen.

Turn ignition switch ‘‘ON’’.

OK
.

CHECK OUT

Erase the engine ‘‘SELF-DIAG RESULTS’’ by using CONSULT.
(Touch ‘‘ERASE’’.)
.

Start the engine.

EL-259

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)
SYMPTOM CHART
SYMPTOM

Displayed ‘‘SELF-DIAG
RESULTS’’ on CONSULT
screen.

SYSTEM
(Malfunctioning
part or mode)

DIAGNOSTIC PROCEDURE
(Reference page)

IMMU

PROCEDURE 1
(EL-261)

IMMU

ECM

PROCEDURE 2
(EL-261)

ECM

+ MIL blinking
+ Engine can start.

Open circuit in battery voltage line of IMMU circuit
Open circuit in ignition line of IMMU circuit
Open circuit in ground line of IMMU circuit
CHAIN OF ECM-IMMU

PROCEDURE 3
(EL-262)

Open or short circuit in communication line
between IMMU and ECM
Open circuit in power source line of ANT/AMP circuit
ECM
IMMU

DIFFERENCE OF KEY

PROCEDURE 4
(EL-264)

+ MIL blinking
+ Engine hard to start

Unregistered key
IMMU
Open or short circuit in communication line
between ANT/AMP and IMMU
Open circuit in power source line of ANT/AMP circuit

CHAIN OF IMMU-KEY

PROCEDURE 5
(EL-265)

Open circuit in ground line of ANT/AMP circuit
Malfunction of key ID chip
IMMU
Antenna amp.

ID DISCORD, IMM-ECM

PROCEDURE 6
(EL-266)

System initialisation has not yet been completed.
ECM

MINGLE NOISE

PROCEDURE 7
(EL-267)

Noise interference in communication line

+ MIL blinking
+ Engine hard to start
+ NATS security indicator
does not blink for 1 minute
after ignition switch is
turned to ‘‘OFF’’.

LOCK MODE

PROCEDURE 9
(EL-268)

LOCK MODE

+ MIL staying ON

DON’T ERASE BEFORE
CHECKING ENG DIAG

WORK FLOW
(EL-259)

Engine trouble data and NATS trouble data have
been detected in ECM
NATS security ind.

+ NATS security ind. does not
light up.
+ Engine can start.

—

PROCEDURE 8
(EL-267)

Open circuit between Fuse and NATS IMMU
Continuation of initialisation mode
NATS IMMU

EL-260

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 1
Self-diagnostic results:
‘‘IMMU’’ displayed on CONSULT screen

Confirm SELF-DIAGNOSTIC RESULTS ‘‘IMMU’’ displayed on CONSULT screen.

.
SEL330U

+ IMMU is malfunctioning.
1. Replace IMMU.
2. Perform initialisation with CONSULT.
For the initialisation procedure, refer to ‘‘CONSULT operation manual NATS
V2.0 (GASOLINE)’’.

DIAGNOSTIC PROCEDURE 2
Self-diagnostic results:
‘‘ECM’’ displayed on CONSULT screen

Confirm SELF-DIAGNOSTIC RESULTS ‘‘ECM’’ displayed on CONSULT
screen.

.
SEL331U

+ ECM is malfunctioning.
1. Replace ECM.
2. Perform initialisation with CONSULT.
For the initialisation procedure, refer to ‘‘CONSULT operation manual NATS
V2.0 (GASOLINE)’’.

EL-261

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 3
Self-diagnostic results:
‘‘CHAIN OF ECM-IMMU’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC
RESULTS ‘‘CHAIN OF ECMIMMU’’ displayed on CONSULT
screen.
OK
SEL333U
.

CHECK POWER SUPPLY CIRCUIT FOR
IMMU.
Check voltage between terminal j
4 of
IMMU and ground with CONSULT or
tester.
Voltage: Battery voltage

NG
c

OK
.

SEL867UD

CHECK IGN SW. ON SIGNAL.
Check voltage between terminal j
3 of
IMMU and ground with CONSULT or
tester.
Voltage: Battery voltage

NG
c

CHECK GROUND CIRCUIT FOR IMMU.
Check harness continuity between IMMU
terminal j
8 ,j
9 and ground.
Continuity should exist.

NG
c

Check the following:
+ 7.5A fuse (No. 50 ,
located in the fuse and
fusible link box)
+ Harness for open or
short between fuse and
IMMU connector

Check the following:
+ 10A fuse [No. 25 ,
located in the fuse block
(J/B)]
+ Harness for open or
short between fuse and
IMMU connector

Repair harness.

SEL868UD
.

CHECK COMMUNICATION ON OPEN
CIRCUIT.
Check harness continuity between the following ECM terminal and IMMU terminal.
ECM j
55 and IMMU j
6
Continuity should exist.
OK
.

j
A
SEL499V

SEL500V

EL-262

NG
c

Repair harness.

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)
j
A

CHECK COMMUNICATION LINE SHORT
CIRCUIT.
1. Disconnect ECM connector and IMMU
connector.
2. Check continuity between IMMU terminal j
6 and ground.
Continuity should not exist.
3. Turn ignition switch to ON.
4. Check voltage between IMMU terminal
j
6 and ground.
No voltage should exist.

NG
c

Repair harness.

OK
.

CHECK NATS ANTENNA AMP. CIRCUIT.
1. Disconnect NATS antenna amp. connector.
2. Turn ignition switch ‘‘ON’’.
3. Check voltage between antenna amp.
terminal j
4 and ground.
Voltage: More than 4.7V
SEL501V

NG
c

Repair harness.

OK
.

(See next page)

.
SEL502V

Touch ‘‘START’’. ECM will then
check its communication interface
by itself.
OK

(See next page)

SEL340U

+ IMMU is malfunctioning.
1. Replace IMMU.
2. Perform initialisation with CONSULT.
For the initialisation procedure, refer
to ‘‘CONSULT operation manual
NATS V2.0 (GASOLINE)’’.

SEL341U

EL-263

NG
c

+ ECM is malfunctioning.
1. Replace ECM.
2. Perform initialisation
with CONSULT.
For the initialisation
procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)

SEL342U

SEL343U

SEL372U
.

END.
(The ignition key was unregistered.)

EL-264

No
c

+ IMMU is malfunctioning.
1. Replace IMMU.
2. Perform initialisation
with CONSULT.
For the initialisation
procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 5
Self-diagnostic results:
‘‘CHAIN OF IMMU-KEY’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC
RESULTS ‘‘CHAIN OF IMMUKEY’’ displayed on CONSULT
screen.
OK
SEL373U

CHECK NATS IGNITION KEY ID CHIP.
Start engine with another registered NATS
ignition key.
Does the engine start?

Yes
c

+ Ignition key ID chip is
malfunctioning.
1. Replace the ignition key.
2. Perform initialisation
with CONSULT.
For the initialisation
procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

.
SEL550V

CHECK IMMU FUNCTION 1.
1. Turn ignition switch to ‘‘ON’’.
2. Check voltage between NATS antenna
amp. terminal j
3 and ground.
Voltage
Time (After turning ignition
switch ‘‘ON’’.)

Voltage [V]

For approx. 0.5 sec.

Approx. 2.3 — 5

After 1 sec.

NOTE:
Do not remove NATS antenna amp. from
the ignition key cylinder.
SEL551V

SEL502V

CHECK IMMU FUNCTION 2.
1. Turn ignition switch ‘‘ON’’.
2. Check voltage between NATS antenna
amp. terminal j
1 and ground.
Voltage:
6 sec. after turning ignition switch
‘‘ON’’
Approx. 4.5 — 5V
NOTE:
Do not remove NATS antenna amp. from
the ignition key cylinder.

Check harness for open or
short between IMMU and
NATS antenna amp. If harness is OK, replace IMMU.
After replacing IMMU, perform initialisation with
CONSULT.
For the initialisation
procedure, refer to ‘‘CONNG
SULT operation manual
c NATS V2.0 (GASOLINE)’’.
c

OK
.

CHECK IMMU OUTPUT VOLTAGE.
1. Turn the ignition switch ‘‘ON’’.
2. Check voltage between NATS antenna
amp. terminal j
4 and ground.
Voltage: More than 4.7V
OK
.

j
A

EL-265

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)
j
A

CHECK ANTENNA AMP. GROUND LINE
CIRCUIT.
1. Turn ignition switch ‘‘OFF’’.
2. Check continuity between NATS
antenna amp. terminal j
2 and ground.
Continuity should exist.

Check harness for open or
short between IMMU and
NATS antenna amp. If harness is OK, replace IMMU.
After replacing IMMU, perform initialization with
CONSULT. For the initialisation procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

SEL504V

NATS antenna amp. is malfunctioning.
When replacing the amp. hold on to amp.
body. Take care not to pull on amp. harness.

DIAGNOSTIC PROCEDURE 6
Self-diagnostic results:
‘‘ID DISCORD, IMM-ECM’’ displayed on CONSULT screen
* ‘‘ID DISCORD, IMM-ECM’’:
Registered ID of IMMU is in
discord with that of ECM.

Confirm SELF-DIAGNOSTIC
RESULTS ‘‘ID DISCORD, IMMECM*’’ displayed on CONSULT
screen.
.
SEL383U

SEL372U

END.
(System initialisation was not completed.)

EL-266

No
c

+ ECM is malfunctioning.
1. Replace ECM.
2. Perform initialisation
with CONSULT.
For the initialisation
procedure, refer to
‘‘CONSULT operation
manual NATS V2.0
(GASOLINE)’’.

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 7
Self-diagnostic results:
‘‘MINGLE NOISE’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC RESULTS ‘‘MINGLE NOISE’’ displayed on CONSULT screen.

Turn off or remove any possible noise sources.
SEL384U
.

Touch ‘‘ERASE’’ on CONSULT SELF-DIAGNOSTIC RESULTS
screen.
.

Start engine.
OK
.

END
SEL385U

DIAGNOSTIC PROCEDURE 8
‘‘NATS SECURITY IND. DOES NOT LIGHT UP’’
CHECK INDICATOR POWER SUPPLY
CIRCUIT.
Check voltage between security indicator
terminal j
1 and ground.
Battery voltage should exist.

NG
c

OK
SEL552V

Check the following.
+ 7.5A fuse [No. 24 ,
located in the fuse block
(J/B)]
+ Harness for open or
short between fuse and
security indicator

Check security indicator.

PERFORM INITIALISATION.
Perform initialisation with CONSULT.
For the initialisation procedure, refer to
‘‘CONSULT operation manual NATS V2.0
(GASOLINE)’’.
Does security indicator operate after
initialisation has been completed?
Yes
.

END

EL-267

No
c

Check harness for open or
short between NATS IMMU
and security indicator.

NATS (Nissan Anti-Theft System)/RHD MODELS
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 9
Self-diagnostic results:
‘‘LOCK MODE’’ displayed on CONSULT screen
Confirm SELF-DIAGNOSTIC RESULTS
‘‘LOCK MODE’’ is displayed on CONSULT
screen.
.
SEL790U

1. Turn the ignition switch to OFF position
and wait 1 minute.
(After 1 minute, security indicator will
blink.)
2. Turn the ignition key switch to ON position with a registered key.
(Do not start engine.) Wait 5 seconds.
3. Return the key to the OFF position.
4. Repeat steps 2 and 3 twice (total of
three cycles).
5. Start the engine.
Does the engine start?

Yes
c

System is OK.
(Now the system is
escaped from ‘‘LOCK
MODE’’.)

No
SEL372U

PERFORM INITIALISATION.
Perform initialisation with CONSULT.
For the initialisation procedure, refer to
‘‘CONSULT operation manual NATS V2.0
(GASOLINE)’’.
Can the system be initialised?
Note: If the initialisation is incompleted or
failed, CONSULT shows
message on the screen.
No
.

Go to DIAGNOSTIC PROCEDURE 5,
EL-265 to check ‘‘CHAIN OF IMMU-KEY’’.

EL-268

Yes
c

System is OK.

LOCATION OF ELECTRICAL UNITS
Engine Compartment

CEL750

EL-269

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — LHD Models

CEL751

EL-270

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — LHD Models
(Cont’d)

CEL752

EL-271

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — RHD Models

CEL816

EL-272

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — RHD Models
(Cont’d)

CEL817

EL-273

LOCATION OF ELECTRICAL UNITS
NOTE

EL-274

HARNESS LAYOUT
How to Read Harness Layout
Example:
G2

B/6

: ASCD ACTUATOR

Connector color / Cavity
Connector number
Grid reference

The following Harness Layouts use a map style grid to help locate connectors on the drawings:
+ Main Harness
+ Engine Room Harness (Engine Compartment)
To
1)
2)
3)
4)
5)

use the grid reference
Find the desired connector number on the connector list.
Find the grid reference.
On the drawing, find the crossing of the grid reference letter column and number row.
Find the connector number in the crossing zone.
Follow the line (if used) to the connector.

CONNECTOR SYMBOL
Main symbols of connector (in Harness Layout) are indicated in the below.
Water proof type

Standard type

Connector type
Male

Female

—

Male

+ Cavity: Less than 4
+ Relay connector
+ Cavity: From 5 to 8
+ Cavity: More than 9
+ Ground terminal etc.

—

EL-275

Female

HARNESS LAYOUT
Outline/LHD Models

CEL753

CEL809

EL-276

HARNESS LAYOUT
Outline/RHD Models

CEL818

CEL811

EL-277

HARNESS LAYOUT
Main Harness/LHD Models

CEL754

EL-278

HARNESS LAYOUT
Main Harness/LHD Models (Cont’d)

CEL755

EL-279

HARNESS LAYOUT
Main Harness/LHD Models (Cont’d)

CEL790

EL-280

HARNESS LAYOUT
NOTE

EL-281

HARNESS LAYOUT
Main Harness/RHD Models

CEL819

EL-282

HARNESS LAYOUT
Main Harness/RHD Models (Cont’d)

CEL820

EL-283

HARNESS LAYOUT
Main Harness/RHD Models (Cont’d)

CEL821

EL-284

HARNESS LAYOUT
NOTE

EL-285

HARNESS LAYOUT
Engine Room Harness/LHD Models

CEL822

EL-286

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)

CEL823

EL-287

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)
PASSENGER COMPARTMENT

CEL758

EL-288

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)

CEL759

EL-289

HARNESS LAYOUT
Engine Room Harness/RHD Models

CEL826

EL-290

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)

CEL827

EL-291

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)
PASSENGER COMPARTMENT

CEL828

EL-292

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)

CEL829

EL-293

HARNESS LAYOUT
Engine Harness

CEL830

EL-294

HARNESS LAYOUT
Engine Control Harness and Alternator
Harness

CEL832

EL-295

HARNESS LAYOUT
Body Harness/LHD Models
WAGON

CEL764

EL-296

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)

CEL765

EL-297

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)
HARDTOP

CEL833

EL-298

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)

CEL843

EL-299

HARNESS LAYOUT
Body Harness/RHD Models
WAGON

CEL834

EL-300

HARNESS LAYOUT
Body Harness/RHD Models (Cont’d)

CEL835

EL-301

HARNESS LAYOUT
Body Harness/RHD Models (Cont’d)
HARDTOP

CEL836

EL-302

HARNESS LAYOUT
Body Harness/RHD Models (Cont’d)

CEL837

EL-303

HARNESS LAYOUT
Body No. 2 Harness/LHD Models
WAGON

CEL766

EL-304

HARNESS LAYOUT
Body No. 2 Harness/LHD Models (Cont’d)
HARDTOP

CEL838

EL-305

HARNESS LAYOUT
Body No. 2 Harness/RHD Models
WAGON

CEL839

EL-306

HARNESS LAYOUT
Body No. 2 Harness/RHD Models (Cont’d)
HARDTOP

CEL840

EL-307

HARNESS LAYOUT
Chassis Harness

CEL767

EL-308

HARNESS LAYOUT
Room Lamp Harness

CEL768

EL-309

HARNESS LAYOUT
LHD MODELS

Front Door Harness (Driver side)

CEL769

RHD MODELS

CEL786

EL-310

HARNESS LAYOUT
LHD MODELS

Front Door Harness (Passenger side)

CEL770

RHD MODELS

CEL787

EL-311

HARNESS LAYOUT
LH SIDE

Rear Door Harness

CEL771

RH SIDE

CEL788

EL-312

HARNESS LAYOUT
Back Door Harness and Rear Window Defogger
Harness

CEL772

EL-313

BULB SPECIFICATIONS
Headlamp
Wattage (12 volt)
High/low (without xenon headlamp)

60/55 (H4)

Exterior Lamp
Wattage (12 volt)
Front turn signal

Parking

Front combination lamp
Side turn signal lamp

5
Turn signal

Stop/Tail

21/5

Back-up

Rear combination lamp

Rear bumper combination lamp

Fog

Turn signal

Stop/Tail

21/5

License plate lamp

High-mounted stop lamp

Interior Lamp
Wattage (12 volt)
Interior room lamp

Map lamp

Vanity mirror lamp

EL-314

WIRING DIAGRAM CODES (CELL CODES)
Use the chart below to find out what each wiring diagram code
stands for.
Code

Section

Wiring Diagram Name

Code

Section

Wiring Diagram Name

A/C,A

Auto Air Conditioner

GLOW

Quick Glow System

A/C CUT

Air Conditioner Cut Control

GOVNR

Electric Governor

A/C,M

Manual Air Conditioner

H/AIM

Headlamp Aiming Control System

A/T

H/LAMP

Headlamp

AAC/V

IACV-AAC Valve

HEATUP

Heat up Switch

ABS

Anti-lock Brake System

HLC

Headlamp Cleaner

ACC/SW

Accelerator Switch (FC)

HORN

Horn

ACL/SW

Accelerator Position Switch

HSEAT

Heated Seat

ADJRES

Adjustment Resistor

IATS

Intake Air Temperature Sensor

APS

Accelerator Position Sensor

IC/FAN

Charge Air Cooler Fan

ASCD

Automatic Speed Control Device

IGN

Ignition System

AT/C

A/T Control

IGN/SG

Ignition Signal

AUDIO

Audio

ILL

Illumination

BACK/L

Back-up Lamp

INJECT

Injector

BCDD

BCDD System

INT/L

Spot, Vanity Mirror Lamps

CD/CHG

CD Auto Changer

Knock Sensor

CHARGE

Charging System

MAFS

Mass Air Flow Sensor

CHIME

Warning Chime

MAIN

CHOKE

Automatic Choke

Main Power Supply and Ground Circuit

CIGAR

Cigarette Lighter

METER

Speedometer, Tachometer, Temp.,
Oil and Fuel Gauges

CKPS

Crankshaft Position Sensor (OBD)

MIL/DL

Mil and Data Link Connectors

CLOCK

Clock

MIRROR

Door Mirror

CMPS

Camshaft Position Sensor

MULTI

Multi-remote Control System

COMPAS

Compass and Thermometer

NATS

Nissan Anti-Theft System

COOL/B

Cool Box

NLS

Needle Lift Sensor

COOL/F

Cooling Fan Control

P/ANT

Power Antenna

CORNER

Cornering Lamp

PLA

Partial Load Advance Control

CSPS

Control Sleeve Position Sensor

PNP/SW

Park/Neutral Position Switch

D/LOCK

Power Door Lock

POWER

Power Supply Routing

DEICER

Wiper Deicer

PST/SW

Power Steering Oil Pressure Switch

DEF

Rear Window Defogger

R/COOL

Rear Cooler System

DIFF/L

Differential Lock Control System

R/FOG

Rear Fog Lamp

DTRL

Headlamp — With Daytime Light
System

R/HEAT

Rear Heater System

ECTS

Engine Coolant Temperature Sensor

ROOM/L

Interior Room Lamp

EGRC/V

EGRC-Solenoid Valve

S/LOCK

Power Door Lock — Super Lock

F/FOG

Front Fog Lamp

S/SIG

Start Signal

F/PUMP

Fuel Pump

S/TANK

Sub Fuel Tank Control System

FCUT

Fuel Cut Solenoid Valve

SEAT

Power Seat

FICD

IACV-FICD Solenoid Valve

SROOF

Sunroof

SRS

Supplemental Restraint System

FTS

Fuel Temperature Sensor

EL-315

WIRING DIAGRAM CODES (CELL CODES)
Code

Section

Wiring Diagram Name

STAB

Rear Stabilizer Release Device Control System

START

Starting System

STOP/L

Stop Lamp

TAIL/L

Parking, License, Tail and Stop
Lamps

TCV

Injection Timing Control Valve

TPS

Throttle Position Sensor

TURN

Turn Signal and Hazard Warning
Lamps

VSS

Vehicle Speed Sensor

WARN

Warning Lamps

WINCH

Electrical Winch

WINDOW

Power Window

WIP/R

Rear Wiper and Washer

WIPER

Front Wiper and Washer

EL-316

SUPER MULTIPLE JUNCTION (SMJ)
LHD MODELS
Installation
To install SMJ, tighten bolts until orange ‘‘fulltight’’ mark appears
and then retighten to specified torque as required.
: 3 — 5 Nzm
(0.3 — 0.5 kg-m, 26 — 43 in-lb)
CAUTION:
Do not overtighten bolts, otherwise, they may be damaged.

CEL773

CEL789

RHD MODELS
Installation
To install SMJ, tighten bolts until orange ‘‘fulltight’’ mark appears
and then retighten to specified torque as required.
: 3 — 5 Nzm
(0.3 — 0.5 kg-m, 26 — 43 in-lb)
CAUTION:
Do not overtighten bolts, otherwise, they may be damaged.

CEL841

CEL842

EL-317

SUPER MULTIPLE JUNCTION (SMJ)
Terminal Arrangement

CEL774

FUSE BLOCK — Junction Box (J/B)
Terminal Arrangement

CEL775

FUSE AND FUSIBLE LINK BOX
Terminal Arrangement

CEL776

ELECTRICAL UNITS
Terminal Arrangement

CEL777

JOINT CONNECTOR (J/C)
Terminal Arrangement

CEL778

ENGINE MECHANICAL
SECTION

CONTENTS
PRECAUTIONS ………………………………………………………1
Parts Requiring Angular Tightening………………………..1
Liquid Gasket Application Procedure ……………………..1
PREPARATION……………………………………………………….2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ……………………………………………..6
NVH Troubleshooting Chart — Engine Noise ………….7
OUTER COMPONENT PARTS …………………………………8
COMPRESSION PRESSURE………………………………….10
Measurement of Compression Pressure……………….10
OIL PAN ……………………………………………………………….13
Removal……………………………………………………………13
Installation…………………………………………………………14
TIMING BELT………………………………………………………..15
Removal……………………………………………………………15
Inspection………………………………………………………….17
Installation…………………………………………………………18
OIL SEAL REPLACEMENT ……………………………………20
TURBOCHARGER…………………………………………………23
Removal and Installation …………………………………….23
Inspection………………………………………………………….24

CHARGE AIR COOLERS……………………………………….27
CYLINDER HEAD………………………………………………….28
Removal……………………………………………………………29
Disassembly………………………………………………………30
Inspection………………………………………………………….31
Assembly ………………………………………………………….37
Installation…………………………………………………………37
VALVE CLEARANCE …………………………………………….40
Checking …………………………………………………………..40
Adjusting …………………………………………………………..41
ENGINE REMOVAL……………………………………………….43
Removal……………………………………………………………44
Installation…………………………………………………………44
CYLINDER BLOCK ……………………………………………….45
Disassembly………………………………………………………46
Inspection………………………………………………………….46
Assembly ………………………………………………………….53
SERVICE DATA AND SPECIFICATIONS (SDS) ……….56
General Specifications………………………………………..56
Inspection and Adjustment ………………………………….56

PRECAUTIONS
Parts Requiring Angular Tightening
+
+

+
+
+

Some important engine parts are tightened using an angulartightening method rather than a torque setting method.
If these parts are tightened using a torque setting method, dispersal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
Although the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
To assure the satisfactory maintenance of the engine, bolts and
nuts must be tightened using an angular-tightening method.
Before tightening the bolts and nuts, ensure that the thread and
seating surfaces are clean and then coated with engine oil.
The bolts and nuts which require the angular-tightening method
are cylinder head bolts.

Liquid Gasket Application Procedure

SEM371C

a. Before applying liquid gasket, use a scraper to remove all
traces of old liquid gasket from mating surface.
b. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.)
+ Be sure liquid gasket is specified width (for oil pan) 3.5
to 4.5 mm (0.138 to 0.177 in) for gasoline engine.
+ Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118
in) wide in areas except oil pan for TB and RD series
engines and 2.5 to 3.5 mm (0.098 to 0.138 in) for TD
series engine.
c. Apply liquid gasket to inner surface around hole perimeter
area.
(Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before refilling engine oil and
engine coolant.

EM-1

PREPARATION
SPECIAL SERVICE TOOLS
* Special tool or commercial equivalent
Tool number
Tool name

Description

ST0501S000*
Engine stand assembly
1 ST05011000
V
Engine stand
2
V ST05012000
Base

Disassembling and assembling

NT042

KV10106500*
Engine stand shaft

NT028

KV1011070
Engine sub-attachment

NT582

KV101092S0
Valve spring compressor
1 KV10109210
V
Compressor
2 KV10109220
V
Adapter

Disassembling and assembling
valve components

NT718

KV10107902
Valve oil seal puller
1 KV10116100
V
Valve oil seal puller
adapter

NT605

EM-2

PREPARATION
* Special tool or commercial equivalent
Tool number
Tool name

Description

KV101151S0
Lifter stopper set
1 KV10115110
V
Camshaft pliers
2
V KV10115120
Lifter stopper

Changing shims

NT041

EM03470000*
Piston ring compressor

Installing piston assembly into cylinder bore

NT044

ST16610001*
Pilot bushing puller

Removing crankshaft pilot bushing

NT045

KV10109300
Puller holder

a = 68 mm (2.68 in)
b = 8 mm (0.31 in) dia.

NT628
1
V
2
V

3
V

ED19601000
Compression gauge
ED19600600
Compression gauge
adapter (for glow plug
hole)
ED19600700
Compression gauge
adapter (for injector
hole)

Checking compression pressure

NT742

KV11100300
Nozzle holder socket

NT563

EM-3

PREPARATION
* Special tool or commercial equivalent
Tool number
Tool name

Description

WS39930000*
Tube presser

Pressing the tube of liquid gasket

NT052

KV10107501
Valve oil seal drift

NT741

KV111033S0
Engine stopper
1 KV10105610
V
Stopper plate
2
V KV10105630
Stopper gear

Preventing crankshaft from rotating

a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 119 (4.69)
f: 12 (0.47)
g: 18 (0.71)
Unit: mm (in)

NT616

EM-4

PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name

Description

Valve guide drift

Removing and installing valve guide
Intake & Exhaust
TB and TD engines
a = 11.5 mm (0.453 in) dia.
b = 7.6 mm (0.299 in) dia.
RD engine
a = 11.5 mm (0.453 in) dia.
b = 6.5 mm (0.256 in) dia.

NT015

Valve guide reamer

Reaming valve guide
guide V
2

1
V

or hole for oversize valve

Intake & Exhaust
TB engine
d1 = 8.0 mm (0.315 in) dia.
d2 = 12.2 mm (0.480 in) dia.
RD engine
d1 = 7.000 mm (0.2756 in) dia.
d2 = 11.19 mm (0.4406 in) dia.
TD engine
d1 = 8.0 mm (0.315 in) dia.

NT016

Valve seat cutter set

Finishing valve seat dimensions

NT048

Front oil seal drift

Installing front oil seal
TB engine
a = 80 mm (3.15 in) dia.
b = 58 mm (2.28 in) dia.
RD engine
a = 52 mm (2.05 in) dia.
b = 41 mm (1.61 in) dia.

NT049

Rear oil seal drift

Installing rear oil seal

a = 100 mm (3.94 in) dia.
b = 78 mm (3.07 in) dia.

NT049

Piston pin drift

Removing and installing piston pin

a = 22.5 mm (0.886 in) dia.
b = 12.5 mm (0.492 in) dia.

NT074

EM-5

PREPARATION
Tool name

Description

Piston ring expander

Removing and installing piston ring

NT030

EM-6

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

SEM808F

EM-7

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart — Engine Noise
Use the chart below to help you find the cause of the problem.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location of
noise
Top of
engine
Rocker
cover
Cylinder
head

Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil pan

Type of
noise

Before
After
warm-up warm-up

When
starting

When
idling

When
racing

While
driving

Check item

Reference
page

Ticking or
clicking

—

Tappet
noise

Valve clearance

EM-41

Rattle

—

Camshaft
bearing
noise

Camshaft journal clearance
Camshaft runout

EM-37

Slap or
knock

—

Piston pin
noise

Piston and piston pin clearance
Connecting rod bushing
clearance

EM-47, 53

EM-48, 49

Slap or rap

—

Piston slap
noise

Piston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsion

Knock

Connecting
rod bearing
noise

Connecting rod bushing
clearance (Small end)
Connecting rod bearing
clearance (Big end)

EM-52, 53

Knock

—

Main bearing noise

Main bearing oil clearance
Crankshaft runout

EM-51

Whine or
hissing

—

Timing belt
noise (too
tight)

Loose timing belt
Belt contacting case

EM-18

Timing belt
cover

Front of
engine

Source of
noise

Clatter

—

Timing belt
noise (too
loose)

Squeaking
or fizzing

—

Other drive
belts
(Sticking or
slipping)

Drive belts deflection

Idler pulley bearing operation

Water pump operation

Creaking

Other drive
belts (Slipping)

Squall
Creak

—

Water pump
noise

A: Closely related B: Related C: Sometimes related —: Not related
*1: MA section (‘‘Checking Drive Belts’’, ‘‘ENGINE MAINTENANCE’’)
*2: LC section (‘‘Water Pump Inspection’’, ‘‘ENGINE COOLING SYSTEM’’)

EM-8

OUTER COMPONENT PARTS

SEM780F

EM-9

OUTER COMPONENT PARTS

SEM781F

EM-10

COMPRESSION PRESSURE
Measurement of Compression Pressure
1. Warm up engine sufficiently.
2. Disconnect injection tube on nozzle side and loosen injection
tubes on pump side. Release clamps on injection tubes.
+ Use two wrenches to prevent delivery holder on pump side
from loosening.

SEM702B

SEM703B

3. Remove spill-tube assembly.
+ To prevent spill tube from breaking, remove it by gripping
nozzle holder.

SEM704B

4. Remove all injection nozzles using Tool or a suitable tool.

SEM705B

5. Turn ignition switch OFF and disconnect harness connector
(black colored) at injection pump.

SEM789F

EM-11

COMPRESSION PRESSURE
Measurement of Compression Pressure
(Cont’d)
6. Fit compression gauge adapter to cylinder head.

SEM706B

7. Crank engine and read gauge indication.
Crank speed: 200 rpm
Compression pressure:
Standard
3,040 kPa (30.4 bar, 31 kg/cm2, 441 psi)
Limit
2,452 kPa (24.5 bar, 25 kg/cm2, 356 psi)
Differential limit between cylinders
490 kPa (4.9 bar, 5 kg/cm2, 71 psi)
8. If the pressure appears low, pour about 3 m! (0.11 Imp fl oz)
of engine oil through nozzle holes and repeat test.
For indications of test, refer to the following table.
Gauge indication during tests

First reading

Trouble diagnosis

Second
reading

+ Piston rings are worn or
damaged.
Increased
reading
SEM857

Same reading
maintained

+ If two adjacent cylinders
are low, gasket is damaged.
+ Valve is sticking.
+ Valve seat or valve contact surface is incorrected.

SEM858

9. Replace nozzle gaskets and install injection nozzles.
New nozzle gasket installation direction is as shown.
Nozzle to cylinder head:
: 59 — 69 Nzm
(6.0 — 7.0 kg-m, 43 — 51 ft-lb)

SEM708B

EM-12

COMPRESSION PRESSURE
Measurement of Compression Pressure
(Cont’d)
10. Install spill tube by holding nozzle holder.
Spill tube nut:
: 39 — 49 Nzm
(4 — 5 kg-m, 29 — 36 ft-lb)

SEM704B

11. Install injection tubes using two wrenches as shown.
Injection tube:
: 22 — 25 Nzm
(2.2 — 2.5 kg-m, 16 — 18 ft-lb)

SEM702B

SEM703B

12. Initialize the ECM.
Refer to EC section (‘‘HOW TO ERASE DTC’’).

EM-13

OIL PAN

SEM782F

Removal
1. Remove oil pan guard.

SEM783F

2. Drain engine oil.
+ When installing drain plug washer, ensure it faces in correct
direction.
+ Discard oil drain plug washer and install a new one.
Drain plug:
: 29 — 39 Nzm (3.0 — 4.0 kg-m, 22 — 29 ft-lb)

SEM063B

EM-14

OIL PAN
Removal (Cont’d)
3. Remove engine gussets and oil pan bolts.
+ Remove bolts/nuts in numerical order shown in figure, alternating left and right ones toward the center.

SEM739B

4. Remove oil pump assembly.

SEM432C

Installation
Always install with new oil seal.
1. Install oil pump assembly.
Location

Bolt length mm (in)

1
V
2
V
3
V
4
V

20 (0.79)
35 (1.38)
45 (1.77)
55 (2.17)

SEM794F

2. Install oil pan. Tighten bolts in the order shown in the figure.
+ Always replace oil pan gaskets with new ones when reassembling.
+ Install oil pan gasket after cleaning the contacting surface.
+ Oil pan bolts/nuts:
Bolt
: 8 — 12 Nzm (0.8 — 1.2 kg-m, 69 — 104 in-lb)
Nut
: 10 — 14 Nzm (1.0 — 1.4 kg-m, 87 — 122 in-lb)

3. Install engine gusset and oil pan guard.

SEM739BA

EM-15

TIMING BELT
CAUTION:
+ Do not bend or twist timing belt.
+ After removing timing belt, do not turn crankshaft and
camshaft separately because valves will strike piston
heads.
+ Make sure that timing belt, camshaft sprocket, crankshaft
sprocket, idler pulley, injection pump pulley and belt tensioner are clean and free from oil and water.
+ Align white lines on timing belt with punch mark on camshaft sprocket, crankshaft sprocket and injection pump
pulley.
+ Installation should be carried out when engine is cold.

SMA767BA

Removal
1.
2.
+
+
+
3.

Remove radiator shroud.
Remove the following belts.
Power steering drive belt
A/C compressor drive belt
Alternator drive belt
Remove cooling fan coupling and water pump pulley.

EM-16

TIMING BELT
Removal (Cont’d)
4. Set No. 1 cylinder at bottom dead center (BDC) on its expansion stroke, as shown.

SMA768B

5. Remove the starter motor and wipe off the liquid gasket remaining on the connecting part.
6. Install the ring gear stopper using the bolt holes for fixing the
starter motor.
7. Remove crankshaft pulley using puller.
Be sure to securely attach puller jaws. Attach jaws only to the
rear side of pulley.
8. Remove front cover.

SMA769B

9. Remove tensioner spring and loosen belt tensioner lock nut.
10. Remove timing belt.
After removing timing belt, do not turn crankshaft and camshaft separately, because valves will strike piston heads.

SMA770B

EM-17

TIMING BELT
Inspection
Visually check the condition of timing belt.
Replace if any abnormality is found.
Item to check

Problem

Cause

Tooth is broken/tooth root
is cracked.

+ Camshaft jamming
+ Distributor jamming
+ Damaged camshaft/crankshaft oil seal

SEM394A

Back surface is cracked/
worn.

+ Tensioner jamming
+ Overheated engine
+ Interference with belt cover

SEM395A

Side surface is worn.

+ Improper installation of belt
+ Malfunctioning crankshaft pulley plate/timing belt
plate

+ Belt corners are worn and round.
+ Wicks are frayed and coming out.

SEM396A

Teeth are worn.

+
+
+
+
+

Poor belt cover sealing
Coolant leakage at water pump
Camshaft not functioning properly
Distributor not functioning properly
Excessive belt tension

+ Canvas on tooth face is worn down.
+ Canvas on tooth is fluffy, rubber layer is worn
down and faded white, or weft is worn down and
invisible.
SEM397A
Oil/Coolant or water is
stuck to belt.

+ Poor oil sealing of each oil seal
+ Coolant leakage at water pump
+ Poor belt cover sealing

—

EM-18

TIMING BELT
Installation
1. Confirm that No. 1 cylinder is set at BDC on its expansion
stroke as follows:
Confirm that crankshaft key is at the bottom.
2. Set timing belt.
a. Ensure timing belt, sprockets and pulleys are clean and
free from oil or water. Do not bend or twist timing belt too
much.
b. Align white lines on timing belt with matching mark on
camshaft sprocket, crankshaft sprocket and injection
pump pulley.
c. Point arrow on timing belt toward front.

SMA771B

EM-19

TIMING BELT
Installation (Cont’d)
3. Install tensioner spring and tighten belt tensioner lock nut.
: 32 — 40 Nzm
(3.3 — 4.1 kg-m, 24 — 30 ft-lb)

SMA770B

4.
5.
6.
7.

Install front cover.
Install crankshaft pulley.
Install water pump pulley and cooling fan coupling.
Apply liquid gasket to the connecting surface and install the
starter motor.
Use Genuine Liquid Gasket or equivalent.

8. Install drive belts and check drive belt deflections by pushing
midway between pulleys.
Refer to MA section (‘‘Checking Drive Belts’’).

SMA015C

EM-20

OIL SEAL REPLACEMENT
VALVE OIL SEAL
1. Remove timing belts.
2. Remove camshaft sprocket and back covers.
3. Remove camshaft brackets by loosening bracket nuts from
center to outside in two or three stages.
4. Remove camshaft oil seals and camshaft.

SEM716B

5. Remove valve lifters and mark order No. on each lifter.
6. Replace valve oil seal according to the following procedure.
When replacing valve oil seal, set the corresponding piston at
TDC. Failure to do so causes the valve to drop into the cylinder.
1) Set No. 1 cylinder at TDC.

SEM790F

2) Remove valve springs and valve oil seals for No. 1 and No. 6
cylinders. Valve spring seats should not be removed.

SEM745B

3) Install new valve oil seals for No. 1 and No. 6 cylinders as
illustrated. Reinstall valve springs. (narrow pitch side toward
cylinder head)
4) Install valve spring retainers on intake valves and valve rotators
on exhaust valves, and remount valve assembly.
5) Set No. 2 cylinder at TDC.
6) Replace valve oil seals for No. 2 and No. 5 cylinders according
to steps 2) and 3).
7) Set No. 3 cylinder at TDC.
Replace valve oil seals for No. 3 and No. 4 cylinders according
to steps 2) and 3).
9) Install valve lifters in original positions.

SEM746B

EM-21

OIL SEAL REPLACEMENT
CAMSHAFT AND CRANKSHAFT OIL SEAL INSTALLING
DIRECTION AND MANNER
+
+
+

When installing camshaft and crankshaft oil seals, be careful to install them correctly, as shown in the figure.
Apply engine oil to oil seal lip, outer face, camshaft and
bracket.
Wipe off excess oil after installing oil seal.

SEM715A

CAMSHAFT OIL SEALS
1. Remove timing belts, sprockets and back covers.
2. Pull out oil seal with a suitable tool.

SEM743B

3. Install new oil seals with a suitable tool.

SEM733B

CRANKSHAFT FRONT OIL SEAL
1.
2.
3.
4.

Remove
Remove
Remove
Remove

valve timing belt and crankshaft sprocket.
oil pan and oil pan gasket.
oil pump assembly.
front oil seal with a suitable tool.

SEM893A

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

SEM894A

EM-22

OIL SEAL REPLACEMENT
CRANKSHAFT REAR OIL SEAL
1. Remove transmission assembly. (Refer to ‘‘REMOVAL AND
INSTALLATION’’ in MT section.)
2. Remove clutch cover assembly.
3. Remove flywheel and rear plate.
4. Remove oil pan and oil pan gasket.
5. Remove oil seal retainer assembly.
6. Remove traces of liquid gasket using a scraper.

SEM896A

7. Remove rear oil seal from retainer.

SEM895A

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

SEM897A

9. Apply a continuous bead of liquid gasket to rear oil seal
retainer.
a. Coat of liquid gasket should be maintained within 2.0 to 3.0
mm (0.079 to 0.118 in) dia. range.
b. Attach oil seal retainer to cylinder block within five minutes after coating.
c. Wait at least 30 minutes before refilling engine oil or starting engine.
d. Use Genuine Liquid Gasket or equivalent.
SLC822

SEM144B

EM-23

TURBOCHARGER

SEM784F

Removal and Installation
1.
2.
+
+
+
+
+
+
+
3.

Drain engine coolant.
Remove the following:
Air duct and hoses
Air intake pipe
EGR pipe
Heat shield plates
Intake manifold
Front (exhaust) tube
Oil tube and water tube
Remove exhaust manifold with turbocharger from cylinder
head.
4. When installing turbocharger to exhaust manifold, securely
tighten nuts and lock the nuts.
+ Turbocharger should not be disassembled.

EM-24

TURBOCHARGER
Inspection

SEM796C

OIL AND WATER TUBES
Check tubes for clogging.

ROTOR SHAFT
1. Check rotor shaft for smooth rotating.

SEM798C

2. Check rotor shaft for carbon deposits.

SEM799C

EM-25

TURBOCHARGER
Inspection (Cont’d)
3. Measure runout of rotor shaft.
Runout (Total indicator reading):
0.056 — 0.127 mm (0.0022 — 0.0050 in)

SEM800C

4. Measure end play of rotor shaft.
End play:
0.013 — 0.097 mm (0.0005 — 0.0038 in)

SEM801C

TURBINE WHEEL
Check turbine wheel for the following:
+ Oil
+ Carbon deposits
+ Deformed fins
+ Contact with turbine housing

SEM802C

COMPRESSOR WHEEL
Check compressor wheel for the following:
+ Oil
+ Deformed fins
+ Contact with compressor housing

SEM803C

WASTEGATE VALVE
Remove rod pin and check wastegate valve for cracks, deformation
and smooth movement.
Check valve seat surface for smoothness.

SEM804C

EM-26

TURBOCHARGER
Inspection (Cont’d)
WASTEGATE VALVE ACTUATOR
Apply air pressure to wastegate valve actuator and check it for
smooth movement.
+ Do not keep applying air pressure to the actuator.
+ The air pressure should be in the range of 108 to 118 kPa
(1.08 to 1.18 bar, 1.1 to 1.2 kg/cm2, 16 to 17 psi).

SEM805C

EM-27

CHARGE AIR COOLERS

SEM791F

EM-28

CYLINDER HEAD

SEM785F

EM-29

CYLINDER HEAD
CAUTION:
+ When installing sliding parts such as camshaft and oil
seal, be sure to apply new engine oil on their sliding surfaces.
+ When tightening cylinder head bolts, apply new engine oil
to thread portions and seat surfaces of bolts.

Removal
1. Remove charge air cooler assembly.
2. Set No. 1 cylinder at BDC on its expansion stroke.
3. Drain engine coolant from drain plugs on cylinder block and
radiator.
4. Remove air cleaner and/or air duct.
5. Remove timing belt.

6. Remove rocker cover securing bolts/nuts in numerical order
shown in figure.
To install rocker cover, tighten bolts/nuts in reverse order of
removal. Tighten in two or three stages.

SEM786F

7. Remove camshaft sprocket, injection pump drive sprocket and
back cover.
8. Disconnect exhaust manifold from exhaust tube.

SEM711B

9. Remove intake and exhaust manifold.
To install manifolds, tighten bolts/nuts in reverse order of
removal. Tighten in two or three stages.

SEM431C

EM-30

CYLINDER HEAD
Removal (Cont’d)
10. Remove fuel injection tube assembly and spill tube.
11. Remove cylinder head bolts in numerical order and remove
cylinder head.

SEM703B

Disassembly
1.
a.
b.
c.
2.

Remove following parts:
Thermostat housing
Engine slinger
Glow plate and glow plugs
Remove camshaft bracket securing nuts in numerical order
shown in figure in two or three stages.
To install camshaft bracket caps, tighten nuts in reverse order
of removal. Tighten in two or three stages.

SEM714B

3. Remove camshaft and oil seal.
4. Remove valve lifters.

5. Remove valve component parts with tool.

SEM716B

EM-31

CYLINDER HEAD
Inspection
CYLINDER HEAD DISTORTION

SEM718B

Warpage of surface:
Less than 0.1 mm (0.004 in)
If beyond the specified limit, replace it or resurface it.
Resurfacing limit:
The resurfacing limit of cylinder head is determined by the
cylinder block resurfacing in an engine.
Amount of cylinder head resurfacing is ‘‘A’’.
Amount of cylinder block resurfacing is ‘‘B’’.
The maximum limit is as follows:
A + B = 0.1 mm (0.004 in)
Nominal cylinder head height:
139.9 — 140.1 mm (5.508 — 5.516 in)

VALVE GUIDE CLEARANCE

SEM719B

1. Insert the valve stem into the valve guide and move it back,
forth and slide it.
If valve stem makes a clatter and moves back and forth excessively out of line, or if it does not slide well, replace valve or
valve guide, or both.
2. Install valve stem into the valve guide.
3. Measure the deflection.
Stem to guide deflection limit:
0.1 mm (0.004 in)
(Half of dial gauge reading)
4. If it exceeds the limit, check valve to valve guide clearance.
(1) Measure valve stem diameter and guide inner diameter.
(2) Check that clearance is within the specification.
Valve to valve guide clearance limit:
0.1 mm (0.004 in)
(3) If it exceeds the limit, replace valve or valve guide.

EM030

VALVE GUIDE REPLACEMENT
1. Heat cylinder head 150 to 160°C (302 to 320°F) in oil.
2. Remove the guide with suitable tool.

SEM871

EM-32

CYLINDER HEAD
Inspection (Cont’d)
3. Drive in the new guide until it projects out 10.3 mm (0.406 in).
4. Ream the bore using suitable tool.
Reaming bore:
7.000 — 7.018 mm (0.2756 — 0.2763 in)

SEM872

COMBUSTION CHAMBER REPLACEMENT
Usually combustion chamber should not be removed.
However, if there are cracks or extensive damage, it should be
replaced.
1. Remove glow plug connecting plate, glow plugs and injection
nozzle.
2. Remove combustion chamber so that cylinder head will not be
damaged.
Be careful not to scratch inside of nozzle hole.
SEM720B

3. Install combustion chamber.
(1) Heat cylinder head 150 to 160°C (302 to 320°F) in oil.
(2) Align combustion chamber knock pin with cylinder head notch,
and install it into cylinder head using a plastic-tip hammer.

SEM721B

VALVE SEATS
1. Check valve and valve seat for contact.
Coat the valve face with prussian red lead. If contact is wrong,
correct valve seat. If the valve red lead appears 360° around
face, the valve stem and face are concentric. If not, repair or
replace valve.

SEM722B

2. Check valve seats for any evidence of pitting on valve contact
surface, and reseat or replace if worn out excessively.
Correct valve seat surface.
+ When repairing valve seat, check valve and valve guide for
wear beforehand. If worn, replace them. Then correct valve
seat.
+ Cut with both hands to uniform the cutting surface.

EM-33

CYLINDER HEAD
Inspection (Cont’d)
VALVE SEAT REPLACEMENT

SEM795A

1. Bore out old seat until it collapses.
The machine depth stop should be set so that boring cannot
continue beyond the bottom face of the seat recess in cylinder
head.
2. Ream the cylinder head recess.
Reaming bore for service valve seat
[Oversize 0.5 mm (0.020 in)]:
Intake
40.954 — 40.932 mm (1.6124 — 1.6115 in)
Exhaust
34.954 — 34.932 mm (1.3761 — 1.3753 in)
Reaming should be done to the concentric circles around the
valve guide center so that valve seat will have the correct fit.

3. Heat cylinder head to a temperature of 150 to 160°C (302 to
320°F) and press fit seat until it seats on the bottom.
4. Install valve seat.
When replacing valve seat, valve should also be replaced.

SEM008A

5. Cut or grind valve seat using suitable tool at the specified
dimensions as shown in SDS.
The cutting should be done with both hands for uniform cutting.

SEM876

6. Apply small amount of fine grinding compound to valve contacting face and put valve into guide.
Lap valve against its seat until proper valve seating is obtained.
Remove valve and then clean valve and valve seat.

SEM877

EM-34

CYLINDER HEAD
Inspection (Cont’d)
7. Measure distance from cylinder head surface to intake and
exhaust valves. If specified distance is exceeded, replace
valve(s) or valve seat(s).
Specified distance: mm (in)
Standard
−0.069 to 0.269 (−0.0027 to 0.0106)

SEM787F

VALVE DIMENSIONS
1. Check dimensions in each valve. For dimensions, refer to SDS.
2. Correct or replace any valve that is out of tolerance.

EM030

3. Valve face or valve stem end surface should be refaced by
using a valve grinder.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace the valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.

EM111

VALVE SPRING SQUARENESS
Check valve spring for squareness using a steel square and surface plate.
If spring is out-of-square ‘‘S’’ more than specified limit, replace with
new one.
Out-of-square:
Outer
Less than 1.9 mm (0.075 in)
Inner
Less than 1.6 mm (0.063 in)
SEM333

VALVE SPRING PRESSURE LOAD
Measure the free length and the tension of each spring. If the
measured value exceeds the specified limit, replace spring. Refer
to SDS.

EM113

EM-35

CYLINDER HEAD
Inspection (Cont’d)
VALVE LIFTER
1. Check contact and sliding surfaces for wear or scratches.

SEM723B

2. Check diameter of a valve lifter.
Outer diameter:
34.960 — 34.975 mm (1.3764 — 1.3770 in)

SEM724B

3. Check valve lifter guide bore.
Bore diameter:
34.998 — 35.018 mm (1.3779 — 1.3787 in)
Standard clearance:
0.023 — 0.058 mm (0.0009 — 0.0023 in)

SEM725B

If valve lifters are noisy, check valve lifter.
(1) Depress plunger forcibly with your finger.
If it moves about 1 mm (0.04 in), it indicates air is inside valve lifter.
(2) Reinstall valve lifter.
(3) Bleed air by running engine at 2,400 rpm under no-load for
about 20 minutes.
CAUTION:
When camshaft is removed to install, remove or inspect
hydraulic valve lifters, do not start engine for at least 30 minutes after reinstalling camshaft. (Wait until hydraulic valve lifters have reached their set lengths.) Before starting engine,
rotate crankshaft by hand to ensure pistons do not interfere
with valves.
(4) Next check to ensure all air is bled. [Refer to step (1) above.]
(5) If there is still air, replace valve lifter.

EM-36

CYLINDER HEAD
Inspection (Cont’d)
CAMSHAFT VISUAL CHECK
Check camshaft for scratches, seizure and wear.

CAMSHAFT END PLAY
1. Install camshaft in cylinder head.
2. Measure camshaft end play.
Camshaft end play:
0.065 — 0.169 mm (0.0026 — 0.0067 in)

SEM726B

CAMSHAFT JOURNAL CLEARANCE
1. Measure the inner diameter of camshaft bearing.
Standard inner diameter:
30.000 — 30.021 mm (1.1811 — 1.1819 in)

SEM727B

2. Measure the outer diameter of camshaft journal.
Standard outer diameter:
29.935 — 29.955 mm (1.1785 — 1.1793 in)
If the clearance is greater than the maximum, replace camshaft
and/or cylinder head.
Maximum clearance:
0.045 — 0.086 mm (0.0018 — 0.0034 in)

SEM728B

CAMSHAFT RUNOUT
Camshaft runout [TIR (Total Indicator Reading)]:
Limit 0.02 mm (0.0008 in)
If beyond the limit, replace.

SEM729B

CAMSHAFT CAM HEIGHT
Standard cam height:
Intake
48.005 — 48.195 mm (1.8900 — 1.8974 in)
Exhaust
49.505 — 49.695 mm (1.9490 — 1.9565 in)
Cam wear:
Limit 0.15 mm (0.0059 in)
If wear is beyond the limit, replace.
SEM730B

EM-37

CYLINDER HEAD
Assembly
1. Install valve component parts.
Install valve spring with its narrow pitch side toward cylinder
head side.
a. When installing valve, apply engine oil on the valve stem
and lip of valve oil seal.
b. Check whether the valve face is free from foreign matter.

SEM202

c. Install valve spring retainers on the intake side and valve
rotators on the exhaust side.
d. Valve rotators cannot be disassembled.

SEM731BB

2. Set camshaft.
Set camshaft so that dowel pin faces up.
3. Install cam bracket caps so that front mark faces forward.
Cam bracket nut (Tighten in two or three stages):
: 21 — 26 Nzm
(2.1 — 2.7 kg-m, 15 — 20 ft-lb)

SEM732B

4. Apply engine oil to new oil seal and install it.

SEM733B

Installation
1. Install cylinder head gasket.
a. When replacing only cylinder head gasket, install same
grade gasket as the one formerly used.
b. When replacing or repairing cylinder block, cylinder head,
piston, connecting rod and crankshaft, select gasket as
follows:

EM-38

CYLINDER HEAD
Installation (Cont’d)
Step 1:
Measure piston projection.
1) Set dial gauge on cylinder block surface to zero.
2) Set dial gauge at measuring point of piston, being careful not
to disturb its zero setting.

SEM734B

3) Set each piston at its Top Dead Center. With piston held in that
position, measure its projections at four points, M1, M2, M3 and
M4, and record measured values.
Be sure to measure the projection at four points for every cylinder as shown.

SEM735B

Step 2:
Calculate the average value of measured projections for each cylinder.
Step 3:
Calculate the average value of projections for all pistons.
Step 4:
Round off the average value.
Step 5:
Determine the gasket thickness, referring to chart A.

Relation between piston projection and cylinder head gasket
(Chart A)
Unit: mm (in)
Grade
A
B
C
SEM736B

Average values
piston projections

Gasket thickness

Less than
0.79 (0.0311)
0.79 — 0.875
(0.0311 — 0.0344)
More than
0.875 (0.0344)

1.42±0.05
(0.0559±0.0020)
1.50±0.05
(0.0591±0.0020)
1.58±0.05
(0.0622±0.0020)

Number of
identifications
1
2
3

Step 6:
Check to see if the average value of each projection in step 2 is
larger than the max. value of the standard projection (of selected
gasket) plus 0.08 mm (0.0031 in).
Step 7:
If it is, use gasket that is 1 grade thicker.
If it is not, use gasket that was selected in step 4.

EM-39

CYLINDER HEAD
Installation (Cont’d)
2. Install cylinder head.
(1) Make sure that No. 1 cylinder is at Bottom Dead Center.
(2) Make sure that No. 1 cam of camshaft is at BDC on its expansion stroke.

SEM732B

SEM737BA

(3) Tighten cylinder head bolts to the specified torque in the
sequence as follows:
+ Tightening procedure.
M12 bolt
1st
Tighten all bolts to 29 Nzm (3.0 kg-m, 22 ft-lb).
2nd Tighten all bolts to 113 Nzm (11.5 kg-m, 83 ft-lb).
3rd
Loosen all bolts completely.
4th
Tighten all bolts to 29 Nzm (3.0 kg-m, 22 ft-lb).
5th
Tighten all bolts to 108 to 118 Nzm (11 to 12 kg-m, 80 to
87 ft-lb) or if you have an angle wrench, turn all bolts 89
to 92 degrees clockwise.
M8 bolt
16 — 21 Nzm (1.6 — 2.1 kg-m, 12 — 15 ft-lb)

3. Install front back cover and camshaft pulley.
Front back cover:
: 3 — 5 Nzm
(0.3 — 0.5 kg-m, 26 — 43 in-lb)
Camshaft pulley:
: 123 — 132 Nzm
(12.5 — 13.5 kg-m, 90 — 98 ft-lb)

SEM711B

4. Install timing belt. Refer to ‘‘Replacing Timing Belt’’ in section
MA.
5. Install rocker cover. Refer to EM-30.
Apply sealant to rocker cover gasket as shown.
Do not apply too much sealant.
6. Install intake and exhaust manifold. Refer to EM-30.

SEM738B

EM-40

VALVE CLEARANCE
Checking
Check valve clearance while engine is warm and not running.
1. Remove rocker cover.
2. Set No. 1 cylinder at TDC on its compression stroke.
+ Align pointer with TDC mark on crankshaft pulley.
+ Check that valve lifters on No. 1 cylinder are loose and valve
lifters on No. 6 are tight.
If not, turn crankshaft one revolution (360°) and align as
described above.
SEM790F

3. Check only those valves shown in the figure.
No. 1
No. 1 cylinder at TDC

No. 2

INT

EXH

INT

EXH

No. 3
INT

No. 4

EXH

INT

EXH

No. 5
INT

EXH

No. 6
INT

EXH

SEM799F

+
+

Using a feeler gauge, measure clearance between valve lifter
and camshaft.
Record any valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim.
Valve clearance for checking (Hot):
Intake
0.28 — 0.38 mm (0.011 — 0.015 in)
Exhaust
0.32 — 0.42 mm (0.013 — 0.017 in)

SEM634F

4. Turn crankshaft one revolution (360°) and align mark on crankshaft pulley with pointer.
5. Check only those valves shown in the figure.
No. 1
INT
No. 6 cylinder at TDC

SEM800F

EXH

No. 2
INT

No. 3

EXH

INT

EXH

No. 4
INT

No. 5

EXH

INT

EXH

No. 6
INT

EXH

+ Use the same procedure as mentioned in step 4.
6. If all valve clearances are within specification, install the following parts:
+ Rocker cover

EM-41

VALVE CLEARANCE
Adjusting
Adjust valve clearance while engine is cold.
1. Turn crankshaft. Position cam lobe upward on camshaft for
valve that must be adjusted.

SEM636F

SEM637F

2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A), rotate notch toward center of cylinder
head. (See figure.) This will simplify shim removal later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.
4. Place Tool (B) between camshaft and valve lifter to retain valve
lifter.
CAUTION:
+ Tool (B) must be placed as close to camshaft bracket as
possible.
+ Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).

6. Remove adjusting shim using a small screwdriver and a magnetic finger.
7. Determine replacement adjusting shim size using the following
formula.
+ Use a micrometer to determine thickness of removed shim.
+ Calculate thickness of new adjusting shim so valve clearance
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
S = Standard valve clearance
SEM638F

Unit: mm (in)
HOT
COLD

SEM145D

Intake
Exhaust
Intake

0.28 — 0.38 (0.0110 — 0.0150)
0.32 — 0.42 (0.0126 — 0.0165)
0.26 — 0.34 (0.0102 — 0.0134)

Exhaust

0.30 — 0.38 (0.0118 — 0.0150)

Intake:
N = R + [M − S]
Exhaust:
N = R + [M − S]
Shims are available in 15 sizes from 2.20 mm (0.0866 in) to 2.90
mm (0.1142 in), in steps of 0.05 mm (0.0020 in).

EM-42

VALVE CLEARANCE
Adjusting (Cont’d)
+

Select the closest size shim to the calculated thickness. Refer
to chart in SDS, EM-60.

AEM236

8. Install new shim using a suitable tool.
+ Install with the surface on which the thickness is stamped
facing down.
9. Place Tool (A) as explained in steps 2 and 3.
10. Remove Tool (B).
11. Remove Tool (A).
12. Recheck valve clearance.
Valve clearance:
Unit: mm (in)

Intake
Exhaust

For adjusting
Hot
Cold* (reference data)
0.28 — 0.38
0.26 — 0.34
(0.011 — 0.015)
(0.010 — 0.013)
0.32 — 0.42
0.30 — 0.38
(0.013 — 0.017)
(0.012 — 0.015)

*: At a temperature of approximately 20°C (68°F)
Whenever valve clearances are adjusted to cold specifications, check that
the clearances satisfy hot specifications and adjust again if necessary.

EM-43

ENGINE REMOVAL

SEM433C

EM-44

ENGINE REMOVAL
Removal
1. Remove engine, transmission and transfer’s undercovers, oil
pan guard and hood.
2. Drain engine coolant.
3. Remove charge air cooler assembly.
4. Remove vacuum hoses, fuel tubes, harnesses, and connectors
and so on.
5. Remove radiator assembly.
6. Remove drive belts.
7. Remove power steering oil pump, alternator and air conditioner
compressor.
8. Remove starter motor assembly.
9. Remove front exhaust tube.
10. Remove transmission from vehicle.
Refer to MT section.
11. Hoist engine with engine slingers and remove engine mounting
bolts from both sides.
12. Remove engine from vehicle.

Installation
+

Install in reverse order of removal.

EM-45

CYLINDER BLOCK

SEM788F

EM-46

CYLINDER BLOCK
CAUTION:
+ When installing sliding parts such as bearings and
pistons, apply engine oil to the sliding surfaces.
+ Place removed parts, such as bearings and bearing caps,
in their proper order and direction.
+ When installing connecting rod bolts and main bearing cap
bolts, apply new engine oil to threads and seating surfaces
of nuts.
+ Do not allow any magnetic materials to contact the ring
gear teeth of drive plate.

Disassembly
PISTON AND CRANKSHAFT
1.
2.
3.
4.
5.
6.
7.

Place engine on a work stand.
Remove timing belt and injection pump.
Drain coolant and remove water pump.
Remove front cover.
Drain oil.
Remove oil pan and oil pump.
Remove cylinder head.

SEM750B

8. Remove pistons with connecting rod.
+ To disassemble piston and connecting rod, remove snap ring
first. Then heat piston to 60 to 70°C (140 to 158°F) and use
piston pin press to remove pin.
+ When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
+ When replacing piston rings, if there is no punchmark,
install with either side up.

SEM877B

9. Remove bearing cap bolts and main bearing caps in the order
shown, then remove crankshaft.
+ Loosen bolts in two or three steps.

SEM801F

Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole ‘‘dp’’.
Standard diameter ‘‘dp’’:
26.995 — 27.005 mm (1.0628 — 1.0632 in)

SEM672E

EM-47

CYLINDER BLOCK
Inspection (Cont’d)
2. Measure outer diameter of piston pin ‘‘Dp’’.
Standard diameter ‘‘Dp’’:
26.994 — 27.000 mm (1.0628 — 1.0630 in)
3. Calculate piston pin clearance.
dp − Dp = −0.004 to 0 mm (−0.0002 to 0 in)
If it exceeds the above value, replace piston assembly with pin.

PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0.060 — 0.093 mm (0.0024 — 0.0037 in)
2nd ring
0.040 — 0.073 mm (0.0016 — 0.0029 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
SEM024AA

PISTON RING END GAP

SEM822B

End gap:
Top ring
0.20 — 0.28 mm (0.0079 — 0.0110 in)
2nd ring
0.20 — 0.46 mm (0.0079 — 0.0181 in)
Oil ring
0.30 — 0.56 mm (0.0118 — 0.0220 in)
Max. limit of ring gap:
0.4 mm (0.016 in)
If out of specification, replace piston ring. If gap still exceeds maximum limit with new ring, rebore cylinder and use oversized piston
and piston rings. Refer to SDS, EM-62.
+ When replacing the piston, check cylinder block surface
for scratches or seizure. If scratches or seizure are found,
hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION
Bend:
Limit 0.025 mm (0.0010 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.025 mm (0.0010 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.

SEM038F

EM-48

CYLINDER BLOCK
Inspection (Cont’d)
CYLINDER BLOCK DISTORTION AND WEAR

SEM907A

1. Clean upper surface of cylinder block. Using a reliable straightedge and feeler gauge, check the flatness of cylinder block
surface.
+ Check along six positions as shown in figure.
Limit:
0.10 mm (0.0039 in)
2. If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by the
amount of cylinder head resurfacing.
Amount of cylinder head resurfacing is ‘‘A’’.
Amount of cylinder block resurfacing is ‘‘B’’.
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
227.40 — 227.50 mm (8.9527 — 8.9567 in)
3. If necessary, replace cylinder block.

PISTON-TO-BORE CLEARANCE

SEM908A

1. Using a bore gauge, measure cylinder bore for wear, out-ofround and taper.
Standard inner diameter ‘‘Db’’:
85.000 — 85.030 mm (3.3465 — 3.3476 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (X − Y):
Less than 0.015 mm (0.0006 in)
Taper (A − B or A − C):
Less than 0.010 mm (0.0004 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder block if
necessary.
2. Check for scratches and seizure. If seizure is found, hone it.

SEM909A

EM-49

CYLINDER BLOCK
Inspection (Cont’d)
3. Measure piston skirt diameter.
Piston diameter ‘‘A’’:
Refer to SDS, EM-61.
Measuring point ‘‘a’’ (Distance from the bottom):
18 mm (0.71 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance ‘‘B’’ = Bore measurement
‘‘C’’ − Piston diameter ‘‘A’’:
0.025 — 0.045 mm (0.0010 — 0.0018 in)

SEM181B

5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS,
EM-61.
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter ‘‘A’’.
Rebored size calculation:
D=A+B−C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)

SEM755B

7. Install main bearing cap and tighten bolts to 90 to 100 Nzm (9.2
to 10.2 kg-m, 67 to 74 ft-lb). This will prevent distortion of cylinder bores.
8. Cut cylinder bores.
+ When any cylinder needs boring, all other cylinders must
also be bored.
+ Do not cut too much out of cylinder bore at a time. Cut only
0.05 mm (0.0020 in) or so at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
+ Measurement should be done after cylinder bore cools
down.

EM-50

CYLINDER BLOCK
Inspection (Cont’d)
CRANKSHAFT

SEM316A

1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-ofround.
Out-of-round (X − Y):
Main journal
Less than 0.005 mm (0.0002 in)
Pin journal
Less than 0.0025 mm (0.0001 in)
Taper (A − B):
Main journal
Less than 0.005 mm (0.0002 in)
Pin journal
Less than 0.0025 mm (0.0001 in)

3. Measure crankshaft runout.
Runout (Total indicator reading):
Standard Less than 0.025 mm (0.0010 in)
Limit 0.05 mm (0.0020 in)

SEM906A

BEARING CLEARANCE
+

Use Method A or Method B. Method A is preferred because it
is more accurate.

Method A (Using bore gauge and micrometer)
Main bearing
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.

SEM157B

2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order in two or three stages. Refer
to EM-54.
3. Measure inner diameter ‘‘A’’ of each main bearing.

SEM753B

EM-51

CYLINDER BLOCK
Inspection (Cont’d)
4. Measure outer diameter ‘‘Dm’’ of each crankshaft main journal.
5. Calculate main bearing clearance.
Main bearing clearance = A − Dm:
Standard 0.036 — 0.063 mm (0.0014 — 0.0025 in)
Limit 0.12 mm (0.0047 in)
If it exceeds the limit, replace bearing.
+ If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.

AEM033

If crankshaft or cylinder block is replaced, select thickness of
main bearings as follows:
a. Grade number of each cylinder block main journal is punched
on the respective cylinder block. These numbers are punched
in either Arabic or Roman numerals.
+

SEM912A

b. Grade number of each crankshaft main journal is punched on
the respective crankshaft. These numbers are punched in
either Arabic or Roman numerals.
c. Select main bearing with suitable thickness according to the
following table.
Main bearing grade number:
Main journal grade number

SEM911A

Crankshaft
journal grade
number

For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number = 1 + 2 = 3

Connecting rod bearing (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque. Refer to EM-20.
3. Measure inner diameter ‘‘C’’ of each bearing.

AEM027

EM-52

CYLINDER BLOCK
Inspection (Cont’d)

AEM034

4. Measure outer diameter ‘‘Dp’’ of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C − Dp:
Standard
0.014 — 0.054 mm (0.0006 — 0.0021 in)
Limit
0.090 mm (0.0035 in)
If it exceeds the limit, replace bearing.
+ If it still exceeds the limit even with a new bearing, regrind crank
pin and use undersized bearings.
+ Refer to SDS for regrinding crankshaft and available service parts.

Method B (Using plastigage)
CAUTION:
+ Do not turn crankshaft or connecting rod while plastigage
is being inserted.
+ If incorrect bearing clearance exists, use a thicker or
undersized main bearing to ensure specified clearance.

EM142

CONNECTING ROD BUSHING CLEARANCE (Small end)
1. Measure inner diameter ‘‘C’’ of bushing.
2. Measure outer diameter ‘‘Dp’’ of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance = C − Dp
Standard:
0.025 — 0.044 mm (0.0010 — 0.0017 in)
If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin.
SEM673E

REPLACEMENT OF CONNECTING ROD BUSHING
(Small end)
1. Drive in small end bushing until it is flush with end surface of
rod.
Be sure to align the oil holes.
2. Ream the bushing so that clearance with piston pin is within
specification.
Clearance between connecting rod bushing and piston pin:
0.005 — 0.017 mm (0.0002 — 0.0007 in)
SEM062A

FLYWHEEL/DRIVE PLATE RUNOUT
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)
CAUTION:
+ Be careful not to damage the ring gear teeth.
+ Check the drive plate for deformation or cracks.
+ Do not allow any magnetic materials to contact the ring
gear teeth.
+ Do not resurface drive plate. Replace as necessary.
SEM929A

SMA for double-mass flywheel inspection procedure

EM-53

CYLINDER BLOCK
Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.

SEM146B

2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,
piston pin, connecting rod and new snap ring.
+ Align the direction of piston and connecting rod.
+ Numbers stamped on connecting rod and cap correspond
to each cylinder.
+ After assembly, make sure connecting rod swings
smoothly.

SEM754B

3. Set piston rings as shown.
CAUTION:
+ When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
+ Install new piston rings either side up if there is no punchmark.

SEM156B

Align piston rings so that end gaps are positioned as
shown.

SEM160B

CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.
+ Confirm that correct main bearings are selected by using
Method A or Method B. Refer to EM-52.
+ Apply new engine oil to bearing surfaces.

SEM157B

EM-54

CYLINDER BLOCK
Assembly (Cont’d)
2. Install crankshaft and main bearing caps and tighten bolts to
the specified torque.
+ Apply new engine oil to the bolt thread and seat surface.
+ Prior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat the bearing cap.
+ Tighten bearing cap bolts gradually in two or three steps.
Start with center bearing and move outward as shown in
figure.
+ After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
SEM801FA

3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.050 — 0.18 mm (0.0020 — 0.0071 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace thrust bearing with a new one.

SEM756B

4. Install connecting rod bearings in connecting rods and connecting rod caps.
+ Confirm that correct bearings are selected. Refer to ‘‘Connecting rod bearing (Big end)’’, EM-52.
+ Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
+ Apply new engine oil to bearing surfaces, bolt threads and
seating surfaces.

SEM757B

5.
a.
+
+
+
+

Install pistons with connecting rods.
Install them into corresponding cylinders with Tool.
Make sure connecting rod does not scratch cylinder wall.
Make sure connecting rod bolts do not scratch crankshaft
pin journals.
Arrange so that front mark on piston head faces toward
front of engine.
Apply new engine oil to piston rings and sliding surface of
piston.

SEM936A

b. Install connecting rod caps.
+ Apply new engine oil to bolt threads and nut seating surfaces.
Tighten connecting rod cap nuts using the following procedure.
(1) Tighten to 14 to 16 Nzm
(1.4 to 1.6 kg-m, 10 to 12 ft-lb).
(2) Turn nuts 60 to 65° clockwise with an angle wrench. If
an angle wrench is not available, tighten nuts to 37 to
45 Nzm (3.8 to 4.6 kg-m, 27 to 33 ft-lb).
SEM759B

EM-55

CYLINDER BLOCK
Assembly (Cont’d)
6. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.20 — 0.30 mm (0.0079 — 0.0118 in)
Limit
0.40 mm (0.0157 in)
If beyond the limit, replace connecting rod and/or crankshaft.

SEM760B

EM-56

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Cylinder arrangement
Displacement

VALVE TIMING

In-line 6
cm3 (cu in)

Bore and stroke

mm (in)

Without warm-up three way catalyst

2,826 (172.44)
85 x 83 (3.35 x 3.27)

Valve arrangement

OHC

Firing order

1-5-3-6-2-4

Number of piston rings
Compression

Oil

Number of main bearings

Compression ratio

21.8
EM120

Unit: degree
a

248

220

Inspection and Adjustment
COMPRESSION PRESSURE
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Compression pressure
Standard

3,040 (30.4, 31, 441)

Minimum

2,452 (24.5, 25, 356)

Differential limit between
cylinders

490 (4.9, 5, 71)

CYLINDER HEAD
Unit: mm (in)

Head surface distortion

Standard

Limit

Less than
0.03 (0.0012)

0.1 (0.004)

SEM795F

Nominal cylinder head height ‘‘H’’
Resurfacing limit

139.9 — 140.1
(5.508 — 5.516)
0.1 (0.004)

EM-57

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
VALVE

Valve guide
Unit: mm (in)

Unit: mm (in)

SEM188A

SEM796F

Valve head diameter ‘‘D’’
Intake

39.0 — 39.3 (1.535 — 1.547)

Exhaust

32.0 — 32.3 (1.260 — 1.272)

Standard

Service

Intake

11.023 — 11.034
(0.4340 — 0.4344)

11.233 — 11.234
(0.4422 — 0.4423)

Exhaust

11.023 — 11.034
(0.4340 — 0.4344)

11.233 — 11.234
(0.4422 — 0.4423)

Valve guide

Outer
diameter

Valve length ‘‘L’’
Intake

101.53 — 101.97
(3.9972 — 4.0146)

Exhaust

101.38 — 101.82
(3.9913 — 4.0087)

Valve guide
Inner diameter (Finished size)

Valve stem diameter ‘‘d’’
Intake

6.965 — 6.980 (0.2742 — 0.2748)

Exhaust

6.945 — 6.960 (0.2734 — 0.2740)

Cylinder head
valve guide
hole diameter

Valve seat angle ‘‘α’’

Intake

7.000 — 7.018 (0.2756 — 0.2763)

Exhaust

7.000 — 7.018 (0.2756 — 0.2763)

Intake

10.975 — 10.996
(0.4321 — 0.4329)

11.185 — 11.196
(0.4404 — 0.4408)

Exhaust

10.975 — 10.996
(0.4321 — 0.4329)

11.185 — 11.196
(0.4404 — 0.4408)

Intake
45°15′ — 45°45′

Interference fit of valve
guide

Exhaust
Valve margin ‘‘T’’
Intake

1.35 — 1.65 (0.0531 — 0.0650)

Exhaust

1.65 — 1.95 (0.0650 — 0.0768)

Valve margin ‘‘T’’ limit

More than 0.5 (0.020)

Valve stem end surface
grinding limit

Less than 0.2 (0.008)

Lifter guide hole diameter

34.998 — 35.018
(1.3779 — 1.3787)

Clearance between lifter and lifter guide hole

0.023 — 0.058
(0.0009 — 0.0023)

Limit

Intake

0.020 — 0.050
(0.0008 — 0.0020)

0.1 (0.004)

Exhaust

0.040 — 0.070
(0.0016 — 0.0028)

0.1 (0.004)

Valve deflection limit

0.2 (0.008)

Projection length ‘‘L’’

10.2 — 10.4 (0.402 — 0.409)

Unit: mm (in)
34.960 — 34.975
(1.3764 — 1.3770)

Standard

Stem to guide
clearance

Valve lifter
Valve lifter diameter

0.027 — 0.059 (0.0011 — 0.0023)

EM-58

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Valve seat
Unit: mm (in)

SEM788BA

SEM773BA

SEM790BA

SEM789BA

Cylinder head to valve distance

Valve spring
Unit: mm (in)

Free height

mm (in)

Outer

42.25 (1.6634)

Inner

36.57 (1.4398)

Pressure height/Load
mm/N (mm/kg, in/lb)
Outer

25.7/437.69 (25.7/44.63,
1.012/98.41)

Inner

22.2/233.21 (22.2/23.78,
0.874/52.43)

Out-of-square
SEM724C

Standard
Intake

−0.069 to 0.269
(−0.0027 to 0.0106)

Exhaust

−0.069 to 0.269
(−0.0027 to 0.0106)

EM-59

mm (in)

Outer

1.9 (0.075)

Inner

1.6 (0.063)

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Available shim
Thickness mm (in)

Identification mark

2.90 (0.1142)

2.90

2.85 (0.1122)

2.85

2.80 (0.1102)

2.80

2.75 (0.1083)

2.75

2.70 (0.1063)

2.70

2.65 (0.1043)

2.65

2.60 (0.1024)

2.60

2.55 (0.1004)

2.55

2.50 (0.0984)

2.50

2.45 (0.0965)

2.45

2.40 (0.0945)

2.40

2.35 (0.0925)

2.35

2.30 (0.0906)

2.30

2.25 (0.0886)

2.25

2.20 (0.0866)

2.20

SEM797F

CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)

Valve clearance
Unit: mm (in)
For adjusting
Hot

Cold*

Intake

0.28 — 0.38
(0.011 — 0.015)

0.26 — 0.34
(0.010 — 0.013)

Exhaust

0.32 — 0.42
(0.013 — 0.017)

0.30 — 0.38
(0.012 — 0.015)

Standard

Limit

Camshaft journal to
bearing clearance

0.045 — 0.086
(0.0018 — 0.0034)

0.1 (0.004)

Inner diameter of camshaft bearing

30.000 — 30.021
(1.1811 — 1.1819)

—

Outer diameter of camshaft journal

29.935 — 29.955
(1.1785 — 1.1793)

—

Camshaft runout [TIR*]

—

0.02 (0.0008)

Camshaft sprocket
runout [TIR*]

Less than
0.25 (0.0098)

—

Camshaft end play

0.065 — 0.169
(0.0026 — 0.0067)

0.20 (0.0079)

*: At a temperature of approximately 20°C (68°F)
Whenever valve clearances are adjusted to cold specifications,
check that the clearances satisfy hot specifications and adjust
again if necessary.

EM671

Cam height ‘‘A’’
Intake

48.005 — 48.195 (1.8900 — 1.8974)

Exhaust

49.505 — 49.695 (1.9490 — 1.9565)

Wear limit of cam height

0.15 (0.0059)

Valve lift
Intake

8.27 (0.326)

Exhaust

9.43 (0.371)

*: Total indicator reading

EM-60

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
CYLINDER BLOCK

PISTON, PISTON RING AND PISTON PIN
Unit: mm (in)

Piston
Unit: mm (in)

SEM964EA

SEM750C

Piston skirt diameter ‘‘A’’
Standard

SEM686DA

Surface flatness
Standard
Limit

Less than 0.03 (0.0012)
0.1 (0.004)

Cylinder bore

Grade No. 1

85.000 — 85.010 (3.3465 — 3.3468)

Grade No. 2

85.010 — 85.020 (3.3468 — 3.3472)

Grade No. 3

85.020 — 85.030 (3.3472 — 3.3476)
0.20 (0.0079)

Less than 0.015 (0.0006)

Taper (A − B and A − C)
Less than 0.010 (0.0004)

Difference in inner diameter between cylinders
Limit

84.970 — 84.980 (3.3453 — 3.3457)

Grade No. 3

84.980 — 84.990 (3.3457 — 3.3461)

0.50 (0.0197) oversize (Service)

85.460 — 85.490 (3.3646 — 3.3657)

1.00 (0.0394) oversize (Service)

85.960 — 85.990 (3.3842 — 3.3854)

Piston pin hole diameter

Out-of-round (X − Y)

Standard

Grade No. 2

Piston clearance to cylinder
block

Standard

84.960 — 84.970 (3.3449 — 3.3453)

‘‘a’’ dimension

Inner diameter

Wear limit

Grade No. 1

Less than 0.05 (0.0020)

Main journal inner
diameter
Grade No. 0

58.645 — 58.654 (2.3089 — 2.3092)

Grade No. 1

58.654 — 58.663 (2.3092 — 2.3096)

Grade No. 2

58.663 — 58.672 (2.3096 — 2.3099)

EM-61

14.5 (0.571)
0.030 — 0.050 (0.0012 — 0.0020)
26.995 — 27.005 (1.0628 — 1.0632)

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Piston ring

CONNECTING ROD
Unit: mm (in)

Side clearance

Unit: mm (in)
Center distance

Top

140.0 (5.512)

Bend [per 100 (3.94)]
Standard
Limit

0.060 — 0.093
(0.0024 — 0.0037)

Limit
Torsion [per 100 (3.94)]

0.1 (0.004)

Limit

2nd
Standard
Limit

0.040 — 0.073
(0.0016 — 0.0029)
0.1 (0.004)

Oil
Standard
Limit

Connecting rod small end
inner diameter

30.000 — 30.013 (1.1811 — 1.1816)

Piston pin bushing inner
diameter*

27.025 — 27.038 (1.0640 — 1.0645)

0.030 — 0.063
(0.0012 — 0.0025)
—

Grade No. 0

53.000 — 53.007 (2.0866 — 2.0869)

Grade No. 1

53.007 — 53.013 (2.0869 — 2.0871)

Side clearance

Top

Standard

Limit

0.20 — 0.28
(0.0079 — 0.0110)

Limit
*: After installing in connecting rod

1.0 (0.039)

2nd
Standard
Limit

0.38 — 0.53
(0.0150 — 0.0209)
1.0 (0.039)

Oil
Standard
Limit

0.30 — 0.56
(0.0118 — 0.0220)
1.0 (0.039)

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

26.994 — 27.000 (1.0628 — 1.0630)
0.002 — 0.006 (0.0001 — 0.0002)

Piston pin to connecting rod
bushing clearance
Standard

0.025 (0.0010)

Connecting rod big end inner
diameter

Ring gap

Standard

0.025 (0.0010)

0.025 — 0.044 (0.0010 — 0.0017)

* Values measured at ambient temperature of 20°C (68°F)

EM-62

0.20 — 0.30 (0.0079 — 0.0118)
0.40 (0.0157)

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
CRANKSHAFT

MAIN BEARING
Unit: mm (in)

Main journal dia. ‘‘Dm’’
Grade No. 0

54.967 — 54.975 (2.1641 — 2.1644)

Grade No. 1

54.959 — 54.967 (2.1637 — 2.1641)

Grade No. 2

54.951 — 54.959 (2.1634 — 2.1637)

Pin journal dia. ‘‘Dp’’
Grade No. 0

49.968 — 49.974 (1.9672 — 1.9675)

Grade No. 1

49.961 — 49.968 (1.9670 — 1.9672)

Center distance ‘‘r’’

41.47 — 41.53 (1.6327 — 1.6350)

Out-of-round (X − Y)
SEM157B

Standard

Main journal Less than 0.005 (0.0002)
Pin journal Less than 0.0025 (0.0001)

Taper (A − B)
Standard

Main journal Less than 0.005 (0.0002)
Pin journal Less than 0.0025 (0.0001)

Standard
Unit: mm (in)

Runout [TIR]
Standard

Less than 0.025 (0.0010)

Limit

Less than 0.05 (0.0020)

Grade
number

Thickness ‘‘T’’

1.813 — 1.817
(0.0714 — 0.0715)

Black

1.817 — 1.821
(0.0715 — 0.0717)

Brown

1.821 — 1.825
(0.0717 — 0.0719)

1.825 — 1.829
(0.0719 — 0.0720)

Yellow

1.829 — 1.833
(0.0720 — 0.0722)

Blue

Free end play
Standard
Limit

0.05 — 0.18 (0.0020 — 0.0071)
0.30 (0.0118)

Identification
color

Width ‘‘W’’

19.7 — 19.9
(0.776 — 0.783)

—

Undersize
Unit: mm (in)
Undersize

Thickness ‘‘T’’

Main journal
diameter ‘‘Dm’’

0.25 (0.0098)

2.109 — 2.117
(0.0830 — 0.0833)

Grind so that bearing
clearance is the
specified value.

SEM645

CONNECTING ROD BEARING
Connecting rod bearing
Standard size
Unit: mm (in)
EM715

EM-63

Grade
number

Thickness ‘‘T’’

1.492 — 1.496
(0.0587 — 0.0589)

1.496 — 1.500
(0.0589 — 0.0591)

1.500 — 1.504
(0.0591 — 0.0592)

Width ‘‘W’’

Identification
color
Black

19.9 — 20.1
(0.783 — 0.791)

Yellow
Brown

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Undersize

MISCELLANEOUS COMPONENTS
Unit: mm (in)

Undersize

Thickness ‘‘T’’

0.08 (0.0031)

1.536 — 1.540
(0.0605 — 0.0606)

0.12 (0.0047)

1.556 — 1.560
(0.0613 — 0.0614)

0.25 (0.0098)

1.621 — 1.625
(0.0638 — 0.0640)

Crank pin journal
diameter ‘‘Dp’’

Grind so that bearing
clearance is the
specified value.

Unit: mm (in)
Camshaft sprocket runout limit
[TIR]

0.1 (0.004)

Flywheel runout limit [TIR]

0.1 (0.004)

Drive plate runout limit [TIR]

0.1 (0.004)

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

0.036 — 0.063 (0.0014 — 0.0025)
0.12 (0.0047)

Connecting rod bearing clearance
Standard
Limit

0.031 — 0.055 (0.0012 — 0.0022)
0.11 (0.0043)

EM-64

FRONT AXLE &
FRONT SUSPENSION
SECTION

CONTENTS
PRECAUTIONS AND PREPARATION……………………….1
Precautions …………………………………………………………1
Special Service Tools …………………………………………..1
Commercial Service Tools …………………………………….2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ……………………………………………..3
NVH Troubleshooting Chart…………………………………..3
FRONT AXLE AND FRONT SUSPENSION ……………….4
ON-VEHICLE SERVICE …………………………………………..5
Front Axle and Front Suspension Parts ………………….5
Front Wheel Bearing…………………………………………….5
Front Wheel Alignment …………………………………………8
FRONT AXLE — Drive flange and Free-running
Hub………………………………………………………………………10
FRONT AXLE — Manual-lock Free-running Hub ……11
Removal……………………………………………………………11
Installation…………………………………………………………12
Inspection………………………………………………………….12
FRONT AXLE — Auto-lock Free-running Hub ……….13
Removal……………………………………………………………13
Installation…………………………………………………………13

FRONT AXLE — Wheel Hub and Rotor Disc …………14
Removal and Installation …………………………………….14
Inspection………………………………………………………….15
Assembly ………………………………………………………….15
FRONT AXLE — Knuckle Flange…………………………..17
Removal……………………………………………………………17
Inspection………………………………………………………….19
Installation…………………………………………………………19
Knuckle Flange Grease Seal……………………………….21
FRONT AXLE — Drive Shaft …………………………………23
Inspection………………………………………………………….23
Installation…………………………………………………………23
FRONT SUSPENSION …………………………………………..24
Shock Absorber …………………………………………………25
Stabilizer Bar …………………………………………………….25
Coil Spring ………………………………………………………..25
Leading Arm………………………………………………………26
Panhard Rod……………………………………………………..26
SERVICE DATA AND SPECIFICATIONS (SDS) ……….27
General Specifications………………………………………..27
Inspection and Adjustment ………………………………….27

PRECAUTIONS AND PREPARATION
Precautions
+

+
+
+

When installing rubber parts, final tightening must be carried out under unladen condition* with tires on ground.
* Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
Use flare nut wrench when removing and installing brake
tubes.
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Always torque brake lines when installing.

SBR820BA

Special Service Tools
Tool number
Tool name

Description

ST29020001
Gear arm puller

Removing tie-rod and drag link

a: 34 mm (1.34 in)
b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)

NT551

KV401021S0
Bearing race drift

Installing wheel bearing outer race

NT153

KV40105400
Wheel bearing
lock nut wrench

Removing and installing wheel bearing lock
nut

NT154

GG94310000
Flare nut torque wrench

Removing and installing brake piping

a: 10 mm (0.39 in)

NT406

FA-1

PRECAUTIONS AND PREPARATION
Commercial Service Tools
Tool name

Description

Equivalent to GG94310000
1 Flare nut crowfoot
V
2 Torque wrench
V

Removing and installing each brake piping

a: 10 mm (0.39 in)

NT360

Hub cap drift

Installing hub cap

a: 57 mm (2.24 in) dia.
b: 46 mm (1.81 in) dia.

NT115

FA-2

FRONT
AXLE AND
FRONT
SUSPENSION

Symptom

TIRES

ROAD
WHEEL

AXLE
SHAFT
X X X X X

X
X

X: Applicable

FA-3

X X X
X
X
X X
X
X

X X X

X
X

X X X
X X X
X
X X X
X X X

X X X X X

X
X
X

X X
X X
X X

X
X
X

X X X X X
X
X X X
X X X

X X

X X X

X X X
X X
X
X
X X X X
X X
X

—
—
—
—
FA-23

Non-uniformity
Incorrect tire size
Excessive joint angle
Joint sliding resistance

Refer to FRONT AXLE AND FRONT SUSPENSION in this chart.
NVH in RA section
Refer to TIRES in this chart.
Refer to ROAD WHEEL in this chart.
Refer to AXLE SHAFT in this chart.
NVH in BR section
NVH in ST section

TIRES
ROAD WHEEL
AXLE SHAFT
BRAKES
STEERING

NVH in PD section

DIFFERENTIAL
REAR AXLE AND REAR SUSPENSION

X X
X
X

FRONT AXLE AND FRONT SUSPENSION

NVH in PD section

PROPELLER SHAFT

—

Deformation or damage

Imbalance

—

Uneven tire wear

FA-8

Out-of-round

—

FA-5

Wheel bearing damage

Incorrect air pressure

FA-25

Stabilizer bar fatigue

Imbalance

FA-8

—

Spring fatigue

X
X
X
X
X
Incorrect wheel alignment

—

Parts interference

X
X
X
X
X

FA-24

—

Bushing or mounting deterioration

X
X
X
X
X
Suspension looseness

FA-4

Noise
Shake
Vibration
Shimmy
Judder
Poor quality ride
or handling
Noise
Shake
Vibration
Shimmy
Judder
Poor quality ride
or handling
Noise
Shake
Shimmy, judder
Poor quality ride
or handling
Noise, vibration
Shake
FA-25

Possible cause and SUSPECTED PARTS
Shock absorber deformation, damage or deflection

Reference page

Improper installation, looseness

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X
X
X
X
X
X
X
X
X
X
X X X
X X X
X
X
X
X
X
X
X
X
X
X

X X X

X X X X
X
X X
X
X X
X X
X X

X X

X X X
X X X
X
X
X
X
X

X X
X X X X X X
X
X X
X X X X

X
X
X
X
X

X X X
X X X
X X

X X
X X

FRONT AXLE AND FRONT SUSPENSION

SFA850B

FA-4

ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts

SMA525A

Check front axle and front suspension parts for excessive play,
cracks, wear and other damage.
+ Shake each front wheel to check for excessive play.
+ Make sure that cotter pin is inserted.
+ Retighten all axle and suspensions nuts and bolts to the specified torque.
Tightening torque:
Refer to FRONT SUSPENSION (FA-24).
+ Check front axle and front suspension parts for wear, cracks
and other damage.
+

Check shock absorber for oil leakage and other damage.

Check knuckle flange for grease leakage and knuckle flange
grease seal for cracks and other damage.

SFA851B

SFA852B

Front Wheel Bearing
+
+
+

Check that wheel bearings operate smoothly.
Check axial end play.
Axial end play:
0 mm (0 in)
Adjust wheel bearing preload if there is any axial end play or
wheel bearing does not turn smoothly.

SFA413A

FA-5

ON-VEHICLE SERVICE
Front Wheel Bearing (Cont’d)
PRELOAD ADJUSTMENT
Adjust wheel bearing preload after wheel bearing has been
replaced or front axle has been reassembled.
Adjust wheel bearing preload as follows:
1. Before adjustment, thoroughly clean all parts to prevent dirt
entry.

SFA853B

2. Apply multi-purpose grease sparingly to the following parts:
+ Wheel hub (as shown at left)

SFA469A

+
+
+

Wheel bearing
Grease seal lip
Contact surface between wheel bearing lock washer (chamfered side) and outer wheel bearing

FA781

3. Tighten wheel bearing lock nut with Tool.
: 167 — 196 Nzm (17 — 20 kg-m, 123 — 145 ft-lb)
4. Turn wheel hub several times in both directions.
5. Loosen wheel bearing lock nut so that torque becomes 0 Nzm
(0 kg-m, 0 ft-lb).
6. Retighten wheel bearing lock nut with Tool.
: 3 — 5 Nzm (0.3 — 0.5 kg-m, 26 — 43 in-lb)

SFA748BA

FA-6

ON-VEHICLE SERVICE
Front Wheel Bearing (Cont’d)
7. Turn wheel hub several times in both directions.
8. Retighten wheel bearing lock nut with Tool.
: 3 — 5 Nzm (0.3 — 0.5 kg-m, 26 — 43 in-lb)
9. Again turn wheel hub several times in both directions.

SFA854B

10. Measure starting force ‘‘A’’ at wheel hub bolt.

SFA855B

SFA470AA

11. Tighten lock nut until screw hole is aligned with screw hole in
lock washer. Lock washer may be used with either side up.
Temporarily tighten lock washer using screw.
12. Turn wheel hub several times in both directions.
13. Measure starting force ‘‘B’’ at wheel hub bolt. Refer to procedure 10.
14. Wheel bearing preload ‘‘C’’ can be calculated as shown below.
C=B−A
Wheel bearing preload ‘‘C’’:
0 — 18.6 N (0 — 1.9 kg, 0 — 4.2 lb)
15. If wheel bearing preload ‘‘C’’ is outside specifications, loosen
lock nut and adjust wheel bearing preload ‘‘C’’ to 0 to 18.6 N
(0 to 1.9 kg, 0 to 4.2 lb) range.
16. Measure wheel bearing axial end play.
Axial end play:
0 mm (0 in)

SFA856B

17. Tighten screw.
: 1.2 — 1.8 Nzm (0.12 — 0.18 kg-m, 10.4 — 15.6 in-lb)
18. Recheck to ensure that wheel bearing preload and axial end
play are within specified ranges.

SFA470AA

FA-7

ON-VEHICLE SERVICE
Front Wheel Bearing (Cont’d)
19. Pack drive flange groove with grease, apply grease to O-ring
and mating surface of drive flange, and install flange.

SFA417A

20. Place snap ring in drive shaft groove. Choose snap ring so that
the gap between groove and snap ring is 0.4 mm (0.016 in) or
less.
Refer to SDS for selection of snap ring.

SFA418AA

Front Wheel Alignment
Before checking front wheel alignment, be sure to make a preliminary inspection (Unladen*).
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.

SFA356B

PRELIMINARY INSPECTION
1. Check tires for wear and improper inflation.
2. Check wheel runout on outside and inside.
Wheel runout average
[(Outside runout value + Inside runout value) x 0.5]:
Refer to SDS (FA-27).
3. Check front wheel bearings for looseness.
4. Check front suspension for looseness.
5. Check steering linkage for looseness.
6. Check that shock absorbers work properly.
7. Check vehicle posture (Unladen).

CAMBER, CASTER AND KINGPIN INCLINATION
Camber, caster and kingpin inclination are preset at factory
and cannot be adjusted.
1. Measure camber, caster and kingpin inclination of both right
and left wheels with a suitable alignment gauge.
Camber, Caster and Kingpin inclination:
Refer to SDS (FA-27).
2. If camber, caster or kingpin inclination is not within
specification, inspect front suspension parts. Replace damaged
or worn out parts.
SFA894

FA-8

ON-VEHICLE SERVICE
Front Wheel Alignment (Cont’d)
TOE-IN

SFA614B

Measure toe-in using the following procedure.
WARNING:
+ Always perform the following procedure on a flat surface.
+ Make sure that no person is in front of the vehicle before
pushing it.
1. Bounce front of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of the tread (rear side) of both tires at
the same height of hub center. This mark is a measuring point.
4. Measure distance ‘‘A’’ (rear side).
5. Push the vehicle slowly ahead to rotate the wheels 180 degrees
(1/2 turn).
If the wheels have rotated more than 180 degrees (1/2 turn), try
the above procedure again from the beginning. Never push
vehicle backward.
6. Measure distance ‘‘B’’ (front side).
Total toe-in:
Refer to SDS (FA-27).

SFA234AC

7. Adjust toe-in by varying the length of steering tie-rod.
(1) Loosen lock nuts.
(2) Adjust toe-in by screwing tie-rod in and out.
Make sure both tie-rods are the same length.
(3) Tighten lock nuts to specified torque.
Lock nut tightening torque:
Refer to ST section (‘‘POWER STEERING GEAR
AND LINKAGE’’).

SFA857B

FRONT WHEEL TURNING ANGLE

SFA439BA

Turning angle is set by stroke length of steering gear rack and
cannot be adjusted.
1. Set wheels in straight-ahead position. Then move vehicle forward until front wheels rest on turning radius gauge properly.
2. Rotate steering wheel all the way right and left; measure turning angle.
Do not hold the steering wheel on full lock for more than 15
seconds.
Wheel turning angle (Full turn):
Refer to SDS (FA-27).
3. Adjust by stopper bolt if necessary.
: 30 — 40 Nzm (3.1 — 4.1 kg-m, 22 — 30 ft-lb)

SFA858B

FA-9

FRONT AXLE — Drive flange and Free-running Hub

SFA859B

FA-10

FRONT AXLE — Manual-lock Free-running Hub

SFA427AA

Removal
1. Set knob of manual-lock free-running hub to the ‘‘FREE’’ position.

SFA428A

2. Loosen bolts and remove free-running hub assembly.

SFA187

3. Remove snap ring and take off drive clutch.

SFA188

4. Take out bushing and spacer from wheel hub.

SFA189

FA-11

FRONT AXLE — Manual-lock Free-running Hub
Installation
Install free-running hub in the reverse order of removal.
Apply multi-purpose grease to bushing and drive clutch
before installing on wheel hub and axle shaft, respectively.

SFA860B

+
+

Install drive clutch.
Place snap ring in drive shaft groove.
Axial end play:
0.4 mm (0.016 in) or less
Snap ring size:
Refer to SDS.

SFA200

When installing manual-lock free-running hub, make sure the
position ‘‘FREE’’.
Apply multi-purpose grease to drive shaft end.
+ Check operation of manual-lock free-running hub after installing it.
+

SFA428A

Inspection
+
+

Check that hub moves smoothly and freely.
Check that clutch moves smoothly in the body.

FA-12

FRONT AXLE — Auto-lock Free-running Hub

SFA861B

Removal
1. Set the auto-lock free-running hub at the condition ‘‘LOCK’’.
2. Remove auto-lock free-running hub assembly.

SFA862B

3. Remove snap ring.
4. Remove spindle washer and thrust washer.
5. After installing auto-lock free-running hub, check operation of it.
When installing it, apply recommended grease to drive shaft
end.

SFA863B

Installation
1. When installing hub’s mating parts (such as thrust washer and
spindle washer) on drive shaft, select suitable snap ring so that
end play between drive shaft and its mating parts is within
specifications.
Axial end play:
0.4 mm (0.016 in) or less
Snap ring size:
Refer to SDS.
SFA433AA

2. Install auto-lock free-running hub assembly to wheel hub.
+ When installing auto-lock free-running hub assembly, be sure
to align outer brake pawl with notch in spindle.
+ After inserting auto-lock free-running hub assembly into bore in
wheel hub, make sure there is no clearance between hub
assembly and wheel hub. If clearance exists, the cause may be
one of the following:
(1) Hub assembly is set in ‘‘LOCK’’ position.
(2) Outer brake pawl is not aligned with notch in spindle.
SFA864B

FA-13

FRONT AXLE — Wheel Hub and Rotor Disc
Removal and Installation

SFA865B

CAUTION:
Before removing the front axle assembly, disconnect the ABS
wheel sensor from the assembly. Then move it away from the
front axle assembly area. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative.
1. Remove free-running hub assembly.
Refer to FRONT AXLE — Auto-lock or Manual-lock Free-running Hub.
2. Remove brake caliper assembly.
Brake hose need not be disconnected from brake caliper.
In this case, suspend caliper assembly with wire so as not to
stretch brake hose.
Be careful not to depress brake pedal, or piston will pop out.
Make sure brake hose is not twisted.
3. Remove ABS sensor.

4. Remove lock washer.

SFA470AA

5. Remove wheel bearing lock nut with Tool.

SFA748BA

6. Remove wheel hub and wheel bearing.
Be careful not to drop outer bearing.
7. After installing wheel hub and wheel bearing, adjust wheel
bearing preload.
Refer to ‘‘Front Wheel Bearing’’, ‘‘ON-VEHICLE SERVICE’’,
FA-5.

SFA866B

FA-14

FRONT AXLE — Wheel Hub and Rotor Disc
Removal and Installation (Cont’d)
8. Separate brake disc to hub.

SFA193

Inspection
Thoroughly clean wheel bearings and wheel hub.

WHEEL BEARING
+

Make sure wheel bearing rolls freely and is free from noise,
crack, pitting or wear.

WHEEL HUB
+
SFA435A

Check wheel hub for crack by using a magnetic exploration or
dyeing test.

Assembly
1. Install bearing outer race with Tool until it seats in hub.

SFA197

2. Install the sensor rotor using suitable drift and press. (Models
with ABS)
Always replace sensor rotor with new one.
Pay attention to the direction of front sensor rotor as shown in
figure.

SBR400DA

3. Pack multi-purpose grease to hub and hub cap.

SFA469A

FA-15

FRONT AXLE — Wheel Hub and Rotor Disc
Assembly (Cont’d)
4. Apply multi-purpose grease to each bearing cone.

FA781

5. Pack grease seal lip with multi-purpose grease, then install it
into wheel hub with suitable drift.

SFA126

6. Install hub to brake rotor.
: 50 — 68 Nzm (5.1 — 6.9 kg-m, 37 — 50 ft-lb)

SFA199

FA-16

FRONT AXLE — Knuckle Flange

SFA867B

Removal
Drain differential oil completely prior to removal.
1. Remove baffle plate and knuckle spindle.

SFA868B

2. Draw out drive shaft.
Draw out to remove the drive shaft in the axial direction with
the flat surface facing up.

SFA869B

FA-17

FRONT AXLE — Knuckle Flange
Removal (Cont’d)
3. Disconnect tie-rod ends.
Refer to ST section.

4. Remove upper and lower bearing caps with inner bearing and
O-ring.

SFA870B

5. Remove seal guard fixing bolts.

SFA871B

6. Remove seal guard.
Separate scraper, grease seal and supporting ring from knuckle
flange.

SFA872B

7. Remove knuckle flange, supporting ring, grease seal and
scraper from axle case.

SFA873B

FA-18

FRONT AXLE — Knuckle Flange
Removal (Cont’d)
8. Remove bearing outer race and kingpin plug.

SFA874B

9. Remove oil seal from axle shaft.

SFA875B

Inspection
KNUCKLE FLANGE BEARING CAP
Replace knuckle flange bearing if it is worn, pitted or corroded.

SFA870B

KNUCKLE FLANGE
Replace knuckle flange if it is cracked.

SFA894B

Installation
1. Check kingpin plug for damage before installing. If damaged,
use a new one.

SFA877B

FA-19

FRONT AXLE — Knuckle Flange
Installation (Cont’d)
2. Using Tool, place bearing outer race in trunnion socket.

SFA878B

3. Install oil seal with tool.

SFA879B

4. Place scraper, grease seal and supporting ring in axle case.
Grease lip and circumference seals in axle case.

SFA880B

5. Apply recommended grease around trunnion socket spherical
area, then place knuckle flange in trunnion socket.

SFA881B

6. Adjust rotating force of knuckle flange (at hinge pin) to 4.9 to
14.7 N (0.5 to 1.5 kg, 1.1 to 3.3 lb) range by adding or removing upper and lower shims of same thickness. This adjustment
must be made without installing grease seal and axle shaft.
Shim thicknesses: Refer to SDS.

SFA882B

FA-20

FRONT AXLE — Knuckle Flange
Installation (Cont’d)
7. Install bearing cap with inner bearing and adjusting shim.
Before installing seal guard, scraper, grease seal and supporting ring (as a unit), apply approx. 50 g (1.76 oz) of wheel bearing grease to perimeters shown in figure at left.
Slits located in scraper and supporting ring should point
straight downward when installed.

SFA883B

8. When installing grease seal guard, adjust so painted surface is
visible.

SFA876B

Install knuckle flange stopper bolt and nut on stopper side of
axle case.
After installing tie rod, adjust it to specified steering angle
using turning radius gauge, then tighten with lock nut.

SFA884B

Knuckle Flange Grease Seal
To replace only knuckle flange grease seal, proceed as follows.

REMOVAL
1. Turn steering wheel to both the extreme right and left, and
remove grease seal guard and scraper from knuckle flange.
2. Extract grease seal and remove it by cutting it from axle case.

SFA885B

FA-21

FRONT AXLE — Knuckle Flange
Knuckle Flange Grease Seal (Cont’d)
INSTALLATION
1. Cut off a part of new grease seal and fill lip portion with grease.
Then insert grease seal into axle case.
Cut grease seal so that cut surface is straight.

SFA886B

2. Apply adhesive to cut surface of grease seal.
Install grease seal so that its cut surface is above knuckle
flange.
Be sure not to allow adhesive to protrude beyond cut surface
of grease seal.

SFA887B

3. Install scraper and grease seal guard on knuckle flange.
After replacing grease seal, adjust steering wheel to specified
turning angle with a turning radius gauge. Then tighten lock
nut.
4. When installing grease seal guard, adjust so painted surface is
visible.

SFA876B

FA-22

FRONT AXLE — Drive Shaft
Inspection
Check wheel shaft for signs of binding when turned in a twisting
motion. Also check for cracks or damage.

SFA447A

Installation
+

Before positioning drive shaft in axle case, pack shaft joint with
recommended grease. Refer to MA section (‘‘Fluids and
Lubricants’’, ‘‘RECOMMENDED FLUIDS AND LUBRICANTS’’).

SFA448A

+ Install drive shaft.
Insert the drive shaft with the flat surface facing up.

SFA869B

FA-23

FRONT SUSPENSION

SFA889B

FA-24

FRONT SUSPENSION
Shock Absorber
REMOVAL AND INSTALLATION
1. Support front axle case with jack.
2. Remove both upper and lower sides fixing nuts.

INSPECTION

SFA890B

Except for nonmetallic parts, clean all parts with suitable solvent
and dry with compressed air.
Use compressed air to blow dirt and dust off of nonmetallic parts.
+ Check for oil leakage and cracks. Replace if necessary.
+ Check piston rod for cracks, deformation and other damage.
Replace if necessary.
+ Check rubber parts for wear, cracks, damage and deformation.
Replace if necessary.

Stabilizer Bar
REMOVAL
+

Remove stabilizer bar connecting bolts and clamp bolts.

INSPECTION
+
+

Check stabilizer bar for twist and deformation.
Replace if necessary.
Check rubber bushing for cracks, wear and deterioration.
Replace if necessary.

SFA891B

INSTALLATION
+

Install stabilizer bar with ball joint socket properly placed.

SFA896B

Coil Spring
INSPECTION
Visually check for cracks or damage. If faulty, replace.
Ensure that springs are installed correctly. Incorrect installation will cause vehicle not set in horizontal posture.

SFA897B

FA-25

FRONT SUSPENSION
Leading Arm
INSPECTION
Check for cracks, bends or damage. Also check bushing.

SFA460A

If bushing is faulty, replace it using suitable tool.
When installing bushing, make sure that it is positioned as shown.

SFA892B

Panhard Rod
INSPECTION
+

Check for cracks or other damage. Replace if necessary.

SFA462A

Panhard rod bushing
Removal
+ Using a press and suitable tool as shown in figure at left,
remove bushing from vehicle side.
+ Using a flat-bladed screwdriver, pry bushing out of axle case.

SRA030A

Installation
+ Using suitable tool shown in figure at left, gradually press bushing into place.
Always install new bushing. Do not tap end face of bushing
directly with a hammer. Apply soap water to outer wall of bushing before installation.

SFA893B

FA-26

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Suspension type

Rigid axle, leading arm and panhard rod with
coil spring

Strut type

Double-acting hydraulic

Stabilizer bar

Standard equipment

Inspection and Adjustment
WHEEL ALIGNMENT (Unladen*1)
Applied model

Wagon

Camber

Minimum

0° (0.00°)

Nominal

0°30′ (0.50°)

Maximum

1°00′ (1.00°)

Degree minute
(Decimal degree) Left and right difference
Caster

45′ (0.75°) or less

Minimum

3°00′ (3.00°)

3°20′ (3.33°)

Nominal

3°30′ (3.50°)

3°50′ (3.83°)

Maximum

4°00′ (4.00°)

4°20′ (4.33°)

Degree minute
(Decimal degree) Left and right difference
Kingpin inclination

45′ (0.75°) or less

Minimum

13°45′ (13.75°)

Nominal

14°30′ (14.50°)

Degree minute
(Decimal degree) Maximum
Total toe-in
Distance (A − B)

15°15′ (15.25°)

Minimum

0 (0)

Nominal

1 (0.04)

mm (in) Maximum

Angle (left plus right)

2 (0.08)

Minimum

0′ (0.00°)

Nominal
Degree minute
(Decimal degree) Maximum

5′ (0.08°)

Wheel turning angle
Inside

Hardtop

10′ (0.17°)

Minimum

33°00′ (33.00°)

Nominal
Degree minute
(Decimal degree) Maximum

35°00′ (35.00°)
35°00′ (35.00°)

Minimum

29°00′ (29.00°)

Nominal

31°00′ (31.00°)

Full turn*2
Outside

Degree minute
(Decimal degree) Maximum

31°00′ (31.00°)

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

WHEEL RUNOUT AVERAGE*
Steel

Aluminum

Wheel type
6JJ-16

8JJ-16

6JJ-16

8JJ-16

Radial runout limit
mm (in)

1.2
(0.047)

0.8
(0.031)

0.3
(0.012)

Lateral runout limit
mm (in)

1.2
(0.047)

0.8
(0.031)

0.3
(0.012)

*: Wheel runout average = (Outside runout value + Inside runout value) x 0.5

FA-27

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
WHEEL BEARING

DRIVE SHAFT

Wheel bearing axial end play

Birfield joint axial end play
mm (in)

0 (0)

mm (in)
Wheel bearing lock nuts

0 (0)

Grease

Tightening torque

Type

167 — 196 (17 — 20, 123 — 145)

Nzm (kg-m, ft-lb)

Capacity

Retightening torque after
untightened
Nzm (kg-m, in-lb)

Multi-purpose grease
g (oz)

3 — 5 (0.3 — 0.5, 26 — 43)

Measured starting force
At wheel hub bolt

N (kg, lb)

Adjusting snap rings
mm (in)

Turning adjusting nut in tightening
direction and measuring starting
force
At wheel hub bolt

N (kg, lb)
Calculated wheel bearing preload;
B−A
At wheel hub bolt

0 — 18.6 (0 — 1.9, 0 — 4.2)

N (kg, lb)

KNUCKLE FLANGE BEARING
Flange turning torque
Without trunnion seal
and drive shaft
Nzm (kg-m, ft-lb)
At knuckle arm ‘‘F’’
N (kg, lb)

1 — 3 (0.1 — 0.3, 0.7 — 2.2)

4.9 — 14.7 (0.5 — 1.5, 1.1 — 3.3)
Thickness

Adjusting shims mm (in)

0.075
0.127
0.254
0.500
0.762

(0.0030)
(0.0050)
(0.0100)
(0.0197)
(0.0300)

50 — 60 (1.76 — 2.12)

Drive shaft axial end play
mm (in)

Part number
40606-44000
40605-44000
40604-44000
40571-01J00
40603-44000

SFA882B

FA-28

0.4 (0.016) or less
Thickness

Part number

1.1
1.3
1.5
1.7
1.9
2.1

39253-01J00
39253-01J01
39253-01J02
39253-01J03
39253-01J04
39253-01J05

(0.043)
(0.051)
(0.059)
(0.067)
(0.075)
(0.083)

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
SECTION

CONTENTS
ACCELERATOR CONTROL SYSTEM ………………………1
Accelerator Control System…………………………………..1

FUEL SYSTEM ……………………………………………………….2
EXHAUST SYSTEM ………………………………………………..3

ACCELERATOR CONTROL SYSTEM
Accelerator Control System
a. Warm up engine to normal operating temperature.
b. Check to see if throttle valve fully opens when accelerator pedal is fully depressed and if it returns
to idle position when released.
c. Adjust accelerator pedal free play by turning adjusting nut.
d. Check accelerator control parts for improper contact with any adjacent parts.
e. When connecting accelerator wire, be careful not to twist or scratch its inner wire.
f. Apply a light coat of recommended multi-purpose grease to all sliding or friction surfaces. Do not
apply grease to wire.

YFE001

FE-1

FUEL SYSTEM

SFE514A

FE-2

EXHAUST SYSTEM
CAUTION:
+ Always replace exhaust gaskets with new ones when reassembling. If gasket is left on flange surface, scrape off
completely as shown at left.
+ With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
+ Ensure that mounting brackets and mounting insulators
are installed properly and free from undue stress. Improper
installation could result in excessive noise or vibration.
SFE180A

SFE516A

FE-3

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SERVICE MANUAL ON CD!
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may have regarding this Service Manual publication.
Please print this form and type or print your comments below. Mail or fax to:
NISSAN EUROPE S.A.S.
S320 Service Engineering
2, Avenue de Denis Papin
ZIPEC — F92350 Le Plessis Robinson
France
Fax: + 33 (0) 1 41 07 16 81

SERVICE MANUAL:

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Please comment:

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

Date

Your Name

Position :

Dealer

Dealer No. :

Address

City

Telephone

Fax

E-mail

Country :

CEL773

CEL789

CEL841

CEL842

EL-317

SUPER MULTIPLE JUNCTION (SMJ)
Terminal Arrangement

CEL774

FUSE BLOCK — Junction Box (J/B)
Terminal Arrangement

CEL775

FUSE AND FUSIBLE LINK BOX
Terminal Arrangement

CEL776

ELECTRICAL UNITS
Terminal Arrangement

NCEL777

JOINT CONNECTOR (J/C)
Terminal Arrangement

CEL778

Edition: February 1998
Release: February 1998 (01)
Publication No.: SM8E-0Y61E0E
Reference No.: 7711346063

QUICK REFERENCE INDEX

GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL

PATROL GR

ENGINE LUBRICATION &
COOLING SYSTEMS

MODEL Y61 SERIES

ENGINE CONTROL SYSTEM

ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEM

CLUTCH

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

TRANSFER

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

FRONT AXLE & FRONT SUSPENSION

REAR AXLE & REAR SUSPENSION

BRAKE SYSTEM

STEERING SYSTEM

RESTRAINT SYSTEM

BODY & TRIM

HEATER & AIR CONDITIONER

ELECTRICAL SYSTEM

ALPHABETICAL INDEX

IDX

NISSAN EUROPE S.A.S.
© 1998 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.

FOREWORD
This manual contains maintenance and repair procedures for NISSAN
PATROL GR, model Y61 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

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

NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

GENERAL INFORMATION
SECTION

CONTENTS
PRECAUTIONS ………………………………………………………1
Precaution for Supplemental Restraint System
(SRS) ‘‘AIR BAG’’ and ‘‘SEAT BELT
PRE-TENSIONER’’………………………………………………1
General Precautions …………………………………………….2
Precautions for Multiport Fuel Injection System
or ECCS Engine ………………………………………………….3
Precautions for Three Way Catalyst
(If so equipped)……………………………………………………4
Precautions for Engine Oils…………………………………..4
Precautions for Fuel …………………………………………….5
Precautions for Air Conditioning …………………………….5
HOW TO USE THIS MANUAL………………………………….6
HOW TO READ WIRING DIAGRAMS……………………….8
Sample/Wiring Diagram — EXAMPL —………………….8
Description ………………………………………………………..10
HOW TO CHECK TERMINAL…………………………………17
How to Probe Connectors …………………………………..17
How to Check Enlarged Contact Spring of
Terminal ……………………………………………………………18
Waterproof Connector Inspection …………………………19
Terminal Lock Inspection …………………………………….19
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR
AN ELECTRICAL INCIDENT ………………………………….20

Work Flow…………………………………………………………20
Incident Simulation Tests…………………………………….21
Circuit Inspection ……………………………………………….24
HOW TO FOLLOW FLOW CHART IN TROUBLE
DIAGNOSES …………………………………………………………30
How to Follow This Flow Chart ……………………………31
CONSULT CHECKING SYSTEM …………………………….33
Function and System Application …………………………33
Lithium Battery Replacement ………………………………33
Checking Equipment…………………………………………..33
Loading Procedure …………………………………………….34
CONSULT Data Link Connector (DLC) Circuit……….34
IDENTIFICATION INFORMATION……………………………35
Model Variation ………………………………………………….35
Identification Number………………………………………….36
Dimensions ……………………………………………………….38
Wheels & Tires ………………………………………………….38
LIFTING POINTS AND TOW TRUCK TOWING………..39
Screw Jack ……………………………………………………….39
Garage Jack and Safety Stand ……………………………39
2-pole Lift ………………………………………………………….40
Tow Truck Towing ………………………………………………41
SAE J1930 TERMINOLOGY LIST …………………………..43
SAE J1930 Terminology List ……………………………….43

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

Precaution for Supplemental Restraint System
(SRS) ‘‘AIR BAG’’ and ‘‘SEAT BELT
PRE-TENSIONER’’

SGI646

The Supplemental Restraint System such as ‘‘AIR BAG’’ and
‘‘SEAT BELT PRE-TENSIONER’’ used along with a seat belt, helps
to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The SRS system composition which is
available to NISSAN MODEL Y61 is as follows (The composition
varies according to the destination.):
Driver air bag module (located in the center of the steering wheel),
front passenger air bag module (located on the instrument panel on
passenger side), seat belt pre-tensioner, a diagnosis sensor unit,
warning lamp, wiring harness and spiral cable.
Information necessary to service the system safely is included in
the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event of
a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN
dealer.
+ Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system. For removal of
Spiral Cable and Air Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
Spiral cable and wiring harnesses are covered with yellow
insulation either just before the harness connectors or for
the complete harness are related to the SRS.

GI-1

PRECAUTIONS
General Precautions
+

Do not operate the engine for an extended period of time without proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazardous materials.
Do not smoke while working on the vehicle.

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

SGI285

SGI231

Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.

To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.

Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate covers.
Take caution that keys, buckles or buttons do not scratch paint.

SEF289H

SGI233

SGI234

GI-2

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

Precautions for Multiport Fuel Injection System
or ECCS Engine
+

+
SGI787

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

GI-3

PRECAUTIONS
Precautions for Three Way Catalyst
(If so equipped)
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the
instructions below:
+ Use unleaded gasoline only. Leaded gasoline will seriously
damage the three way catalyst.
+ When checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
+ Do not run engine when the fuel tank level is low, otherwise the
engine may misfire causing damage to the catalyst.
Do not place the vehicle on flammable material. Keep flammable
material off the exhaust pipe and the three way catalyst.

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

HEALTH PROTECTION PRECAUTIONS
+
+
+
+
+
+
+
+
+
+
+
+

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

ENVIRONMENTAL PROTECTION PRECAUTIONS
Burning used engine oil in small space heaters or boilers can be
recommended only for units of approved design. The heating system must meet the requirements of HM Inspectorate of Pollution for
small burners of less than 0.4 MW. If in doubt check with the
appropriate local authority and/or manufacturer of the approved
appliance.

GI-4

PRECAUTIONS
Precautions for Engine Oils (Cont’d)
Dispose of used oil and used oil filters through authorized waste
disposal contractors to licensed waste disposal sites, or to the
waste oil reclamation trade. If in doubt, contact the local authority
for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or drains,
or into water courses.
The regulations concerning the pollution of the environment
will vary from country to country.

Precautions for Fuel
GASOLINE ENGINE:
Three way catalyst equipped models … unleaded gasoline of at
least 91 octane (RON)
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst.
Except for the above models … unleaded or leaded gasoline of
above 88 octane (RON)
Use unleaded fuel if instructed on the fuel filler lid.

DIESEL ENGINE*:
Diesel fuel of above 45 cetane for TD42 engine and above 50 cetane for RD28ET engine
* If two types of diesel fuel are available, use summer or winter
fuel properly according to the following temperature conditions.
+ Above −7°C (20°F) … Summer type diesel fuel.
+ Below −7°C (20°F) … Winter type diesel fuel.
CAUTION:
+ Do not use home heating oil, gasoline, or other alternate
fuels in your diesel engine. The use of those can cause
engine damage.
+ Do not use summer fuel at temperature below −7°C (20°F).
The cold temperature will cause wax to form in the fuel. As
a result, it may prevent the engine from running smoothly.
+ Do not add gasoline or other alternate fuels to diesel fuel.

Precautions for Air Conditioning
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA section (‘‘HFC134a (R-134a) Service Procedure’’, ‘‘SERVICE PROCEDURES’’)
for specific instructions.

GI-5

HOW TO USE THIS MANUAL
+
+
+
+
+
+

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

SBR364AC

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

GI-6

HOW TO USE THIS MANUAL
The following SYMBOLS AND ABBREVIATIONS are used:
,
: Tightening torque
,
4WD
: Should be lubricated with grease.
2WD
Unless otherwise indicated, use recA/C
ommended multi-purpose grease.
P/S
: Should be lubricated with oil.
SST
: Sealing point
SAE
: Checking point
: Always replace after every disasATF
sembly.
j
P
D1
: Apply petroleum jelly.
D2
: Apply ATF.
.
: Select with proper thickness.
D3
D4
>
: Adjustment is required.
SDS
: Service Data and Specifications
OD
LH, RH
: Left-Hand, Right-Hand
22
FR, RR
: Front, Rear
21
M/T
: Manual Transaxle/Transmission
12
11

+
+
+

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

4-Wheel Drive
2-Wheel Drive
Air Conditioner
Power Steering
Special Service Tools
Society of Automotive Engineers,
Inc.
Automatic Transmission Fluid
Drive range 1st gear
Drive range 2nd gear
Drive range 3rd gear
Drive range 4th gear
Overdrive
2nd range 2nd gear
2nd range 1st gear
1st range 2nd gear
1st range 1st gear

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

GI-7

HOW TO READ WIRING DIAGRAMS
Sample/Wiring Diagram — EXAMPL —
+

For Description, refer to GI-10.

YGI001

GI-8

HOW TO READ WIRING DIAGRAMS
Sample/Wiring Diagram — EXAMPL — (Cont’d)
OPTIONAL SPLICE

SGI942

GI-9

HOW TO READ WIRING DIAGRAMS
Description
Number

Item

Description

1
V

Power condition

+ This shows the condition when the system receives battery positive voltage (can
be operated).

2
V

Fusible link

+ The double line shows that this is a fusible link.
+ The open circle shows current flow in, and the shaded circle shows current flow
out.

3
V

Fusible link/fuse location

+ This shows the location of the fusible link or fuse in the fusible link or fuse box.
For arrangement, refer to EL section (‘‘POWER SUPPLY ROUTING’’).

Fuse

+ The single line shows that this is a fuse.
+ The open circle shows current flow in, and the shaded circle shows current flow
out.

5
V

Current rating

+ This shows the current rating of the fusible link or fuse.

6
V

Connectors

+ This shows that connector E3 is female and connector M1 is male.
+ The G/R wire is located in the 1A terminal of both connectors.
+ Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is
SMJ connector. Refer to GI-16.

7
V
8
V
9
V

Optional splice

+ The open circle shows that the splice is optional depending on vehicle application.

Splice

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

Page crossing

+ This arrow shows that the circuit continues to an adjacent page.
+ The A will match with the A on the preceding or next page.

10
V
11
V
12
V

Common connector

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

Option abbreviation

+ This shows that the circuit is optional depending on vehicle application.

Relay

+ This shows an internal representation of the relay. For details, refer to EL section
(‘‘STANDARDIZED RELAY’’).

13
V

Connectors

+ This shows that the connector is connected to the body or a terminal with bolt or
nut.

14
V

Wire color

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

15
V

Option description

+ This shows a description of the option abbreviation used on the page.

16
V

Switch

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

17
V

Assembly parts

+ Connector terminal in component shows that it is a harness incorporated assembly.

18
V

Cell code

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

GI-10

HOW TO READ WIRING DIAGRAMS
Description (Cont’d)
Number

Item

Description

19
V

Current flow arrow

+ Arrow indicates electric current flow, especially where the direction of standard
flow (vertically downward or horizontally from left to right) is difficult to follow.
+ A double arrow ‘‘b—c’’ shows that current can flow in either direction depending
on circuit operation.

20
V

System branch

+ This shows that the system branches to another system identified by cell code
(section and system).

Page crossing

+ This arrow shows that the circuit continues to another page identified by cell code.
+ The C will match with the C on another page within the system other than the
next or preceding pages.

22
V
23
V
24
V

Shielded line

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

Component box in wave
line

+ This shows that another part of the component is also shown on another page
(indicated by wave line) within the system.

Component name

+ This shows the name of a component.

25
V

Connector number

+ This shows the connector number.
+ The letter shows which harness the connector is located in.
Example: M: main harness. For detail and to locate the connector, refer to EL section (‘‘Main Harness’’, ‘‘HARNESS LAYOUT’’). A coordinate grid is included for
complex harnesses to aid in locating connectors.

26
V
27
V
28
V

Ground (GND)

+ The line spliced and grounded under wire color shows that ground line is spliced
at the grounded connector.

Ground (GND)

+ This shows the ground connection.

Connector views

+ This area shows the connector faces of the components in the wiring diagram on
the page.

29
V

Common component

+ Connectors enclosed in broken line show that these connectors belong to the
same component.

30
V

Connector color

+ This shows a code for the color of the connector. For code meaning, refer to wire
color codes, Number V
14 of this chart.

31
V

Fusible link and fuse box

+ This shows the arrangement of fusible link(s) and fuse(s), used for connector
views of ‘‘POWER SUPPLY ROUTING’’ in EL section.
The open square shows current flow in, and the shaded square shows current
flow out.

32
V

Reference area

+ This shows that more information on the Super Multiple Junction (SMJ) and Joint
Connectors (J/C) exists on the foldout page. Refer to GI-16 for details.

GI-11

HOW TO READ WIRING DIAGRAMS
Description (Cont’d)
CONNECTOR SYMBOLS
Most of connector symbols in wiring diagrams are shown from the
terminal side.
+ Connector symbols shown from the terminal side are enclosed
by a single line and followed by the direction mark
.
+

Connector symbols shown from the harness side are enclosed
by a double line and followed by the direction mark
.

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

SGI364

SGI363

GI-12

HOW TO READ WIRING DIAGRAMS
Description (Cont’d)
Harness indication
+
+

Letter designations next to test meter probe indicate harness
(connector) wire color.
Connector numbers in a single circle M33 indicate harness connectors.

Component indication
+

Connector numbers in a double circle indicate component connectors.

AGI070

SWITCH POSITIONS
Switches are shown in wiring diagrams as if the vehicle is in the
‘‘normal’’ condition.
A vehicle is in the ‘‘normal’’ condition when:
+ ignition switch is ‘‘OFF’’,
+ doors, hood and trunk lid/back door are closed,
+ pedals are not depressed, and
+ parking brake is released.

SGI860

GI-13

HOW TO READ WIRING DIAGRAMS
Description (Cont’d)
DETECTABLE LINES AND NON-DETECTABLE LINES
In some wiring diagrams, two kinds of lines, representing wires,
with different weight are used.
+ A line with regular weight (wider line) represents a ‘‘detectable
line for DTC (Diagnostic Trouble Code)’’. A ‘‘detectable line for
DTC’’ is a circuit in which ECM (Engine Control Module) can
detect its malfunctions with the on board diagnostic system.
+ A line with less weight (thinner line) represents a ‘‘non-detectable line for DTC’’. A ‘‘non-detectable line for DTC’’ is a circuit
in which ECM cannot detect its malfunctions with the on board
diagnostic system.

SGI862-A

GI-14

HOW TO READ WIRING DIAGRAMS
Description (Cont’d)
MULTIPLE SWITCH
The continuity of multiple switch is described in two ways as shown
below.
+ The switch chart is used in schematic diagrams.
+ The switch diagram is used in wiring diagrams.

SGI875

GI-15

HOW TO READ WIRING DIAGRAMS
Description (Cont’d)
FOLDOUT PAGE
The foldout page should be opened when reading wiring diagram.

Super multiple junction (SMJ)
In wiring diagram, connectors consisting of terminals having terminal numbers with an alphabet (1B, 0D, etc.)
are SMJ connectors.
If connector numbers are shown in Reference Area, these connector symbols are not shown in Connector
Area. For terminal arrangement of these connectors, refer to the foldout page at the end of this manual.

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

SGI943

GI-16

HOW TO CHECK TERMINAL
How to Probe Connectors
Connector damage and an intermittent connection can result from
improperly probing of the connector during circuit checks.
The probe of a digital multimeter (DMM) may not correctly fit the
connector cavity. To correctly probe the connector, follow the procedures below using a ‘‘T’’ pin. For the best contact grasp the ‘‘T’’
pin using an alligator clip.

PROBING FROM HARNESS SIDE
Standard type (not waterproof type) connector should be probed
from harness side with ‘‘T’’ pin.
+ If the connector has a rear cover such as a ECM connector,
remove the rear cover before probing the terminal.
+ Do not probe waterproof connector from harness side.
Damage to the seal between wire and connector may
result.

SGI841

PROBING FROM TERMINAL SIDE
Female terminal
There is a small notch above each female terminal. Probe each
terminal with the ‘‘T’’ pin through the notch.
Do not insert any object other than the same type male terminal into female terminal.
+

SEL265V

Some connectors do not have a notch above each terminal. To
probe each terminal, remove the connector retainer to make
contact space for probing.

SEL266V

Male terminal
Carefully probe the contact surface of each terminal using a ‘‘T’’
pin.
Do not bend terminal.

SEL267V

GI-17

HOW TO CHECK TERMINAL
How to Check Enlarged Contact Spring of
Terminal
An enlarged contact spring of a terminal may create intermittent
signals in the circuit.
If the intermittent open circuit occurs, follow the procedure below to
inspect for open wires and enlarged contact spring of female terminal.

1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire.
Use a male terminal which matches the female terminal.
2. Disconnect the suspected faulty connector and hold it terminal
side up.

SEL270V

3. While holding the wire of the male terminal, try to insert the
male terminal into the female terminal.
Do not force the male terminal into the female terminal with
your hands.

SEL271V

4. While moving the connector, check whether the male terminal
can be easily inserted or not.

SEL272V

If the male terminal can be easily inserted into the female
terminal, replace the female terminal.

SEL273V

GI-18

HOW TO CHECK TERMINAL
Waterproof Connector Inspection
If water enters the connector, it can short interior circuits. This may
lead to intermittent problems.
Check the following items to maintain the original waterproof characteristics.

RUBBER SEAL INSPECTION
+
SEL275V

Most waterproof connectors are provided with a rubber seal
between the male and female connectors. If the seal is missing,
the waterproof performance may not meet specifications.
The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the
rubber seal is properly installed on either side of male or female
connector.

WIRE SEAL INSPECTION
The wire seal must be installed on the wire insertion area of a
waterproof connector. Be sure that the seal is installed properly.

Terminal Lock Inspection
Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

SEL330V

GI-19

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Work Flow

SGI838

STEP
STEP 1

DESCRIPTION
Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHAT

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

WHEN

Date, Time of Day, Weather Conditions, Frequency.

WHERE

Road Conditions, Altitude and Traffic Situation.

HOW

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

STEP 2

Operate the system, road test if necessary.
Verify the parameter of the incident.
If the problem can not be duplicated, refer to ‘‘Incident Simulation Tests’’ next page.

STEP 3

Get the proper diagnosis materials together including:
POWER SUPPLY ROUTING
System Operation Descriptions
Applicable Service Manual Sections
Check for any Service Bulletin.
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.

STEP 4

Inspect the system for mechanical binding, loose connectors or wiring damage.
Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness
Layouts.

STEP 5

Repair or replace the incident circuit or component.

STEP 6

Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps.

GI-20

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests
INTRODUCTION
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The
following section illustrates ways to simulate the conditions/environment under which the owner experiences
an electrical incident.
The section is broken into the six following topics:
+ Vehicle vibration
+ Heat sensitive
+ Freezing
+ Water intrusion
+ Electrical load
+ Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of
the problem.

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

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

Hint
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs
intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean
the terminals on related connectors in the system.

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

SGI839

GI-21

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

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

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

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

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

HEAT SENSITIVE
The owner’s problem may occur during hot weather or after car has
sat for a short time. In such cases you will want to check for a heat
sensitive condition.
To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent.
Do not heat components above 60°C (140°F). If incident occurs
while heating the unit, either replace or properly insulate the component.
SGI842

GI-22

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont’d)
FREEZING

SGI843

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

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

SGI844

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

COLD OR HOT START UP
On some occasions an electrical incident may occur only when the
car is started cold. Or it may occur when the car is restarted hot
shortly after being turned off. In these cases you may have to keep
the car overnight to make a proper diagnosis.
SGI845

GI-23

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection
INTRODUCTION
In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before
beginning it is important to have all available information on the system to be tested. Also, get a thorough
understanding of system operation. Then you will be able to use the appropriate equipment and follow the
correct test procedure.
You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring
harness or electrical component to do this.

OPEN

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

SHORT

There are two types of shorts.
+ SHORT CIRCUIT

When a circuit contacts another circuit and causes the
normal resistance to change.

+ SHORT TO GROUND

When a circuit contacts a ground source and grounds the
circuit.

TESTING FOR ‘‘OPENS’’ IN THE CIRCUIT
Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This
will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

SGI846

Continuity check method
The continuity check is used to find an open in the circuit. The Digital Multimeter (DMM) set on the resistance
function will indicate an open circuit as over limit (OL, no beep tone or no ohms symbol). Make sure to always
start with the DMM at the highest resistance level.
To help in understanding the diagnosis of open circuits please refer to the schematic above.
1.
2.
3.
4.

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

GI-24

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont’d)
Voltage check method
To help in understanding the diagnosis of open circuits please refer to the previous schematic.
In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function.
1. Connect one probe of the DMM to a known good ground.
2. Begin probing at one end of the circuit and work your way to the other end.
3. With SW1 open, probe at SW1 to check for voltage.
voltage;
open is further down the circuit than SW1.
no voltage; open is between fuse block and SW1 (point A).
4. Close SW1 and probe at relay.
voltage;
open is further down the circuit than the relay.
no voltage; open is between SW1 and relay (point B).
5. Close the relay and probe at the solenoid.
voltage;
open is further down the circuit than the solenoid.
no voltage; open is between relay and solenoid (point C).
Any powered circuit can be diagnosed using the approach in the above example.

TESTING FOR ‘‘SHORTS’’ IN THE CIRCUIT
To simplify the discussion of shorts in the system please refer to the schematic below.

SGI847

Resistance check method
1. Disconnect the battery negative cable and remove the blown fuse.
2. Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the
fuse.
3. Connect one probe of the ohmmeter to the load side of the fuse terminal. Connect the other probe to a
known good ground.
4. With SW1 open, check for continuity.
continuity;
short is between fuse terminal and SW1 (point A).
no continuity; short is further down the circuit than SW1.
5. Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good
ground. Then, check for continuity.
continuity;
short is between SW1 and the relay (point B).
no continuity; short is further down the circuit than the relay.
6. Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and
a known good ground. Then, check for continuity.
continuity;
short is between relay and solenoid (point C).
no continuity; check solenoid, retrace steps.

GI-25

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont’d)
Voltage check method
1. Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.
2. Turn the ignition key to the ON or START position. Verify battery voltage at the B + side of the fuse terminal (one lead on the B + terminal side of the fuse block and one lead on a known good ground).
3. With SW1 open and the DMM leads across both fuse terminals, check for voltage.
voltage;
short is between fuse block and SW1 (point A).
no voltage; short is further down the circuit than SW1.
4. With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check
for voltage.
voltage;
short is between SW1 and the relay (point B).
no voltage; short is further down the circuit than the relay.
5. With SW1 closed, relay contacts jumped with fused jumper wire check for voltage.
voltage;
short is down the circuit of the relay or between the relay and the disconnected solenoid
(point C).
no voltage; retrace steps and check power to fuse block.

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

SGI853

GI-26

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

Measuring voltage drop — Accumulated method
1. Connect the voltmeter across the connector or part of the circuit you want to check. The positive lead of
the voltmeter should be closer to power and the negative lead closer to ground.
2. Operate the circuit.
3. The voltmeter will indicate how many volts are being used to ‘‘push’’ current through that part of the circuit.
Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

SGI974

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

GI-27

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont’d)

SGI854

GI-28

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont’d)
CONTROL UNIT CIRCUIT TEST
System Description: When the switch is ON, the control unit lights up the lamp.

AGI059

GI-29

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

AGI056

GI-30

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
How to Follow This Flow Chart
Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in
enclosed blocks, as shown in the following example.
b
CHECK POWER SUPPLY.
1) Turn ignition switch ‘‘ON’’.
2) Check voltage between terminal

and ground.
Battery voltage should exist.

1
V

Check item being performed.
Procedure, steps or
measurement results

Measurement results
Required results are indicated in bold type in the corresponding block, as shown below:
These have the following meanings:
Battery voltage → 11 — 14V or approximately 12V
Voltage: Approximately 0V → Less than 1V

Cross reference of work symbols in the text and
illustrations
Illustrations are provided as visual aids for work procedures.
indicated in the left upper portion of
For example, symbol
each illustration corresponds with the symbol in the flow chart
for easy identification. More precisely, the procedure under the
‘‘CHECK POWER SUPPLY’’ outlined previously is indicated by
illustration
.

Symbols used in illustrations
Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with
each symbol.

DIRECTION MARK
Refer to ‘‘CONNECTOR SYMBOLS’’ on GI-12.

GI-31

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
How to Follow This Flow Chart (Cont’d)
KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES
Symbol

Symbol explanation

Symbol

Symbol explanation

Check after disconnecting the connector
to be measured.

Procedure with CONSULT

Check after connecting the connector to
be measured.

Procedure without CONSULT

Insert key into ignition switch.

A/C switch is ‘‘OFF’’.

Remove key from ignition switch.

A/C switch is ‘‘ON’’.

Turn ignition switch to ‘‘OFF’’ position.

REC switch is ‘‘ON’’.

Turn ignition switch to ‘‘ON’’ position.

REC switch is ‘‘OFF’’.

Turn ignition switch to ‘‘START’’ position.

DEF switch is ‘‘ON’’.

Turn ignition switch from ‘‘OFF’’ to ‘‘ACC’’
position.

Apply positive voltage from battery with
fuse directly to components.

Turn ignition switch from ‘‘ACC’’ to ‘‘OFF’’
position.

Drive vehicle.

Turn ignition switch from ‘‘OFF’’ to ‘‘ON’’
position.

Disconnect battery negative cable.

Turn ignition switch from ‘‘ON’’ to ‘‘OFF’’
position.

Depress brake pedal.

Do not start engine, or check with engine
stopped.

Release brake pedal.

Start engine, or check with engine running.

Depress accelerator pedal.

Apply parking brake.

Release accelerator pedal.

Release parking brake.
Check after engine is warmed up sufficiently.
Voltage should be measured with a voltmeter.
Circuit resistance should be measured
with an ohmmeter.
Current should be measured with an
ammeter.

GI-32

Pin terminal check for SMJ type ECM
and TCM connectors.
For details regarding the terminal
arrangement, refer to the foldout page.

CONSULT CHECKING SYSTEM
Function and System Application
Diagnostic
test mode

Function

ECCS

Air bag

ABS*

Work support

This mode enables a technician to adjust
some devices faster and more accurately by
following the indications on CONSULT.

—

Self-diagnostic
results

Self-diagnostic results can be read and
erased quickly.

Trouble diagnostic
record

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

—

ECU discriminated
No.

Classification number of a replacement ECU
can be read to prevent an incorrect ECU
from being installed.

—

Data monitor

Input/Output data in the ECM can be read.

—

Active test

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

—

ECM part number

ECM part number can be read.

—

Function test

Conducted by CONSULT instead of a technician to determine whether each system is
‘‘OK’’ or ‘‘NG’’.

—

x: Applicable
*: EE960 program card is not applicable to ABS. Use on board diagnostic system with ABS warning lamp until the next program card
will be introduced.

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

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

Tool name

Description

NISSAN CONSULT
1 CONSULT unit
V
and accessories
2
V Program card
EE960

NT004

GI-33

CONSULT CHECKING SYSTEM
Loading Procedure

SGI983

CONSULT Data Link Connector (DLC) Circuit

SGI984

INSPECTION PROCEDURE
If the CONSULT cannot diagnose the system properly, check the following items.
Symptom
CONSULT cannot access
any system.

Check item
+ CONSULT DLC power supply circuit (Terminal 7) and ground circuit (Terminal
(For detailed circuit, refer to ‘‘MIL & Data Link Connectors Wiring Diagram’’ in EC section.)
+ CONSULT DDL cable

+ CONSULT program card (Check the appropriate CONSULT program card for the system. Refer
CONSULT cannot access
to GI-33.)
individual system. (Other sys+ Power supply and ground circuit for the control unit of the system
tems can be accessed.)
(For detailed circuit, refer to wiring diagram for each system.)
+ Open or short circuit between the system and CONSULT DLC
(For detailed circuit, refer to wiring diagram for each system.)

GI-34

IDENTIFICATION INFORMATION
Model Variation
Model

Hardtop

Station Wagon
2nd center split bench seat

Rear seat arrangement
Destination

Steering
position

Forward facing

Seatless

3rd seat
Seatless

Engine
Front differential

Forward facing

Side facing

—

H233B

Rear differential
Transmission

Transfer

RHD

Europe

RD28ETi

FS5R30A

H233B

Grade

TX12A

KWBSREFY61UEA

—

TWBSREFY61UEA

KWBSRFFY61UEA

—

TWBSRFFY61UEA

—

TWBSRHFY61UEA

—

S
SE

LHD

KWBSLEFY61UGA KWBSLEFY61USP TWBSLEFY61USP TWBSLEFY61UGA

—

KWBSLFFY61UGA

—

TWBSLFFY61USP

TWBSLFFY61UGA

—

TWBSLFFY61USA

—

TWBSLHFY61UGA

—

TWBSLHFY61USA

—

Prefix and suffix designations
T

Y61

A
A: 3rd seat forward facing
P: without 3rd seat

E: RHD for Europe
G: Central/South Europe
S: North Europe

U: Turbocharger engine

F: 5-speed floor shift manual transmission

E: S F: SE H: SE

L: LH drive R: RH drive
S: Long wheelbase (4WD)
WB: RD28ETi engine

T: Station Wagon
K: Hardtop

GI-35

IDENTIFICATION INFORMATION
Identification Number

Vehicle identification plate
Front

Vehicle
identification
number

SGI037A

VEHICLE IDENTIFICATION NUMBER (Chassis number)
Prefix and suffix designations
JN1

Y61

XXXXXX
Vehicle serial number

0: Stopgap (no meaning)
U: For Europe
S: Long wheelbase
D: RD28ETi engine
T: Station Wagon K: Hardtop
JN1: Japan produced vehicle

GI-36

IDENTIFICATION INFORMATION
Identification Number (Cont’d)
IDENTIFICATION PLATE

SGI851

ENGINE SERIAL NUMBER

SGI028A

MANUAL TRANSMISSION SERIAL NUMBER

SGI018A

TRANSFER SERIAL NUMBER

SGI020A

GI-37

IDENTIFICATION INFORMATION
Dimensions
Wagon

Hardtop

Overall length

mm (in)

4,965 (195.5)
5,010 (197.2)*

4,395 (173.0)
4,440 (174.8)*

Overall width

mm (in)

1,840 (72.4)
1,930 (76.0)*

Overall height

mm (in)

1,855 (73.0)

1,840 (72.4)

Front tread

mm (in)

1,555 (61.2)
1,605 (63.2)*

Rear tread

mm (in)

1,575 (62.0)
1,625 (64.0)*

Wheelbase

mm (in)

2,970 (116.9)

2,400 (94.5)

*: For models equipped with 265/70R16 tires

Wheels & Tires
Road wheel
Size

6JJ-16*1

8JJ-16*1

Offset mm (in)

35 (1.38)

10 (0.39)

235/80R16 109S

265/70R16 112S

Tire size

*1: Steel wheel and Aluminum wheel

GI-38

LIFTING POINTS AND TOW TRUCK TOWING
WARNING:
+ Never get under the vehicle while it is supported only by the jack. Always use safety stands to
support the frame when you have to get under the vehicle.
+ Place wheel chocks at both front and back of the wheel which is diagonally opposite the jack
position.
Example: If the jack is positioned at the LH front wheel, place wheel chocks at RH rear wheel.

Screw Jack

SGI016A

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

SGI021A

GI-39

LIFTING POINTS AND TOW TRUCK TOWING
2-pole Lift
WARNING:
When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of
the vehicle are well balanced.
When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines.

Put the attachment in the slit of the lift pad to prevent the frame from
slipping.

SGI531

Use suitable stands at the correct places as illustrated, to prevent
the vehicle from becoming unbalanced.

SGI022A

SGI526

GI-40

LIFTING POINTS AND TOW TRUCK TOWING
Tow Truck Towing
CAUTION:
+ All applicable local laws regarding the towing operation
must be obeyed.
+ It is necessary to use proper towing equipment to avoid
possible damage to the vehicle during a towing operation.
+ Attach safety chains for all towing.
+ When towing, make sure that the transmission, steering
system and power train are in good order. If any unit is
damaged, a dolly must be used.
+ When towing with the front wheels on the ground:
Turn the ignition key to the ‘‘OFF’’ position and secure the
steering wheel in a straight-ahead position with a rope or
similar device. Never place the ignition key in the ‘‘LOCK’’
position. This will result in damage to the steering lock
mechanism.
+ When towing manual transmission models with the rear
wheels on the ground:
Release the parking brake and move the gearshift lever to
neutral (‘‘N’’ position).
+ For 4-wheel drive models:
Set the manual-lock free-running hubs to the free position and
2-way lock free-running hubs to the auto position. (See
‘‘
Transfer case shifting procedures for 4-wheel drive
vehicles’’ in ‘‘Starting and driving’’ section.) Move the transfer
case shift lever into the ‘‘2H’’ position and the transmission shift
lever into the neutral (‘‘N’’) position.
Do not shift the transfer lever to the ‘‘4L’’ position. This will
cause damage to the transmission.

NISSAN recommends that a dolly be used as illustrated.

SGI023A

If you have to tow a manual transmission model with front
wheels raised (with rear wheels on ground)
Observe the following restricted raising heights.
+ Do not raise the front end over !.
Wagon
! = 600 mm (23.62 in)
Hardtop
! = 500 mm (19.69 in)

SGI024A

GI-41

LIFTING POINTS AND TOW TRUCK TOWING
Tow Truck Towing (Cont’d)
If you have to tow an automatic transmission model
with four wheels on ground or tow an automatic
transmission model with front wheels raised (with rear
wheels on ground)
Observe the following restricted towing speeds, distances and raising heights.
+ Speed: Below 50 km/h (30 MPH)
+ Distance: Less than 65 km (40 miles)
+ Do not raise the front end over !.
Wagon
! = 600 mm (23.62 in)
Hardtop
! = 500 mm (19.69 in)
If the speed, distance or height must necessarily be greater,
remove the propeller shaft beforehand to prevent damage to the
transmission.
CAUTION:
+ Never tow your vehicle from the rear (i.e., backward) with
four wheels on the ground as this may cause serious and
expensive damage to the transmission.
+ Be sure to place the transfer case shift lever into the ‘‘2H’’
position and the transmission shift lever into the neutral
(‘‘N’’) position if the vehicle is to be towed.

TOWING HOOKS
The towing hooks are provided only for emergency.
+ Use the towing hooks only, not other parts of the vehicle.
Otherwise, the vehicle body will be damaged.
+ Use the towing hooks only to free a vehicle stuck in sand,
snow, mud, etc. Never tow the vehicle for long distances using
only the towing hooks.
+ The towing hook is under tremendous force when used to free
a stuck vehicle. Always pull the cable straight out from the front
or rear of the vehicle. Never pull on the hook at a sideways
angle.

SGI025A

GI-42

SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
***: Not applicable
NEW ACRONYM /
ABBREVIATION

NEW TERM

OLD TERM

Air cleaner

ACL

Air cleaner

Barometric pressure

BARO

***

Barometric pressure sensor-BCDD

BAROS-BCDD

BCDD

Camshaft position

CMP

***

Camshaft position sensor

CMPS

Crank angle sensor

Canister

***

Canister

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Data link connector for CONSULT

DLC for CONSULT

Diagnostic connector for CONSULT

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read only
memory

EEPROM

***

Electronic ignition system

EI system

Ignition timing control

Engine control

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

***

Engine speed

RPM

Engine speed

Erasable programmable read only memory

EPROM

***

Evaporative emission canister

EVAP canister

Canister

GI-43

SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List (Cont’d)
***: Not applicable
NEW ACRONYM /
ABBREVIATION

NEW TERM

OLD TERM

Evaporative emission system

EVAP system

Evaporative emission control system

Exhaust gas recirculation valve

EGR valve

Exhaust gas recirculation control-BPT valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve

EGR control solenoid valve

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read
only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel trim

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid
valve

IACV-idle up control solenoid
valve

Idle up control solenoid valve

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

Detonation sensor

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

Manifold differential pressure sensor

MDPS

***

Exhaust gas recirculation temperature sensor
EGR temperature sensor

GI-44

SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List (Cont’d)
***: Not applicable
NEW ACRONYM /
ABBREVIATION

NEW TERM

OLD TERM

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection System

MFI system

Fuel injection control

Neutral position switch

***

Neutral switch

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

Oxidation catalyst

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

***

Supercharger bypass

SCB

***

System readiness test

SRT

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way + oxidation catalyst

TWC + OC

Catalyst

GI-45

SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List (Cont’d)
***: Not applicable
NEW ACRONYM /
ABBREVIATION

NEW TERM

OLD TERM

Three way + oxidation catalytic converter system TWC + OC system

***

Throttle body

Throttle chamber

SPI body
Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid
Lock-up solenoid

Transmission control module

TCM

A/T control unit

Turbocharger

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter system

WU-OC system

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

GI-46

HEATER &
AIR CONDITIONER
SECTION

CONTENTS
MANUAL AND AUTO
PRECAUTIONS AND PREPARATION……………………….1
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’……………1
Precautions for Working with HFC-134a (R-134a) …..1
General Refrigerant Precautions ……………………………2
Precautions for Refrigerant Connection ………………….2
Precautions for Servicing Compressor……………………6
Special Service Tools …………………………………………..6
HFC-134a (R-134a) Service Tools and
Equipment…………………………………………………………..7
Precautions for Service Equipment ………………………..9
DESCRIPTION ………………………………………………………11
Refrigeration Cycle …………………………………………….11
Component Layout …………………………………………….12
Discharge Air Flow……………………………………………..13
REAR HEATER
TROUBLE DIAGNOSES ………………………………………..14
Wiring Diagram — R/HEAT —/LHD Models ………….14
Wiring Diagram — R/HEAT —/RHD Models………….15
MANUAL
DESCRIPTION ………………………………………………………16
System Description…………………………………………….16
Control Operation ………………………………………………16
TROUBLE DIAGNOSES ………………………………………..17
Component Location…………………………………………..17
Wiring Diagram — A/C, M — ………………………………19
How to Perform Trouble Diagnoses for Quick
and Accurate Repair …………………………………………..21
Operational Check ……………………………………………..22
Intake Door Motor………………………………………………24
Blower Motor……………………………………………………..28
Insufficient Cooling …………………………………………….32
Trouble Diagnoses for Abnormal Pressure ……………36
Insufficient Heating …………………………………………….39

Air Outlet…………………………………………………………..41
Magnet Clutch……………………………………………………43
Noise………………………………………………………………..48
AUTO
DESCRIPTION ………………………………………………………49
Introduction ……………………………………………………….49
Features……………………………………………………………49
Overview of Control System………………………………..52
Control Operation ………………………………………………53
TROUBLE DIAGNOSES ………………………………………..55
Component Location…………………………………………..55
Circuit Diagram ………………………………………………….57
Wiring Diagram — A/C, A — ……………………………….58
Auto Amp. Terminals and Reference Value……………61
Self-diagnosis ……………………………………………………63
How to Perform Trouble Diagnoses for Quick
and Accurate Repair …………………………………………..69
Operational Check ……………………………………………..70
A/C System……………………………………………………….73
Mode Door Motor……………………………………………….75
Air Mix Door Motor …………………………………………….79
Intake Door Motor………………………………………………82
Blower Motor……………………………………………………..86
Magnet Clutch……………………………………………………92
Insufficient Cooling …………………………………………….98
Insufficient Heating …………………………………………….99
Noise………………………………………………………………100
Self-diagnosis ………………………………………………….101
Memory Function ……………………………………………..102
Ambient Sensor ……………………………………………….103
In-vehicle Sensor ……………………………………………..105
Sunload Sensor ……………………………………………….107
Intake Sensor…………………………………………………..110

MANUAL AND AUTO
SERVICE PROCEDURES …………………………………….112
HFC-134a (R-134a) Service Procedure ………………112
Maintenance of Lubricant Quantity in
Compressor …………………………………………………….114
Ventilation Air Filter…………………………………………..116
Refrigerant Lines ……………………………………………..117

Checking Refrigerant Leaks ………………………………119
Compressor Mounting ………………………………………122
Compressor — DKS-17CH………………………………..123
Compressor Clutch …………………………………………..123
SERVICE DATA AND SPECIFICATIONS ……………….126
General Specifications………………………………………126
Inspection and Adjustment ………………………………..126

When you read wiring diagrams:
+ Read GI section, ‘‘HOW TO READ WIRING DIAGRAMS’’.
+ See EL section, ‘‘POWER SUPPLY ROUTING’’ for power distribution circuit.
When you perform trouble diagnoses, read GI section, ‘‘HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES’’ and ‘‘HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT’’.

PRECAUTIONS AND PREPARATION

MANUAL AND AUTO

Precautions for Working with HFC-134a
(R-134a)
WARNING:
+ CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor failure is likely to occur.
+ Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor failure is likely to occur.
+ The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The
following handling precautions must be observed:
a: When removing refrigerant components from a vehicle, immediately cap (seal) the component
to minimize the entry of moisture from the atmosphere.
b: When installing refrigerant components to a vehicle, do not remove the caps (unseal) until
just before connecting the components. Connect all refrigerant loop components as quickly
as possible to minimize the entry of moisture into system.
c: Only use the specified lubricant from a sealed container. Immediately reseal containers of
lubricant. Without proper sealing, lubricant will become moisture saturated and should not
be used.
d: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose
and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a)
refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
e: Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam
parts. Damage may result.

HA-1

PRECAUTIONS AND PREPARATION

MANUAL AND AUTO

General Refrigerant Precautions
WARNING:
+ Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
+ Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
+ Do not store or heat refrigerant containers above 52°C.
+ Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
+ Do not intentionally drop, puncture, or incinerate refrigerant containers.
+ Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
+ Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
+ Do not introduce compressed air to any refrigerant container or refrigerant component.

Precautions for Refrigerant Connection
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
+ Expansion valve to cooling unit
+ A part of high-pressure line

FEATURES OF NEW TYPE REFRIGERANT CONNECTION
+

The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby
facilitating piping connections.

SHA815E

CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse
O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.

HA-2

MANUAL AND AUTO
PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont’d)

O-ring part numbers and specifications
Connection
type

O-ring
size

New
Former
New
Former
SHA814E

New
Former
New
Former

HA-3

8
12
16
19

Part number

mm (in) W

mm (in)

92471 N8210

6.8 (0.268)

1.85 (0.0728)

92470 N8200

6.07 (0.2390)

1.78 (0.0701)

92472 N8210

10.9 (0.429)

2.43 (0.0957)

92475 71L00

11.0 (0.433)

2.4 (0.094)

92473 N8210

13.6 (0.535)

2.43 (0.0957)

92475 72L00

14.3 (0.563)

2.3 (0.091)

92474 N8210

16.5 (0.650)

2.43 (0.0957)

92477 N8200

17.12 (0.6740)

1.78 (0.0701)

MANUAL AND AUTO
PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont’d)

O-RING AND REFRIGERANT CONNECTION
LHD models

SHA029F

HA-4

MANUAL AND AUTO
PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont’d)
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system
is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove
it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
+ When the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber.
+ When connecting tubes, always use a torque wrench and a back-up wrench.
+ After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
+ When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for
connection.
+ Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
+ Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
+ Always replace used O-rings.
+ When connecting tube, apply lubricant to portions shown in illustration. Be careful not to apply
lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0
+ O-ring must be closely attached to inflated portion of tube.
+ After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
+ After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten
connections of seal seat to the specified torque.

RHA861F

HA-5

PRECAUTIONS AND PREPARATION

MANUAL AND AUTO

Precautions for Servicing Compressor
+
+
+
+
+
+

Plug all openings to prevent moisture and foreign matter from entering.
When the compressor is removed, store it in the same position as it is when mounted on the car.
When replacing or repairing compressor, follow ‘‘Maintenance of Lubricant Quantity in Compressor’’ exactly. Refer to HA-114.
Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with
lubricant, wipe it off by using a clean waste cloth moistened with thinner.
After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.

Special Service Tools
Tool number
Tool name

Description

KV99231260
Clutch disc wrench

Removing shaft nut and clutch disc

NT204

KV992T0001
Clutch disc puller

Removing clutch disc

NT206

KV992T0002
Pulley installer

Installing pulley

NT207

HA-6

PRECAUTIONS AND PREPARATION

MANUAL AND AUTO

HFC-134a (R-134a) Service Tools and
Equipment
Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant.
Separate and non-interchangeable service equipment must be used for each type of refrigerant/lubricant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor failure will result.
Tool name

Description

Note

HFC-134a (R-134a) refrigerant

Container color: Light blue
Container marking: HFC-134a (R-134a)
Fitting size: Thread size
+ large container 1/2″-16 ACME

NT196

Nissan A/C System Oil
Type S

Type: Poly alkylene glycol oil (PAG), type S
Application: HFC-134a (R-134a) swash plate
(piston) compressors (Nissan only)
Lubricity: 40 m! (1.4 Imp fl oz)

NT197

Recovery/Recycling/
Recharging equipment

Function: Refrigerant Recovery and Recycling
and Recharging

NT195

Electrical leak detector

Power supply:
+ DC 12V (Cigarette lighter)

NT198

Manifold gauge set (with
hoses and couplers)

Identification:
+ The gauge face indicates R-134a.
Fitting size: Thread size
+ 1/2″-16 ACME

NT199

HA-7

MANUAL AND AUTO
PRECAUTIONS AND PREPARATION
HFC-134a (R-134a) Service Tools and
Equipment (Cont’d)
Tool name

Description

Note
Hose color:
+ Low hose: Blue with black stripe
+ High hose: Red with black stripe
+ Utility hose: Yellow with black stripe or
green with black stripe
Hose fitting to gauge:
+ 1/2″-16 ACME

Service hoses
+ High side hose
+ Low side hose
+ Utility hose

NT201

Service couplers
+ High side coupler
+ Low side coupler

Hose fitting to service hose:
+ M14 x 1.5 fitting is optional or
permanently attached.

NT202

Refrigerant weight scale

For measuring of refrigerant
Fitting size: Thread size
+ 1/2″-16 ACME

NT200

Vacuum pump
(Including the isolator
valve)

Capacity:
+ Air displacement: 4 CFM
+ Micron rating: 20 microns
+ Oil capacity: 482 g (17 oz)
Fitting size: Thread size
+ 1/2″-16 ACME

NT203

HA-8

PRECAUTIONS AND PREPARATION

MANUAL AND AUTO

Precautions for Service Equipment
RECOVERY/RECYCLING EQUIPMENT
Follow the manufacturer’s instructions for machine operation and
machine maintenance. Never introduce any refrigerant other than
that specified into the machine.

ELECTRONIC LEAK DETECTOR
Follow the manufacture’s instructions for tester operation and tester
maintenance.

VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric
pressure. So the vacuum pump lubricant may migrate out of the
pump into the service hose. This is possible when the pump is
switched off after evacuation (vacuuming) and hose is connected
to it.
To prevent this migration, use a manual valve situated near the
hose-to-pump connection, as follows.
+ Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump.
+ For pumps without an isolator, use a hose equipped with a
manual shut-off valve near the pump end. Close the valve to
isolate the hose from the pump.
+ If the hose has an automatic shut off valve, disconnect the hose
from the pump: as long as the hose is connected, the valve is
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
RHA270D

MANIFOLD GAUGE SET
Be certain that the gauge face indicates R-134a or 134a. Make
sure the gauge set has 1/2″-16 ACME threaded connections for
service hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) along with specified lubricant.

SHA533D

SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive
shut off devices (either manual or automatic) near the end of the
hoses opposite the manifold gauge.

RHA272D

HA-9

MANUAL AND AUTO
PRECAUTIONS AND PREPARATION
Precautions for Service Equipment (Cont’d)

SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to
an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
will not properly connect to the CFC-12 (R-12) system. However, if
an improper connection is attempted, discharging and contamination may occur.
Shut-off valve rotation

A/C service valve

Clockwise

Open

Counterclockwise

RHA273D

REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls
refrigerant flow electronically, the hose fitting must be 1/2″-16
ACME.

RHA274D

CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be
vented into air from cylinder’s top valve when filling the cylinder with
refrigerant. Also, the accuracy of the cylinder is generally less than
that of an electronic scale or of quality recycle/recharge equipment.

HA-10

DESCRIPTION

MANUAL AND AUTO

Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant flow is in the standard pattern. Refrigerant flows through the compressor, condenser, liquid
tank, evaporator and back to the compressor.
The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion
valve, located inside the evaporator case.

FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the
evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the compressor operation. When the evaporator coil temperature rises above the specification, the thermo control amplifier allows compressor operation.

REFRIGERANT SYSTEM PROTECTION
Dual-pressure switch
The dual-pressure switch is located on the liquid tank. If the system pressure rises or falls out of specifications,
the switch opens to interrupt compressor clutch operation.

RHA735G

HA-11

DESCRIPTION

MANUAL AND AUTO

Component Layout

RHA699G

HA-12

DESCRIPTION

MANUAL AND AUTO

Discharge Air Flow

RHA700G

HA-13

TROUBLE DIAGNOSES

REAR HEATER

Wiring Diagram — R/HEAT —/LHD Models

THA165

HA-14

TROUBLE DIAGNOSES

REAR HEATER

Wiring Diagram — R/HEAT —/RHD Models

THA166

HA-15

MANUAL

DESCRIPTION
System Description
SWITCH AND THEIR CONTROL FUNCTIONS
Knob/Switch position
Knob/Switch

Air outlet

Intake air

Compressor

—

ON*

VENT

—

B/L

—

FOOT

—

D/F

FRE

—

DEF

FRE

ON*

—

A/C
A/C

j
j

j
Mode
j

j
j
j
*: Compressor is operated by dual-pressure switch.

Control Operation

RHA582G

FAN CONTROL KNOB
This knob turns the fan ON and OFF, and controls fan speed.

MODE CONTROL KNOB
This knob controls the outlet air flow.

TEMPERATURE CONTROL KNOB
This knob allows adjustment of the temperature of the outlet air.

RECIRCULATION (REC) SWITCH
OFF position: Outside air is drawn into the passenger compartment.
ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.

AIR CONDITIONER SWITCH
The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the compressor will turn ON. The indicator lamp will also light.
The air conditioner cooling function operates only when the engine is running.

HA-16

TROUBLE DIAGNOSES

MANUAL

Component Location
ENGINE COMPARTMENT

RHA641G

HA-17

TROUBLE DIAGNOSES
Component Location (Cont’d)

MANUAL

PASSENGER COMPARTMENT

SHA063F

HA-18

TROUBLE DIAGNOSES

MANUAL

Wiring Diagram — A/C, M —

YHA157

HA-19

TROUBLE DIAGNOSES
Wiring Diagram — A/C, M — (Cont’d)

MANUAL

YHA158

HA-20

MANUAL

TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
WORK FLOW

SHA900E

*1: HA-22

SYMPTOM TABLE
Symptom

Reference page

+ Intake door does not change.

+ Go to Trouble Diagnosis Procedure for Intake Door
Motor Circuit.

HA-24

+ Blower motor does not rotate at all.

+ Go to Trouble Diagnosis Procedure for Blower Motor
Circuit.

HA-28

+ Insufficient cooling.

+ Go to Trouble Diagnosis Procedure for Insufficient
Cooling.

HA-32

+ Insufficient heating.

+ Go to Trouble Diagnosis Procedure for Insufficient
Heating.

HA-32

+ Air outlet does not change.

+ Go to Trouble Diagnosis Procedure for Air Outlet.

HA-41

+ Magnet clutch does not engage when A/C switch and
fan switch are ON.

+ Go to Trouble Diagnosis Procedure for Magnet Clutch
Circuit.

HA-43

+ Noise

+ Go to Trouble Diagnosis Procedure for Noise.

HA-48

HA-21

TROUBLE DIAGNOSES

MANUAL

Operational Check
The purpose of the operational check is to confirm that the system
operates properly.

CONDITIONS
Engine running at normal operating temperature.

PROCEDURE
1. Check blower
a. Turn fan control knob to 1-speed.
Blower should operate on 1-speed.
b. Then turn fan control knob to 2-speed.
c. Continue checking blower speed until all four speeds are
checked.
d. Leave blower on 4-speed.
RHA583G

2. Check discharge air
a. Turn mode control knob.

RHA584G

b. Confirm that discharge air comes out according to the air distribution table at left.
Refer to ‘‘Discharge Air Flow’’ in ‘‘DESCRIPTION’’ (HA-13).

RHA654F

HA-22

TROUBLE DIAGNOSES
Operational Check (Cont’d)

MANUAL

3. Check recirculation
a. Press recirculation switch.
Recirculation indicator should light.
b. Listen for intake door position change (you should hear blower
sound change slightly).

RHA585G

4. Check temperature decrease
a. Turn temperature control knob to full cold.
b. Check for cold air at discharge air outlets.

RHA586G

5. Check temperature increase
a. Turn temperature control knob to full hot.
b. Check for hot air at discharge air outlets.

RHA587G

6. Check air conditioner switch
Turn fan control knob to the desired (1 to 4-speed) position and
push the air conditioner switch to turn ON the air conditioner.
The indicator light should come on when air conditioner is ON.

RHA588G

HA-23

MANUAL

TROUBLE DIAGNOSES
Intake Door Motor
TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR
SYMPTOM:
+ Intake door does not change.

Inspection flow

RHA592G

*1: HA-26

*2: HA-22

*3: HA-21

HA-24

TROUBLE DIAGNOSES
Intake Door Motor (Cont’d)

MANUAL

SYSTEM DESCRIPTION
Intake door motor

RHA589G

The intake door motor is installed on the intake unit. Using a link it
opens and closes the intake door.
When RECIRCULATION switch is at REC, the ground line of the
motor is switched from terminal j
14 to j
13 . This starts the motor
because the position switch contacts built into it make current flow.
When RECIRCULATION switch is at FRE, the ground line is
switched from terminal j
13 to j
14 . The contacts turn along with the
motor. When they reach the non-current flow position, the motor will
stop. The motor always turns in the same direction.

HA-25

MANUAL

TROUBLE DIAGNOSES
Intake Door Motor (Cont’d)
DIAGNOSTIC PROCEDURE
SYMPTOM: Intake door does not change.

RHA350FB

CHECK POWER SUPPLY FOR INTAKE
DOOR MOTOR.
Disconnect intake door motor harness connector.
Do approx. 12 volts exist between intake
door motor harness terminal No. j
1 and
body ground?

No
c

Check 10A (No.
) fuse
at fuse block.
(Refer to ‘‘POWER SUPPLY ROUTING’’ in EL section and Wiring Diagram.)

Yes
.

CHECK GROUND CIRCUIT FOR INTAKE
DOOR MOTOR.
Check continuity between intake door
motor harness terminal and body ground.
Recirculation
switch condition

Terminal
j
14

FRE

j
13

REC

Body ground

Continuity should exist.
OK

NG
c

Disconnect recirculation
switch harness connector.

Note

Check continuity between
recirculation switch harness
terminal No. j
1 (j
2 ) and
intake door motor harness
terminal No. j
13 (j
14 ).
Continuity should exist.
If OK, check harness for
short.
OK

CHECK INTAKE DOOR LINKAGE.
Refer to Control Linkage Adjustment. (HA27)
OK
RHA590G

Replace intake door motor.

j
A

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

RHA591G

HA-26

MANUAL

TROUBLE DIAGNOSES
Intake Door Motor (Cont’d)
j
A
Note

CHECK GROUND CIRCUIT FOR RECIRCULATION SWITCH.
Check circuit continuity between recirculation switch harness terminal No. j
4 and
body ground.
Continuity should exist.
If OK, check harness for short.
OK
.

RHA582FB

CHECK RECIRCULATION SWITCH.
(Refer to Electrical Components Inspection.) (HA-27)

NG
c

Replace recirculation
switch.

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

ELECTRICAL COMPONENTS INSPECTION
Recirculation switch
Check continuity between terminals at each switch position.
Terminal No.

RHA768F

(+)

(−)

j
1

j
4

j
2

Recirculation
switch condition

Continuity

REC

Yes

FRE

REC

FRE

Yes

j
4

CONTROL LINKAGE ADJUSTMENT
Intake door motor
1. Install intake door motor on intake unit.
Ensure that the intake door motor lever is fitted into the slit
portion of intake door link.
2. Connect the intake door motor harness connector.
3. Turn ignition switch to ON.
4. Check that intake door operates properly when RECIRCULATION switch is turned ON and OFF.
RHA593F

HA-27

MANUAL

TROUBLE DIAGNOSES
Blower Motor
TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR
SYMPTOM:
+ Blower motor does not rotate at all.

Inspection flow

RHA593G

*1: HA-31

*2: HA-22

*3: HA-21

HA-28

MANUAL

TROUBLE DIAGNOSES
Blower Motor (Cont’d)
INCIDENT

Fan fails to rotate.

Fan does not rotate at 1-speed.

Fan does not rotate at 2-speed.

Fan does not rotate at 3-speed.

Fan does not rotate at 4-speed.

Flow chart
No.

DIAGNOSTIC PROCEDURE
SYMPTOM: Blower motor does not rotate.
+ Perform PRELIMINARY CHECK 1 before referring to the
following flow chart.
cj
E

Check if blower motor rotates properly
at each fan speed.
Conduct checks as per flow chart at
left.

cj
D
cj
C
cj
B
(Go to next page.)

CHECK POWER SUPPLY FOR BLOWER
MOTOR.
Disconnect blower motor harness connector.
Do approx. 12 volts exist between blower
motor harness terminal No. j
2 and body
ground?

No
c

Check 15A (No.
and
No.
) fuses at fuse
block.
(Refer to ‘‘POWER SUPPLY ROUTING’’ in EL section and Wiring Diagram.)

Yes
.

RHA596G

NG Reconnect blower motor
1. Turn fan control knob to any position
c
harness connector.
except OFF.
2. Check circuit continuity between blower
motor harness terminal No. j
1 and body
ground.
Continuity should exist.
OK

CHECK BLOWER MOTOR.
(Refer to Electrical Components Inspection.) (HA-31)
NG

Replace blower motor.
RHA597G
.

No
Disconnect blower motor
CHECK BLOWER MOTOR CIRCUIT
c
and resistor harness conBETWEEN BLOWER MOTOR AND
nectors.
RESISTOR.
Do approx. 12 volts exist between resistor
harness terminal No. j
4 and body ground?
.

Yes

Disconnect fan switch harness connector.

Note

Check circuit continuity
between blower motor harness terminal No. j
1 and
resistor harness terminal
No. j
4 .
Continuity should exist.
If OK, check harness for
short.

RHA598G

j
A
(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

RHA599G

HA-29

MANUAL

TROUBLE DIAGNOSES
Blower Motor (Cont’d)
j
A
Note

CHECK GROUND CIRCUIT FOR FAN
SWITCH.
Check circuit continuity between fan switch
harness terminal No. j
5 and body ground.
OK
.

RHA600G

CHECK RESISTOR AFTER DISCONNECTING IT.
(Refer to Electrical Components Inspection.)
(HA-31)
OK

j
B

j
C

j
D

NG
.

j
E

Replace resistor.
.

Reconnect resistor harness connector.

RHA601G

CHECK FAN SWITCH CIRCUIT.
Do approx. 12 volts exist between each fan switch harness terminal and body ground?
Flow chart
No.

Terminal No.
⊕

Voltage
@

j
1
j
2
Body ground

Approx. 12V

j
3
j
4

Yes

RHA602G

No
Note

Check circuit continuity
between fan switch harness
terminal and resistor harness terminal.
Terminal No.
Fan
switch

Resistor

j
4

j
3

j
2

j
1

Continuity

Yes

If OK, check harness for
short.
.

CHECK FAN SWITCH AFTER DISCONNECTING IT.
(Refer to Electrical Components
Inspection.) (HA-31)

NG
c

Replace fan switch.

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

HA-30

MANUAL

TROUBLE DIAGNOSES
Blower Motor (Cont’d)
ELECTRICAL COMPONENTS INSPECTION
Fan switch

Check continuity between terminals at each switch position.
KNOB POSITION

Continuity between terminals

OFF
1

j
1 —j
6 —j
5

j
2 —j
6 —j
5

j
3 —j
6 —j
5

j
4 —j
6 —j
5

RHA594G

Blower motor
Confirm smooth rotation of the blower motor.
+ Ensure that there are no foreign particles inside the intake unit.

Blower resistor
Check resistance between terminals.
Terminal No.
Resistance
(+)

(−)
Approx. 1.4 — 1.6Ω

j
2
j
1
j
3
RHA595G

HA-31

j
4

Approx. 2.5 — 2.8Ω
Approx. 0.5 — 0.6Ω

MANUAL

TROUBLE DIAGNOSES
Insufficient Cooling
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING
SYMPTOM:
+ Insufficient cooling.

Inspection flow

RHA603G

*1: HA-40
*2: HA-35
*3: HA-33

*4: HA-22
*5: HA-21

*6: HA-0
*7: HA-47

HA-32

TROUBLE DIAGNOSES
Insufficient Cooling (Cont’d)

MANUAL

PERFORMANCE TEST DIAGNOSES

MHA649A

*1: HA-35

*2: HA-35

*3: HA-36

HA-33

TROUBLE DIAGNOSES
Insufficient Cooling (Cont’d)

MANUAL

MHA650A

HA-34

MANUAL

TROUBLE DIAGNOSES
Insufficient Cooling (Cont’d)
PERFORMANCE CHART
Test condition

Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well-ventilated place)
Doors: Closed
Door window: Open
Hood: Open
TEMP.: Max. COLD
Discharge Air: Face Vent
REC switch: (Recirculation) set
FAN speed: High speed
Engine speed: Idle speed
Operate the air conditioning system to 10 minutes before taking
measurements.
Rear cooler: ON (For rear cooler equipped model only)

Test reading (Single A/C equipped model)
Recirculating-to-discharge air temperature table
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator °C (°F)
Relative humidity %

Air temperature °C (°F)
25 (77)

8.0 — 10.0 (46 — 50)

30 (86)

12.0 — 15.0 (54 — 59)

35 (95)

16.0 — 20.0 (61 — 68)

40 (104)

20.5 — 24.5 (69 — 76)

25 (77)

10.4 — 13.0 (51 — 55)

30 (86)

15.0 — 18.0 (59 — 64)

35 (95)

19.5 — 23.4 (67 — 74)

40 (104)

24.5 — 28.5 (76 — 83)

50 — 60

60 — 70

Ambient air temperature-to-operating pressure table
Ambient air
Relative humidity %

High-pressure (Discharge side)
kPa (bar, kg/cm2, psi)

Low-pressure (Suction side)
kPa (bar, kg/cm2, psi)

25 (77)

1,373 — 1,471 (13.73 — 14.71,
14.0 — 15.0, 199 — 213)

196 — 245 (1.96 — 2.45,
2.0 — 2.5, 28 — 36)

30 (86)

1,275 — 1,520 (12.75 — 15.20,
13.0 — 15.5, 185 — 220)

226 — 284 (2.26 — 2.84,
2.3 — 2.9, 33 — 41)

35 (95)

1,412 — 1,716 (14.12 — 17.16,
14.4 — 17.5, 205 — 249)

255 — 314 (2.55 — 3.14,
2.6 — 3.2, 37 — 46)

40 (104)

1,608 — 1,932 (16.08 — 19.32,
16.4 — 19.7, 233 — 280)

294 — 353 (2.94 — 3.53,
3.0 — 3.6, 43 — 51)

Air temperature
°C (°F)

50 — 70

HA-35

TROUBLE DIAGNOSES

MANUAL

Trouble Diagnoses for Abnormal Pressure
Whenever system’s high or low-pressure side is abnormal, diagnose using a manifold gauge. The marker
above the gauge scale in the following table indicates the standard (normal) pressure range. Since the standard (normal) pressure differs from vehicle to vehicle, refer to HA-35 (‘‘Ambient air temperature-to-operating
pressure table’’).
Gauge indication

Refrigerant cycle

Both high and low-pressure
sides are too high.

Probable cause

+ Pressure is reduced soon
after water is splashed on
condenser.

Excessive refrigerant charge in
refrigeration cycle.

Air suction by cooling fan is
insufficient.

Insufficient condenser cooling
performance.
↓
j
1 Condenser fins are clogged.
j
2 Improper fan rotation of
cooling fan.
+ Low-pressure pipe is not
Poor heat exchange in concold.
denser.
+ When compressor is stopped (After compressor operation
high-pressure value quickly
stops, high pressure decreases
drops by approximately 196
too slowly.)
2
kPa
(2.0
bar,
2
kg/cm
↓
,
28
AC359A
psi). It then decreases gradu- Air in refrigeration cycle.
ally thereafter.
Engine tends to overheat.
Engine cooling systems malfunction.
+ An area of the low-pressure + Excessive liquid refrigerant
on low-pressure side.
pipe is colder than areas
+ Excessive refrigerant disnear the evaporator outlet.
charge flow.
+ Plates are sometimes cov+ Expansion valve is open a
ered with frost.
little compared with the
specification.
↓
j
1 Improper thermal valve
installation.
j
2 Improper expansion valve
adjustment.
High-pressure side is too high
High-pressure tube or parts
Upper side of condenser and
and low-pressure side is too
located between compressor
high-pressure side are hot,
low.
and condenser are clogged or
however, liquid tank is not so
crushed.
hot.

AC360A

HA-36

Corrective action
Reduce refrigerant until specified pressure is obtained.

+ Clean condenser.
+ Check and repair cooling fan
as necessary.

Evacuate repeatedly and
recharge system.

Check and repair each engine
cooling system.
Replace expansion valve.

+ Check and repair or replace
malfunctioning parts.
+ Check lubricant for contamination.

MANUAL
TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont’d)
Gauge indication

Refrigerant cycle

High-pressure side is too low
and low-pressure side is too
high.

Probable cause

High and low-pressure sides
become equal soon after compressor operation stops.

Corrective action

Compressor pressure operation Replace compressor.
is improper.
↓
Damaged inside compressor
packings.

No temperature difference
Compressor pressure operation Replace compressor.
between high and low-pressure is improper.
sides.
↓
Damaged inside compressor
packings.

AC356A

Both high and low-pressure
sides are too low.

+ There is a big temperature
difference between receiver
drier outlet and inlet. Outlet
temperature is extremely low.
+ Liquid tank inlet and expansion valve are frosted.
+ Temperature of expansion
valve inlet is extremely low
as compared with areas near
liquid tank.
+ Expansion valve inlet may be
frosted.
+ Temperature difference
occurs somewhere in highpressure side.
AC353A + Expansion valve and liquid
tank are warm or only cool
when touched.
There is a big temperature difference between expansion
valve inlet and outlet while the
valve itself is frosted.

An area of the low-pressure
pipe is colder than areas near
the evaporator outlet.
Air flow volume is not enough
or is too low.

Liquid tank inside is clogged a
little.

+ Replace liquid tank.
+ Check lubricant for contamination.

+ Check and repair malfuncHigh-pressure pipe located
tioning parts.
between liquid tank and expan+ Check lubricant for contamision valve is clogged.
nation.

Low refrigerant charge.
↓
Leaking fittings or components.
Expansion valve closes a little
compared with the specification.
↓
j
1 Improper expansion valve
adjustment.
j
2 Malfunctioning thermal
valve.
j
3 Outlet and inlet may be
clogged.
Low-pressure pipe is clogged
or crushed.

Check refrigerant for leaks.
Refer to ‘‘Checking Refrigerant
Leaks’’, HA-119.
+ Remove foreign particles by
using compressed air.
+ Check lubricant for contamination.

+ Check and repair malfunctioning parts.
+ Check lubricant for contamination.
Compressor pressure operation Replace compressor.
is improper.

HA-37

MANUAL
TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont’d)
Gauge indication

Refrigerant cycle

Low-pressure side sometimes
becomes negative.

Probable cause

Corrective action

+ Air conditioner system does
not function and does not
cyclically cool the compartment air.
+ The system constantly functions for a certain period of
time after compressor is
stopped and restarted.

Refrigerant does not discharge + Drain water from refrigerant
or replace refrigerant.
cyclically.
+ Replace liquid tank.
↓
Moisture is frozen at expansion
valve outlet and inlet.
↓
Water is mixed with refrigerant.

Liquid tank or front/rear side of
expansion valve’s pipe is
frosted or dewed.

High-pressure side is closed
and refrigerant does not flow.
↓
Expansion valve or liquid tank
is frosted.

AC354A

Low-pressure side becomes
negative.

AC362A

HA-38

Leave the system at rest. Start
it again to check whether or not
the problem is caused by water
or foreign particles.
+ If water is the cause, initially
cooling is okay. Then the
water freezes, causing a
blockage. Drain water from
refrigerant or replace refrigerant.
+ If due to foreign particles,
remove expansion valve and
remove the particles with dry
and compressed air.
+ If either of the above methods cannot correct the
problem, replace expansion
valve.
+ Replace liquid tank.
+ Check lubricant for contamination.

MANUAL

TROUBLE DIAGNOSES
Insufficient Heating
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING
SYMPTOM:
+ Insufficient heating.

Inspection flow

RHA604G

*1: HA-40
*2: HA-40

*3: HA-22

*4: HA-21

HA-39

TROUBLE DIAGNOSES
Insufficient Heating (Cont’d)

MANUAL

CONTROL LINKAGE ADJUSTMENT
Water cock control rod
When adjusting water cock control rod, first disconnect
temperature control cable from air mix door lever and then
adjust control rod. Reconnect temperature control cable
and readjust it. (Refer to TEMPERATURE CONTROL
CABLE.)
1. Push air mix door lever in direction of arrow.
2. Pull control rod of water cock in direction of arrow so as to make
clearance of about 2 mm (0.08 in) between ends of rod and link
lever and connect the rod to door lever.
After connecting control rod, check it operates properly.
+

SHA522E

Temperature control cable
1. Move the temperature control knob to the full hot position.
2. Set the air mix door lever in the full hot position.
3. Pull on the cable cover in the direction of the arrow, then clamp
it.
After positioning control cable, check that it operates properly.

RHA632EA

HA-40

MANUAL

TROUBLE DIAGNOSES
Air Outlet
TROUBLE DIAGNOSIS PROCEDURE FOR AIR OUTLET
SYMPTOM:
+ Air does not change.

Inspection flow

RHA605G

*1: HA-42
*2: HA-22

*3: HA-21

*4: HA-13

HA-41

TROUBLE DIAGNOSES
Air Outlet (Cont’d)

MANUAL

CONTROL LINKAGE ADJUSTMENT
Mode control cable
1. Turn the mode control knob to the DEF position.
2. Set the side link in the DEF position by hand.
3. Pull on the cable cover in the direction of the arrow, then clamp
it.
After positioning control cable, check that it operates properly.

RHA630EA

HA-42

MANUAL

TROUBLE DIAGNOSES
Magnet Clutch
TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH
SYMPTOM:
+ Magnet clutch does not operate when A/C switch and fan switch are ON.

Inspection flow

RHA606G

*1: HA-119
*2: HA-44

*3: HA-22

*4: HA-21

HA-43

MANUAL

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
DIAGNOSTIC PROCEDURE

SYMPTOM: Magnet clutch does not engage when A/C switch
and fan switch are ON.
Yes
CHECK POWER SUPPLY FOR COMPRESSOR.
Disconnect compressor harness connector.
Do approx. 12 volts exist between compressor harness terminal No. j
1 and body
ground?
RHA747FE

Check magnet clutch coil.
NG
.

Replace magnet clutch.
Refer to HA-123.

Disconnect A/C relay.
Note

CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS TERMINAL NO. j
7 AND COMPRESSOR HARNESS TERMINAL NO. j
1 .
Continuity should exist.
If OK, check harness for short.
OK
RHA607GA

CHECK POWER SUPPLY FOR A/C
RELAY.
Disconnect A/C relay.
Do approx. 12 volts exist between A/C
relay harness terminal Nos. j
1 ,j
6 and
body ground?

No
c

Yes
.

CHECK A/C RELAY AFTER DISCONNECTING IT.
Refer to HA-47.
.
RHA608G

CHECK POWER SUPPLY
CIRCUIT AND 10A (No.
) FUSES AT FUSE
BLOCK.
Refer to EL section (‘‘Wiring
Diagram’’, ‘‘POWER SUPPLY ROUTING’’).

Replace A/C relay.

j
A
(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

HA-44

MANUAL

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
A
.

Reconnect A/C relay.
.

CHECK COIL SIDE CIRCUIT OF A/C
RELAY.
Do approx. 12 volts exist between ECM
(ECCS control module) harness terminal
No. j
9 and body ground?

No
c

Yes

RHA749FA

Disconnect A/C relay.
Disconnect ECM (ECCS
control module) harness
connector.
Note

CHECK CIRCUIT CONTINUITY BETWEEN A/C
RELAY HARNESS TERMINAL NO. j
2 AND ECM
(ECCS CONTROL MODULE) HARNESS TERMINAL NO. j
9 .
Continuity should exist.
If OK, check harness for
short.
.
RHA609G

CHECK VOLTAGE FOR ECM (ECCS control module).
Do approx. 12 volts exist between ECM
(ECCS control module) harness terminal
No. j
46 and body ground?
.

No
c

CHECK ECM (ECCS control module). Refer to EC
section.

Yes

Disconnect ECM (ECCS control module)
harness connector.
Disconnect dual-pressure switch harness
connector.
Note

.
RHA610G

CHECK CIRCUIT CONTINUITY
BETWEEN ECM (ECCS CONTROL MODULE) HARNESS TERMINAL NO. j
46 AND
DUAL-PRESSURE SWITCH HARNESS
TERMINAL NO. j
2 .
Continuity should exist.
If OK, check harness for short.
.

OK
NG

CHECK DUAL-PRESSURE SWITCH.
Refer to HA-47.
.

Check refrigerant charge
amount.
.

Disconnect thermo control amp. switch
harness connector.

Replace dual-pressure
switch.

RHA611G

Note

CHECK CIRCUIT CONTINUITY
BETWEEN DUAL-PRESSURE SWITCH
HARNESS TERMINAL NO. j
1 AND
THERMO CONTROL AMP. HARNESS
TERMINAL NO. j
3 .
Continuity should exist.
If OK, check harness for short.
.

RHA612G

j
B
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

HA-45

MANUAL

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
B

RHA615G

CHECK POWER SUPPLY
CHECK POWER SUPPLY FOR THERMO No
c
CIRCUIT AND 10A FUSES
CONTROL AMP.
AT FUSE BLOCK.
Disconnect thermo control amp. harness
Refer to EL section (‘‘Wiring
connector.
Diagram’’, ‘‘POWER SUPDo approx. 12 volts exist between thermo
PLY ROUTING’’).
control amp. harness terminal No. j
1 and
body ground?
Yes
.

CHECK BODY GROUND CIRCUIT FOR
THERMO CONTROL AMP.
Turn A/C switch ON.
Does continuity exist between thermo
control amp. harness terminal j
2 and
body ground?

No
c

CHECK THERMO CONTROL AMP.
Refer to HA-47.

Yes
RHA616G

Disconnect A/C switch harness connector.
.

CHECK A/C SWITCH.
Refer to HA-47.

Replace A/C switch.

Replace fan switch.

OK
.

Disconnect fan switch harness connector.

Note

.
RHA613G

CHECK CIRCUIT CONTINUITY
BETWEEN A/C SWITCH HARNESS
TERMINAL NO. j
2 AND FAN SWITCH
HARNESS TERMINAL NO. j
6 .
Continuity should exist.
If OK, check harness for short.
OK
Note

RHA614G

CHECK BODY GROUND CIRCUIT FOR
FAN SWITCH.
Does continuity exist between fan switch
harness terminal No. j
5 and body
ground?
Yes
.

CHECK FAN SWITCH.
Refer to HA-31.

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

HA-46

MANUAL

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
ELECTRICAL COMPONENTS INSPECTION
A/C switch

Check continuity between terminals at each switch position.
Switch condition

Terminal No.
Continuity

A/C

(+)

(−)

j
2

j
1

Yes

OFF

RHA626G

A/C relay
Check continuity between terminals j
3 and j
5 ,j
6 and j
7 .
Condition

Continuity

12V direct current supply between
terminals j
1 and j
2

Yes

No current supply

SEC202B

Dual-pressure switch
ON
kPa (bar, kg/cm2, psi)

OFF
kPa (bar, kg/cm2, psi)

Low-pressure side

Increasing to 157 — 216
(1.57 — 2.16, 1.6 — 2.2,
23 — 31)

Decreasing to 157 — 196
(1.57 — 1.96, 1.6 — 2.0,
23 — 28)

High-pressure side

Decreasing to 1,863 2,256 (18.6 — 22.6,
19 — 23, 270 — 327)

Increasing to 2,452 2,844 (24.5 — 28.4,
25 — 29, 356 — 412)

Thermo amp. operation

Tester

Decreasing to 0.1 — 0.9
(32 — 34)

Turn OFF

Approx. 12V

Increasing to 2.5 — 3.5
(37 — 38)

Turn ON

Approx. 0V

RHA628G

Thermo control amp.
Evaporator outlet air
temperature
°C (°F)

RHA736G

HA-47

MANUAL

TROUBLE DIAGNOSES
Noise
TROUBLE DIAGNOSIS PROCEDURE FOR NOISE
SYMPTOM:
+ Noise

Inspection flow

SHA909E

*1: HA-123

*2: HA-125

*3: HA-120

HA-48

DESCRIPTION

AUTO

Introduction
AIR CONDITIONER LAN SYSTEM OVERVIEW CONTROL SYSTEM
The LAN system consists of auto amp., air mix door motor and mode door motor.
A configuration of these components is shown in the diagram below.

RHA439G

Features
SYSTEM CONSTRUCTION (LAN)
A small network is constructed between the auto amplifier, air mix door motor and mode door motor. The auto
amplifier and motors are connected by data transmission lines and motor power supply lines. The LAN network is built through the ground circuits of the two motors.
Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted
through the data transmission lines connecting the auto amplifier and two motors.
The following functions are contained in LCUs built into the air mix door motor and the mode door motor.
+ Address
+ Motor opening angle signals
+ Data transmission
+ Motor stop and drive decision
+ Opening angle sensor (PBR function)
+ Comparison
+ Decision (Auto amplifier indicated value and motor opening angle comparison)

RHA440GA

HA-49

DESCRIPTION
Features (Cont’d)

AUTO

Operation
The auto amplifier receives data from each of the sensors. The amplifier sends air mix door and mode door
opening angle data to the air mix door motor LCU and mode door motor LCU.
The air mix door motor and mode door motor read their respective signals according to the address signal.
Opening angle indication signals received from the auto amplifier and each of the motor position sensors are
compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/
COLD or DEFROST/VENT operation is selected. The new selection data is returned to the auto amplifier.

RHA441GA

Transmission data and transmission order
Amplifier data is transmitted consecutively to each of the door motors following the form shown in figure below.
Start: Initial compulsory signal sent to each of the door motors.
Address: Data sent from the auto amplifier is selected according to data-based decisions made by the air mix
door motor and mode door motor.
If the addresses are identical, the opening angle data and error check signals are received by the door motor
LCUs. The LCUs then make the appropriate error decision. If the opening angle data is normal, door control
begins.
If an error exists, the received data is rejected and corrected data received. Finally, door control is based upon
the corrected opening angle data.
Opening angle: Data that shows the indicated door opening angle of each door motor.
Error check: Procedure by which sent and received data is checked for errors. Error data is then compiled.
The error check prevents corrupted data from being used by the air mix door motor and mode door motor.
Error data can be related to the following problems.
+ Abnormal electrical frequency
+ Poor electrical connections
+ Signal leakage from transmission lines
+ Signal level fluctuation
Stop signal: At the end of each transmission, a stop operation, in-operation, or internal problem message is
delivered to the auto amplifier. This completes one data transmission and control cycle.

HA-50

DESCRIPTION
Features (Cont’d)

AUTO

RHA442G

Air mix door control (Automatic temperature control)
The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined
value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.

Fan speed control
Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle
temperature, intake temperature, amount of sunload and air mix door position.
With FAN switch set to ‘‘AUTO’’, the blower motor starts to gradually increase air flow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing.

Intake door control
The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle
temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor.

Outlet door control
The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle
temperature, intake temperature and amount of sunload.

Magnet clutch control
The ECM (ECCS control module) controls compressor operation using input signals from the throttle position
sensor and auto amplifier.

Self-diagnostic system
The self-diagnostic system is built into the auto amplifier (LCU) to quickly locate the cause of problems.

HA-51

DESCRIPTION

AUTO

Overview of Control System
The control system consists of input sensors, switches, the automatic amplifier (microcomputer) and outputs.
The relationship of these components is shown in the diagram below:

RHA732G

HA-52

DESCRIPTION

AUTO

Control Operation

RHA727G

Display screen
Displays the operational status of the system.

AUTO switch
The compressor, intake doors, air mix door, outlet doors, and blower speed are automatically controlled so
that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator.

Temperature dial (Potentio Temperature Control)
Increases or decreases the set temperature.

OFF switch
The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet
doors are set to the foot (80% foot and 20% defrost) position.

FAN switch
Manual control of the blower speed. Four speeds are available for manual control (as shown on the display
screen):
low
, medium low
, medium high
, high

RECIRCULATION switch
OFF position: Automatic control resumes.
ON position: Interior air is recirculated inside the vehicle.

DEFROSTER switch
Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.

MODE switch
Control the air discharge outlets.

HA-53

DESCRIPTION
Control Operation (Cont’d)

AUTO

FRESH switch
OFF position: Automatic control resumes.
ON position: Outside air is drawn into the passenger compartment.

A/C switch
Manual control of the compressor operation. When the A/C switch indicator illuminates, compressor operation
is being carried out.

HA-54

TROUBLE DIAGNOSES

AUTO

Component Location
ENGINE COMPARTMENT

RHA697G

HA-55

TROUBLE DIAGNOSES
Component Location (Cont’d)

AUTO

PASSENGER COMPARTMENT

RHA698G

HA-56

TROUBLE DIAGNOSES

AUTO

Circuit Diagram

THA153

HA-57

TROUBLE DIAGNOSES

AUTO

Wiring Diagram — A/C, A —

YHA159

HA-58

TROUBLE DIAGNOSES
Wiring Diagram — A/C, A — (Cont’d)

AUTO

YHA160

HA-59

TROUBLE DIAGNOSES
Wiring Diagram — A/C, A — (Cont’d)

AUTO

YHA161

HA-60

TROUBLE DIAGNOSES

AUTO

Auto Amp. Terminals and Reference Value
INSPECTION OF AUTO AMP.
+

Measure voltage between each terminal and body ground by
following ‘‘AUTO AMP. INSPECTION TABLE’’.

Pin connector terminal layout

RHA629G

RHA630G

HA-61

AUTO
TROUBLE DIAGNOSES
Auto Amp. Terminals and Reference Value
(Cont’d)

AUTO AMP. INSPECTION TABLE
TERMINAL
No.

ITEM

Voltage
V

CONDITION

Power supply for IGN

—

Approximately 12

Power supply for BAT

—

Approximately 12

Ground

Compressor ON signal

—

—
ON

Approximately 0

OFF

Approximately 12

Compressor

Power supply for mode and air mix
door motor

In-vehicle sensor

—

Approximately 12

Ambient sensor

—

Sunload sensor

—

Ground

Power supply for illumination

Intake door position switch

14
15

—

RECIRCULATION

Approximately 0
Approximately 12

FRESH

Approximately 0

RECIRCULATION or 20% FRESH

Approximately 12

Intake door position switch
LAN signal

—

Approximately 5.5

Low, middle low or middle high

Approximately 2.5 — 3.0

High

Approximately 9 — 10

Fan control amp. control signal

Blower motor feed back

Power supply for blower motor

Thermal transmitter

Intake door position switch

Sensor ground

—

Intake sensor

—

Approximately 12

FRESH or 20% FRESH

—

Illumination switch ON

Fan speed
—

Approximately 12
—

—

Approximately 12
—

20% FRESH

Approximately 0

RECIRCULATION or FRESH

Approximately 12
—
—

Rear cooler ON

Approximately 0

Rear cooler relay
Rear cooler OFF

Approximately 12

Rear cooler switch ON

Approximately 0

Rear cooler switch OFF

Approximately 12

Rear cooler switch

HA-62

AUTO

TROUBLE DIAGNOSES
Self-diagnosis
INTRODUCTION AND GENERAL DESCRIPTION

(Ignition switch OFF → ON)
.

Within 5 seconds after starting engine (ignition
switch is turned ‘‘ON’’), press

switch for

at least 5 seconds.

The self-diagnostic system diagnoses sensors, door motors,
blower motor, etc. by system line. Refer to applicable sections
(items) for details. Shifting from normal control to the self-diagnostic system is accomplished by starting the engine (turning the ignition switch from ‘‘OFF’’ to ‘‘ON’’) and pressing ‘‘
’’ switch for at
’’ switch must be pressed within 5 secleast 5 seconds. The ‘‘
onds after starting the engine (ignition switch is turned ‘‘ON’’). This
system will be canceled by either pressing
(AUTO) switch or
turning the ignition switch ‘‘OFF’’. Shifting from one step to another
is accomplished by means of turning temperature dial clockwise or
counterclockwise, as required.
Additionally shifting from STEP 4 to AUXILIARY MECHANISM is
accomplished by means of pushing
(fan) switch.

STEP 1 — LEDs and LCD are checked.
m

Left turn

Right turn

STEP 2 — Input signals from each sensor are
checked.
m

Left turn

Right turn

STEP 3 — Mode and intake door motor position switch is checked.

Left turn

Ignition switch: OFF

Self-diagnostic function is canceled.

(AUTO) switch: ON

Right turn

Note

STEP 4 — Actuators are checked.
m

AUXILIARY MECHANISM — Temperature setting trimmer

Note:
For STEP 4, engine must be running for
compressor to operate.

HA-63

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)

RHA526G

STEP-BY-STEP PROCEDURE
Turn ignition switch ON.
.

Set in self-diagnostic mode. Within 5 seconds after starting engine (ignition switch is
switch for at
turned ‘‘ON’’.), press
least 5 seconds.

RHA527G

STEP 1 — LEDs AND LCD ARE CHECKED. No
Malfunctioning
c
Do all LEDs and LCD illuminate?
switch, LED or LCD.
Replace A/C auto amp.
Yes
.

Turn temperature dial clockwise.
.

Advance to self-diagnosis STEP 2?

No
c

Yes

Malfunctioning temperature
dial.
Replace A/C auto amp.

Turn temperature dial counterclockwise.
.

Return to self-diagnosis STEP 1?
Yes
.

Turn temperature dial clockwise.
.

j
A
(Go to next page.)

HA-64

No
c

Malfunctioning temperature
dial.
Replace A/C auto amp.

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
j
A

STEP 2 — SENSOR CIRCUITS ARE
CHECKED FOR OPEN OR SHORT
CIRCUIT.
Does code No.
appear on the display?

Yes

RHA970DA
.

Turn temperature
dial clockwise.

Refer to the following chart for malfunctioning code
No.
(If two or more sensors malfunction, corresponding
code Nos. blink respectively two times.)

Code No.

A/C LED

RHA528G

A/C LED

Malfunctioning sensor
(including circuits)

Reference
page

Ambient sensor

HA-103

In-vehicle sensor

HA-105

Sunload sensor*1

HA-107

Air mix door motor
(LCU) PBR

HA-79

.
B
j
(Go to next page.)

A/C LED

*1: Conduct self-diagnosis STEP 2 under sunshine.
When conducting indoors, aim a light (more than
60W) at sunload sensor, otherwise Code No.
will indicate despite that sunload sensor is functioning properly.

RHA501A

HA-65

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
j
B

STEP 3 — MODE DOOR POSITIONS
ARE CHECKED.
Does code No.
appear on the display?

Yes
RHA869DC
.

Turn temperature
dial clockwise.

Mode door motor position switch is malfunctioning.
(If two or more mode doors are out of order, corresponding code numbers blink respectively two
times.)
Code
No.*1

Mode door position

Reference
page

VENT
B/L
RHA168DA

FOOT

HA-75

F/D

j
C
(Go to next page.)

DEF

*1: If mode door motor harness connector is
disconnected, the following display pattern will
appear.
→
→
→
→
→
−
RHA498A

HA-66

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
j
C

STEP 4 — OPERATION OF EACH ACTUATOR IS CHECKED.
Engine running.
Press DEF switch, code No. of each actuator test is indicated on the display.
RHA495A

Refer to the following chart and confirm
discharge air flow, air temperature, blower
motor voltage and compressor operation.
Checks must be made visually, by listening to any noise, or by touching air
outlets with your hand, etc. for
improper operation.
Actuator test pattern
Code
No.

Mode door

Intake
door

Air
mix
door

Blower
motor

Compressor

FICD

REC

Full
Cold

4 — 5V

REC

Full
Cold

911V

20%
FRE

Full
Hot

7 — 9V

OFF

FRE

Full
Hot

7 — 9V

OFF

FRE

Full
Hot

7 — 9V

OFF

FRE

Full
Hot

10 12V

OFF

VENT

B/L

FOOT

RHA654FF
F/D

DEF

OK
.

Turn ignition switch OFF or AUTO switch
ON.

END

HA-67

NG
c

+ Air outlet does not
change.
Go to HA-75.
+ Intake door does not
change.
Go to HA-82.
+ Discharge air temperature does not change.
Go to HA-79.
+ Magnet clutch does not
engage.
Go to HA-92.
+ Blower motor operation is
malfunctioning.
Go to HA-86.

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)

AUTO

AUXILIARY MECHANISM: Temperature setting trimmer
The trimmer compensates for differences in range of ±3°C between
temperature setting (displayed digitally) and temperature felt by
driver.
Operating procedures for this trimmer are as follows:
+ Begin Self-diagnosis STEP 4 mode.
+ Press
(fan) switch to set system in auxiliary mode.
+ Turn temperature dial clockwise or counterclockwise as
desired. Temperature will change at a rate of 1°C each time a
switch is pressed.

RHA581G

When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial condition, i.e.
0°C.

HA-68

TROUBLE DIAGNOSES

AUTO

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
WORK FLOW

SHA900E

*1: Operational Check (HA-70)

SYMPTOM TABLE
Symptom

Reference page

+ A/C system does not come on.

+ Go to Trouble Diagnosis Procedure for A/C system.

HA-73

+ Go to Trouble Diagnosis Procedure for Mode Door Motor.
(LAN).

HA-75

+ Go to Trouble Diagnosis Procedure for Air Mix Door Motor
(LAN).

HA-79

+ Go to Trouble Diagnosis Procedure for Intake Door Motor.

HA-82

+ Blower motor operation is malfunctioning
under out of starting fan speed control.

+ Go to Trouble Diagnosis Procedure for Blower Motor.

HA-86

+ Magnet clutch does not engage.

+ Go to Trouble Diagnosis Procedure for Magnet Clutch.

HA-92

+ Insufficient cooling.

+ Go to Trouble Diagnosis Procedure for Insufficient Cooling.

HA-98

+ Insufficient heating.

+ Go to Trouble Diagnosis Procedure for Insufficient Heating.

HA-99

+ Noise.

+ Go to Trouble Diagnosis Procedure for Noise.

HA-100

+ Self-diagnosis cannot be performed.

+ Go to Trouble Diagnosis Procedure for Self-diagnosis.

HA-101

+ Memory function does not operate.

+ Go to Trouble Diagnosis Procedure for Memory Function.

HA-102

+ Air outlet does not change.
+ Mode door motor does not operate normally.
+ Discharge air temperature does not
change.
+ Air mix door motor does not operate normally.
+ Intake door does not change.
+ Intake door motor does not operate normally.
+ Blower motor operation is malfunctioning.

HA-69

TROUBLE DIAGNOSES

AUTO

Operational Check
The purpose of the operational check is to confirm that the system
operates properly.

CONDITIONS
+

Engine running and at normal operating temperature.

PROCEDURE
1. Check memory function
a.
b.
c.
d.
e.
f.

Set the temperature 25°C.
Press OFF switch.
Turn the ignition off.
Turn the ignition on.
Press the AUTO switch.
Confirm that the set temperature remains at previous temperature.
g. Press OFF switch.
RHA517G

2. Check blower
a. Press fan switch one time.
Blower should operate on low speed.
The fan symbol should have one blade lit
.
b. Press fan switch one more time, and continue checking blower
speed and fan symbol until all speeds are checked.
c. Leave blower on MAX speed .

RHA518G

3. Check discharge air
a. Press mode switch four times and DEF button.

RHA519G

RHA520G

HA-70

TROUBLE DIAGNOSES
Operational Check (Cont’d)

AUTO

b. Confirm that discharge air comes out according to the air distribution table at left.
Refer to ‘‘Discharge Air Flow’’ (HA-13).
NOTE:
Confirm that the compressor clutch is engaged (visualinspection) and intake door position is at FRESH when the DEF
is selected.
Intake door position is checked in the next step.

RHA654FD

4. Check recirculation
a. Press REC
switch.
Recirculation indicator should illuminate.
b. Listen for intake door position change (you should hear blower
sound change slightly).

RHA521G

5. Check temperature dial
a.
b.
c.
d.

Turn temperature dial counterclockwise until 18°C is displayed.
Check for cold air at discharge air outlets.
Turn temperature dial clockwise until 32°C is displayed.
Check for hot air at discharge air outlets.

RHA522G

HA-71

TROUBLE DIAGNOSES
Operational Check (Cont’d)

AUTO

6. Check AUTO mode
a. Press AUTO switch.
b. Display should indicate AUTO.
Confirm that the compressor clutch engages (audio or visual
inspection).
(Discharge air and blower speed will depend on ambient,
in-vehicle, and set temperatures.)

RHA523G

7. Check FRESH switch
a. Press FRE switch.
FRESH indicator should illuminate.
b. Listen for intake door position change. (You should hear a slight
change in blower sound.)

RHA524G

8. Check A/C switch
a. Press A/C switch.
A/C indicator should illuminate.
b. Confirm that the compressor clutch is engaged.

RHA525G

HA-72

TROUBLE DIAGNOSES

AUTO

A/C System
TROUBLE DIAGNOSIS PROCEDURE FOR A/C SYSTEM
SYMPTOM:
+ A/C system does not come on.

Inspection flow

SHA019F

*1: HA-74

*2: HA-70

COMPONENT DESCRIPTION
Automatic amplifier (Auto amp.)

RHA629G

The auto amplifier has a built-in microcomputer which processes
information sent from various sensors needed for air conditioner
operation. The air mix door motor, mode door motor, intake door
motor, blower motor and compressor are then controlled.
The auto amplifier is unitized with control mechanisms. Signals
from various switches and Potentio Temperature Control (PTC) are
directly entered into auto amplifier.
Self-diagnostic functions are also built into auto amplifier to provide
quick check of malfunctions in the auto air conditioner system.
Potentio temperature control (PTC)
The PTC is built into the A/C auto amp. It can be set at an interval
of 1°C in the 18°C to 32°C temperature range by turning the temperature dial. The set temperature is digitally displayed.

RHA746G

HA-73

AUTO

TROUBLE DIAGNOSES
A/C System (Cont’d)
DIAGNOSTIC PROCEDURE

RHA632G

Auto amp. check
Check power supply circuit for auto amp. with ignition switch ON.
Measure voltage across terminal Nos. j
1 ,j
2 ,j
20 and body ground.
Voltmeter terminal
%

Voltage

j
1
j
2
j
20
RHA633G

HA-74

Body ground

Approx. 12V

AUTO

TROUBLE DIAGNOSES
Mode Door Motor
TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR MOTOR (LAN)
SYMPTOM:
+ Air outlet does not change.
+ Mode door motor does not operate normally.

Inspection flow

SHA020F

*1:
*2:
*3:
*4:
*5:

HA-13
HA-70
HA-64
HA-65
HA-66

*6: HA-67
*7: HA-103
*8: HA-105
*9: HA-107
*10: HA-110

HA-75

*11: HA-79
*12: HA-65
*13: HA-77
*14: HA-70
*15: HA-69

TROUBLE DIAGNOSES
Mode Door Motor (Cont’d)

AUTO

SYSTEM DESCRIPTION
Component parts
Mode door control system components are:
1) Auto amp.
2) Mode door motor (LCU)
3) In-vehicle sensor
4) Ambient sensor
5) Sunload sensor
6) Intake sensor

System operation
The auto amplifier receives data from each of the sensors. The amplifier sends air mix door and mode door
opening angle data to the air mix door motor LCU and mode door motor LCU.
The air mix door motor and mode door motor read their respective signals according to the address signal.
Opening angle indication signals received from the auto amplifier and each of the motor position sensors are
compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/
COLD or DEFROST/VENT operation is selected. The new selection data is returned to the auto amplifier.

SHA006FA

HA-76

AUTO

TROUBLE DIAGNOSES
Mode Door Motor (Cont’d)
Mode door control specification

RHA730G

COMPONENT DESCRIPTION
The mode door motor is attached to the heater unit. It rotates so
that air is discharged from the outlet set by the auto amplifier. Motor
rotation is conveyed to a link which activates the mode door.

CONTROL LINKAGE ADJUSTMENT
Mode door
1. Install mode door motor on heater unit and connect it to main
harness.
2. Set up code No.
in Self-diagnosis STEP 4. Refer to HA-67.
3. Move side link by hand and hold mode door in DEF mode.
4. Make sure mode door operates properly when changing from
code No.
to
by pushing DEF switch.
RHA631G

VENT

B/L

HA-77

B/L

FOOT

F/D

DEF

AUTO

TROUBLE DIAGNOSES
Mode Door Motor (Cont’d)
DIAGNOSTIC PROCEDURE

SYMPTOM: Mode door motor and/or air mix door motor do not
operate normally.
CHECK POWER SUPPLY FOR AUTO
AMP. (LCU) SIDE.
Do approx. 12 volts exist between auto
amp. (LCU) terminal j
15 and body ground?

No
c

Replace auto amp. (LCU).

Yes
RHA636G

CHECK SIGNAL AUTO AMP. (LCU) SIDE.
Do approx. 5.5 volts exist between auto
amp. (LCU) terminal j
5 and body ground?

No
c

Replace auto amp. (LCU).

Yes
Note

CHECK POWER SUPPLY FOR MOTOR
SIDE.
Do approx. 12 volts exist between door
motor (LCU) harness terminal j
31 and body
ground?
Yes
RHA635G

Note

CHECK SIGNAL MOTOR SIDE.
Do approx. 5.5 volts exist between door
motor (LCU) terminal j
32 and body ground?
Yes
Note

CHECK MOTOR GROUND CIRCUIT.
Check harness continuity between door
motor (LCU) harness terminal j
3 and body
ground.
OK
.
RHA638G

Disconnect the mode door motor and air
mix door motor connector.
.

CHECK THE MODE DOOR MOTOR
OPERATION.
Reconnect the mode door motor and confirm the motor operation.

Mode door motor operates normally.
OK
c

Replace the air mix door
motor.

NG
.

Disconnect the mode door motor.
.
RHA637G

CHECK THE AIR MIX DOOR MOTOR
OPERATION.
Reconnect the air mix door motor and confirm the motor operation.

Air mix door motor operates normally.
OK
c

Replace the mode door
motor.

NG
.

Replace the auto amp. (LCU).

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

RHA639G

HA-78

AUTO

TROUBLE DIAGNOSES
Air Mix Door Motor
TROUBLE DIAGNOSIS PROCEDURE FOR AIR MIX DOOR (LAN)
SYMPTOM:
+ Discharge air temperature does not change.
+ Air mix door motor does not operate.

Inspection flow

SHA021F

*1:
*2:
*3:
*4:

HA-64
HA-65
HA-67
HA-103

*5:
*6:
*7:
*8:

*9: HA-69
*10: HA-78
*11: HA-81
*12: HA-70

HA-105
HA-107
HA-110
HA-79

HA-79

TROUBLE DIAGNOSES
Air Mix Door Motor (Cont’d)

AUTO

SYSTEM DESCRIPTION
Component parts
Air
1)
2)
3)
4)
5)
6)

mix door control system components are:
Auto amp.
Air mix door motor (LCU)
In-vehicle sensor
Ambient sensor
Sunload sensor
Intake sensor

RHA424GB

HA-80

AUTO

TROUBLE DIAGNOSES
Air Mix Door Motor (Cont’d)
Air mix door control specification

RHA690G

COMPONENT DESCRIPTION
The air mix door motor is attached to the heater unit. It rotates so
that the air mix door is opened or closed to a position set by the
auto amplifier. Motor rotation is then conveyed through a shaft and
the air mix door position is then fed back to the auto amplifier by
PBR built-in air mix door motor.

CONTROL LINKAGE ADJUSTMENT
Air mix door (Water cock)
RHA696G

1. Install air mix door motor on heater unit and connect it to main
harness.
2. Set up code No.
in Self-diagnosis STEP 4. Refer to HA-67.
3. Move air mix door lever by hand and hold it in full cold position.
4. Attach air mix door lever to rod holder.
5. Make sure air mix door operates properly when changing from
code No.
to
by pushing DEF switch.

Full cold

SHA522E

Full hot

6. Set up code No.
in Self-diagnosis STEP 4.
7. Attach water cock cable to air mix door linkage and secure with
clip.
8. Rotate and hold water cock lever AND plate in the full cold
position (CLOCKWISE completely).
9. Attach water cock cable to plate and secure with clip (white
mark on cable housing should be centered under the retaining
clip).
10. Check that water cock operates properly when changing from
code No.
to
by pushing DEF switch. (After several
cycles, water cock lever should be midpoint of plate opening
when code No.
is set.)

HA-81

AUTO

TROUBLE DIAGNOSES
Intake Door Motor
TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR
SYMPTOM:
+ Intake door does not change.
+ Intake door motor does not operate normally.

Inspection flow

SHA022F

*1:
*2:
*3:
*4:

HA-64
HA-65
HA-67
HA-103

*5:
*6:
*7:
*8:

*9: HA-85
*10: HA-84
*11: HA-70
*12: HA-69

HA-105
HA-107
HA-110
HA-79

HA-82

TROUBLE DIAGNOSES
Intake Door Motor (Cont’d)

AUTO

SYSTEM DESCRIPTION
Component parts
Intake door control system components are:
1) Auto amp.
2) Intake door motor
3) A/C LAN system (PBR built-in mode motor and air mix door motor)
4) In-vehicle sensor
5) Ambient sensor
6) Sunload sensor
7) Intake sensor

System operation
The intake door control determines intake door position based on the ambient temperature, the intake air
temperature and the in-vehicle temperature. When the A/C, DEFROSTER, or OFF switches are pushed, the
auto amplifier sets the intake door at the ‘‘Fresh’’ position.

RHA640G

HA-83

AUTO

TROUBLE DIAGNOSES
Intake Door Motor (Cont’d)
Intake door control specification

RHA692G

COMPONENT DESCRIPTION
The intake door motor is attached to the intake unit. It rotates so
that air is drawn from inlets set by the auto amplifier. Motor rotation is conveyed to a lever which activates the intake door.

CONTROL LINKAGE ADJUSTMENT
Intake door
1. Install intake door motor on intake unit and connect it to main
harness.
2. Set up code No.
in Self-diagnosis STEP 4. Refer to HA-67.
3. Move intake door link by hand and hold it in REC position.
4. Attach intake door lever to rod holder.
5. Make sure intake door operates properly when changing from
code No.
to
by pushing DEF switch.
RHA593F

REC

HA-84

20% FRE

FRE

AUTO

TROUBLE DIAGNOSES
Intake Door Motor (Cont’d)
DIAGNOSTIC PROCEDURE

SYMPTOM: Intake door motor does not operate normally.
+ Perform Self-diagnosis STEP 4 before referring to the flow
chart.

SHA858EB

CHECK POWER SUPPLY FOR INTAKE
DOOR MOTOR.
Disconnect intake door motor harness
connector.
Do approx. 12 volts exist between intake
door motor harness terminal No. j
1 and
body ground?

No
c

Check power supply circuit
and 10A fuse (No. 6 ,
located in the fuse block).

Yes
Note

CHECK FOR AUTO AMP. OUTPUT.
Set up Self-diagnosis STEP 4.
Measure voltage across auto amp. harness terminals and body ground.
RHA081GB

Terminal No.
Code No.

⊕

Condition

j
13
REC

j
23

12
12

j
14
j
13
j
23

Voltage
V

Body
ground

20%
FRE

j
14

NG
c

Check circuit continuity
between each terminal on
auto amp. and on intake
door motor.
Terminal No.

⊕

Intake door
Auto amp.
motor
j
j
13
13

j
23

j
14

FRE

j
23

Yes

12
12

j
13

Continuity

12
0

j
14
0V: Approx. 0V
12V: Approx. 12V

Replace auto amp.

RHA642G

OK
.

Replace intake door motor.

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

RHA634G

HA-85

AUTO

TROUBLE DIAGNOSES
Blower Motor
TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR
SYMPTOM:
+ Blower motor operation is malfunctioning.
+ Blower motor operation is malfunctioning under out of starting fan speed control.

Inspection flow

SHA026F

*1:
*2:
*3:
*4:

HA-64
HA-65
HA-67
HA-89

*5:
*6:
*7:
*8:

*9: HA-79
*10: HA-70
*11: HA-69

HA-103
HA-105
HA-107
HA-110

HA-86

TROUBLE DIAGNOSES
Blower Motor (Cont’d)

AUTO

SYSTEM DESCRIPTION
Component parts
Fan speed control system components are:
1) Auto amp.
2) Fan control amp.
3) A/C LAN system (PBR built in mode door motor and air mix door motor)
4) In-vehicle sensor
5) Ambient sensor
6) Sunload sensor
7) Intake sensor

System operation

SHA006FB

Automatic mode
In the automatic mode, the blower motor speed is calculated by the automatic amplifier based on inputs from
the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor. The blower motor applied
voltage ranges from approximately 5 volts (lowest speed) to 12 volts (highest speed).
The control blower speed (in the range of 5 to 12V), the automatic amplifier supplies a gate voltage to the fan
control amplifier. Based on this voltage, the fan control amplifier controls the voltage supplied to the blower
motor.

Starting fan speed control
Start up from ‘‘COLD SOAK’’ condition (Automatic mode)
In a cold start up condition where the engine coolant temperature is below 50°C, the blower will not operate
for a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient
and engine coolant temperature.
In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described above.
After this delay, the blower will operate at low speed until the engine coolant temperature rises above 55°C,
at which time the blower speed will increase to the objective speed.
Start up from normal or ‘‘HOT SOAK’’ condition (Automatic mode)
The blower will begin operation momentarily after the AUTO button is pushed. The blower speed will gradually rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective
blower speed).

HA-87

TROUBLE DIAGNOSES
Blower Motor (Cont’d)

AUTO

Blower speed compensation
Sunload
When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low
speed. The low speed will vary depending on the sunload. During conditions of high sunload, the blower low
speed is ‘‘normal’’ low speed (approx. 6V). During low or no sunload conditions, the low speed will drop to
‘‘low’’ low speed (approx. 5V).
Ambient
When the ambient temperature is in the ‘‘moderate’’ range [10 − 15°C], the computed blower voltage will be
compensated (reduced) by up to 3.5V (depending on the blower speed). In the ‘‘extreme’’ ambient ranges
[below 0°C and above 20°C] the computed objective blower voltage is not compensated at all. In the ambient temperature ranges between ‘‘moderate’’ and ‘‘extreme’’ [0 — 10°C and 15 — 20°C], the amount of compensation (for a given blower speed) varies depending on the ambient temperature.

Fan speed control specification

RHA694G

COMPONENT DESCRIPTION
Fan control amplifier
The fan control amplifier is located on the cooling unit. The fan
control amp. receives a gate voltage from the auto amp. to steplessly maintain the blower fan motor voltage in the 5 to 12 volt
range (approx.).

RHA695G

HA-88

AUTO

TROUBLE DIAGNOSES
Blower Motor (Cont’d)
DIAGNOSTIC PROCEDURE

SYMPTOM: Blower motor operation is malfunctioning under
Starting Fan Speed Control.
CHECK POWER SUPPLY FOR FAN
CONTROL AMP.
Disconnect fan control amp. harness connector.
Do approx. 12 volts exist between fan
control amp. harness terminal No. j
1 and
body ground?

No
c

RHA087GB

CHECK POWER SUPPLY
FOR BLOWER MOTOR.
Disconnect blower motor
harness connector.
Do approx. 12 volts exist
between blower motor harness terminal No. j
2 and
body ground?

Yes
No

Yes
Note

CHECK BODY GROUND CIRCUIT FOR
FAN CONTROL AMP.
Does continuity exist between fan control
amp. harness terminal No. j
3 and body
ground?

Check
power supply circuit
and 15A
fuses (No.
1 and 2 ,
located in
the fuse
block).

Yes

RHA643G
.

Note

Reconnect fan control amp. harness connector.

Check circuit continuity
between blower motor harness terminal No. j
1 and
fan control amp. harness
terminal No. j
1 .
OK

RHA644G

CHECK FOR AUTO AMP. OUTPUT.
Set up Self-diagnosis STEP 4.
Measure voltage across fan control amp.
harness terminal No. j
2 and body ground.

CHECK BLOWER
MOTOR.
(Refer to HA-91.)
NG

Terminal No.
Code No.

⊕

−
Body ground

j
2

Voltage

Replace blower motor.
Approx.
2.5 — 3V
Approx.
9 — 10V

A
cj

(Go to next page.)

OK
.

Replace fan control amp.

RHA645G

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

RHA646G

HA-89

AUTO

TROUBLE DIAGNOSES
Blower Motor (Cont’d)
j
A
.

Disconnect auto amp. and fan control amp.
harness connector.

Note

RHA647G

Does continuity exist between auto amp.
harness terminal No. j
17 and fan control
amp. harness terminal No. j
2 ?
Continuity should exist.
If OK, check harness for short.
Yes
.

CHECK FAN FEED BACK CIRCUIT.
Do approx. 12 volts exist between auto
amp. harness terminal No. j
20 and body
ground?

No
c

Yes
RHA648G

Note

Do approx. 12 volts exist between auto
amp. harness terminal No. j
18 and body
ground?
Yes

RHA649G

Check power supply circuit
and 15A fuses (No. 1
and 2 , located in the fuse
block).
Refer to EL section (‘‘Wiring
Diagram’’, ‘‘POWER SUPPLY ROUTING’’).

No
c

Check circuit continuity
between blower motor harness terminal No. j
1 and
auto amp. harness terminal
No. j
18 .
Continuity should exist.
If OK, check harness for
short.

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

RHA650G

RHA651G

HA-90

TROUBLE DIAGNOSES
Blower Motor (Cont’d)

AUTO

COMPONENT INSPECTION
Blower motor
Confirm smooth rotation of the blower motor.
+ Ensure that there are no foreign particles inside the intake unit.

RHA941F

HA-91

AUTO

TROUBLE DIAGNOSES
Magnet Clutch
TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH
SYMPTOM:
+ Magnet clutch does not engage.

Inspection flow

SHA023F

*1:
*2:
*3:
*4:

HA-64
HA-65
HA-67
HA-94

*5:
*6:
*7:
*8:

*9: HA-79
*10: HA-70
*11: HA-69
*12: HA-35

HA-103
HA-105
HA-107
HA-110

HA-92

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)

AUTO

SYSTEM DESCRIPTION
Auto amplifier controls compressor operation by ambient temperature and signal from ECM (ECCS control module).

Low temperature protection control
Auto amplifier will turn the compressor ‘‘ON’’ or ‘‘OFF’’ as determined by a signal detected by ambient sensor.
When ambient temperatures are greater than 1°C, the compressor
turns ‘‘ON’’. The compressor turns ‘‘OFF’’ when ambient temperatures are less than −2°C.
RHA094GA

HA-93

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
DIAGNOSTIC PROCEDURE

Check magnet clutch coil.
NG
.

Replace magnet clutch.
Refer to HA-123.

Disconnect A/C relay.
Note

CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS TERMINAL NO. j
7 AND COMPRESSOR HARNESS TERMINAL NO. j
1 .
Continuity should exist.
If OK, check harness for short.
OK
RHA652G

CHECK POWER SUPPLY FOR A/C
RELAY.
Disconnect A/C relay.
Do approx. 12 volts exist between A/C
relay harness terminal Nos. j
1 ,j
6 and
body ground?

No
c

Yes
.

CHECK A/C RELAY AFTER DISCONNECTING IT.
Refer to HA-97.
ECCS
RHA096GA engine
models

CHECK POWER SUPPLY
CIRCUIT AND 10A (No.
) FUSE AT FUSE
BLOCK.
Refer to EL section (‘‘Wiring
Diagram’’, ‘‘POWER SUPPLY ROUTING’’).

Except for
ECCS
engine
models

Replace A/C relay.

j
A
(Go to next page.)

B
j

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

RHA653G

RHA654G

HA-94

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
A
.

Reconnect A/C relay.

RHA655G

CHECK COIL SIDE CIRCUIT OF A/C
RELAY.
Do approx. 12 volts exist between ECM
(ECCS control module) harness terminal
No. j
9 and body ground?

No
c

Disconnect A/C relay.
Disconnect ECM (ECCS
control module) harness
connector.

Yes
.

RHA656G

Note

CHECK CIRCUIT CONTINUITY BETWEEN A/C
RELAY HARNESS TERMI2 AND ECM
NAL NO. j
(ECCS CONTROL MODULE) HARNESS TERMINAL NO. j
9 .
Continuity should exist.
If OK, check harness for
short.

CHECK VOLTAGE FOR ECM (ECCS control module).
Do approx. 12 volts exist between ECM
(ECCS control module) harness terminal
No. j
46 and body ground?

No
c

CHECK ECM (ECCS control module). Refer to EC
section.

Yes
.

Disconnect ECM (ECCS control module)
harness connector.
Disconnect dual-pressure switch harness
connector.
RHA657G

Note

CHECK CIRCUIT CONTINUITY
BETWEEN ECM (ECCS CONTROL MODULE) HARNESS TERMINAL NO. j
46 , j
21
AND DUAL-PRESSURE SWITCH HARNESS TERMINAL NO. j
2 .
Continuity should exist.
If OK, check harness for short.
OK
RHA658G

CHECK DUAL-PRESSURE SWITCH.
Refer to HA-97.
.

NG
c

Replace dual-pressure
switch.

j
C

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-95

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
B

Note

Check circuit continuity between A/C relay
harness terminal No. j
2 and dual-pressure
switch harness terminal No. j
2 .
Continuity should exist.
If OK, check harness for short.
Yes

RHA659G
.

CHECK DUAL-PRESSURE SWITCH.
Refer to HA-97.

Replace dual-pressure
switch.

OK
j
C

RHA660G

CHECK THERMO CONTROL AMP. CIRCUIT.
Do approx. 12 volts exist between thermo
control amp. harness terminal No. j
3 and
body ground?

No
D
cj

Yes
.

CHECK POWER SUPPLY FOR THERMO
AMP.
Do approx. 12 volts exist between thermo
control amp. harness terminal No. j
1 and
body ground?

No
c

Check power supply circuit
and 10A fuse (No.
,
located in the fuse block).

Yes
RHA661G

Note

Check circuit continuity between thermo
control amp. harness terminal No. j
2 and
auto amp. harness terminal No. j
4 .
Continuity should exist.
If OK, check harness for short.
OK
.

CHECK THERMO CONTROL AMP.
Refer to HA-47.
RHA662G

Replace thermo amp.
c

OK
.

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-96

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
D

Note

Check circuit continuity between dual-pressure switch harness terminal No. j
1 and
thermo control amp. harness terminal No.
j
3 .
Continuity should exist.
If OK, check harness for short.
RHA663G

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

COMPONENT INSPECTION
A/C relay
Check continuity between terminal Nos. j
3 and j
5 ,j
6 and j
7 .
Conditions

Continuity

12V direct current supply between terminal Nos.
j
1 and j
2

Yes

No current supply

If NG, replace relay.
SEC202B

Dual-pressure switch
ON
kPa (bar, kg/cm2, psi)

OFF
kPa (bar, kg/cm2, psi)

Low-pressure
side

Increasing to
157 — 216 (1.57 — 2.16,
1.6 — 2.2, 23 — 31)

Decreasing to
157 — 196 (1.57 — 1.96,
1.6 — 2.0, 23 — 28)

High-pressure
side

Decreasing to
1,863 — 2,256 (18.6 — 22.6,
19 — 23, 270 — 327)

Increasing to
2,452 — 2,844 (24.5 — 28.4,
25 — 29, 356 — 412)

RHA628G

HA-97

AUTO

TROUBLE DIAGNOSES
Insufficient Cooling
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING
SYMPTOM:
+ Insufficient cooling.

Inspection flow

SHA053F

*1:
*2:
*3:
*4:

HA-64
HA-65
HA-67
HA-78

*5:
*6:
*7:
*8:

*9: HA-33
*10: HA-68
*11: HA-70

HA-82
HA-89
HA-94
HA-79

HA-98

AUTO

TROUBLE DIAGNOSES
Insufficient Heating
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING
SYMPTOM:
+ Insufficient heating.

Inspection flow

SHA024F

*1:
*2:
*3:
*4:

HA-70
HA-64
HA-65
HA-67

*8: HA-94
*9: HA-79
*10: HA-68

*5: HA-75
*6: HA-85
*7: HA-89

HA-99

AUTO

TROUBLE DIAGNOSES
Noise
TROUBLE DIAGNOSIS PROCEDURE FOR NOISE
SYMPTOM:
+ Noise

Inspection flow

SHA896EA

*1: HA-123
*2: HA-125

*3: HA-114

*4: HA-70

HA-100

AUTO

TROUBLE DIAGNOSES
Self-diagnosis
TROUBLE DIAGNOSIS PROCEDURE FOR SELF-DIAGNOSIS
SYMPTOM:
+ Self-diagnosis cannot be performed.

Inspection flow

SHA037F

*1: HA-74
*2: HA-103
*3: HA-105

*7: HA-70
*8: HA-69

*4: HA-107
*5: HA-110
*6: HA-79

HA-101

AUTO

TROUBLE DIAGNOSES
Memory Function
TROUBLE DIAGNOSIS PROCEDURE FOR MEMORY FUNCTION
SYMPTOM:
+ Memory function does not operate.

Inspection flow

SHA027F

*1: HA-74

*2: HA-70

*3: HA-64

HA-102

TROUBLE DIAGNOSES

AUTO

Ambient Sensor
COMPONENT DESCRIPTION
The ambient sensor is attached in front of the driver’s side condenser. It detects ambient temperature and converts it into a resistance value which is then input into the auto amplifier.

RHA670G

AMBIENT TEMPERATURE INPUT PROCESS
The automatic amplifier includes a ‘‘processing circuit’’ for the ambient sensor input. However, when the temperature detected by the
ambient sensor increases quickly, the processing circuit retards the
auto amp. function. It only allows the auto amp. to recognize an
ambient temperature increase of 0.33°C per 100 seconds.
As an example, consider stopping for a cup of coffee after high
speed driving. Although the actual ambient temperature has not
changed, the temperature detected by the ambient sensor will
increase. This is because the heat from the engine compartment
can radiate to the front grille area, location of the ambient sensor.

HA-103

AUTO

TROUBLE DIAGNOSES
Ambient Sensor (Cont’d)
DIAGNOSTIC PROCEDURE

SYMPTOM: Ambient sensor circuit is open or shorted. (
or
A/C LED
is indicated on auto amp. as a result of conducting
Self-diagnosis STEP 2.)

RHA051GC

CHECK AMBIENT SENSOR CIRCUIT
BETWEEN AMBIENT SENSOR AND
AUTO AMP.
Disconnect ambient sensor harness connector.
Do approx. 5 volts exist between ambient
sensor harness terminal No. j
9 and body
ground?

No
c

Disconnect auto amp. harness connector.

Note

Check circuit continuity
between ambient sensor
harness terminal No. j
9
and auto amp. harness
terminal No. j
9 .

Yes

OK
.

Disconnect auto amp. harness connector.

Replace auto amp.

RHA671G

Note

Check circuit continuity between ambient
sensor harness terminal No. j
24 and auto
amp. harness terminal No. j
24 .
OK
.

CHECK AMBIENT SENSOR.
(Refer to HA-105.)

NG
c

Replace ambient sensor.

OK
RHA672G

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

RHA673G

HA-104

AUTO

TROUBLE DIAGNOSES
Ambient Sensor (Cont’d)
COMPONENT INSPECTION
Ambient sensor

After disconnecting ambient sensor harness connector, measure
resistance between terminals j
9 and j
24 at sensor harness side,
using the table below.
Temperature °C (°F)

Resistance kΩ

RHA674G

−15 (5)

12.73

−10 (14)

9.92

−5 (23)

7.80

0 (32)

6.19

5 (41)

4.95

10 (50)

3.99

15 (59)

3.24

20 (68)

2.65

25 (77)

2.19

30 (86)

1.81

35 (95)

1.51

40 (104)

1.27

45 (113)

1.07

In-vehicle Sensor
COMPONENT DESCRIPTION
In-vehicle sensor
The in-vehicle sensor is located on instrument lower panel. It converts variations in temperature of compartment air drawn from the
aspirator into a resistance value. It is then input into the auto amplifier.
RHA675G

Aspirator
The aspirator is located in front of heater unit. It produces vacuum
pressure due to air discharged from the heater unit, continuously
taking compartment air in the aspirator.

RHA636F

RHA482A

HA-105

AUTO

TROUBLE DIAGNOSES
In-vehicle Sensor (Cont’d)
DIAGNOSTIC PROCEDURE

SYMPTOM: In-vehicle sensor circuit is open or shorted.
A/C LED
(
or
is indicated on auto amp. as a result of conducting Self-diagnosis STEP 2.)

RHA056GE

CHECK IN-VEHICLE SENSOR CIRCUIT
BETWEEN IN-VEHICLE SENSOR AND
AUTO AMP.
Disconnect in-vehicle sensor harness connector.
Do approx. 5 volts exist between in-vehicle sensor harness terminal No. j
8 and
body ground?

No
c

Disconnect auto amp. harness connector.

Note

Check circuit continuity
between in-vehicle sensor
harness terminal No. j
8
and auto amp. harness
terminal No. j
8 .

Yes

OK
.

Disconnect auto amp. harness connector.

Replace auto amp.

RHA676G

Note

Check circuit continuity between in-vehicle
sensor harness terminal No. j
24 and auto
amp. harness terminal No. j
24 .
OK
.

CHECK IN-VEHICLE SENSOR.
(Refer to HA-107.)

NG
c

Replace in-vehicle sensor.

OK
RHA677G

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

RHA678G

HA-106

AUTO

TROUBLE DIAGNOSES
In-vehicle Sensor (Cont’d)
COMPONENT INSPECTION
In-vehicle sensor

After disconnecting in-vehicle sensor harness connector, measure
resistance between terminals j
8 and j
24 at sensor harness side,
using the table below.

RHA679G

Temperature °C (°F)

Resistance kΩ

−15 (5)

12.73

−10 (14)

9.92

−5 (23)

7.80

0 (32)

6.19

5 (41)

4.95

10 (50)

3.99

15 (59)

3.24

20 (68)

2.65

25 (77)

2.19

30 (86)

1.81

35 (95)

1.51

40 (104)

1.27

45 (113)

1.07

Sunload Sensor
COMPONENT DESCRIPTION
The sunload sensor is located on the right defroster grille. It detects
sunload entering through windshield by means of a photo diode.
The sensor converts the sunload into a current value which is then
input into the auto amplifier.

RHA682G

SUNLOAD INPUT PROCESS
The auto amp. also includes a processing circuit which ‘‘average’’
the variations in detected sunload over a period of time. This prevents drastic swings in the ATC system operation due to small or
quick variations in detected sunload.
For example, consider driving along a road bordered by an occasional group of large trees. The sunload detected by the sunload
sensor will vary whenever the trees obstruct the sunlight. The processing circuit averages the detected sunload over a period of time,
so that the (insignificant) effect of the trees momentarily obstructing the sunlight does not cause any change in the ATC system
operation. On the other hand, shortly after entering a long tunnel,
the system will recognize the change in sunload, and the system
will react accordingly.

HA-107

AUTO

TROUBLE DIAGNOSES
Sunload Sensor (Cont’d)
DIAGNOSTIC PROCEDURE

SYMPTOM: Sunload sensor circuit is open or shorted. (
or
A/C LED
is indicated on auto amp. as a result of conducting
Self-diagnosis STEP 2.)

RHA061GC

CHECK SUNLOAD SENSOR CIRCUIT
BETWEEN SUNLOAD SENSOR AND
AUTO AMP.
Disconnect sunload sensor harness connector.
Do approx. 5 volts exist between sunload
sensor harness terminal No. j
10 and body
ground?

No
c

Disconnect auto amp. harness connector.

Note

Check circuit continuity
between sunload sensor
harness terminal No. j
10
and auto amp. harness
terminal No. j
10 .

Yes

OK
.

Disconnect auto amp. harness connector.

Replace auto amp.

RHA680G

Note

Check circuit continuity between sunload
sensor harness terminal No. j
24 and auto
amp. harness terminal No. j
24 .
OK
.

CHECK SUNLOAD SENSOR.
(Refer to HA-109.)

NG
c

Replace sunload sensor.

OK
RHA681G

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

RHA683G

HA-108

TROUBLE DIAGNOSES
Sunload Sensor (Cont’d)

AUTO

COMPONENT INSPECTION
Sunload sensor
Measure voltage between auto amp. terminal j
10 and body ground.
+ When checking sunload sensor, select a place where sun
shines directly on it.

RHA684G

SHA930E

HA-109

AUTO

TROUBLE DIAGNOSES
Intake Sensor
COMPONENT DESCRIPTION

The intake sensor is located on the cooling unit. It converts temperature of air after it passes through the evaporator into a resistance value. The value is then input to the auto amplifier.

RHA685G

DIAGNOSTIC PROCEDURE
SYMPTOM: Intake sensor circuit is open or shorted.

RHA957FA

CHECK INTAKE SENSOR CIRCUIT
BETWEEN INTAKE SENSOR AND AUTO
AMP.
Disconnect intake sensor harness connector.
Do approx. 5 volts exist between intake
sensor harness terminal No. j
25 and body
ground?

No
c

Disconnect auto amp. harness connector.

Note

Check circuit continuity
between intake sensor harness terminal No. j
25 and
auto amp. harness terminal
No. j
25 .
Continuity should exist.
If OK, check harness for
short.

Yes

OK
.

Disconnect auto amp. harness connector.

Replace auto amp.

RHA686G

Note

Check circuit continuity between intake
sensor harness terminal No. j
24 and auto
amp. harness terminal No. j
24 .
Continuity should exist.
If OK, check harness for short.
OK
.
RHA687G

CHECK INTAKE SENSOR.
(Refer to HA-111.)

NG
c

Replace intake sensor.

OK
.

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

RHA688G

HA-110

AUTO

TROUBLE DIAGNOSES
Intake Sensor (Cont’d)
COMPONENT INSPECTION
Intake sensor

After disconnecting intake sensor harness connector, measure
resistance between terminals j
25 and j
24 at sensor harness side,
using the table below.
Temperature °C (°F)

Resistance kΩ

−20 (−4)

16.2

−10 (14)

9.8

0 (32)

6.0

10 (50)

3.94

20 (68)

2.64

25 (77)

2.12

30 (86)

1.82

40 (104)

1.27

RHA689G

HA-111

MANUAL AND AUTO

SERVICE PROCEDURES

HFC-134a (R-134a) Service Procedure
Set the recovery/recycling equipment.
.

Recovered lubricant. Refer to
‘‘CHECKING AND ADJUSTING’’,
HA-114.

Discharge refrigerant into recovery/
recycling equipment.
.

Repair or replace parts.
.

Evacuate (over 25 minutes).

Check air tightness.

.
c

Repair.

Partial charging [approx. 200 g
(7.05 oz)].
.

Preliminary refrigerant leak check.
Refer to ‘‘PRELIMINARY CHECK’’,
HA-119.
OK
.

Complete charging (specified amount
less partial charge amount)
Refer to SDS.
*2

Check for refrigerant leaks.
Refer to ‘‘CHECKING PROCEDURE’’, NG
HA-120.
OK
.

Check for A/C operation and A/C cool- ………………
ing performance

Performance Test Diagnoses
Refer to HA-33.

Remove service couplers from A/C
service valves.
.

Recover refrigerant in charging hoses.
.

Remove service tools.
.

Reinstall service valve caps.
Note: *1 Before charging refrigerant, ensure engine is OFF.
*2 Before checking for leaks, start engine to activate air conditioner system then turn engine OFF.
Service valve caps must be installed to prevent leakage.

HA-112

MANUAL AND AUTO
SERVICE PROCEDURES
HFC-134a (R-134a) Service Procedure (Cont’d)

SETTING OF SERVICE TOOLS AND EQUIPMENT
DISCHARGING REFRIGERANT
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements of HFC-134a (R-134a) recycling equipment or HFC-134a (R-134a) recovery equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and
safety information may be obtained from refrigerant and lubricant manufacturers.

SHA539DC

EVACUATING SYSTEM AND CHARGING REFRIGERANT

SHA540DC

HA-113

MANUAL AND AUTO

SERVICE PROCEDURES

Maintenance of Lubricant Quantity in
Compressor
The lubricant used to lubricate the compressor circulates through
the system with the refrigerant. Add lubricant to compressor when
replacing any component or after a large gas leakage occurred. It
is important to maintain the specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
+ Lack of lubricant: May lead to a seized compressor
+ Excessive lubricant: Inadequate cooling (thermal exchange
interference)

LUBRICANT
Name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0

CHECKING AND ADJUSTING
Adjust the lubricant quantity according to the flowchart shown
below.

START
.

Yes

Can lubricant return operation be performed?
+ A/C system works properly.
+ There is no evidence of a large amount of
lubricant leakage.

Should the compressor be replaced?
No

Yes

Perform lubricant return operation, proceeding as follows:
——————————————————————————————————————————————————————————————————————————————————————1. Start engine, and set the following conditions:
+ Test condition
Engine speed: Idling to 1,200 rpm
A/C or AUTO switch: ON
Blower speed: Max. position
Temp. control: Optional [Set so that intake air temperature is
25 to 30°C (77 to 86°F).]
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant
return operation.

j
A
(Go to next page.)

Is there any part to be replaced?
(Evaporator, condenser, liquid tank or in
case there is evidence of a large amount of
lubricant leakage.)

Yes
c

After replacing any of the following major components, add the correct
amount of lubricant to the system.
Amount of lubricant to be added

Part replaced
Evaporator
Condenser

Carry out the A/C performance test.

Lubricant to be added to system
Amount of lubricant
m! (Imp fl oz)
75 (2.6)
75 (2.6)

Liquid tank

5 (0.2)

In case of refrigerant leak

30 (1.1)
—

Remarks
—
—
Add if compressor is not
replaced. *1
Large leak
Small leak*2

*1: If compressor is replaced, addition of lubricant is included in the flow
chart.
*2: If refrigerant leak is small, no addition of lubricant is needed.

HA-114

MANUAL AND AUTO
SERVICE PROCEDURES
Maintenance of Lubricant Quantity in
Compressor (Cont’d)
j
A
.

1. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/
recycling equipment.
2. Remove the drain plug of the ‘‘old’’ (removed) compressor. Drain the lubricant into a graduated container and record the
amount of drained lubricant.
3. Remove the drain plug and drain the lubricant from the ‘‘new’’ compressor into a separate, clean container.
4. Measure an amount of new lubricant installed equal to amount drained from ‘‘old’’ compressor. Add this lubricant to ‘‘new’’
compressor through the suction port opening.
5. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to ‘‘new’’ compressor through the suction port opening.
6. Torque the drain plug.
14 — 16 Nzm (1.4 — 1.6 kg-m, 10 — 12 ft-lb)
7. If the liquid tank also needs to be replaced, add an additional 5 m! (0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m! (0.2 Imp fl oz) of lubricant if only replacing the compressor.

RHA065DE

HA-115

SERVICE PROCEDURES

MANUAL AND AUTO

Ventilation Air Filter
FUNCTION
Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing ventilation air filter into cooling unit.

RHA042G

REPLACEMENT TIMING
Replace ventilation air filter.
Refer to ‘‘PERIODIC MAINTENANCE’’ in MA section.
Caution label is fixed inside the glove box.

SHA868E

REPLACEMENT PROCEDURES
+
+
+
+
+
+

Remove glove box.
Remove instrument reinforcement from instrument panel.
Remove ventilation air filter fixed clip.
Take out ventilation air filter from cooling unit.
Replace with new one and reinstall on cooling unit.
Reinstall instrument reinforcement, glove box and undercover.

RHA953F

HA-116

SERVICE PROCEDURES
FOR LHD MODELS
RD engine

MANUAL AND AUTO

Refrigerant Lines
+ Refer to page HA-3 regarding ‘‘Precautions for Refrigerant
Connection’’.

RHA747G

HA-117

SERVICE PROCEDURES
Refrigerant Lines (Cont’d)

MANUAL AND AUTO

FOR RHD MODELS
RD engine

RHA740G

HA-118

SERVICE PROCEDURES

MANUAL AND AUTO

Checking Refrigerant Leaks
PRELIMINARY CHECK
Perform a visual inspection of all refrigeration parts, fittings, hoses,
and components for signs of A/C lubricant leakage, damage and
corrosion.

PRECAUTIONS FOR HANDLING LEAK DETECTOR

SHA705EB

When performing a refrigerant leak check, use an A/C leak detector or equivalent. Ensure that the instrument is calibrated and set
properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak
detector properly, read the operating instructions and perform any
specified maintenance.
Other gases in the work area or substances on the A/C
components, for example, anti-freeze, windshield washer
fluid, solvents and cleaners, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Do not
allow the sensor tip of the detector to come into contact with
any substance. This can also cause false readings and may
damage the detector.

1. Position probe approximately 5 mm (3/16 in) away from point
to be checked.

SHA707EA

2. When testing, circle each fitting completely with probe.

SHA706E

HA-119

MANUAL AND AUTO
SERVICE PROCEDURES
Checking Refrigerant Leaks (Cont’d)
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.

SHA708EA

CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no
refrigerant vapor or tobacco smoke in the vicinity of the
vehicle. Perform the leak test in calm area (low air/wind movement) so that the leaking refrigerant is not dispersed.
1. Turn engine off.
2. Connect a suitable A/C manifold gauge set to the A/C service
ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.452
bar, 3.52 kg/cm2, 50 psi) above 16°C (61°F). If less than
specification, evacuate and recharge the system with the specified amount of refrigerant.
NOTE: At temperatures below 16°C (61°F), leaks may not be
detected since the system may not reach 345 kPa
(3.452 bar, 3.52 kg/cm2, 50 psi).
4. Conduct the leak test from the high side to the low side at points
a , j
b ……). Refer to HA-117.
in alphabetical order (j
Perform a leak check for the following areas carefully. Clean the
component to be checked and move the leak detector probe
completely around the connection/component.
+ Compressor
Check the fitting of high and low pressure hoses, relief valve
and shaft seal.
+ Liquid tank
Check the pressure switch, tube fitting, weld seams and the
fusible plug mounts.
+ Service valves
Check all around the service valves. Ensure service valve caps
are secured on the service valves (to prevent leaks).
NOTE: After removing A/C manifold gauge set from service
valves, wipe any residue from valves to prevent any
false readings by leak detector.
+ Cooling unit (Evaporator)
Turn blower fan on ‘‘High’’ for at least 15 seconds to dissipate
any refrigerant trace in the cooling unit. Insert the leak detector
probe into the drain hose immediately after stopping the
engine. (Keep the probe inserted for at least ten seconds.)
5. If a leak detector detects a leak, verify at least once by blowing
compressed air into area of suspected leak, then repeat check.
6. Do not stop when one leak is found. Continue to check for
additional leaks at all system components.
7. Start engine.
8. Set the heater A/C control as follows:
a. A/C switch ON
b. Face mode
c. Recirculation switch ON
d. Max cold temperature
e. Fan speed high

HA-120

MANUAL AND AUTO
SERVICE PROCEDURES
Checking Refrigerant Leaks (Cont’d)
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4
through 6 above.

Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector on the high pressure line. The pressure in the high pressure line will gradually
drop after refrigerant circulation stops and pressure in the low
pressure line will gradually rise, as shown in the graph. Leaks
are more easily detected when pressure is high.

SHA839E

11. Discharge A/C system using approved refrigerant recovery
equipment. Repair the leaking fitting or component as necessary.
12. Evacuate and recharge A/C system and perform the leak test
to confirm no refrigerant leaks.
13. Conduct A/C performance test to ensure system works properly.

HA-121

SERVICE PROCEDURES

MANUAL AND AUTO

Compressor Mounting

RHA842AA

HA-122

SERVICE PROCEDURES

MANUAL AND AUTO

Compressor — DKS-17CH

SHA049F

Compressor Clutch
REMOVAL
+

When removing center bolt, hold clutch disc with clutch disc
wrench.

Remove the drive plate using Tool.
Insert holder’s three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate. Then, tighten the center bolt
to remove the drive plate.
After removing the drive plate, remove the shims from either the
drive shaft or the drive plate.

Remove the snap ring using external snap ring pliers.

SHA792E

SHA793E

SHA794E

HA-123

MANUAL AND AUTO
SERVICE PROCEDURES
Compressor Clutch (Cont’d)
+

Pulley removal
Use any commercially available pulley puller and tool. Position
the center of it on the end of the tool, and remove the pulley
assembly.
For pressed pulleys
To prevent deformation of the pulley groove, the puller
claws should be hooked under the pulley (not into the
groove). For machine latched pulleys
Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.

Remove the three field coil fixing screws and remove the field
coil.

SHA050F

SHA051F

INSPECTION
Clutch disc: If the contact surface shows signs of damage due to
excessive heat, replace clutch disc and pulley.
Pulley: Check the appearance of the pulley assembly. Check the
contact surface of the pulley for any sign of excessive grooving due
to slippage. If any sign is found, replace both the pulley and clutch
disc. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation.
Coil: Check coil for loose connection or cracked insulation.
RHA075C

INSTALLATION
+ Install the field coil.
Be sure to align the coil’s pin with the hole in the compressor’s front head.

SHA051F

Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.

SHA797EA

HA-124

MANUAL AND AUTO
SERVICE PROCEDURES
Compressor Clutch (Cont’d)
+

Install the drive plate on the drive shaft, together with the original shim(s). Press the drive plate down by hand.

SHA798E

Using the holder to prevent drive plate rotation, tighten the bolt
to 12 to 14 Nzm (1.2 to 1.4 kg-m, 9 to 10 ft-lb) torque.
After tightening the bolt, check that the pulley rotates
smoothly.
+

SHA799E

Check clearance around the entire periphery of clutch disc.
Disc-to-pulley clearance:
0.3 — 0.6 mm (0.012 — 0.024 in)
If the specified clearance is not obtained, replace adjusting
shim and readjust.

BREAK-IN OPERATION

SHA052F

When replacing compressor clutch assembly, always conduct the
break-in operation. This is done by engaging and disengaging the
clutch about thirty times. Break-in operation raises the level of
transmitted torque.

HA-125

SERVICE DATA AND SPECIFICATIONS
(SDS)

MANUAL AND AUTO

General Specifications
COMPRESSOR

LUBRICANT

Model
Type
Displacement

cm (cu in)/rev.

Cylinder bore x stroke

mm (in)

Direction of rotation
Drive belt

ZEXEL make DKS-17CH

Model

ZEXEL make DKS-17CH

Swash plate

Type

KLH00-PAGS0

168 (10.25)

Capacity

37.0 x 25.8 (1.457 x 1.016)
Clockwise
(Viewed from drive end)

m! (lmp fl oz)

Total in system

300 (10.6)

Compressor (Service parts)
charging amount

300 (10.6)

A Type

Inspection and Adjustment
REFRIGERANT

COMPRESSOR
Front A/C

Type
Capacity

Model

HFC-134a (R-134a)
kg (lb)

Clutch disc-to-pulley clearance
mm (in)

0.75 — 0.85
(1.65 — 1.87)

ENGINE IDLING SPEED (When A/C is ON.)
+

Refer to EC section.

BELT TENSION
+

Refer to MA section (‘‘Checking Drive Belts’’,
‘‘ENGINE MAINTENANCE’’).

HA-126

DKS-17CH
0.3 — 0.6
(0.012 — 0.024)

ALPHABETICAL INDEX
SECTION

IDX

ALPHABETICAL INDEX

A/C HFC134a (R134a) system service
procedure…………………………………………..HA-112
A/C HFC134a system service equipment precaution……………………………………..HA-9
A/C air flow……………………………………………..HA-13
A/C component layout………………………………HA-12
A/C compressor precaution…………………………HA-6
A/C compressor special service tool ………..HA-6, 7
A/C control linkage adjustment (auto
A/C)…………………………………………………….HA-77
A/C control operation (manual A/C) ……………HA-16
A/C harness layout (manual A/C) ………………HA-17
A/C lubricant (R134a)……………………………..HA-114
A/C relay…………………………………………………HA-97
A/C self-diagnoses (auto A/C)……………………HA-63
A/CCUT — Wiring diagram ……………………….EC-186
A/T control …………………………………………….EC-174
ABS sensor rotor ……………………………………..FA-15
ACC/SW — Wiring diagram ………………………EC-105
ACL/SW — Wiring diagram……………………….EC-164
ADJRES — Wiring diagram ………………………..EC-91
APS — Wiring diagram …………………………….EC-138
AT/C — Wiring diagram…………………………….EC-174
AUDIO — Wiring diagram………………………….EL-168
Accelerator position sensor……………………..EC-138
Accelerator position switch………………………EC-164
Accelerator switch (F/C)………………………….EC-105
Adjustment resistor…………………………………..EC-91
Air bag disposal……………………………………….RS-17
Air bag ……………………………………………………..RS-8
Air bleeding (hydraulic clutch) ……………………..CL-6
Air bleeding for brake system ……………………..BR-4
Air cleaner filter replacement…………………….MA-18
Air conditioner cut control …………………………EC-19
Air flow meter — See Mass air flow
sensor …………………………………………………EC-73
Air mix door control linkage
adjustment…………………………………………HA-81
Alternator…………………………………………………EL-56
Antenna — See Power antenna …………………EL-181
Audio and A/C control removal and
installation — See Instrument panel ………….BT-11
Audio …………………………………………………….EL-168
Auto lock free running hub ………………………..FA-13
Automatic amplifier…………………………………..HA-61
Axle housing (rear)…………………………………….RA-9

BACK/L — Wiring diagram…………………………..EL-78
Back door opener — See Back door………………BT-6
Back door trim………………………………………….BT-24
Back door window…………………………………….BT-45
Back door………………………………………………….BT-6

Back-up lamp switch (M/T) …………………………MT-4
Back-up lamp …………………………………………..EL-78
Battery…………………………………………………….EL-37
Baulk ring (M/T)……………………………………….MT-10
Body alignment ………………………………………..BT-49
Body mounting …………………………………………BT-48
Brake booster ………………………………………….BR-15
Brake fluid change …………………………………….BR-3
Brake fluid level and line check …………………..BR-3
Brake fluid level ………………………………………MA-23
Brake hydraulic line……………………………………BR-5
Brake inspection ……………………………………..MA-24
Brake master cylinder ………………………………BR-12
Brake pedal …………………………………………….BR-10
Bulb specifications ………………………………….EL-314
Bumper, front …………………………………………… BT-4
Bumper, rear ……………………………………………..BT-6

CD/CHG — Wiring diagram ……………………….EL-176
CHIME — Wiring diagram………………………….EL-136
CIGAR — Wiring diagram………………………….EL-156
CKPS — Wiring diagram…………………………..EC-143
CLOCK — Wiring diagram…………………………EL-157
CMPS — Wiring diagram ……………………………EC-68
COMPAS — Wiring diagram ………………………EL-117
CONSULT for ECCS ………………………………..EC-36
CONSULT general information……………………GI-33
COOL/F — Wiring diagram ……………………….EC-112
CSPS — Wiring diagram…………………………….EC-86
Cab body…………………………………………………BT-47
Camshaft inspection ………………………………..EM-36
Camshaft position sensor (PUMP)……………..EC-68
Center case (Transfer)………………………………TF-10
Charge air cooler fan control …………………..EC-177
Charge air temperature sensor ………………..EC-121
Chassis and body maintenance ………………..MA-20
Cigarette lighter………………………………………EL-156
Circuit breaker………………………………………….EL-14
Clock …………………………………………………….EL-157
Clutch booster……………………………………………CL-9
Clutch cover…………………………………………….CL-14
Clutch damper …………………………………………..CL-7
Clutch disc ………………………………………………CL-13
Clutch fluid level………………………………………MA-20
Clutch master cylinder ………………………………..CL-7
Clutch operating cylinder …………………………….CL-8
Clutch pedal………………………………………………CL-5
Clutch release bearing………………………………CL-11
Clutch release mechanism ………………………..CL-11
Clutch withdrawal lever……………………………..CL-11
Coil spring (front) ……………………………………..FA-25
Coil spring (rear) ……………………………………..RA-14
Collision diagnosis……………………………………RS-45
Combination meter removal and installation — See Instrument panel………………….BT-11

IDX-2

ALPHABETICAL INDEX
Combination meter………………………………….EL-102
Combination switch…………………………………..EL-57
Combustion chamber replacement…………….EM-32
Compass ……………………………………………….EL-116
Compression pressure……………………………..EM-10
Compressor special service tool ………………….HA-6
Connecting rod………………………………………..EM-47
Connecting rod………………………………………..EM-51
Connector inspection…………………………………GI-17
Console box — See Instrument panel …………..BT-11
Control lever (Transfer)……………………………….TF-9
Control sleeve position sensor…………………..EC-86
Coolant mixture ratio………………………………..MA-11
Coolant replacement………………………………..MA-14
Cooling circuit (engine)……………………………….LC-9
Cooling fan control …………………………………EC-112
Cooling fan motor…………………………………..EC-120
Cooling fan relay ……………………………………EC-120
Cooling fan………………………………………………LC-15
Counter gear (M/T)…………………………………..MT-10
Counter gear (Transfer) …………………………….TF-11
Coupling sleeve (M/T) ………………………………MT-10
Crankcase emission control system See Positive crankcase ventilation………….EC-21
Crankcase ventilation system — See
Positive crankcase ventilation ………………..EC-21
Crankshaft position sensor (TDC)…………….EC-143
Crankshaft………………………………………………EM-50
Cylinder block ……………………………………EM-45, 48
Cylinder head………………………………………….EM-28

D/LOCK — Wiring diagram………………………..EL-205
DEF — Wiring diagram ……………………………..EL-159
DEICER — Wiring diagram………………………..EL-167
DTRL — Wiring diagram ……………………………..EL-67
Data link connector for Consult………………….EC-36
Daytime light system…………………………………EL-65
Diagnosis sensor unit……………………………….RS-12
Diagnostic trouble code (DTC) for
ECCS OBD system ………………………………EC-30
Differential carrier assembly………………………PD-31
Differential carrier disassembly ………………….PD-14
Differential gear oil replacement………………..MA-22
Dimensions ………………………………………………GI-38
Dome light — See Interior lamp …………………..EL-93
Door glass…………………………………………………BT-9
Door lock…………………………………………………..BT-9
Door mirror………………………………………………BT-46
Door trim …………………………………………………BT-18
Door, front …………………………………………………BT-9
Door, rear ………………………………………………..BT-10
Drive belt inspection ………………………………..MA-12
Drive chain (Transfer) ……………………………….TF-11
Drive pinion diff. inspection ……………………….PD-19
Drive pinion height …………………………………..PD-27
Drive shaft (front) ……………………………………..FA-23
Dual pressure switch ………………………………..HA-11

Dual pressure switch………………………………..HA-97

ECCS basic inspection……………………………..EC-46
ECCS circuit diagram ……………………………….EC-11
ECCS component parts location………………….EC-8
ECCS on board diagnostic system …………….EC-30
ECCS symptom matrix chart……………………..EC-48
ECCS system diagram and chart ………………EC-12
ECCS-D control module…………………….EC-54, 110
ECM input/output signal ……………………………EC-54
ECTS — Wiring diagram …………………………….EC-78
EGR control (EGRC) — solenoid valve ………EC-155
EGR control valve ………………………………….EC-161
EGRC/V — Wiring diagram……………………….EC-155
Electric governor ………………………………EC-95, 148
Electric sunroof ………………………………………EL-186
Electrical diagnoses…………………………………..GI-20
Electrical unit………………………………………….EL-321
Electrical units location ……………………………EL-269
Electronic fuel injection pump ……………………EC-27
Engine compartment…………………………………BT-49
Engine coolant temperature sensor
(ECTS)………………………………………………..EC-78
Engine oil filter replacement ……………………..MA-14
Engine oil precautions …………………………………GI-4
Engine oil replacement …………………………….MA-13
Engine outer component parts ……………………EM-8
Engine removal ……………………………………….EM-43
Engine room — See Engine
compartment ………………………………………..BT-49
Engine serial number ………………………………..GI-37
Exhaust system inspection ……………………….MA-20
Exhaust system …………………………………………FE-3
Exterior……………………………………………………BT-26

FCUT — Wiring diagram …………………………..EC-129
FTS — Wiring diagram……………………………..EC-134
Fan control amp. ……………………………………..HA-88
Final drive disassembly…………………………….PD-14
Final drive removal and installation…………….PD-11
Finisher, interior — See Trim ……………………….BT-14
Floor trim…………………………………………………BT-14
Flow charts ………………………………………………GI-30
Fluids……………………………………………………….MA-9
Flywheel (clutch)…………………………………CL-13, 14
Flywheel runout……………………………………….EM-52
Fog lamp, rear …………………………………………EL-80
Fork rod (M/T) …………………………………………MT-12
Front axle ………………………………………………..FA-10
Front bumper …………………………………………….BT-4
Front case (Transfer) ………………………………..TF-10
Front disc brake ………………………………………BR-20
Front door …………………………………………………BT-9

IDX-3

ALPHABETICAL INDEX
Front drive shaft (Transfer) ………………………..TF-11
Front final drive disassembly (4WD)…………..PD-14
Front final drive removal and installation (4WD)……………………………………………PD-11
Front passenger air bag………………………..RS-8, 14
Front seat belt …………………………………………..RS-2
Front seat………………………………………………..BT-32
Front suspension ……………………………………..FA-24
Front washer ………………………………………….EL-141
Front wiper …………………………………………….EL-141
Fuel cut control (at no load & high
engine speed)………………………………………EC-20
Fuel cut solenoid valve …………………………..EC-129
Fuel filler lid……………………………………………….BT-6
Fuel filter replacement ……………………………..MA-16
Fuel gauge …………………………………………….EL-102
Fuel injection system………………………………..EC-15
Fuel line inspection ………………………………….MA-17
Fuel precautions …………………………………………GI-5
Fuel temperature sensor …………………………EC-134
Fuse block……………………………………………..EL-319
Fuse ……………………………………………………….EL-14
Fusible link ………………………………………………EL-14

GLOW — Wiring diagram………………………….EC-150
GOVNR — Wiring diagram …………………………EC-95
Garage jack and safety stand …………………….GI-39
Gauges………………………………………………….EL-102
Gear components (M/T) ……………………………MT-10
Glass ………………………………………………………..BT-9
Glow plug ………………………………………EC-150, 154
Glow relay ……………………………………..EC-150, 154
Grease …………………………………………………….MA-9
Ground distribution……………………………………EL-15

Hood…………………………………………………………BT-4
Horn ……………………………………………………..EL-155
How to erase DTC for ECCS OBD
system ………………………………………………..EC-30

IATS — Wiring diagram…………………………….EC-121
IC/FAN — Wiring diagram …………………………EC-177
ILL — Wiring diagram …………………………………EL-87
INT/L — Wiring diagram…………………………….EL-101
Identification plate……………………………………..GI-37
Idle speed inspection ……………………………….MA-19
Idle speed……………………………………………….EC-46
Illumination ………………………………………………EL-86
In vehicle sensor ……………………………………HA-105
Injection nozzle inspection………………………..MA-18
Injection nozzle………………………………………..EC-22
Injection timing control valve……………………EC-100
Instrument panel ………………………………………BT-11
Intake door control linkage adjustment ……….HA-84
Intake door motor …………………………………….HA-25
Intake sensor …………………………………………HA-111
Interior lamp …………………………………………….EL-93
Interior …………………………………………………….BT-14

Jacking points…………………………………………..GI-39
Joint connector (J/C)……………………………….EL-322
Journal bearing assembly (propeller
shaft)…………………………………………………….PD-8
Journal bearing disassembly (propeller
shaft)…………………………………………………….PD-7
Junction box (J/B) …………………………………..EL-319

H
L

H/AIM — Wiring diagram …………………………….EL-71
H/LAMP — Wiring diagram………………………….EL-61
HEAT UP — Wiring diagram ……………………..EC-182
HFC134a (R134a) system service
procedure…………………………………………..HA-112
HLC — Wiring diagram ……………………………..EL-153
HORN — Wiring diagram…………………………..EL-155
Harness connector inspection …………………….GI-17
Harness connector……………………………………..EL-2
Harness layout ……………………………………….EL-275
Headlamp aiming control …………………………..EL-70
Headlamp leveler — See Headlamp
aiming control……………………………………….EL-70
Headlamp wiper ……………………………………..EL-153
Headlamp………………………………………………..EL-61
Headlining — See Roof trim ………………………..BT-20
Heat up switch……………………………………….EC-182
Heated seat……………………………………………..BT-34

LSV (Load sensing valve) …………………………..BR-6
Lifting points …………………………………………….GI-40
Limited slip diff. adjustment……………………….PD-23
Limited slip diff. assembly …………………………PD-24
Limited slip diff. disassembly …………………….PD-21
Limited slip diff. inspection ………………………..PD-21
Location of electrical units ……………………….EL-269
Lock, door …………………………………………………BT-9
Lubricant (R134a) A/C…………………………….HA-114
Lubricants…………………………………………………MA-9
Lubrication circuit (engine) ………………………….LC-3
Lubrication-locks, hinges and hood
latches ………………………………………………..MA-27
Luggage compartment trim………………………..BT-14
Luggage room lamp………………………………….EL-93

IDX-4

ALPHABETICAL INDEX
M

M/T major overhaul ……………………………………MT-9
M/T removal and installation ……………………….MT-5
MAFS — Wiring diagram…………………………….EC-73
MAIN — Wiring diagram……………………………..EC-62
METER — Wiring diagram…………………………EL-104
MIL & Data link connectors circuit ……………EC-187
MIL/DL — Wiring diagram …………………………EC-187
MIRROR — Wiring diagram……………………….EL-188
Main drive gear (M/T)……………………………….MT-10
Main gear (Transfer) …………………………………TF-11
Mainshaft (M/T) ……………………………………….MT-10
Mainshaft (Transfer) ………………………………….TF-11
Maintenance (engine) ………………………………MA-12
Major overhaul (Transfer) ………………………….TF-10
Malfunction indicator lamp (MIL)………………..EC-31
Manifold tightening torque (intake &
exhaust)………………………………………………MA-12
Manual lock free running hub …………………….FA-11
Manual transmission number ……………………..GI-37
Mass air flow sensor (MAFS)…………………….EC-73
Master cylinder (brake) …………………………….BR-12
Meter …………………………………………………….EL-102
Mirror, door………………………………………………BT-46
Mirror, outside ………………………………………….BT-46
Mode door control linkage adjustment………..HA-77
Model variation …………………………………………GI-35
Molding — See Exterior ………………………………BT-26
Multiport fuel injection precautions………………..GI-3

NATS (Nissan Anti-theft System)………………EL-240
NATS — Wiring diagram……………………………EL-241
NLS — Wiring diagram……………………………..EC-125
NVH Troubleshooting (PD)………………………….PD-4
NVH troubleshooting (BR)…………………………..BR-2
NVH troubleshooting (EM)………………………….EM-6
NVH troubleshooting (FA)……………………………FA-3
NVH troubleshooting (MT) ………………………….MT-3
NVH troubleshooting (RA)…………………………..RA-3
NVH troubleshooting (RA)…………………………..RA-3
NVH troubleshooting (ST)……………………………ST-3
NVH troubleshooting (Transfer) ……………………TF-3
NVH troubleshooting CL……………………………..CL-3
Needle lift sensor …………………………………..EC-125
Neutral position switch (M/T) ………………………MT-4
Neutral position switch ……………………………EC-169

Oil pressure (engine) ………………………………….LC-3
Oil pump (engine) ………………………………………LC-4
Oil seal replacement (engine)……………………EM-20
Oil seal replacement (front final drive
4WD)…………………………………………………..PD-10
Oil seal replacement (front of final
drive)…………………………………………………..PD-10
Operating cylinder (clutch)…………………………..CL-8
Outside mirror ………………………………………….BT-46

P/ANT — Wiring diagram…………………………..EL-181
PCV (positive crankcase ventilation) ………….EC-21
PNP/SW — Wiring diagram ………………………EC-169
POWER — Wiring diagram……………………………EL-6
Park/Neutral position switch…………………….EC-169
Periodic maintenance (for Europe)………………MA-4
Pinion bearing preload diff. ……………………….PD-27
Pinion gear height diff. ……………………………..PD-27
Piston assembly………………………………………EM-46
Piston pin inspection………………………………..EM-46
Piston ring inspection……………………………….EM-47
Piston to bore clearance…………………………..EM-48
Power antenna……………………………………….EL-181
Power door lock ……………………………………..EL-204
Power door lock ……………………………………..EL-211
Power door mirror …………………………………..EL-188
Power seat …………………………………………….EL-190
Power steering fluid level…………………………….ST-5
Power steering gear………………………………….ST-12
Power steering hydraulic pressure ……………….ST-6
Power steering oil pump ……………………………ST-15
Power steering system bleeding…………………..ST-6
Power supply routing ………………………………….EL-5
Power window………………………………………..EL-196
Pre-delivery inspection……………………………….MA-2
Precautions (General) …………………………………GI-2
Pressure plate — See Clutch cover ……………..CL-14
Priming pump ………………………………………….EC-46
Propeller shaft greasing……………………………MA-21
Propeller shaft inspection …………………………MA-21
Propeller shaft on vehicle service ………………..PD-6
Propeller shaft vibration ……………………………..PD-6
Propeller shaft …………………………………………..PD-5

Quick-glow system check………………………..EC-153
Quick-glow system …………………………………EC-150
O
R

Oil
Oil
Oil
Oil

change (capacity) …………………………………MA-9
cooler (engine) ……………………………………..LC-7
jet………………………………………………………..LC-7
pan (engine) ………………………………………EM-13

R/FOG — Wiring diagram……………………………EL-80
R/HEAT — Wiring diagram………………………….HA-14

IDX-5

ALPHABETICAL INDEX
ROOM/L — Wiring diagram …………………………EL-95
Radiator ………………………………………………….LC-14
Radio — See Audio…………………………………..EL-168
Rear axle (disc brake type)…………………………RA-6
Rear bumper ……………………………………………..BT-6
Rear case (Transfer)…………………………………TF-10
Rear combination lamp removal and
installation ……………………………………………BT-26
Rear cover packing replacement diff…………..PD-11
Rear disc brake ……………………………………….BR-24
Rear door ………………………………………………..BT-10
Rear fog lamp ………………………………………….EL-80
Rear heater — Wiring diagram ……………………HA-14
Rear seat belt……………………………………………RS-5
Rear seat ………………………………………………..BT-35
Rear side window …………………………………….BT-44
Rear suspension ……………………………………..RA-12
Rear washer…………………………………………..EL-145
Rear window defogger…………………………….EL-158
Rear window ……………………………………………BT-42
Rear wiper……………………………………………..EL-145
Refrigerant connection precaution ……………….HA-2
Refrigerant discharging evacuating
charging …………………………………………….HA-113
Refrigerant general precaution…………………….HA-2
Refrigerant lines …………………………………….HA-117
Refrigeration cycle……………………………………HA-11
Release bearing (clutch)……………………………CL-11
Removal and installation (Transfer)………………TF-8
Reverse idler shaft (M/T) ………………………….MT-10
Reverse lamp switch (M/T) — See
Back-up lamp switch (M/T)………………………MT-4
Reverse main gear (M/T) ………………………….MT-10
Ring gear diff. inspection ………………………….PD-19
Road wheel size ……………………………………….GI-38
Roof trim …………………………………………………BT-20
Room lamp — See Interior lamp ………………….EL-93
Rotor disc (front) ………………………………………FA-14

S/LOCK — Wiring diagram ………………………..EL-215
S/SIG — Wiring diagram …………………………..EC-162
SAE J1930 terminology list ………………………..GI-43
SEAT — Wiring diagram ……………………………EL-190
SMJ (super multiple junction) …………………..EL-317
SROOF — Wiring diagram ………………………..EL-186
SRS — See Supplemental Restraint
System………………………………………………….RS-8
SRS Trouble diagnoses ……………………………RS-22
STAB — Wiring diagram …………………………….RA-18
START — Wiring diagram……………………………EL-45
Screw jack ……………………………………………….GI-39
Seal — See Exterior …………………………………..BT-26
Seat belt inspection …………………………………MA-27
Seat belt pre-tensioner disposal ………………..RS-17
Seat belt pre-tensioner……………………………..RS-12
Seat belt, front…………………………………………..RS-2
Seat belt, rear……………………………………………RS-5

Seat, front ……………………………………………….BT-32
Seat, rear ………………………………………………..BT-35
Seat, second (2nd) …………………………………..BT-35
Seat, third (3rd)………………………………………..BT-37
Second (2nd) seat ……………………………………BT-35
Self-diagnostic results ………………………………EC-31
Shift control (Transfer) ………………………………TF-12
Shift control components (M/T)………………….MT-12
Shift fork (M/T) ………………………………………..MT-12
Shift lever ……………………………………………….MT-12
Shock absorber (front) ………………………………FA-25
Shock absorber (rear) ………………………………RA-14
Side bearing preload (front final drive
4WD)…………………………………………………..PD-27
Side bearing preload diff. ………………………….PD-27
Side trim………………………………………………….BT-14
Side window — See Rear side window…………BT-44
Speedometer………………………………………….EL-102
Spiral cable……………………………………………..RS-13
Stabilizer bar (front) ………………………………….FA-25
Stabilizer bar (rear) ………………………………….RA-15
Stabilizer release device — Wiring
diagram……………………………………………….RA-18
Stabilizer release device …………………………..RA-16
Standardized relay ……………………………………..EL-3
Start signal ……………………………………………EC-162
Starter …………………………………………………….EL-51
Starting system ………………………………………..EL-45
Steering gear and linkage inspection …………MA-26
Steering linkage ……………………………………….ST-19
Steering switch…………………………………………EL-59
Steering wheel and column …………………………ST-8
Steering wheel play ……………………………………ST-4
Steering wheel turning force………………………..ST-6
Striking rod (M/T) …………………………………….MT-12
Sub-gear (M/T) ………………………………………..MT-10
Sunload sensor ……………………………………..HA-107
Sunroof, electric ……………………………………..EL-186
Sunroof……………………………………………………BT-39
Super lock ……………………………………………..EL-211
Supplemental Restraint System…………………..RS-8
Supplemental restraint system — Wiring
diagram……………………………………………….RS-27
Symbols and abbreviations ………………………….GI-7
Synchronizer (M/T)…………………………………..MT-10

TCV — Wiring diagram …………………………….EC-100
Tachometer ……………………………………………EL-102
Thermometer………………………………………….EL-116
Thermostat………………………………………………LC-12
Third (3rd) seat ………………………………………..BT-37
Three way catalyst precautions…………………….GI-4
Throttle control solenoid valve …………………EC-155
Throttle control solenoid valve …………………EC-161
Throwout bearing — See Clutch release
bearing ………………………………………………..CL-11
Thrust washer selection diff. ……………………..PD-27

IDX-6

ALPHABETICAL INDEX
Tie-rod ball joints………………………………………ST-19
Tie-rod …………………………………………………….ST-19
Timing belt………………………………………………EM-15
Tire rotation …………………………………………….MA-25
Tire size …………………………………………………..GI-38
Tooth contact (front final drive 4WD) ………….PD-29
Tooth contact diff. …………………………………….PD-29
Tow truck towing……………………………………….GI-41
Towing point……………………………………………..GI-42
Transfer case …………………………………………..TF-10
Transfer fluid replacement ………………………..MA-21
Transfer serial number ………………………………GI-37
Transmission case (M/T)…………………………….MT-9
Trim ………………………………………………………..BT-14
Trouble diagnoses …………………………………….GI-30
Turbocharger charge air cooler …………………EM-27
Turbocharger…………………………………………..EM-23
Two-pole lift ……………………………………………..GI-40

Under body ……………………………………………..BT-51

VSS — Wiring diagram ………………………………EC-82
Vacuum hose (brake system) ……………………BR-17
Vacuum hose (brake system) ……………………BR-18
Vacuum hose drawing (ECCS) ………………….EC-13
Valve clearance……………………………………….EM-40
Valve guide …………………………………………….EM-31
Valve lifter ………………………………………………EM-35
Valve seat ………………………………………………EM-32
Valve spring ……………………………………………EM-34

Vehicle identification number………………………GI-36
Vehicle speed sensor (VSS) ……………………..EC-82
Viscosity number (SAE)……………………………MA-10

WARN — Wiring diagram ………………………….EL-123
WINDOW — Wiring diagram ……………………..EL-198
WIP/R — Wiring diagram…………………………..EL-146
WIPER — Wiring diagram …………………………EL-142
Warning chime ……………………………………….EL-135
Warning lamps ……………………………………….EL-121
Washer, front………………………………………….EL-141
Washer, rear…………………………………………..EL-145
Water pump …………………………………………….LC-10
Water temperature gauge ………………………..EL-102
Weatherstrip — See Exterior ……………………….BT-26
Wheel alignment (front) ………………………………FA-8
Wheel bearing (front axle) …………………………..FA-5
Wheel bearing (rear) ………………………………….RA-5
Wheel hub (front) ……………………………………..FA-14
Wheel size ……………………………………………….GI-38
Window, back door …………………………………..BT-45
Window, door …………………………………………….BT-9
Window, rear side …………………………………….BT-44
Window, side — See Rear side window………..BT-44
Windshield……………………………………………….BT-42
Wiper deicer…………………………………………..EL-166
Wiper, front…………………………………………….EL-141
Wiper, rear …………………………………………….EL-145
Wiring diagram (cell code) list ………………….EL-315
Wiring diagrams………………………………………….GI-8
Withdrawal lever (clutch) …………………………..CL-11

IDX-7

ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION

LC
LC

CONTENTS
PRECAUTIONS AND PREPARATION……………………….1
Liquid Gasket Application Procedure ……………………..1
Special Service Tools …………………………………………..2
ENGINE LUBRICATION SYSTEM …………………………….3
Lubrication Circuit ………………………………………………..3
Oil Pressure Check………………………………………………3
Oil Pump …………………………………………………………….4
Oil Cooler……………………………………………………………7
Oil Jet…………………………………………………………………7
Turbocharger ………………………………………………………8
ENGINE COOLING SYSTEM……………………………………9
Cooling Circuit …………………………………………………….9

System Check……………………………………………………..9
Water Pump ………………………………………………………10
Thermostat………………………………………………………..12
Radiator ……………………………………………………………14
Refilling Engine Coolant ……………………………………..14
Cooling Fan (Crankshaft driven) ………………………….15
Cooling Fan (Motor driven)………………………………….15
Radiator (Aluminum type)……………………………………16
Overheating Cause Analysis ……………………………….20
SERVICE DATA AND SPECIFICATIONS (SDS) ……….21
Engine Lubrication System………………………………….21
Engine Cooling System ………………………………………21

PRECAUTIONS AND PREPARATION
Liquid Gasket Application Procedure

SEM164F

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

AEM080

LC-1

PRECAUTIONS AND PREPARATION
Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool name

Description

ST25051001*
Oil pressure gauge

Measuring oil pressure
Maximum measuring range:
2,452 kPa (24.5 bar, 25
kg/cm2, 356 psi)
NT558

ST25052000*
Hose

Adapting oil pressure gauge
to cylinder block

NT559

EG17650301
Radiator cap tester
adapter

Adapting radiator cap tester
to radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

NT564

KV99103510
Radiator plate pliers A

Installing radiator upper and
lower tanks

NT224

KV99103520
Radiator plate pliers B

Removing radiator upper and
lower tanks

NT225

WS39930000
Tube presser

Pressing the tube of liquid gasket

NT052

LC-2

ENGINE LUBRICATION SYSTEM
Lubrication Circuit

SLC201B

Oil Pressure Check
WARNING:
+ Be careful not to burn yourself, as the engine and oil may
be hot.
+ Oil pressure check should be done in ‘‘Neutral’’ gear position.

SLC694A

1. Check oil level.
2. Remove oil pressure switch.

SLC194B

LC-3

ENGINE LUBRICATION SYSTEM
Oil Pressure Check (Cont’d)
3. Install pressure gauge.
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.

SLC993

Engine
rpm

Approximate discharge pressure
kPa (bar, kg/cm2, psi)

Idle speed
3,000

More than 78 (0.78, 0.8, 11)
318.7 — 424.6
(3.19 — 4.25, 3.25 — 4.33, 46.2 — 61.6)

If difference is extreme, check oil passage and oil pump for oil
leaks.
6. Install oil pressure switch with sealant.
Use proper liquid sealant.
Oil pressure switch:
: 10 — 16 Nzm (1.0 — 1.6 kg-m, 87 — 139 in-lb)

Oil Pump
REMOVAL AND INSTALLATION
1. Disconnect battery terminal.
2. Drain engine oil.
3. Drain coolant from radiator and cylinder block. Refer to MA
section (‘‘Changing Engine Coolant’’, ‘‘ENGINE MAINTENANCE’’).
4. Remove radiator shroud.
5. Remove drive belts. Refer to MA section (‘‘Checking Drive
Belts’’).
6. Remove crankshaft pulley and front upper and lower belt covers. Refer to EM section (‘‘TIMING BELT’’).
7. Remove oil pan. Refer to EM section (‘‘OIL PAN’’).
8. Remove oil strainer.
9. Remove oil pump assembly.
10. Installation is in reverse order of removal.
+ Before installing oil pump, remove liquid gasket from mating
surface of oil pump using a scraper.
Be sure liquid gasket in grooves is also removed.
+ Remove liquid gasket from mating surface of cylinder block.
+ Clean all traces of liquid gasket using white gasoline.

LC-4

ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)

SLC195B

REGULATOR VALVE INSPECTION
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil and check to make sure
that it falls smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump assembly.

SLC295

OIL PRESSURE RELIEF VALVE INSPECTION
Inspect oil pressure relief valve for movement, cracks and breaks
by pushing the ball. If replacement is necessary, remove valve by
prying it out with a screwdriver.
Install a new valve in place by tapping it.

SLC994

LC-5

ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
OIL PUMP INSPECTION
Using a feeler gauge, check the following clearance.
Unit: mm (in)
Body to outer gear clearance

1
V

Inner gear to crescent clearance

2
V
Outer gear to crescent clearance V
3
Housing to inner gear clearance V
4
Housing to outer gear clearance V
5

SLC779

Inner gear to brazed portion of housing
clearance V
6 =A− B

0.11 — 0.20 (0.0043 — 0.0079)
0.216 — 0.326 (0.0085 — 0.0128)
0.21 — 0.32 (0.0083 — 0.0126)
0.05 — 0.09 (0.0020 — 0.0035)
0.05 — 0.11 (0.0020 — 0.0043)
0.106 — 0.152 (0.0042 — 0.0060)

If it exceeds the limit, replace gear set or entire oil pump
assembly.

SLC780

SLC015A

SLC016A

LC-6

ENGINE LUBRICATION SYSTEM
Oil Cooler
REMOVAL AND INSTALLATION

SLC196B

Install oil cooler as shown in the figure.

INSPECTION
1. Check oil cooler element and bracket for cracks.
2. Check coolant inlet of oil cooler for clogging by blowing through
it. Replace it if necessary.

Oil Jet
INSPECTION
1. Push cut-off valve of oil jet bolt with a clean resin or brass rod
and make sure that cut-off valve moves smoothly with proper
repulsion.
2. Make sure that the oil jet passage is not clogged. Clean with a
wire if necessary.

SLC015

LC-7

ENGINE LUBRICATION SYSTEM
Oil Jet (Cont’d)
When installing oil jet, align oil jet’s boss with hole on cylinder block.
Oil jet bolt:
: 30 — 40 Nzm (3.1 — 4.1 kg-m, 22 — 30 ft-lb)

SLC975

Turbocharger

SLC197B

+
+
+

Before removing water tube, drain coolant first.
Be careful not to deform tubes.
After installation, run engine for a few minutes, and check
for oil leakage.

LC-8

ENGINE COOLING SYSTEM
Cooling Circuit

SLC226A

System Check
WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around cap and carefully loosen it a quarter turn to release built-up pressure. Then remove the cap
completely.

CHECKING COOLING SYSTEM HOSES
Check hoses for proper attachment, leaks, cracks, damage, loose
connections, chafing and deterioration.

CHECKING RADIATOR CAP
Apply pressure to radiator cap by means of a cap tester to see if it
is satisfactory.
Radiator cap relief pressure:
78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2, 11 — 14 psi)

SLC613

LC-9

ENGINE COOLING SYSTEM
System Check (Cont’d)
Pull the negative pressure valve to open it. Check that it closes
completely when released.

SMA967B

CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system by means of a tester to check
for leakage.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
CAUTION:
Use of pressure higher than the specified value may cause
damage to radiator.

SMA007D

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

REMOVAL

SMA003D

1. Drain coolant from radiator and cylinder block.
Cylinder block drain plug (Use proper sealant):
: 34 — 44 Nzm (3.5 — 4.5 kg-m, 25 — 33 ft-lb)
Refer to MA section (‘‘Changing Engine Coolant’’, ‘‘ENGINE
MAINTENANCE’’).
2. Remove radiator shroud.
3. Remove drive belts. Refer to MA section (‘‘Checking Drive
Belts’’).
4. Remove fan coupling with fan.
5. Remove water pump.

LC-10

ENGINE COOLING SYSTEM
Water Pump (Cont’d)

SLC997-A

INSPECTION
1. Check for rusted or corroded body assembly and vane.
2. Check for excessive end play and rough operation.

INSTALLATION
Remove liquid gasket from mating surface of pump housing
using a scraper.
Be sure liquid gasket in grooves is also removed.
+ Remove liquid gasket from mating surface of cylinder block.
+ Clean all traces of liquid gasket using white gasoline.
+

SLC998

+
+

Cut off tip of nozzle of liquid gasket tube at point shown in figure.
Use Genuine Liquid Gasket or equivalent.

SLC822

LC-11

ENGINE COOLING SYSTEM
Water Pump (Cont’d)
Apply a continuous bead of liquid gasket to mating surface of
pump housing as shown.
a. Be sure diameter of liquid gasket is within 2.0 to 3.0 mm
(0.079 to 0.118 in) dia. range.
b. Attach pump housing to cylinder block within five minutes
of applying liquid gasket.
c. After installing pump housing, wait at least 30 minutes
before starting engine.
+

SLC001A

Thermostat

SLC002A

INSPECTION
1. Check valve seating condition at ordinary temperatures. It
should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Valve opening temperature
Maximum valve lift

C° (°F)
mm/°C (in/°F)

82.0 (180)
10/90 (0.39/194)

3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.
SLC343

INSTALLATION
+
+
+

Remove liquid gasket from mating surface of thermostat using
a scraper.
Similarly, remove liquid gasket from mating surface of cylinder
block.
Clean all traces of liquid gasket using white gasoline.

Scraper
SLC790

LC-12

ENGINE COOLING SYSTEM
Thermostat (Cont’d)
+
+

Cut off tip of nozzle of liquid gasket at point shown in figure.
Use Genuine Liquid Gasket or equivalent.

SLC822
Diameter of liquid gasket:
2.0 — 3.0 mm (0.079 — 0.118 in)

Apply a continuous bead of liquid gasket to mating surface of
water inlet.
a. Be sure diameter of liquid gasket is within 2.0 to 3.0 mm (0.079
to 0.118 in).
b. Attach water inlet to cylinder block within five minutes after
applying liquid gasket.
c. After installing water inlet, wait at least 30 minutes before refilling coolant and starting engine.
+

SLC824

LC-13

ENGINE COOLING SYSTEM
Radiator
REMOVAL AND INSTALLATION
1.
2.
3.
4.
5.
6.
7.

Remove under cover.
Drain coolant from radiator drain plug.
Disconnect radiator upper and lower hoses.
Remove radiator lower shroud.
Disconnect reservoir tank hose.
Remove radiator.
After repairing or replacing radiator, install any part removed in
reverse order of removal.

SLC198B

Refilling Engine Coolant
For details on refilling engine coolant, refer to MA section (‘‘REFILLING ENGINE COOLANT’’, ‘‘Changing Engine Coolant’’).

LC-14

ENGINE COOLING SYSTEM
Cooling Fan (Crankshaft driven)
DISASSEMBLY AND INSTALLATION
+
+
+
SLC176B

Do not release the drive belt tension by removing the fan/water
pump pulley.
Fan coupling cannot be disassembled and should be replaced
F is present, install fan so that side
as a unit. If front mark j
F faces the front.
marked j
Install the drive belt only after the fan and fan coupling to water
pump flange bolts/nuts have been properly torqued.
Proper alignment of these components is essential. Improper
alignment will cause them to wobble and may eventually cause
the fan to separate from the water pump causing extensive
damage.

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

SLC072

Cooling Fan (Motor driven)
Cooling fan is controlled by ECM. For details, refer to ‘‘Cooling
Fan’’, ‘‘TROUBLE DIAGNOSIS FOR DTC 28’’ in EC section.

SLC177B

LC-15

ENGINE COOLING SYSTEM
Radiator (Aluminum type)

SLC882AB

Aluminum radiator can be disassembled by using special procedures and special service tools.

DISASSEMBLY
1. Remove tank with Tool.

SLC903

Grip the crimped edge and bend it upwards so that Tool slips
off.
Do not bend excessively.
+

SLC893

LC-16

ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
In areas where Tool cannot be used, use a screwdriver to bend
the edge up.
Be careful not to damage tank.
+

SLC908A

2. Make sure the edge stands straight up.
3. Remove oil cooler from tank. (A/T model only)

SLC931

ASSEMBLY
1. Install oil cooler.
Pay attention to direction of conical washer.

SLC894

2. Clean contact portion of tank.

SLC932

3. Install sealing rubber.
Push it in with fingers.
Be careful not to twist sealing rubber.

SLC917A

LC-17

ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
4. Caulk tank in specified sequence with Tool.

SLC904

SLC896

Use pliers in the locations where Tool cannot be used.

SLC897

5. Make sure that the rim is completely crimped down.
Standard height ‘‘H’’:
10.0 — 11.0 mm (0.394 — 0.433 in)
6. Confirm that there is no leakage.
Refer to Inspection.

SLC554A

LC-18

ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
INSPECTION
1. Apply pressure with Tool.
Specified pressure value:
98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler as well.

SLC933

2. Check for leakage.

SLC934

LC-19

ENGINE COOLING SYSTEM
Overheating Cause Analysis
Symptom

Check items

Water pump malfunction

Worn or loose drive belt

Thermostat stuck closed
Poor heat transfer

—
Dust contamination or paper
clogging

Damaged fins

—

Mechanical damage
Clogged radiator cooling tube

Excess foreign material (rust,
dirt, sand, etc.)

Cooling fan does not operate
Fan coupling does not operate
Reduced air flow

—

High resistance to fan rotation
Damaged fan blades

Cooling
system parts
malfunction

Damaged radiator shroud

—

Improper coolant mixture ratio

—

Poor coolant quality

—

—
Loose clamp

Cooling hose
Cracked hose
Water pump

Poor sealing
Loose

Radiator cap
Poor sealing

Coolant leaks

O-ring for damage, deterioration or improper fitting

Insufficient coolant
Radiator

Cracked radiator tank
Cracked radiator core

Reservoir tank

Cracked reservoir tank
Cylinder head deterioration

Overflowing reservoir tank

Exhaust gas leaks into cooling
system

Cylinder head gasket deterioration
High engine rpm under no load

Abusive driving

Driving in low gear for extended
time
Driving at extremely high speed

—

Overload on engine

Powertrain system malfunction
Installed improper size wheels
and tires

Except
cooling
system parts
malfunction

—

Dragging brakes
Improper ignition timing
Blocked bumper

—
Installed car brassiere

Blocked radiator grille
Blocked or restricted air flow
Blocked radiator

Mud contamination or paper
clogging
—

Blocked condenser
—
Installed large fog lamp

LC-20

—

SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Lubrication System
Oil pressure check

Oil pump

Engine
rpm

Approximate discharge pressure
kPa (bar, kg/cm2, psi)

Idle speed
3,000

More than 78 (0.78, 0.8, 11)
318.7 — 424.6
(3.19 — 4.25, 3.25 — 4.33, 46.2 — 61.6)

Body to outer gear clearance
1
V

Unit: mm (in)
0.11 — 0.20 (0.0043 — 0.0079)

Inner gear to crescent
clearance V
2

0.216 — 0.326 (0.0085 — 0.0128)

Outer gear to crescent
clearance V
3

0.21 — 0.32 (0.0083 — 0.0126)

Housing to inner gear
clearance V
4

0.05 — 0.09 (0.0020 — 0.0035)

Housing to outer gear
clearance V
5

0.05 — 0.11 (0.0020 — 0.0043)

Inner gear to brazed portion
of housing clearance V
6

0.106 — 0.152 (0.0042 — 0.0060)

Engine Cooling System
Thermostat
Valve opening temperature
Maximum valve lift

Radiator
C° (°F)
mm/°C (in/°F)

82.0 (180)

Cap relief pressure

10/95 (0.39/203)
Leakage test pressure

LC-21

Unit: kPa (bar, kg/cm2, psi)
78 — 98
(0.78 — 0.98, 0.8 — 1.0, 11 — 14)
157 (1.57, 1.6, 23)

MAINTENANCE
SECTION

CONTENTS
PRECAUTIONS AND PREPARATION……………………….1
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’……………1
Special Service Tools …………………………………………..1
PRE-DELIVERY INSPECTION ITEMS……………………….2
GENERAL MAINTENANCE ……………………………………..3
PERIODIC MAINTENANCE ……………………………………..4
Engine Oil & Minor Service …………………………………..4
Engine and Emission Control Service…………………….5
Chassis and Body Services…………………………………..6
Maintenance Under Severe Driving Conditions ……….8
RECOMMENDED FLUIDS AND LUBRICANTS………….9
Fluids and Lubricants …………………………………………..9
SAE Viscosity Number ……………………………………….10
Anti-freeze Coolant Mixture Ratio ………………………..11
ENGINE MAINTENANCE ……………………………………….12
Checking Tightening Torque ………………………………..12
Checking Drive Belt ……………………………………………12
Changing Engine Oil…………………………………………..13
Changing Engine Oil Filter ………………………………….14
Changing Engine Coolant……………………………………14
Checking Cooling System …………………………………..16
Checking and Replacing Fuel Filter and Draining
Water ……………………………………………………………….16
Checking Fuel Lines …………………………………………..17
Cleaning and Replacing Air Cleaner Filter …………….18
Checking Injection Nozzle …………………………………..18
Checking Idle Speed ………………………………………….19
Timing Belt Replacement…………………………………….19
CHASSIS AND BODY MAINTENANCE …………………..20
Checking Exhaust System…………………………………..20
Checking Clutch Fluid Level and Leaks………………..20
Checking Clutch System …………………………………….20

Checking M/T Oil Level and Leaks ………………………20
Changing M/T Oil……………………………………………….20
Checking Water Entry…………………………………………21
Checking Transfer Fluid Level……………………………..21
Changing Transfer Fluid ……………………………………..21
Checking Propeller Shaft…………………………………….21
Greasing Nipples of Propeller Shafts ……………………21
Checking Differential Gear Oil……………………………..22
Changing Differential Gear Oil …………………………….22
Checking Front Wheel Bearing Grease ………………..22
Repacking Front Wheel Bearing and Axle Joint
Grease ……………………………………………………………..23
Checking Free-running Hub Grease …………………….23
Checking Water Entry in Knuckle Flange………………23
Checking Brake Fluid Level and Leaks…………………23
Checking Brake System ……………………………………..24
Changing Brake Fluid …………………………………………24
Checking Brake Booster, Vacuum Hoses,
Connections and Check Valve …………………………….24
Checking Disc Brake ………………………………………….24
Balancing Wheels ………………………………………………25
Tire Rotation ……………………………………………………..25
Checking Power Steering Fluid and Lines …………….26
Checking Steering Damper …………………………………26
Checking Steering Gear Box and Linkage…………….26
Lubricating Locks, Hinges and Hood Latches………..27
Checking Seat Belts, Buckles, Retractors,
Anchors and Adjusters………………………………………..27
Checking Body Corrosion……………………………………28
SERVICE DATA AND SPECIFICATIONS (SDS) ……….29
Engine Maintenance …………………………………………..29
Chassis and Body Maintenance…………………………..29

PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’
The Supplemental Restraint System such as ‘‘AIR BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’ used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS composition which is available to NISSAN MODEL Y61 is as follows (The composition varies
according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.

Special Service Tools
Tool number
Tool name

Description

EG17650301
Radiator cap
tester adapter

Adapting radiator
cap tester to radiator
filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

NT564

KV10113600
Fuel filter wrench
Oil filter wrench

Removing fuel filter
Removing oil filter

a: Max. 100 mm
(3.94 in) dia.

NT553

MA-1

PRE-DELIVERY INSPECTION ITEMS
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.

UNDER HOOD — engine off

UNDER BODY

h Radiator coolant level and coolant hose connections for leaks
h Battery fluid level, specific gravity and conditions of battery terminals
h Drive belts tension
h Fuel filter for water or dusts, and fuel lines and
connections for leaks
h Engine oil level and oil leaks
h Clutch and brake reservoir fluid level and fluid
lines for leaks
h Windshield and rear window washer and headlamp cleaner reservoir fluid level
h Power steering reservoir fluid level and hose
connections for leaks

h Manual transmission/transaxle gear oil, transfer
fluid and differential gear oil level
h Brake and fuel lines and oil/fluid reservoirs for
leaks
h Tighten bolts and nuts of steering linkage and
gear box, suspension, propeller shafts and drive
shafts
X
h Tighten rear body bolts and nuts (Models with
wooden bed only)

ON INSIDE AND OUTSIDE
X
h
Remove front spring/strut spacer (If applicable)
h Operation of all instruments, gauges, lights and
accessories
h Operation of horn(s), wiper and washer
h Steering lock for operation
h Check air conditioner for gas leaks
h Front and rear seats, and seat belts for operation
h All moldings, trims and fittings for fit and alignment
h All windows for operation and alignment
h Hood, trunk lid, door panels for fit and alignment
h Latches, keys and locks for operation
h Weatherstrips for adhesion and fit
h Headlamp aiming
h Tighten wheel nuts (Inc. inner nuts if applicable)
h Tire pressure (Inc. spare tire)
h Check front wheels for toe-in
h Install clock/voltmeter/room lamp fuse (If applicable)
X
h
Install deodorizing filter to air purifier (If applicable)
X
h
Remove wiper blade protectors (If applicable)

ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing
and kickdown
h Steering control and returnability
h Engine performance
h Squeaks and rattles
h
h
h
h

ENGINE OPERATING AND HOT
h Adjust idle mixture and speed (and ignition timing*1)
h Automatic transmission/transaxle fluid level
h Engine idling and stop knob operation (Diesel
only)

FINAL INSPECTION
h Install necessary parts (outside mirror, wheel
covers, seat belts, mat, carpet or mud flaps)
h Inspect for interior and exterior metal and paint
damage
h Check for spare tire, jack, tools (wheel chock),
and literature
h Wash, clean interior and exterior
*1: Not required on models with a direct ignition system
X
h : Not applicable to this model.

MA-2

GENERAL MAINTENANCE
General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the
checks and inspections themselves or they can have their NISSAN dealers do them.
Item

Reference pages

OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise
specified.
Tires Check the pressure with a gauge periodically when at a service station, including the
spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or
excessive wear.

—

Windshield wiper blades Check for cracks or wear if they do not wipe properly.

—

Doors and engine hood Check that all doors, the engine hood, the trunk lid and back door
operate properly. Also ensure that all latches lock securely. Lubricate hinges, latches, rollers and
links if necessary. Make sure that the secondary latch keeps the hood from opening when the
primary latch is released.
When driving in areas using road salt or other corrosive materials, check for lubrication frequently.

MA-27

Tire rotation Tires should be rotated every 5,000 km (3,000 miles) for 4WD models.

MA-25

INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc.
Lights Make sure that the headlights, stop lights, tail lights, turn signal lights, and other lights
are all operating properly and installed securely. Also check headlight aim.

—

Warning lights and chimes Make sure that all warning lights and chimes are operating properly.

—

Steering wheel Check for change in the steering conditions, such as excessive free play, hard
steering or strange noises.
Free play: Less than 35 mm (1.38 in)

—

Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for
cuts, fraying, wear or damage.

MA-27

UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the
engine oil or refuel.
Windshield washer fluid Check that there is adequate fluid in the tank.

—

Engine coolant level Check the coolant level when the engine is cold.

MA-14, 15

Engine oil level Check the level after parking the vehicle on a level spot and turning off the
engine.

MA-13, 14

Brake and clutch fluid level Make sure that the brake and clutch fluid levels are between the
‘‘MAX’’ and ‘‘MIN’’ lines on the reservoir.

MA-20, 23

Battery Check the fluid level in each cell. It should be between the ‘‘MAX’’ and ‘‘MIN’’ lines.

MA-3

—

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

Engine Oil & Minor Service
Annual driving distance below 30,000 km (18,000 miles)
Abbreviations: R = Replace, I = Inspect and correct or replace as necessary.
MAINTENANCE OPERATION
Perform either at number of kilometers (miles) or
months, whichever comes first.

km x 1,000

(Miles x 1,000)

(6)

(12)

(18)

(24)

(30)

(36)

(42)

(48)

(54)

Months

Reference
page

Underhood and under vehicle
Engine oil (Use API CD oil).

MA-14

Engine oil filter.

MA-14

Drive belts

MA-12

NOTE: Maintenance items with ‘‘.’’ should be performed more frequently according to ‘‘Maintenance Under Severe Driving
Conditions’’.

Annual driving distance over 30,000 km (18,000 miles)
Abbreviations: R = Replace, I = Inspect and correct or replace as necessary.
MAINTENANCE OPERATION
km x 1,000

(Miles x 1,000)

(6)

(12)

(18)

(24)

(30)

(36)

(42)

(48)

(54)

Reference
page

Underhood and under vehicle
Engine oil (Use API CD oil).

MA-14

Engine oil filter.

MA-14

Drive belts

MA-12

NOTE: Maintenance items with ‘‘.’’ should be performed more frequently according to ‘‘Maintenance Under Severe Driving
Conditions’’.

MA-4

PERIODIC MAINTENANCE
Engine and Emission Control Service
Annual driving distance below 30,000 km (18,000 miles)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust.
MAINTENANCE OPERATION
Perform either at number of kilometers (miles)
or months, whichever comes first.

[ ]: At the specified mileage only

MAINTENANCE INTERVAL
km x 1,000

(Miles x 1,000)

(6)

(12)

(18)

(24)

(30)

(36)

(42)

(48)

(54)

Months

Reference
page

Underhood and under vehicle
Engine anti-freeze coolant (Ethylene glycol base, LLC)

See NOTE (2)

Cooling system

MA-14

MA-16

Fuel lines

MA-17

Fuel filter

MA-16

Air cleaner filter (Viscous paper type).

MA-18

Intake & exhaust valve clearance
Injection nozzles

See NOTE (3)

MA-18

Timing belts for camshaft and injection pump

[R]

NOTE: (1) Maintenance items with ‘‘.’’ should be performed more frequently according to ‘‘Maintenance Under Severe
Driving Conditions’’.
(2) First replace at 80,000 km (48,000 miles) or 48 months, then every 60,000 km (36,000 miles) or 36 months.
(3) If engine power decreases, black smoke is emitted or engine noise increases, check and, if necessary, adjust
the fuel injection nozzle’s starting pressure and the fuel spray pattern.
*1: ‘‘VALVE CLEARANCE’’, RD in EM section
*2: ‘‘TIMING BELT’’ RD in EM section

Annual driving distance over 30,000 km (18,000 miles)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust.
MAINTENANCE OPERATION

MAINTENANCE INTERVAL
km x 1,000

(Miles x 1,000)

(6)

(12)

(18)

(24)

(30)

(36)

(42)

(48)

(54)

Reference
page

Underhood and under vehicle
Engine anti-freeze coolant (Ethylene glycol base, LLC)

See NOTE (2)

Cooling system

R
I

MA-14
MA-16

Fuel lines

MA-17

Fuel filter

MA-16

Air cleaner filter (Viscous paper type).

Intake & exhaust valve clearance
Injection nozzles

MA-18
A

See NOTE (3)

Timing belts for camshaft and injection pump

*1
MA-18

NOTE: (1) Maintenance items with ‘‘.’’ should be performed more frequently according to ‘‘Maintenance Under Severe
Driving Conditions’’.
(2) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles).
(3) If engine power decreases, black smoke is emitted or engine noise increases, check and, if necessary, adjust
the fuel injection nozzle’s starting pressure and the fuel spray pattern.
*1: ‘‘VALVE CLEARANCE’’, RD in EM section
*2: ‘‘TIMING BELT’’, RD in EM section

MA-5

PERIODIC MAINTENANCE
Chassis and Body Services
Annual driving distance below 30,000 km (18,000 miles)
Abbreviations: R = Replace, I = Inspect, and correct or replace as necessary, L = Lubricate, T = Tighten.
[ ]: At the specified mileage only
MAINTENANCE OPERATION
Perform either at number of kilometers (miles) or months,
whichever comes first.

MAINTENANCE INTERVAL
km x 1,000

(Miles x 1,000)

(6)

(12)

(18)

(24)

(30)

(36)

(42)

(48)

(54)

Months
CHASSIS AND BODY

Reference
page

Underhood and under vehicle

Brake & clutch fluid (For level & leaks).

MA-23, 20

Brake fluid.

MA-24

Brake booster vacuum hoses, connections & check valve

MA-24

Power steering fluid & lines (For level & leaks)

MA-26

Brake & clutch systems

MA-24, 20

Manual transmission oil (For leaks)

Manual transmission oil

MA-20

[R]

MA-20
MA-21

Transfer fluid

Limited slip differential (LSD) gear oil (For level & leaks).*1

MA-22

Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system.

MA-26, 20 *2

Greasing points of propeller shaft

MA-21

Drive shafts & steering damper.

Body mounting bolts & nuts
Outside and Inside
Wheel alignment (If necessary, rotate & balance wheels)

MA-25, *5

Brake pads, discs & other brake components.

MA-24

Front wheel bearing grease

MA-22

MA-23

Axle joint in knuckle flange

Free running hub grease

MA-23

Headlamp aiming

Foot brake, parking brake & clutch (For free play, stroke & operation)

Ventilation air filter

*7
R

Body corrosion

Annually

MA-28

Air bag system

See NOTE (1)

NOTE: (1) Inspect after 10 years, then every 2 years.
(2) Maintenance items with ‘‘.’’ should be performed more frequently according to ‘‘Maintenance Under Severe Driving Conditions’’.
*1: Including differential gear with differential lock
*2: ‘‘Front Axle and Front Suspension Parts’’ in FA section, ‘‘Rear Axle and Rear Suspension Parts’’ in RA section
*3: ‘‘FRONT AXLE — Drive Shaft’’ in FA section
*4: ‘‘CAB BODY’’ in BT section
*5: ‘‘Front Wheel Alignment’’ in FA section
*6: ‘‘Aiming Adjustment’’ in EL section
*7: ‘‘Brake Pedal and Bracket’’ in BR section, ‘‘Adjusting Clutch Pedal’’ in CL section
*8: ‘‘Ventilation air filter’’ in HA section
*9: ‘‘Maintenance Items’’ in RS section

MA-6

PERIODIC MAINTENANCE
Chassis and Body Services (Cont’d)
Annual driving distance over 30,000 km (18,000 miles)
Abbreviations: R = Replace. I = Inspect, and correct or replace as necessary, L = Lubricate, T = Tighten.
MAINTENANCE OPERATION

CHASSIS AND BODY

MAINTENANCE INTERVAL
km x 1,000

(Miles x 1,000)

(6)

(12)

(18)

(24)

(30)

(36)

(42)

(48)

(54)

Reference
page

Underhood and under vehicle

Brake & clutch fluid (For level & leaks).

MA-23, 20

Brake fluid.

MA-24

Brake booster vacuum hoses, connections & check valve

MA-24

Power steering fluid & lines (For level & leaks)

MA-26

Brake & clutch systems

MA-24, 20

Manual transmission oil (For leaks)

Manual transmission oil

MA-20

Transfer fluid

MA-21

Limited slip differential (LSD) gear oil (For level & leaks).*1

MA-22

Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system.

MA-26, 20 *2

Geasing points of propeller shaft

MA-21

Drive shafts & steering damper.

Body mounting bolts & nuts

Outside and Inside
Wheel alignment (If necessary, rotate & balance wheels)

MA-25, *5

Brake pads, discs & other brake components.

MA-24

Front wheel bearing grease

Axle joint in knuckle flange

MA-22
MA-23

Free running hub grease

MA-23

Headlamp aiming

Foot brake, parking brake & clutch (For free play, stroke & operation)

Ventilation air filter

Body corrosion

Annually

MA-28

Air bag system

See NOTE (1)

MA-7

PERIODIC MAINTENANCE
Maintenance Under Severe Driving Conditions
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table.

Severe driving conditions
A
B
C
D
E

—
—
—
—
—

Driving under dusty conditions
Driving repeatedly short distances
Towing a trailer or caravan
Extensive idling
Driving in extremely adverse weather conditions or in areas where ambient temperatures
are either extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas

G — Driving in areas using salt or other corrosive
materials
H — Driving on rough and/or muddy roads or in
the desert
I — Driving with frequent use of braking or in
mountainous areas
J — Frequent driving in water

Maintenance operation: Check = Check and correct or replace as necessary.
Maintenance
interval
Driving
condition

Maintenance
item

Maintenance
operation

A B C D . . . . . . Engine oil & oil filter

A . . . . . . . . . Air cleaner filter

Annual driving distance
below 30,000 km
over 30,000 km
(18,000 miles)
(18,000 miles)

Reference
page

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

Every 5,000 km
(3,000 miles)

MA-13, 14

Replace

Every 30,000 km
(18,000 miles) or
18 months

Every 30,000 km
(18,000 miles)

MA-18

Replace

Every 20,000 km
(12,000 miles) or
12 months

Every 30,000 km
(18,000 miles)

MA-16

Every 30,000 km
(18,000 miles) or
18 months

Every 30,000 km
(18,000 miles)

MA-22

Viscous paper type

A . . . E . . . . . Fuel filter

Replace

. . . . . F . . . . Brake fluid

Replace

. . C . . . . H . . Limited slip differential (LSD) gear oil*3
Replace
. . . . . . G H . . Steering gear & linkage, axle & suspension parts &
propeller shaft & exhaust system

Check

. . . . . . G H . J Greasing points of propeller shafts

Lubricate

. . C . . . . H . . Drive shafts & steering damper

Check

A . C . . . G H I . Brake pads, discs & other brake components

Check

MA-24

MA-26, 21,
23 *1
Every 10,000 km
(6,000 miles) or 6
months

Every 15,000 km
(9,000 miles)

. . . . . . . . . J Front wheel bearing grease & free-running hub grease Check

MA-21
*1
MA-24
*2, MA-23

*1: ‘‘Front Axle and Front Suspension Parts’’ in FA section, ‘‘Rear Axle and Rear Suspension’’ in RA section
*2: ‘‘Front Wheel Alignment’’ in FA section
*3: Including differential gear with differential lock

Maintenance for off-road driving
Whenever you drive off-road through sand, mud or water as deep as the wheel hub, more frequent maintenance may be required of the following items:
m Brake pads and discs
m Brake lining and drums
m Brake lines and hoses
m Wheel bearing grease and free-running hub grease
m Differential, transmission and transfer oil
m Steering linkage
m Propeller shafts and front drive shafts
m Air cleaner filter
m Clutch housing (Check water entry. Refer to MA-21.)

MA-8

RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants
Capacity (Approximate)
Liter

Imp measure

With oil filter

6.4

5-5/8 qt

Without oil filter

5.8

5-1/8 qt

11.8

10-3/8 qt

Recommended Fluids/Lubricants

Engine oil (Refill)

Cooling system (with reservoir tank)
With front heater
RHD

With rear heater

Manual transmission
Differential carrier gear oil (without limited slip differential)
Differential carrier gear oil (with limited slip differential)

LHD

11.6

10-1/4 qt

RHD

12.9

11-3/8 qt

LHD

12.7

11-1/8 qt

5.1

9 pt

—

API GL-5*1

—

Gear Oil Hypoid LSD
or equivalent*2

1.9

1-5/8 qt

FS5R30A

Transfer fluid
TX12A
Power steering fluid
Brake and clutch fluid
Multi-purpose grease

Refill to the proper oil level
according to the instructions in
the ‘‘Do-it-yourself operations’’
section
—

—

Propeller shaft grease
Air conditioning system refrigerant
Air conditioning system lubricants

Anti-freeze coolant (Ethylene glycol base)

API GL-4, Viscosity SAE 75W-90 only

Genuine Nissan ATF or equivalent*3 or
API GL-4*1
Type DEXRONTMIII or equivalent
DOT3 or DOT4*5 (US FMVSS No. 116)
NLGI No. 2 (Lithium soap base)
NLGI No. 2 (Molybdenum disulphide
lithium soap base)

—

HFC-134a (R-134a)

—

Nissan A/C System Oil Type S or
exact equivalent

*1: For further details, see ‘‘SAE viscosity number’’.
*2: API GL-5, SAE 140 and 10% volume of LSD Friction Modifier
*3: For more information regarding suitable fluids, contact a Nissan dealer for correct brands of DEXRONTMIII ATF.
*4: If CCMC oils are not available, API CD may be used. However, CCMC oils are strongly recommended if at all possible.
*5: Never mix different types of fluids (DOT3 and DOT4).

MA-9

RECOMMENDED FLUIDS AND LUBRICANTS
SAE Viscosity Number

TI0003

TI0006

For cold areas:
10W-30 is preferable for ambient temperature above −20°C (−4°F).
On turbocharger models, 5W-20 is not recommended. Use 5W-30 only below 0°C
(32°F).
For hot and warm areas:
20W-40 and 20W-50 are suitable.

+
+

MA-10

For cold and warm areas:
75W-90 for transfer and 80W-90 for differential are preferable.
For hot areas:
90 is suitable for ambient temperatures
below 40°C (104°F).

RECOMMENDED FLUIDS AND LUBRICANTS
Anti-freeze Coolant Mixture Ratio
The engine cooling system is filled at the factory with a high-quality,
year-round, anti-freeze coolant solution. The anti-freeze solution
contains rust and corrosion inhibitors. Therefore, additional cooling
system additives are not necessary.
CAUTION:
When adding or replacing coolant, be sure to use only an ethylene glycol anti-freeze with the proper mixture ratio. See the
following examples:
Outside temperature
down to

Antifreeze

Soft
water

°C

°F

−15

30%

70%

−35

−30

50%

The use of other types of coolant solutions may damage your
cooling system.

MA-11

ENGINE MAINTENANCE
Checking Tightening Torque
Checking should be performed while engine is cold.

MANIFOLD BOLTS AND NUTS
Intake and exhaust manifolds:
M10
: 25 — 29 Nzm (2.6 — 3.0 kg-m, 19 — 22 ft-lb)
M8
: 16 — 20 Nzm (1.6 — 2.0 kg-m, 12 — 14 ft-lb)
Nut
: 16 — 20 Nzm (1.6 — 2.0 kg-m, 12 — 14 ft-lb)

Checking Drive Belt

SMA997C

MA-12

ENGINE MAINTENANCE
Checking Drive Belt (Cont’d)
1. Inspect for cracks, fraying, wear or oil adhesion. Replace if
necessary.
The belts should not touch the bottom of the pulley groove.
2. Check drive belt deflection by pushing on the belt midway
between pulleys.
Adjust if belt deflections exceed the limit.
Unit: mm (in)

Alternator
Air conditioner
compressor
Power steering oil
pump
Applied pushing
force

Used belt deflection
Deflection after
Limit
adjustment
17 (0.67) 12 — 14 (0.47 — 0.55)

Deflection of new belt
9 — 11 (0.35 — 0.43)

11 (0.43)

7 — 9 (0.28 — 0.35)

6 — 8 (0.24 — 0.31)

14 (0.55)

10 — 12 (0.39 — 0.47)

9 — 11 (0.35 — 0.43)

98 N (10 kg, 22 lb)

Check drive belt deflections when engine is cold.

Changing Engine Oil

SMA998C

WARNING:
+ Be careful not to burn yourself, as engine oil is hot.
+ Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine components.
2. Remove oil filler cap and drain plug.
3. Drain oil and fill with new engine oil.
Oil grade: CCMC PD1 or PD2
Viscosity:
See ‘‘RECOMMENDED FLUIDS AND
LUBRICANTS’’, MA-9.
Refill oil capacity (approximate):
Without oil filter change
6.4 ! (5-5/8 Imp qt)
With oil filter change
5.8 ! (5-1/8 Imp qt)
CAUTION:
+ Be sure to clean and install oil pan drain plug with washer.
Drain plug:
: 29 — 39 Nzm (3.0 — 4.0 kg-m, 22 — 29 ft-lb)
+ The refill capacity changes depending on the oil temperature and drain time; use these valves as a reference and be
certain to check with the dipstick when changing the oil.

MA-13

ENGINE MAINTENANCE
Changing Engine Oil (Cont’d)
4. Check oil level.
5. Start engine. Check area around drain plug and oil filter for any
sign of oil leakage.
6. Run engine for a few minutes, then turn it off. After several
minutes check oil level.

SMA999C

Changing Engine Oil Filter
1. Remove oil filter with Tool.
WARNING:
Be careful not to burn yourself, as the engine and engine oil
are hot.

SMA001D

2. Clean oil filter mounting surface on cylinder block. Coat rubber
seal of new oil filter with engine oil.
3. Screw in the oil filter until a slight resistance is felt, then tighten
an additional 2/3 of a turn.
4. Add engine oil.
Refer to Changing Engine Oil.
+ Clean excess oil from engine.

SMA010

Changing Engine Coolant
WARNING:
To avoid the danger of being scalded, never change the coolant when the engine is hot.

—DRAINING ENGINE COOLANT—
1. Move heater TEMP control knob all the way to HOT.
2. Open radiator drain plug at the bottom of radiator.

SMA972C

3. Remove radiator filler cap.
Remove reservoir tank, drain coolant, then clean reservoir tank.
Install it temporarily.
+ Be careful not to allow coolant to contact drive belts.

SMA002D

MA-14

ENGINE MAINTENANCE
Changing Engine Coolant (Cont’d)
4. Remove cylinder block drain plug located at left rear of cylinder block.
5. Drain coolant and install reservoir tank, cylinder block drain
plug and radiator drain plug.
6. Fill radiator with water and warm up engine.
7. Stop engine and wait until it cools down.
8. Repeat step 2 through step 7 two or three times.
9. Drain water.

SMA003D

—REFILLING ENGINE COOLANT—
10. Install reservoir tank, radiator drain plug, and cylinder block
drain plugs.
+ Apply sealant to the thread of cylinder block drain plug.
Cylinder block drain plug:
: 34 — 44 Nzm (3.5 — 4.5 kg-m, 25 — 33 ft-lb)
11. Fill radiator and reservoir tank with coolant up to the MAX level
and install radiator cap.
For coolant mixture ratio, refer to MA-11.
SMA182B

SMA412B

SMA004D

Coolant capacity (With reservoir tank): ! (Imp qt)
RHD models
Without rear heater 11.8 (10-3/8)
With rear heater 12.9 (11-3/8)
LHD models
Without rear heater 11.6 (10-1/4)
With rear heater 12.7 (11-1/8)
Reservoir tank capacity (for MAX level):
1.2 ! (1-1/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air in
system to escape.
12. Warm up engine to normal operating temperature.
13. Run engine at 2,000 rpm for 10 seconds and return to idle
speed.
+ Repeat 2 or 3 times.
Watch coolant temperature gauge so as not to overheat the
engine.
14. Stop engine and cool it down.
+ Cool down using a fan to reduce the time.
15. Remove the radiator filler cap and check coolant level.
+ If necessary, refill radiator up to filler neck with coolant.
16. Refill reservoir tank to Max line with coolant.
17. Repeat step 12 through step 16 two or more times.
18. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 2,000 rpm with heater temperature control set at several positions between COOL and HOT.
+ Sound may be noticeable at heater water cock.
19. If sound is heard, bleed air from cooling system by repeating
steps 12 through 16 until coolant level no longer drops.
+ Clean excess coolant from engine.

MA-15

ENGINE MAINTENANCE
Checking Cooling System
CHECKING HOSES AND CLAMPS
Check hoses and clamps for proper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.

CHECKING RADIATOR CAP
Apply pressure to radiator cap with cap tester to see if it is satisfactory.
Radiator cap relief pressure:
78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2, 11 — 14 psi)

SLC613

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

SMA871B

CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system with cap tester to check for
leakage.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
CAUTION:
Use of higher pressure than the specified value may cause
damage to radiator.

SMA007D

Checking and Replacing Fuel Filter and
Draining Water
Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.

CHECKING FUEL FILTER
Check fuel filter for fuel leakage, damage and other abnormal
signs.

REPLACING FUEL FILTER
SMA757B

1. Disconnect harness connector and drain fuel.

MA-16

ENGINE MAINTENANCE
Checking and Replacing Fuel Filter and
Draining Water (Cont’d)
2. Remove fuel filter using band-type filter wrench.
Remove fuel filter and fuel filter sensor.
CAUTION:
Remove fuel filter without spilling fuel. If spilt, wipe off immediately. Be specially careful not to spill fuel on engine mount
insulator.

SMA005D

3. Wipe clean fuel filter mounting surface on fuel filter bracket and
smear a little fuel on rubber seal of fuel filter.
4. Screw fuel filter on until a slight resistance is felt, then tighten
an additional more than 2/3 of a turn.
5. Install fuel filter sensor to new fuel filter.
6. Bleed air from fuel line.
Refer to Bleeding Fuel System in EC section.
7. Start engine and check for leaks.

SMA010

DRAINING WATER
1. Drain water as follows.
Loosen drain cock and drain water.
Loosening drain cock 4 to 5 turns causes water to start draining. Do not remove drain cock by loosening it excessively.
If water does not drain properly, move the priming pump up and
down.

SMA825B

2. Bleed air.

Checking Fuel Lines
Check fuel lines and tank for proper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.
CAUTION:
Keep clean parts with compressed air when assembling.

SMA803A

MA-17

ENGINE MAINTENANCE
Cleaning and Replacing Air Cleaner Filter

SMA006D

VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any cleaning operation between renewal.

Checking Injection Nozzle

EF791A

WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to come into contact with your hand or
body, and make sure that your eyes are properly protected.
1. Install nozzle to injection nozzle tester and bleed air from flare
nut.
2. Check initial injection pressure by pumping tester handle one
full stroke per second.
Initial injection pressure:
Used nozzle
More than 14,220 kPa
(142.2 bar, 145 kg/cm2, 2,062 psi)
New nozzle
14,711 — 15,495 kPa
(147.1 — 155.0 bar, 150 — 158 kg/cm2,
2,133 — 2,247 psi)
+ Always check initial injection pressure before installing
new nozzle.

SEF672A

3. Check spray pattern by pumping tester handle one full stroke
per second.
a. If main spray angle is within 30 degrees as shown, injection nozzle is good.
b. It is still normal even if a thin stream of spray deviates from
main spray (pattern B).
4. If initial injection pressure or injection nozzle is not normal,
adjust or clean injection nozzle.
5. Test again. If it is not corrected, replace nozzle.
Refer to EC section for injection pressure adjustment, cleaning and replacement.
SEF079S

MA-18

ENGINE MAINTENANCE
Checking Injection Nozzle (Cont’d)
6. Install all injection nozzles with Tool and securely connect fuel
spill tube and delivery tubes.
7. Bleed air from fuel system and check for fuel leakage with
engine running.
Injection nozzle to cylinder head:
: 59 — 69 Nzm (6.0 — 7.0 kg-m, 43 — 51 ft-lb)
Spill tube nut:
: 39 — 49 Nzm (4.0 — 5.0 kg-m, 29 — 36 ft-lb)
Injection tube:
: 20 — 25 Nzm (2.2 — 2.5 kg-m, 16 — 18 ft-lb)

Checking Idle Speed
Inspection should be carried out with gears in ‘‘Neutral’’ and
with air conditioner and other electrical loads off.
1. Warm up engine until engine coolant temperature indicator
points to the middle of gauge.
2. Attach a diesel tachotester’s pick-up to No. 1 fuel injection tube.
3. Race engine two or three times and check idle speed.
Idle speed:
Unit: rpm

750−+50
0

Timing Belt Replacement
Refer to EM section.

MA-19

CHASSIS AND BODY MAINTENANCE
Checking Exhaust System
Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, loose connections, chafing and
deterioration.

SMA211A

Checking Clutch Fluid Level and Leaks
If fluid level is extremely low, check clutch system for leaks.

SMA991C

Checking Clutch System
Check fluid lines and operating cylinder for improper attachment,
cracks, damage, loose connections, chafing and deterioration.

SMA992C

Checking M/T Oil Level and Leaks
Never start engine while checking oil level.
1. Check manual transmission for leakage.
2. Check oil level.
Filler plug:
: 25 — 34 Nzm (2.5 — 3.5 kg-m, 18 — 25 ft-lb)

SMA103

Changing M/T Oil
Oil grade:
API GL-4. Refer to ‘‘RECOMMENDED FLUIDS AND
LUBRICANTS’’, MA-9.
Oil capacity:
FS5R50B 3.8 liters (6-3/4 Imp pt)
Refill 2.9 liters (5-1/8 Imp pt)
FS5R30A 5.1 liters (9 Imp pt)
Drain plug:
: 25 — 34 Nzm (2.5 — 3.5 kg-m, 18 — 25 ft-lb)
SMA255A

MA-20

CHASSIS AND BODY MAINTENANCE
Checking Water Entry
Check water entry in the clutch housing by removing the sealing grommet, whenever driving in deep water or mud.

SMA369B

Checking Transfer Fluid Level
Never start engine while checking fluid level.
1. Check transfer for leakage.
2. Check fluid level.
Filler plug:
: 25 — 34 Nzm (2.5 — 3.5 kg-m, 18 — 25 ft-lb)

SMA936B

Changing Transfer Fluid
Fluid grade:
Genuine Nissan ATF or equivalent or API GL-4.
Refer to ‘‘RECOMMENDED FLUIDS AND
LUBRICANTS’’, MA-9.
Fluid capacity:
1.9 liters (1-5/8 Imp qt)
Drain plug:
: 25 — 34 Nzm (2.5 — 3.5 kg-m, 18 — 25 ft-lb)
SMA993C

Checking Propeller Shaft
Check propeller shaft for damage, looseness or grease leakage.
Tightening torque: Refer to PD section.

SMA945B

Greasing Nipples of Propeller Shafts

Front

Apply multi-purpose grease to nipples of propeller shafts.

Grease nipples

SMA043C

MA-21

CHASSIS AND BODY MAINTENANCE
Rear
Grease nipples

SMA944B

Checking Differential Gear Oil
1. Check differential carrier for oil leakage.
2. Check oil level.
Filler plug:
: 59 — 98 Nzm (6 — 10 kg-m, 43 — 72 ft-lb)

Fill to this
level
Filler plug
SMA108-A

Changing Differential Gear Oil
Oil capacity:
Front
5.4 liters (9-1/2 Imp pt)
Rear
H233B (Without diff. lock)
2.4 liters (4-1/4 Imp pt)
H233B (With diff. lock)
3.0 liters (5-1/4 Imp pt)
H260 (Without diff. lock)
4.7 liters (8-1/4 Imp pt)
H260 (With diff. lock)
3.7 liters (6-1/2 Imp pt)
Drain plug:
: 59 — 98 Nzm (6 — 10 kg-m, 43 — 72 ft-lb)

Drain plug

SMA109-A

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

Checking Front Wheel Bearing Grease
+
+
+

Check that wheel bearings operate smoothly.
Check front wheel bearings for grease leakage and water or
dust entry.
Replace front wheel bearings or front wheel bearing grease if
wheel bearings do not turn smoothly.

MA-22

CHASSIS AND BODY MAINTENANCE
Repacking Front Wheel Bearing and Axle Joint
Grease
FRONT WHEEL BEARING GREASE
Apply multi-purpose grease sparingly to the following parts:
+ Threaded portion of spindle
+ Contact surface between wheel bearing washer and outer
wheel bearing
+ Grease seal lip
+ Wheel hub (as shown at the left)
SFA469A

AXLE JOINT GREASE
Drain approximately 2 liters (1-3/4 Imp qt) of differential oil.
Remove knuckle spindle.
Slightly pull out axle and repack axle joint with recommended
grease.
Refer to FA section.
+
+
+

SFA869B

Checking Free-running Hub Grease
Check free-running hub grease for leakage and water or dust entry.

SMA946B

Checking Water Entry in Knuckle Flange
+
+

Check for water entry in knuckle flange by removing one bolt
of lower knuckle flange bearing cap and probing with a suitable
thin bar.
After checking, be sure to reinstall the bolt to a tightening torque
of 30 to 40 Nzm (3.1 to 4.1 kg-m, 22 to 30 ft-lb).

SMA949B

Checking Brake Fluid Level and Leaks
If fluid level is extremely low, check brake system for leaks.

SBR451D

MA-23

CHASSIS AND BODY MAINTENANCE
Checking Brake System
Check brake fluid lines and parking brake cables for improper
attachment, leaks, chafing, abrasion, deterioration, etc.

SBR389C

Changing Brake Fluid
1. Drain brake fluid from each air bleeder valve.
2. Refill until new brake fluid comes out from each air bleeder
valve. Use same procedure as in bleeding hydraulic system to
refill brake fluid. Refer to BR section.
+ Refill with recommended brake fluid.
+ Never reuse drained brake fluid.
+ Be careful not to splash brake fluid on painted areas.

SBR419C

Checking Brake Booster, Vacuum Hoses,
Connections and Check Valve
Check vacuum lines, connections and check valve for improper
attachment, air tightness, chafing and deterioration.

SBR419A

Checking Disc Brake
ROTOR

SMA260A

Check condition and thickness.
Standard thickness:
CL36VE
32.0 mm (1.260
CL18VF
18.0 mm (0.709
Minimum thickness:
CL36VE
30.0 mm (1.181
CL18VF
16.0 mm (0.630

MA-24

in)
in)
in)
in)

CHASSIS AND BODY MAINTENANCE
Checking Disc Brake (Cont’d)
CALIPER
Check for leakage.

SMA922A

PAD
Check for wear or damage.
Standard thickness:
Front 12.0 mm (0.472 in)
Rear 10.0 mm (0.394 in)
Minimum thickness:
2.0 mm (0.079 in)

SMA847B

Balancing Wheels
Adjust wheel balance using the road wheel center.
Wheel balance (Maximum allowable unbalance):
Refer to SDS, MA-29.

Tire Rotation
Wheel nuts:
: 118 — 147 Nzm (12 — 15 kg-m, 87 — 108 ft-lb)

SMA800BB

MA-25

CHASSIS AND BODY MAINTENANCE
Checking Power Steering Fluid and Lines
Check fluid level with engine off.
Check fluid level with dipstick on reservoir cap. Use ‘‘HOT’’
range at fluid temperatures of 50 to 80°C (122 to 176°F). Use
‘‘COLD’’ range at fluid temperatures of 0 to 30°C (32 to 86°F).
CAUTION:
+ Do not overfill.
+ Recommended fluid is Automatic Transmission Fluid type
‘‘DEXRONTMIII’’ or equivalent.
+
+

SST280B

+
+

Check lines for improper attachment, leaks, cracks, damage,
loose connections, chafing or deterioration.
Check rack boots for accumulation of power steering fluid.

SST757C

Checking Steering Damper
Check steering damper for damage and oil leakage.

SMA938A

Checking Steering Gear Box and Linkage
STEERING GEAR
+
+

Check gear housing and boots for looseness, damage or
grease leakage.
Check connection with steering column for looseness.

STEERING LINKAGE
+

Check ball joint, dust cover and other component parts for
looseness, wear, damage or grease leakage.

MA-26

CHASSIS AND BODY MAINTENANCE
Lubricating Locks, Hinges and Hood Latches

SMA994C

Checking Seat Belts, Buckles, Retractors,
Anchors and Adjusters

SMA995C

MA-27

CHASSIS AND BODY MAINTENANCE
Checking Body Corrosion
Visually check the body sheet metal panel for corrosion, paint damage (scratches, chipping, rubbing, etc.) or
damage to the anti-corrosion materials. In particular, check the following locations.
Hemmed portion
Hood front end, door lower end, trunk lid rear end, etc.
Panel joint
Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut tower in engine
compartment, etc.
Panel edge
Trunk lid opening, sunroof opening, fender wheelarch flange, fuel filler lid flange, around holes in panel, etc.
Parts contact
Waist molding, windshield molding, bumper, etc.
Protectors
Damage or condition of mudguard, fender protector, chipping protector, etc.
Anti-corrosion materials
Damage or separation of anti-corrosion materials under the body.
Drain holes
Condition of drain holes at door and side sill.
When repairing corroded areas, refer to the Corrosion Repair Manual.

MA-28

SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Maintenance
INSPECTION AND ADJUSTMENT

Engine oil capacity (Refill capacity)
Unit: ! (Imp qt)

Drive belt deflection
Unit: mm (in)
Used belt deflection
Drive belts

Limit

Deflection
after adjustment

Deflection of
new belt

With air conditioner compressor

17 (0.67)

12 — 14
(0.47 — 0.55)

9 — 11
(0.35 — 0.43)

Without air conditioner compressor

11 (0.43)

7-9
(0.28 — 0.35)

6-8
(0.24 — 0.31)

14 (0.55)

10 — 12
(0.39 — 0.47)

9 — 11
(0.35 — 0.43)

Applied pushing force

6.4 (5-5/8)

Without oil filter change

5.8 (5-1/8)

Coolant capacity (Refill capacity)

Alternator

Power steering oil
pump

With oil filter change

98 N (10 kg, 22 lb)

With reservoir tank
Unit: ! (Imp qt)
With rear heater

Without rear heater

RHD

12.9 (11-3/8)

11.8 (10-3/8)

LHD

12.7 (11-1/8)

Reservoir tank

Chassis and Body Maintenance
INSPECTION AND ADJUSTMENT
Wheel balance
Maximum allowable
unbalance

Dynamic
(At rim flange)

10 (0.35) (one side)
g (oz)

Static

g (oz)

20 (0.71)

MA-29

11.6 (10-1/4)
2.4 (2-1/8)

MANUAL TRANSMISSION
SECTION

CONTENTS
PREPARATION……………………………………………………….1
Special Service Tools …………………………………………..1
Commercial Service Tools …………………………………….2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ……………………………………………..3
NVH Troubleshooting Chart…………………………………..3
ON-VEHICLE SERVICE …………………………………………..4
Replacing Rear Oil Seal ……………………………………….4
Position Switch Check ………………………………………….4
REMOVAL AND INSTALLATION ………………………………5
Removal……………………………………………………………..5
Installation…………………………………………………………..6
DESCRIPTION ………………………………………………………..7
Cross-sectional View ……………………………………………7
AIR BREATHER ……………………………………………………..8
Air Breather Piping ………………………………………………8
MAJOR OVERHAUL ……………………………………………….9

Case Components ……………………………………………….9
Gear Components ……………………………………………..10
Shift Control Components …………………………………..12
DISASSEMBLY……………………………………………………..13
Case Components ……………………………………………..13
Shift Control Components …………………………………..14
Gear Components ……………………………………………..15
INSPECTION…………………………………………………………19
Shift Control Components …………………………………..19
Gear Components ……………………………………………..19
ASSEMBLY…………………………………………………………..21
Gear Components ……………………………………………..21
Shift Control Components …………………………………..29
Case Components ……………………………………………..29
SERVICE DATA AND SPECIFICATIONS (SDS) ……….32
General Specifications………………………………………..32
Inspection and Adjustment ………………………………….33

PREPARATION
Special Service Tools
Tool number
Tool name

Description

ST23540000
Pin punch

Removing and installing retaining pin
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.

NT442

ST30031000
Puller

Removing 1st & 2nd synchronizer assembly
Removing counter gear rear thrust bearing
Removing main drive gear bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.

NT411

ST33230000
Drift

Removing mainshaft and counter gear

a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.

NT084

ST22350000
Drift

Removing and installing mainshaft rear bearing
Removing counter gear front bearing
(Use with KV38100300)
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.

NT065

KV38100300
Drift

Removing counter gear front bearing
(Use with ST22350000)
Installing counter gear rear bearing
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.

NT065

ST30720000
Drift

Removing mainshaft front bearing
Installing mainshaft front bearing
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

NT115

ST33210000
Drift

Installing counter gear front bearing
Installing front cover oil seal

a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.

NT084

ST30613000
Drift

Installing main drive gear bearing

a: 71.5 mm (2.815 in) dia.
b: 47.5 mm (1.870 in) dia.

NT073

MT-1

PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name

Description

ST37750000
Drift

Removing and installing mainshaft
rear bearing
Removing counter gear rear bearing
Installing OD gear bushing
Installing reverse cone
Installing reverse counter gear
Installing counter gear rear end bearing
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.

NT065

ST22452000
Drift

Installing reverse hub

a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.

NT065

Commercial Service Tools
Tool name

Description

Puller

Removing counter gear rear end bearing
Removing reverse synchronizer hub
Removing reverse counter gear
NT077

Drift

1
V
2
V

Installing sub-gear snap ring
Installing OD main gear

1
V

a:
b:
a:
b:

2
V

NT065

MT-2

44.5 mm (1.752 in) dia.
38.5 mm (1.516 in) dia.
44.5 mm (1.752 in) dia.
40.5 mm (1.594 in) dia.

SUSPECTED PARTS (Possible cause)

1
2

Jumps out of gear

MT-3

Symptom
MT-12
MT-10
MT-10
MT-10
MT-10

GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
INSERT SPRING (Damaged)

Refer to MA section (‘‘Checking M/T Oil’’,
‘‘CHASSIS AND BODY MAINTENANCE’’).

SHIFT FORK (Worn)

MT-12

CHECK PLUG RETURN SPRING AND
CHECK BALL (Worn or damaged)

Hard to shift or will not shift
MT-9

OIL SEAL (Worn or damaged)

MT-9

Oil leakage
LIQUID GASKET (Damaged)

OIL (Level too high)

OIL (Wrong)

Noise
OIL (Level low)

FS5R30A

Reference page

Transmission model

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING
NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

3
3

2
2

1
2
2

ON-VEHICLE SERVICE
Replacing Rear Oil Seal
REMOVAL
1. Remove transfer assembly. — Refer to TF section.
2. Pull out rear oil seal.

SMT321B

INSTALLATION
1. Install rear oil seal.
+ Before installing apply multi-purpose grease to seal lip.
2. Install transfer assembly. — Refer to TF section.

SMT322B

Position Switch Check
Switch

Gear position

Continuity

Reverse

Yes

Except reverse

Neutral

Yes

Except neutral

Reverse position switch

Neutral position switch

SMT274D

MT-4

REMOVAL AND INSTALLATION
Removal

SMT321D

1. Remove front and rear propeller shafts. Refer to PD section
(‘‘Removal and Installation’’, ‘‘PROPELLER SHAFT’’).
2. Remove clutch operating cylinder.
3. Remove exhaust front and rear tubes. Refer to FE section
(‘‘EXHAUST SYSTEM’’).
4. Disconnect vehicle speed sensor, back-up lamp switch, 4WD
switch and neutral position switch harness connector.
5. Remove center brake cable. Refer to BR section.
6. Remove shift lever of transmission. Refer to MT-12 (RS5R30A).
7. Remove transfer control lever. Refer to TF section (‘‘Removal’’,
‘‘REMOVAL AND INSTALLATION’’).
8. Support engine by placing a jack under oil pan.
+ Do not place jack under the oil pan drain plug.
9. Remove transmission with transfer from engine.
WARNING:
Support Manual Transmission with transfer, while removing it.

MT-5

REMOVAL AND INSTALLATION
Installation
+

Apply sealant as below:

SMT550D

SMT322D

Tighten bolts securing transmission.
Bolt No.

Tightening torque Nzm (kg-m, ft-lb)

1
V
2
V
3
V
4
V
5
V

39 — 49 (4.0 — 5.0, 29 — 36)

79 (3.11)

39 — 49 (4.0 — 5.0, 29 — 36)

85 (3.35)

29 — 39 (3.0 — 4.0, 22 — 29)

79 (3.11)

29 — 39 (3.0 — 4.0, 22 — 29)

57 (2.24)

29 — 39 (3.0 — 4.0, 22 — 29)

50 (1.97)

Gusset to engine

29 — 39 (3.0 — 4.0, 22 — 29)

35 (1.38)

MT-6

! mm (in)

DESCRIPTION
Cross-sectional View

SMT320D

MT-7

AIR BREATHER
Air Breather Piping

SMT546D

MT-8

MAJOR OVERHAUL
Case Components

SMT544D

MT-9

MAJOR OVERHAUL
Gear Components

SMT797C

MT-10

MAJOR OVERHAUL
Gear Components (Cont’d)

SMT818C

MT-11

MAJOR OVERHAUL
Shift Control Components

SMT370D

MT-12

DISASSEMBLY
Case Components
1. Remove check ball plug, check spring and check ball. Then
remove interlock stopper.
+ If interlock assembly is removed as a unit, the check ball
can fall into transmission case.
+ Be careful not to lose check ball.

SMT366A

2. Remove control housing, return spring and check ball.
+ Be careful not to lose check ball.

SMT438B

3. Drive out retaining pin from striking arm.

SMT439B

4. Remove OD gear case together with striking arm by tapping
lightly.

SMT440B

SMT444B

MT-13

DISASSEMBLY
Case Components (Cont’d)
5. Remove front cover and gasket.

SMT370A

6. Remove stopper ring and main drive bearing snap ring.

SMT371A

7. Remove transmission case by tapping lightly.

SMT822C

8. Remove front cover oil seal.

SMT392A

Shift Control Components
1. Mount adapter plate on vise.
2. Remove OD & reverse fork rod.

SMT823C

MT-14

DISASSEMBLY
Shift Control Components (Cont’d)
3. Drive out retaining pin from striking lever.
4. While pulling out striking rod, remove striking lever and striking
interlock. Then remove 1st & 2nd, 3rd & 4th and reverse shift
fork.

SMT374AA

5. Drive out retaining pin from OD shift fork.
6. Pull out OD fork rod and then remove OD shift fork.

SMT824C

Gear Components
1. Before removing gears and shafts, measure each gear end
play.
Gear end play:
Refer to SDS, MT-33.
+ If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.

SMT376A

2. Remove rear side components on mainshaft and counter gear.
a. Remove reverse coupling sleeve.

SMT825C

b. Remove mainshaft rear snap ring and counter gear rear snap
ring.
c. Remove C-ring holder and mainshaft C-rings from mainshaft.
Use punch and hammer to remove C-rings.

SMT826C

MT-15

DISASSEMBLY
Gear Components (Cont’d)
d. Pull out counter gear rear end bearing.
e. Remove reverse idler gear and reverse idler thrust washers.

SMT827C

Pull out reverse main gear together with mainshaft spacer and
reverse synchronizer hub. Then remove reverse gear needle
bearings.

SMT380A

g. Pull out reverse counter gear.
h. Remove OD coupling sleeve together with OD baulk ring,
reverse baulk ring and spring inserts.

SMT773A

Pull out reverse gear bushing.

Pull out OD counter gear together with reverse cone.

SMT770A

SMT771A

MT-16

DISASSEMBLY
Gear Components (Cont’d)
3. Press out mainshaft and counter gear alternately.

SMT772AA

4.
a.
b.
+

Remove front side components on mainshaft.
Remove 1st gear washer and steel ball.
Remove 1st main gear and 1st gear needle bearing.
Be careful not to lose steel ball.

SMT383A

c. Press out 2nd main gear together with 1st gear bushing and 1st
& 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.

SMT384A

e. Press out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.

SMT385A

MT-17

DISASSEMBLY
Gear Components (Cont’d)
5. Remove front side components on counter gear.
a. Remove counter gear rear thrust bearing.

SMT404AA

b. Remove sub gear components.

SMT470A

6. Remove main drive gear bearing.
a. Remove main drive gear snap ring.
b. Press out main drive gear bearing.

SMT420AA

7. Remove bearings from case components.

SMT483CB

MT-18

INSPECTION
Shift Control Components
+

Check contact surface and sliding surface for wear, scratches,
projections or other damage.

SMT398A

Gear Components
GEARS AND SHAFTS
+
+

Check shafts for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.

SMT386A

SMT423A

SYNCHRONIZERS
+
+
+
+

Check spline portion of coupling sleeves, hubs, and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
Check insert springs for deformation.

SMT427C

+
+

Measure wear of main drive, 1st and OD baulk rings.
Clearance between baulk ring and gear:
Refer to SDS, MT-33.
If the clearance is smaller than the wear limit, replace baulk
ring.

SMT140

MT-19

INSPECTION
Gear Components (Cont’d)

SMT041BC

+ Measure wear of 2nd and 3rd baulk rings.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far as
it will go, measure dimensions ‘‘A’’ and ‘‘B’’.
Standard:
A 0.7 — 0.9 mm (0.028 — 0.035 in)
B 0.6 — 1.1 mm (0.024 — 0.043 in)
Wear limit:
0.2 mm (0.008 in)
+ If dimension ‘‘A’’ or ‘‘B’’ is smaller than the wear limit,
replace outer baulk ring, inner baulk ring and synchronizer
cone as a set.

SMT042B

+ Measure wear of reverse baulk ring.
a. Place baulk ring in position on reverse cone.
b. While holding baulk ring against reverse cone as far as it will
go, measure dimension ‘‘A’’ with dial indicator.
Dimension ‘‘A’’:
Standard −0.1 to 0.35 mm (−0.0039 to 0.0138 in)
Wear limit 0.7 mm (0.028 in)
c. If dimension ‘‘A’’ is larger than the wear limit, replace baulk ring.

SMT424A

BEARINGS
+

Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

SMT418A

MT-20

ASSEMBLY
Gear Components

SMT484CB

1. Install bearings into case components.
2. Install main drive gear bearing.
a. Press main drive gear bearing.

SMT425AA

b. Select proper main drive gear snap ring to minimize clearance
of groove.
Allowable clearance of groove:
0 — 0.1 mm (0 — 0.004 in)
Main drive gear snap ring:
Refer to SDS, MT-33.
c. Install selected snap ring on main drive gear.

SMT426A

3. Install components on counter gear.
a. Install sub-gear components.
+ When installing sub-gear snap ring, tap sub-gear snap ring
into position on counter gear.

SMT577AA

MT-21

ASSEMBLY
Gear Components (Cont’d)
b. Install counter gear rear thrust bearing.

SMT405A

4. Install front side components on mainshaft.
a. Assemble 1st & 2nd synchronizer.

SMT614B

b. Assemble 3rd & 4th synchronizer.

SMT615B

c. Press on 3rd & 4th synchronizer assembly together with 3rd
main gear and 3rd gear needle bearing.
+ Pay attention to direction of synchronizer assembly.

SMT399A

d. Select proper snap ring to minimize clearance of groove.
Allowable clearance of groove:
0 — 0.1 mm (0 — 0.004 in)
Mainshaft front snap ring:
Refer to SDS, MT-33.
e. Install selected snap ring on mainshaft.

SMT400A

MT-22

ASSEMBLY
Gear Components (Cont’d)
f.

Press on 1st & 2nd synchronizer assembly together with 2nd
main gear and 2nd gear needle bearing.

SMT401A

g. Press on 1st gear bushing using 1st gear washer.
h. Install 1st main gear and needle bearing.

SMT402A

i.
+

Install steel ball and 1st gear washer.
Apply multi-purpose grease to steel ball and 1st gear
washer before installing.

SMT403A

5. Select proper counter gear front bearing thrust washer when
replacing transmission case, counter gear, counter gear rear
thrust bearing or sub-gear components.
a. Install counter gear with sub-gear components, counter gear
front and rear bearing thrust washer on adapter plate.
b. Remove counter gear front bearing thrust washer from transmission case.
c. Place adapter plate and counter gear assembly in transmission
case (case inverted).

SMT427AA

MT-23

ASSEMBLY
Gear Components (Cont’d)
d. Tighten adapter plate to transmission case using 2 bolts.
e. Place dial indicator on rear end of counter gear.
f. Move counter gear up and down and measure dial indicator
deflection.
g. Select proper thrust washer using table below as a guide.
Counter gear end play:
0.10 — 0.25 mm (0.0039 — 0.0098 in)
Table for selecting proper counter gear front bearing
thrust washer:
Refer to SDS, MT-34.

SMT578A

6. Select proper reverse idler rear thrust washer when replacing
OD gear case, reverse idler gear, reverse idler shaft or reverse
idler front thrust washer.
a. Install reverse idler front gear, reverse idler needle bearings,
reverse idler front thrust washers and reverse idler shaft into
OD gear case.
+ When replacing reverse idler rear thrust washer, install
either A or B.
Reverse idler rear thrust washer:
Refer to SDS, MT-34.

SMT442B

MT-24

ASSEMBLY
Gear Components (Cont’d)
b. Place dial indicator on front end of reverse idler shaft.
c. Put straightedge on front surface of OD gear case as a stopper of reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 — 0.53 mm (0.0118 — 0.0209 in)
e. If not within specification, replace reverse idler rear thrust
washer with the other (A or B) and check again.

SMT433A

7. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease to
counter gear rear bearing.

SMT438A

b. Install mainshaft a little on mainshaft front bearing.
+ To allow for installation of counter gear, do not install
mainshaft completely.

SMT440A

c. Install counter gear on counter gear rear bearing and install
main drive gear, pilot bearing and spacer on mainshaft.

SMT441A

MT-25

ASSEMBLY
Gear Components (Cont’d)
+

When installing counter gear into counter gear rear
bearing, push up on upper roller of counter gear rear bearing with screwdriver.

SMT442A

d. Install mainshaft and counter gear completely by tapping rear
side of adapter plate and pulling mainshaft.

SMT443A

8. Install rear side components on mainshaft and counter gear.
a. Install OD gear bushing while pushing on the front of counter
gear.

SMT444AA

b. Install OD main gear.
+ Pay attention to direction of OD main gear. (B is wider than
A as shown at left.)
c. Install adapter plate with gear assembly onto transmission
case.
d. Install OD gear needle bearing and then install OD counter gear
and reverse idler shaft.

SMT580AB

e. Install reverse cone.

SMT582AA

MT-26

ASSEMBLY
Gear Components (Cont’d)
f.
+

Install insert springs and reverse baulk ring on OD coupling
sleeve. Then install them and OD baulk ring on OD counter
gear.
Pay attention to direction of OD coupling sleeve.

SMT571AA

SMT583A

g. Install reverse counter gear.
h. Install reverse gear needle bearing and then install reverse
main gear, reverse idler gear and reverse idler thrust washers.

SMT584AA

i.
+

Install reverse hub and mainshaft spacer.
Pay attention to direction of reverse hub.

SMT585AA

j. Install counter gear rear end bearing.
k. Separate adapter plate from transmission case and mount
adapter plate on vice again.

SMT828C

MT-27

ASSEMBLY
Gear Components (Cont’d)
l.

Select proper mainshaft C-ring to minimize clearance of
groove.
Allowable clearance of groove:
0 — 0.1 mm (0 — 0.004 in)
Mainshaft C-ring:
Refer to SDS, MT-34.

SMT829C

m. Install selected C-ring, C-ring holder and mainshaft rear snap
ring.

SMT830C

n. Select proper counter gear rear snap ring to minimize clearance of groove.
Allowable clearance of groove:
0 — 0.1 mm (0 — 0.004 in)
Counter gear rear snap ring:
Refer to SDS, MT-34.
o. Install selected counter gear rear snap ring.

SMT831C

SMT832C

p. Install reverse coupling sleeve.
+ Pay attention to its direction.
q. Measure each gear end play as a final check. Refer to
‘‘DISASSEMBLY’’, MT-15.

SMT833C

MT-28

ASSEMBLY
Shift Control Components
1. Install OD fork rod and OD shift fork. Then install retaining pin
into OD shift fork.
2. Install 1st & 2nd, 3rd & 4th and reverse shift fork onto coupling
sleeve.

SMT834C

3. Install striking rod into hole of shift forks, striking lever and
interlock and then install retaining pin into striking lever.
+ Make sure that striking rod moves smoothly.

SMT374AA

Case Components
1. Install front cover oil seal.
+ Apply multi-purpose grease to seal lip.
2. Install selected counter gear front bearing shim onto transmission case.
+ Apply multi-purpose grease.
3. Apply sealant to mating surface of transmission case.

SMT393AA

4. Install gear assembly onto transmission case.
5. Install check spring and check ball into interlock stopper.
+ Apply multi-purpose grease to check ball.

SMT835C

6. Install interlock stopper assembly and then tighten check ball
plug.
+ Apply sealant to thread of check ball plug.

SMT460A

MT-29

ASSEMBLY
Case Components (Cont’d)
7. Install stopper ring and main drive bearing snap ring.

SMT371A

8. Install front cover and gasket.
+ Apply sealant to thread of 3 bolts shown left.
9. Apply sealant to mating surface of adapter plate.

SMT459A

10. Install OD gear case together with striking arm.

SMT444B

11. Install retaining pin into striking arm.

SMT439B

12. Install return spring and check ball and then install control housing.
+ Apply sealant to mating surface of OD gear case.

SMT445B

MT-30

ASSEMBLY
Case Components (Cont’d)
13. Tighten control housing bolts.
Bolt head size:
A bolts 12 mm (0.47 in)
B bolts 13 mm (0.51 in)

SMT446BA

MT-31

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
RD28ETi
Applied model
4WD
Transmission
Number of speed
Transmission control

FS5R30A
5
Floor direct

Shift pattern

Synchromesh type

Warner

Gear ratio
1st

4.061

2nd

2.357

3rd

1.490

4th

1.000

0.862

Reverse

4.125

Number of teeth
Mainshaft
Drive

1st

2nd

3rd

Reverse

Countershaft
Drive

1st

2nd

3rd

Reverse

Reverse idler gear
Oil capacity ! (Imp pt)

Remarks

22
5.1 (9)
2nd & 3rd double baulk ring
type synchronizer
Reverse breaking mechanism type

MT-32

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment
GEAR END PLAY
Gear

End play

DISTANCE BETWEEN REAR SURFACE OF
REVERSE CONE AND REVERSE BAULK
RING

mm (in)

1st main gear

0.23 — 0.33 (0.0091 — 0.0130)

2nd main gear

0.23 — 0.33 (0.0091 — 0.0130)

3rd main gear

0.06 — 0.16 (0.0024 — 0.0063)

OD counter gear

0.23 — 0.33 (0.0091 — 0.0130)

Reverse main gear

0.33 — 0.43 (0.0130 — 0.0169)

Counter gear

0.10 — 0.25 (0.0039 — 0.0098)

Reverse idler gear

0.30 — 0.53 (0.0118 — 0.0209)

Unit: mm (in)

CLEARANCE BETWEEN BAULK RING AND
GEAR

Dimension ‘‘A’’

Standard

Wear limit

−0.1 to 0.35
(−0.0039 to 0.0138)

0.7 (0.028)

Unit: mm (in)
Standard
1st

1.05 — 1.3 (0.0413 — 0.0512)

Main drive

1.05 — 1.3 (0.0413 — 0.0512)

AVAILABLE SNAP RING

Wear limit

Main drive gear snap ring
0.7 (0.028)

Allowable clearance
Thickness

2nd and 3rd baulk ring

0 — 0.1 mm (0 — 0.004 in)

mm (in)

Part number

1.89 (0.0744)

32204-01G60

1.95 (0.0768)

32204-01G61

1.99 (0.0783)

32204-01G62

2.03 (0.0799)

32204-01G63

2.07 (0.0815)

32204-01G64

2.11 (0.0831)

32204-01G65

Mainshaft front snap ring
Allowable clearance
Thickness

Dimension

Standard

0.7 — 0.9
(0.028 — 0.035)

0.6 — 1.1
(0.024 — 0.043)

mm (in)

0 — 0.1 mm (0 — 0.004 in)
Part number

SMT742C

1.99 (0.0783)

32204-01G62

Unit: mm (in)

2.03 (0.0799)

32204-01G63

2.07 (0.0815)

32204-01G64

2.11 (0.0831)

32204-01G65

2.15 (0.0846)

32204-01G66

2.19 (0.0862)

32204-01G67

Wear limit

0.2 (0.008)

MT-33

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Counter gear rear snap ring
Allowable clearance
Thickness

mm (in)

AVAILABLE SHIM AND WASHER

0 — 0.1 mm (0 — 0.004 in)
Part number

1.32 (0.0520)

32236-01G00

1.38 (0.0543)

32236-01G01

1.44 (0.0567)

32236-01G02

1.50 (0.0591)

32236-01G03

1.56 (0.0614)

32236-01G04

1.62 (0.0638)

32236-01G05

1.68 (0.0661)

32236-01G06

1.74 (0.0685)

32236-01G07

Table for selecting proper counter gear
front bearing thrust washer

AVAILABLE C-RING
Mainshaft C-ring
Allowable clearance
Thickness

mm (in)

Dial indicator deflection
mm (in)

Thickness of
proper washer
mm (in)

Part number

0.93 — 1.02 (0.0366 — 0.0402)

0.80 (0.0315)

32218-01G00

1.01 — 1.10 (0.0398 — 0.0433)

0.88 (0.0346)

32218-01G11

1.09 — 1.18 (0.0429 — 0.0465)

0.96 (0.0378)

32218-01G12

1.17 — 1.26 (0.0461 — 0.0496)

1.04 (0.0409)

32218-01G13

1.25 — 1.34 (0.0492 — 0.0528)

1.12 (0.0441)

32218-01G14

1.33 — 1.42 (0.0524 — 0.0559)

1.20 (0.0472)

32218-01G04

1.41 — 1.50 (0.0555 — 0.0591)

1.28 (0.0504)

32218-01G15

1.49 — 1.58 (0.0587 — 0.0622)

1.36 (0.0535)

32218-01G16

1.57 — 1.66 (0.0618 — 0.0654)

1.44 (0.0567)

32218-01G17

0 — 0.1 mm (0 — 0.004 in)
Part number

2.63 (0.1035)

32348-01G15

2.70 (0.1063)

32348-01G00

2.77 (0.1091)

32348-01G01

2.84 (0.1118)

32348-01G02

2.91 (0.1146)

32348-01G03

2.98 (0.1173)

32348-01G04

3.05 (0.1201)

32348-01G05

3.12 (0.1228)

32348-01G06

3.19 (0.1256)

32348-01G07

3.26 (0.1283)

32348-01G08

3.33 (0.1311)

32348-01G09

3.40 (0.1339)

32348-01G10

3.47 (0.1366)

32348-01G11

3.54 (0.1394)

32348-01G12

3.61 (0.1421)

32348-01G13

3.68 (0.1449)

32348-01G14

Reverse idler rear thrust washer
Thickness

MT-34

mm (in)

Part number

1.97 (0.0776)

32284-01G10

2.07 (0.0815)

32284-01G11

PROPELLER SHAFT &
DIFFERENTIAL CARRIER
SECTION

CONTENTS
PREPARATION……………………………………………………….1
Special Service Tools …………………………………………..1
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ……………………………………………..4
NVH Troubleshooting Chart…………………………………..4
PROPELLER SHAFT ………………………………………………5
Front Propeller Shaft ……………………………………………5
Rear Propeller Shaft …………………………………………….5
On-vehicle Service……………………………………………….6
Removal and Installation ………………………………………7
Inspection……………………………………………………………7
Disassembly………………………………………………………..7
Assembly ……………………………………………………………8
ON-VEHICLE SERVICE (Final Drive) ……………………..10
Front Oil Seal Replacement ………………………………..10
REMOVAL AND INSTALLATION …………………………….11
Removal……………………………………………………………11
Installation…………………………………………………………11
FRONT FINAL DRIVE ……………………………………………12
REAR FINAL DRIVE ……………………………………………..13
DISASSEMBLY……………………………………………………..14
Pre-inspection ……………………………………………………14
Differential Carrier………………………………………………15
Differential Case ………………………………………………..17
INSPECTION…………………………………………………………19
Ring Gear and Drive Pinion ………………………………..19
Differential Case Assembly………………………………….19

Bearing……………………………………………………………..19
LIMITED SLIP DIFFERENTIAL……………………………….20
Preparation for Disassembly ……………………………….20
Disassembly………………………………………………………21
Inspection………………………………………………………….21
Adjustment ………………………………………………………..23
Assembly ………………………………………………………….24
ADJUSTMENT ………………………………………………………27
Drive Pinion Height…………………………………………….27
Tooth Contact…………………………………………………….29
ASSEMBLY…………………………………………………………..31
Differential Case — 4-pinion type —…………………….31
Differential Case — 2-pinion type —…………………….32
Differential Carrier………………………………………………33
DIFFERENTIAL LOCK …………………………………………..37
Actuator and Fork ………………………………………………37
Disassembly………………………………………………………38
Inspection………………………………………………………….39
Assembly ………………………………………………………….40
System Description…………………………………………….43
Component Parts Location ………………………………….44
Wiring Diagram — DIFF/L —/LHD Models ……………45
Wiring Diagram — DIFF/L —/RHD Models……………47
Electrical Components Inspection ………………………..49
SERVICE DATA AND SPECIFICATIONS (SDS) ……….51
Propeller Shaft …………………………………………………..51
Final Drive…………………………………………………………52

PREPARATION
Special Service Tools
*: For front differential carrier only
Tool number
Tool name

Unit application
Description
H233B

ST0501S000
Engine stand
1 ST05011000
V
Engine stand
2 ST05012000
V
Base

Mounting differential attachment

NT042

ST06340000
Differential attachment

Mounting final drive

NT140

ST30611000
Drive pinion bearing outer
race drift bar

Installing pinion rear bearing
outer race
(Use with ST30621000 or
ST30613000)

NT090

ST30613000
Drive pinion front bearing
outer race drift

Installing pinion front bearing
outer race
(Use with ST30613000)
X
a: 71.5 mm (2.815 in) dia.
b: 47.5 mm (1.870 in) dia.

NT073

ST30621000
Drive pinion rear bearing
outer race drift

Installing pinion rear bearing
outer race
(Use with ST30613000)
X*
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.

NT073

ST3090S000
Drive pinion rear bearing
inner race puller set
1 ST30031000
V
Puller
2 ST30911000
V
Base

Removing and installing drive
pinion rear inner race
X
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35 mm (1.38 in) dia.

NT527

PD-1

PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name
ST3127S000
Preload gauge
1 GG91030000
V
Torque wrench
2
V HT62900000
Socket adapter (1/2″)
3 HT62940000
V
Socket adapter (3/8″)
ST3125S000
Drive pinion setting
gauge set
1 ST31251000
V
Drive pinion height
gauge
2 ST31181001
V
Dummy shaft

Unit application
Description
H233B
Measuring pinion bearing
preload and total preload
X

NT124

Selecting pinion height
adjusting washer

NT524

KV40104000
Drive pinion flange
wrench

Removing and installing propeller shaft lock nut and drive
pinion lock nut

NT113

ST0237S000
Differential side bearing
puller set
1 ST33051001
V
Puller
2 ST02371000
V
Adapter

Removing and installing side
bearing inner race
X
a: 40 mm (1.57 in) dia.
b: 50 mm (1.97 in) dia.

NT072

ST33081000
Adapter

Installing side bearing inner
cone
X
a: 43 mm (1.69 in) dia.
b: 33.5 mm (1.319 in) dia.

NT431

ST33190000
Differential side bearing
drift

Installing side bearing inner
cone
a: 52 mm (2.05 in) dia.
b: 45.5 mm (1.791 in) dia.
c: 34 mm (1.34 in) dia.

NT085

KV31100300
Fork rod pin punch

Removing pinion mate shaft
lock pin
X
a: 4.5 mm (0.177 in) dia.

NT410

PD-2

PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name

Unit application
Description
H233B

KV381025S0
Oil seal fitting tool
1 ST30720000
V
Drift bar
2
V KV38102510
Drift

Installing front oil seal

a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
c: 71 mm (2.80 in) dia.
d: 65 mm (2.56 in) dia.

NT525

Adjusting side bearing preload and backlash (ring geardrive pinion)

ST32580000
Differential side bearing
adjusting nut wrench

NT141

ST3125S001
Drive pinion setting
gauge set
1 ST3131251000
Height Gauge
2 ST31181001
Dummy Shaft
3 KV38108700
Spacer [thickness:
2.00 mm (0.0787 in)]

PD-3

PROPELLER
Symptom SHAFT

DIFFERENTIAL
Vibration

Noise
PD-6
PD-19
PD-29
PD-19
PD-14

Excessive runout
Rough gear tooth
Improper gear contact
Tooth surfaces worn
Incorrect backlash

X
X
X

Shake

X
X
X
X
X
X

X: Applicable

PD-4
X
X

Refer to MA section.
Refer to PROPELLER SHAFT in this chart.
Refer to DIFFERENTIAL in this chart.
NVH in FA, RA section
NVH in FA section
NVH in FA section
NVH in RA section
NVH in BR section
NVH in ST section

Improper gear oil
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING

—

PD-6

Rotation imbalance

X
Companion flange excessive runout

—

Noise
Excessive joint angle

Possible cause and
SUSPECTED PARTS
—

Reference page

Uneven rotation torque

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X
X
X
X
X
X
X

X
X
X
X
X
X
X
X
X

X
X

X
X
X

X
X

PROPELLER SHAFT
Front Propeller Shaft

SPD434A

Rear Propeller Shaft

SPD457A

PD-5

PROPELLER SHAFT

SPD458A

On-vehicle Service
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft runout
first.
1. Raise front and rear wheels.
2. Measure propeller shaft runout at several points by rotating
final drive companion flange with hands.
Runout limit: 0.6 mm (0.024 in)
SPD728

3. If runout exceeds specifications, disconnect propeller shaft at
final drive companion flange; then rotate companion flange 180
degrees and reconnect propeller shaft.
4. Check runout again. If runout still exceeds specifications,
replace propeller shaft assembly.
5. Perform road tests.

APPEARANCE CHECKING
+

Inspect propeller shaft tube surface for dents or cracks. If
damaged, replace propeller shaft assembly.

SPD102

PD-6

PROPELLER SHAFT
Removal and Installation
+

Put matchmarks on flanges and separate propeller shaft from
final drive.

SPD103

CAUTION:
When installing the propeller shaft, make sure it is facing the
correct direction. Each model is different.

Inspection
+

Inspect propeller shaft runout. If runout exceeds specifications,
replace propeller shaft assembly.
Runout limit: 0.6 mm (0.024 in)

Inspect journal axial play.
If the play exceeds specifications, replace propeller shaft
assembly.
Journal axial play:
0.02 mm (0.0008 in) or less

Check flange yoke and sleeve yoke for damage or wear.
Replace if necessary.

SPD106

SPD874

SPD189

Disassembly
JOURNAL
1. Put matchmarks on shaft and flange or yoke.

SPD128

PD-7

PROPELLER SHAFT
Disassembly (Cont’d)
2. Remove snap ring.

SPD731

3. Remove pushed out journal bearing by lightly tapping yoke with
a hammer, taking care not to damage journal and yoke hole.

SPD732

4. Remove bearing at opposite side in above operation.
Put marks on disassembled parts so that they can be reinstalled in their original positions from which they were
removed.

SPD131

Assembly
JOURNAL
1. Assemble journal bearing. Apply recommended multi-purpose
grease on bearing inner surface.
When assembling, be careful that needle bearing does not fall
down.

SPD133

2. Select snap ring that will provide specified play in axial direction of journal, and install them. (Refer to SDS.)
Select snap rings with a difference in thickness at both sides
within 0.06 mm (0.0024 in).

SPD134

PD-8

PROPELLER SHAFT
Assembly (Cont’d)
3. Adjust thrust clearance between bearing and snap ring to zero
by tapping yoke.

SPD732

4. Check to see that journal moves smoothly and check for axial
play.
Axial play: 0.02 mm (0.0008 in) or less

SPD874

PD-9

ON-VEHICLE SERVICE (Final Drive)
Front Oil Seal Replacement
1. Remove propeller shaft.
2. Loosen drive pinion nut.
Tool number:
KV40104000

PD237

3. Remove companion flange.

SPD737

4. Remove front oil seal.

SPD738

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Press front oil seal into carrier.
6. Install companion flange and drive pinion nut.
7. Install propeller shaft.
Tool number: KV381025S0

SPD739

PD-10

REMOVAL AND INSTALLATION
Removal
Remove propeller shaft.
Remove drive shaft. Refer to FA section (‘‘FRONT AXLE —
Knuckle Flange’’).
+ Remove axle shaft.
Refer to RA section (‘‘REAR AXLE’’).
+ Remove front and rear final drive mounting bolts.
CAUTION:
+ Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
+ Before removing the final drive assembly or rear axle
assembly, disconnect the ABS sensor harness connector
from the assembly and move it away from the final drive/
rear axle assembly area. Failure to do so may result in the
sensor wires being damaged and the sensor becoming
inoperative.
+
+

SPD103

Installation
+

Fill final drive with recommended gear oil.

Pay attention to the direction of gasket.

SPD123

SPD767

PD-11

FRONT FINAL DRIVE

SPD436A

PD-12

REAR FINAL DRIVE

SPD437A

PD-13

DISASSEMBLY
Pre-inspection

SPD149

Before disassembling final drive, perform the following inspection.
+ Total preload
1) Turn drive pinion in both directions several times to set bearing
rollers.
2) Check total preload with Tool.
Tool number: ST3127S000
Total preload (with front oil seal):
Drive pinion bearing
New parts
1.7 — 2.5 Nzm (17 — 25 kg-cm, 15 — 22 in-lb)
Used parts
1.5 — 1.7 Nzm (15 — 17 kg-cm, 13 — 15 in-lb)

Ring gear to drive pinion backlash
Check ring gear-to-drive pinion backlash with a dial indicator at
several points.
Ring gear-to-drive pinion backlash:
0.15 — 0.20 mm (0.0059 — 0.0079 in)

Ring gear runout
Check runout of ring gear with a dial indicator.
Runout limit:
0.08 mm (0.0031 in)
Tooth contact
Check tooth contact. Refer to ADJUSTMENT (PD-27).

SPD246

SPD247

Side gear to pinion mate gear backlash
Measure clearance between side gear thrust washer and differential case with a feeler gauge.
Clearance between side gear thrust washer and differential case:
0.15 — 0.20 mm (0.0059 — 0.0079 in)

SPD004

PD-14

DISASSEMBLY
Differential Carrier
1. Mount differential carrier on Tools.
Tool number:
A ST0501S000
j
j
B ST06340000

SPD139

2. Put matchmarks on one side of side bearing cap with paint or
punch to ensure that it is replaced in proper position during
reassembly.
Bearing caps are line-bored during manufacture and should
be put back in their original places.

SPD249

3. Remove side lock fingers and side bearing caps.

SPD250

4. Remove side bearing adjuster with Tool.
Tool number:
ST32580000

SPD684

5. Remove differential case assembly with a pry bar.

SPD685

PD-15

DISASSEMBLY
Differential Carrier (Cont’d)
Be careful to keep the side bearing outer races together with
their respective inner cones — do not mix them up.

SPD011

6. Loosen drive pinion nut with Tool.
Tool number: KV38104700

SPD012

7. Remove companion flange with puller.

SPD686

8. Take out drive pinion together with pinion rear bearing inner
cone, drive pinion bearing spacer and pinion bearing adjusting
shim with soft hammer.

SPD687

9. Remove front oil seal and pinion front bearing inner cone.
10. Remove pinion bearing outer races with a brass drift.

SPD563

PD-16

DISASSEMBLY
Differential Carrier (Cont’d)
11. Remove pinion rear bearing inner cone and drive pinion height
adjusting washer with press and Tool.
Tool number: ST30031000 (J22912-01)

SPD018

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
j
A ST33051001 (J22888-20)
j
B ST02371000 (J8107-2)

SPD207A

Be careful not to confuse left and right hand parts.
Keep bearing and bearing race for each side together.

SPD022

2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD024

4. Drive out pinion mate shaft lock pin, with punch from ring gear
side (2-pinion type differential case).
Lock pin is calked at pin hole mouth on differential case.

SPD025

PD-17

DISASSEMBLY
Differential Case (Cont’d)
5. Separate differential case LH and RH (4-pinion type differential
case).
Put matchmarks on both differential case LH and RH sides
prior to separating them.

SPD716

PD-18

INSPECTION
Ring Gear and Drive Pinion
Check gear teeth for scoring, cracking or chipping. If any damaged
part is evident, replace ring gear and drive pinion as a set (hypoid
gear set).

Differential Case Assembly
Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, thrust block and thrust washers.

SPD530

SPD717

Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.

SPD715

PD-19

LIMITED SLIP DIFFERENTIAL

SPD439A

CAUTION:
Do not run engine when one wheel (rear) is off the ground.

Preparation for Disassembly
CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tool.
If it is not within the specifications, inspect components of limited
slip differential.
Differential torque:
108 — 137 Nzm (11 — 14 kg-m, 80 — 101 ft-lb)
Tool number: KV38106400
SPD508

PD-20

LIMITED SLIP DIFFERENTIAL
Disassembly
1. Remove side bearing inner cone with Tool.
2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off gear case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD476

4. Loosen screws on differential cases A and B using a press.
5. Separate differential cases A and B. Draw out component parts
(discs and plates, etc.).
Put marks on gears, discs and plates so that they can be reinstalled in their original positions from which they were
removed.

SPD507

Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If following surfaces are found with burrs or scratches, smooth
with oil stone.

SPD503

1
V
2
V
3
V

Differential case A
Differential case B
Pressure ring

4
V
5
V
6
V

Thrust washer
Pinion mate shaft
Thrust block

PD-21

7
V
8
V

Pinion mate gear
Side gear

LIMITED SLIP DIFFERENTIAL
Inspection (Cont’d)
DISC AND PLATE
1. Clean the discs and plates in suitable solvent and blow dry with
compressed air.
2. Inspect discs and plates for wear, nicks and burrs.

SPD478

3. To test if friction disc or plate is not distorted, place it on a surface plate and rotate it by hand with indicating finger of dial
gauge resting against disc or plate surface.
Allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new plate to eliminate possibility of clutch slippage or sticking.

SPD279

4. Measure frictional surfaces and projected portions of friction
disc, friction plate, spring plate, and determine each part’s differences to see if the specified wear limit has been exceeded.
If any part has worn beyond the wear limit, and deformed or
fatigued, replace it with a new one that is the same thickness
as the projected portion.
Wear limit:
0.1 mm (0.004 in) or less

SPD403

PD-22

LIMITED SLIP DIFFERENTIAL
Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY

SPD761

End play of friction disc and friction plate can be calculated by using
following equation and should be adjusted within following range.
Adjustment can be made by selecting friction disc having two different thicknesses.
End play E:
0.05 — 0.15 mm (0.0020 — 0.0059 in)
E = A − (B + C)
A: Length of differential case contact surface to differential case inner bottom.
B: Total thickness of friction discs, friction plates, spring
disc and spring plate in differential case on one side.
C: Length of differential case contact surface to back side
of side gear.

1. Measure values of ‘‘A’’.
Standard length A:
49.50 — 49.55 mm (1.9488 — 1.9508 in)

SPD417

2. Measure thickness of each disc and plate.
Total thickness ‘‘B’’:
19.24 — 20.26 mm (0.7575 — 0.7976 in)

SPD420

3. Measure values of ‘‘C’’.
(1) Attach a dial indicator to the base plate.
(2) Place differential case B on the base plate, and install a master gauge on case B.
Then adjust the dial indicator scale to zero with its tip on the
master gauge.

SPD418

PD-23

LIMITED SLIP DIFFERENTIAL
Adjustment (Cont’d)
(3) Install pinion mate gears, side gears and pinion mate shaft in
differential case B.
(4) Set dial indicator’s tip on the side gear, and read the indication.
Example:
E = A − D = A − (B + C) = 0.05 to 0.15 mm
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D=B+C
E=A−D
B …. 19.45
SPD419

+C …. 29.7
49.15

A ….. 49.52
−D …. 49.15
0.37

From the above equation, end play of 0.37 mm exceeds the specified range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.

Assembly
Assemble differential case in the reverse order of disassembly,
observing the following.
1. As an aid to installation, apply sufficient amounts of recommended limited slip differential gear oil (refer to MA section) to
the faces of pressure rings, discs and plates to be assembled
together.

SPD479

2. Place differential case B on a level surface, then install thrust
washer.

SPD406

3. Install spring plates, friction plates and friction discs.
Pay particular attention to the direction of clutch plates and
their assembly sequence.

SPD504

PD-24

LIMITED SLIP DIFFERENTIAL
Assembly (Cont’d)
4. Install pressure ring.

SPD481

5. Install side gear by inserting projected portion of disc.

SPD482

6. Install pinion mate gears and shaft.
Always attach pinion mate shaft to ‘‘V’’ groove in pressure ring
with flat surfaces facing up and down.

SPD483

7. Install thrust block.

SPD505

8. Install differential case A side components in the opposite way
of differential case B components.
9. Apply gear oil to differential case A, and attach thrust washer
to it.

SPD506

PD-25

LIMITED SLIP DIFFERENTIAL
Assembly (Cont’d)
10. Install differential case A on differential case B. Align the matching marks on the cases, then install screws while pushing differential case down using a press.
Press force:
7,846 N (800 kg, 1,764 lb)

SPD507

11. After all parts have been assembled, check and adjust the following:

DIFFERENTIAL TORQUE INSPECTION
a. Place side gear in a vise with Tool into the gear splines.
b. Turn side gear several times, then measure the differential
torque after side gear begins to rotate in order to determine
whether it is within the specified range. If it is not, adjust it by
selecting a friction disc. (Refer to SDS for adjustment parts.)
Differential torque:
108 — 137 Nzm (11 — 14 kg-m, 80 — 101 ft-lb)
Tool number: KV38106400
SPD508

SIDE GEAR BACKLASH INSPECTION
Check backlash of side gear on both sides. Using a feeler gauge,
measure clearance between side gear and thrust washer. If it is not
within specifications, adjust it by selecting a thrust washer. (Refer
to SDS.)
Side gear backlash:
Differential case A side
0.05 — 0.20 mm (0.0020 — 0.0079 in)
Differential case B side
0.05 — 0.20 mm (0.0020 — 0.0079 in)
SPD411

12. After checking and adjusting, tighten ring gear bolts in a crisscross fashion.
13. Bend up lock straps to lock bolts in place.
14. Install side bearing inner race with Tool.

PD-26

ADJUSTMENT
To avoid confusion while calculating bearing shims, it is absolutely
necessary to stay with the metric system. If you measure anything
in inches, the results must be converted to the metric system.

Drive Pinion Height
1. First prepare Tools for pinion height adjustment.
:V
1 Height gauge (ST31251000)*
2 Dummy shaft (ST31181001)*
V
3 Spacer KV38108700 [thickness: 2.00mm (0.0787 in)]*
V
4 Feeler gauge (commercial servcie tool)
V
2. To simplify the job, make a chart, like the one below, to organize your calculations.
HUNDREDTHS OF
A MILLIMETER

LETTERS
SPD758

H: Head number
D′: Figure marked on dummy shaft
S: Figure marked on height gauge
N: Measuring clearance
* Set tools are available: ST3125S000 (tools 1 and 2)
ST3125S001 (tools 1, 2 and 3)

3. Write the following numbers down the chart.
H: Head number

SPD542

D′: Figure marked on dummy shaft.

SPD759

PD-27

ADJUSTMENT
Drive Pinion Height (Cont’d)
S: Figure marked on height gauge.

SPD760

4. Place pinion rear bearing inner cone and Tools on gear carrier.
Tool number:
ST31181001

SPD271-A

5. Attach Tool (Height gauge) to gear carrier, and measure the
clearance between the height gauge tip and the dummy shaft
face.
Tool number:
ST31251000

SPD272-A

6. Substitute these values into the equation to calculate the thickness of the washer.
If values signifying H, D′ and S are not given, regard them as
zero and calculate.
T (Thickness of washer)
= N − [(H − D′ − S) x 0.01] + 3.05

PD444-A

PD029

PD-28

ADJUSTMENT
Drive Pinion Height (Cont’d)
Example (H233B):
N = 0.30
H=2
D′ = −1
S=0
T = N − [(H − D′ − S) x 0.01] + 2.75
= 0.40 − [{2 − (−1) − 0} x 0.01] + 2.75
(1)

H ……………………………………………………………… 2
−D′ ……………………………………………………….. −(−1)
3
−S ……………………………………………………………. −0
3

(2)

3
x 0.01
0.03

(3)

N …………………………………………………………. 0.40
−0.03
0.37

(4)

0.37
+2.75
3.12

∴T = 3.12
7. Select the proper pinion height washer.
Drive pinion height adjusting washer:
Refer to SDS (PD-0, 53).
If you cannot find the desired thickness of washer, use washer
with thickness closest to the calculated value.
Example (H233B):
Calculated value … T = 3.12 mm
Used washer … T = 3.12 mm

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation to
one another may be noisy, or have short life or both. With a pattern check, the most desirable contact for low noise level and long
life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD005

PD-29

ADJUSTMENT
Tooth Contact (Cont’d)
3. Hold companion flange steady by hand and rotate the ring gear
in both directions.

SPD695

SPD007-B

PD-30

ASSEMBLY
Differential Case — 4-pinion type —
1. Measure clearance between side gear thrust washer and differential case.
Clearance between side gear thrust washer
and differential case (A — B):
0.15 — 0.20 mm (0.0059 — 0.0079 in)
The clearance can be adjusted with side gear thrust washer.
Refer to SDS.
2. Apply oil to gear tooth surfaces and thrust surfaces and check
that they turn properly.

SPD656

3. Install differential case LH and RH.

SPD643

4. Place differential case on ring gear.
5. Apply locking sealer to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

SPD746

6. Press-fit side bearing inner races on differential case with Tool.
Tool number:
A ST33190000
j
j
B ST02371000

PD353

PD-31

ASSEMBLY
Differential Case — 2-pinion type —
1. Install side gears, pinion mate gears and thrust washers into
differential case.

SPD552

2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.
3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer. Refer to SDS.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and differential case):
0.15 — 0.20 mm (0.0059 — 0.0079 in)

SPD258

4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.

SPD030

5. Apply gear oil to gear tooth surfaces and thrust surfaces and
make sure they turn properly.
6. Install differential case assembly on ring gear.
Tighten bolts in a criss-cross pattern, lightly tapping bolt head
with a hammer.

SPD322

7. Press-fit side bearing inner cones on differential case with Tool.
Tool number:
A ST33190000
j
j
B ST02371000

PD353

PD-32

ASSEMBLY
Differential Carrier
1. Press-fit front and rear bearing outer races with Tools.
Tool number:
A ST30611000
j
j
B ST30621000 (front differential)
or suitable pipe
C ST30701000
j
CAUTION:
Do not damage roller side face.

SPD580

2. Select drive pinion height adjusting washer. Refer to ADJUSTMENT (PD-27).
3. Install drive pinion height adjusting washer in drive pinion, and
press-fit pinion rear bearing inner cone in it, with press and
Tool.
Tool number: ST30911000

SPD377

4. Place pinion front bearing inner cone in gear carrier.

SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Install front oil seal.
Tool number:
A ST30720000
j
B KV38102510
j

SPD451A

PD-33

ASSEMBLY
Differential Carrier (Cont’d)
6. Install drive pinion bearing spacer, pinion bearing adjusting
shim and drive pinion in gear carrier.

SPD935-A

7. Insert companion flange into drive pinion by tapping the companion flange with a soft hammer.

SPD697

8. Tighten pinion nut to the specified torque.
The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: KV38104700

SPD040

SPD149

9. Turn drive pinion in both directions several times, and measure
pinion bearing preload.
Tool number: ST3127S000
Pinion bearing preload (with front oil seal):
1.4 — 1.7 Nzm (14 — 17 kg-cm, 12 — 15 in-lb)
If preload is out of specification, adjust the thickness of spacer and
shim combination by replacing shim and spacer with thinner one.
+ Start from the combination of thickest spacer and shim.
+ Combine each spacer and shim thickness one by one until the
correct specification are achieved.
Drive pinion bearing preload adjusting spacer and
shim:
Refer to SDS (PD-51).

PD-34

ASSEMBLY
Differential Carrier (Cont’d)
10. Install differential case assembly with side bearing outer races
into gear carrier.

PD383

11. Position side bearing adjusters on gear carrier with threads
properly engaged; screw in adjusters lightly at this stage of
assembly.
Tool number:
ST32580000

SPD684

12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
+ Do not tighten at this point to allow further tightening of side
bearing adjusters.

SPD265

13. Tighten both right and left side bearing adjusters alternately and
measure ring gear backlash and total preload at the same time.
Adjust right and left side bearing adjusters by tightening them
alternately so that proper ring gear backlash and total preload
can be obtained.
Ring gear-to-drive pinion backlash:
0.15 — 0.20 mm (0.0059 — 0.0079 in)

SPD246

When checking preload, turn drive pinion in both directions several times to set bearing rollers.
Tool number: ST3127S000
Total preload (with front oil seal):
Drive pinion bearing
New parts
1.7 — 2.5 Nzm (17 — 25 kg-cm, 15 — 22 in-lb)
Used parts
1.5 — 1.7 Nzm (15 — 17 kg-cm, 13 — 15 in-lb)

SPD149

PD-35

ASSEMBLY
Differential Carrier (Cont’d)
14. Tighten side bearing cap bolts.
15. Install side lock finger in place to prevent rotation during operation.

SPD698

16. Check runout of ring gear with a dial indicator.
Runout limit: 0.08 mm (0.0031 in)
+ If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case.
+ If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
17. Check tooth contact. Refer to ADJUSTMENT (PD-27).
SPD247

PD-36

DIFFERENTIAL LOCK

SPD441A

Actuator and Fork

SPD835-A

PD-37

DIFFERENTIAL LOCK
Disassembly
1. Remove side bearing inner cone with Tool. For removal
procedure, refer to ordinary differential case.
2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off the gear with a soft hammer.

SPD839

4. Put marks on both differential cases.
5. Loosen screws on differential cases A and B using a press.
Tool number: ST33081000
6. Separate differential cases A and B.

SPD449A

7. Drive out pinion mate shaft lock pin with Tool.
Draw out component parts.

SPD841

PD-38

DIFFERENTIAL LOCK
Inspection

SPD842

CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If following surfaces are found with burrs or scratches, smooth
with oil stone.
1 Differential case A
V
2 Differential case B
V
3 Side gear thrust washer
V
4 Side gear
V
5 Pinion mate thrust washer
V
6 Pinion mate gear
V
7 Pinion mate shaft
V

ACTUATOR OPERATION
Apply a vacuum pressure of 66.7 kPa (667 mbar, 500 mmHg, 19.69
inHg) and check its operation and leakage within 10 seconds.

SPD906

PD-39

DIFFERENTIAL LOCK
Assembly
DIFFERENTIAL CASE
1. Install side gears, pinion mate gears and thrust washers into
differential case B.
2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.

SPD844

3. Adjust backlash between side gear and pinion mate gear.
+ Opposite side of ring gear:
Select side gear thrust washer by measuring gap with feeler
gauge. Refer to SDS.

SPD845

Ring gear side:
Measure height H1.
Measure height H2.
H2 − H1 = Clearance between the side gear end face and differential case B
Select side gear thrust washer. Refer to SDS.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and differential case):
0.10 — 0.20 mm (0.0039 — 0.0079 in)

SPD846

4. Install pinion mate shaft lock pin with a punch. Make sure lock
pin is flush with case.
5. Install differential case A.
6. Place ring gear on differential case and install it by tightening
bolt. Use locking sealant.
7. Install side bearing inner cone.

SPD847

PD-40

DIFFERENTIAL LOCK
Assembly (Cont’d)
ACTUATOR
+

If same differential carrier is used again, reuse actuator shim or
use a shim of the same thickness when used shim is damaged.

When differential carrier is replaced with a new one, select
actuator shim to keep differential lock mechanism functioning.
When installing the differential lock fork, make sure it is facing
the correct direction.

SPD848

1. Standard length ‘‘A’’ is between specified mounting surface of
actuator and differential case B surface ‘‘P’’. Refer to SDS.

SPD930

2. Install differential carrier on axle case.
3. Rotate ring gear until surface ‘‘P’’ is seen through actuator
mounting hole in axle case.
Measure dimension ‘‘L’’ between actual mounting surface of
actuator on axle case and surface ‘‘P’’, using suitable gauge
tool.
+ Put gauge as shown on drawing.
+ Put mark on gauge at actuator mounting surface.
+ Measure dimension ‘‘L’’.

SPD931

PD-41

DIFFERENTIAL LOCK
Assembly (Cont’d)
4. If shim thickness determined by equation is assumed as ‘‘T’’,
‘‘T’’ will be expressed by equation ‘‘A’’ — ‘‘L’’. Select a combination of shims from those shown in SDS so that shim thickness
is within ‘‘T’’ range. Install actuator using selected shims.

SPD932

PD-42

DIFFERENTIAL LOCK
System Description
The differential lock operates only in 4WD.
The differential lock control unit interrupts current flowing through
differential lock solenoid-2 when vehicle speed exceeds 7 km/h (4
MPH). If the differential lock switch is accidentally turned on when
vehicle speed is greater than 7 km/h (4 MPH), the control unit will
prevent the differential lock from sustaining impact damage.
A warning buzzer will sound when the vehicle is driven over 20
km/h (12 MPH) with the differential lock engaged.

SPD446A

PD-43

DIFFERENTIAL LOCK
Component Parts Location

SPD442A

PD-44

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/LHD Models

TPD013

PD-45

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/LHD Models
(Cont’d)

TPD014

PD-46

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/RHD Models

TPD016

PD-47

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/RHD Models
(Cont’d)

TPD017

PD-48

DIFFERENTIAL LOCK
Electrical Components Inspection
DIFFERENTIAL LOCK INDICATOR SWITCH CHECK
+

Check switch function by checking continuity.
Continuity:
ON Continuity should exist.
OFF Continuity should not exist.
If NG, replace differential lock indicator switch.

SPD443A

DIFFERENTIAL LOCK SOLENOID CHECK
1. Disconnect differential lock solenoid 4-pin connector.
2. Check continuity between terminals V
1 and V
3 , V
2 and
Continuity should exist.
If NG, replace differential lock solenoid.

SPD444A

SPEED SENSOR CHECK
Refer to EL section.

PD-49

4 .
V

DIFFERENTIAL LOCK
Electrical Components Inspection (Cont’d)
DIFFERENTIAL LOCK CONTROL UNIT CHECK
On-vehicle check
Be sure that vehicle is in 4WD.

Operate vehicle at a speed less than 7 km/h (4 MPH) or
when stopping.

Turn differential lock switch ON.

Ensure differential lock indicator lamp is on.

Malfunction is in system other than differential lock control unit, speed sensor. Check and correct.

When speed sensor functions, differential lock control
unit functions improperly.

Yes
.

Turn differential lock switch OFF while driving vehicle at
speed less than 7 km/h (4 MPH) or when stopping.

Drive vehicle at speed greater than 7 km/h (4 MPH) and
turn differential lock switch ON.

Yes

Ensure differential lock indicator lamp is on.
No
.

Differential lock control unit is functioning properly.

Check differential lock control unit.

Unit check
1. Ensure that wiring to differential lock control unit is correct and
that the unit is properly connected to power supply.
2. Place vehicle on a safety stand properly. Ensure that the front
and rear wheels rotate freely.

3. Check output voltage of differential lock at solenoid-2 connector.
+ Vehicle speed less than 7 km/h (4 MPH) on speedometer
Power supply: Approximately 12V
+ Vehicle speed greater than 7 km/h (4 MPH) on speedometer
Output voltage: Approximately 0V

SPD445A

PD-50

SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft
GENERAL SPECIFICATIONS
Front propeller shaft
Applied model

RD28 Engine MT models

Propeller shaft model

2F80B

Number of joints

Type of journal bearing

Solid (Disassembly type)

Coupling type with transmission

Flange type

Distance between yokes
mm (in)

73 (2.87)

Shaft length (Spider-tospider)
mm (in)

832 (32.76)

Shaft outer diameter
mm (in)

50.8 (2.000)

Rear propeller shaft
Applied model
Engine

RD28

Transmission
Body
Propeller shaft model

M/T
Hardtop

Wagon

2F100H

2F80B

Number of joints

Type of journal bearing

Solid (Disassembly type)

Coupling type with transmission

Flange type

Distance between yokes
mm (in)

94 (3.70)

73 (2.87)

Shaft length (Spider-tospider)
mm (in)

440 (17.32)

1,033 (40.67)

Shaft outer diameter
mm (in)

57 (2.24)

89.6 (3.528)

INSPECTION AND ADJUSTMENT

Available snap rings

Service data

2F80B

Propeller shaft model

2F80B, 2F100H

Propeller shaft runout limit
mm (in)
Journal axial play

mm (in)

0.6 (0.024)
0.02 (0.0008)

PD-51

Thickness mm (in)

Color

Part number

1.99 (0.0783)

White

37146-C9400

2.02 (0.0795)

Yellow

37147-C9400

2.05 (0.0807)

Red

37148-C9400

2.08 (0.0819)

Green

37149-C9400

2.11 (0.0831)

Blue

37150-C9400

2.14 (0.0843)

Light brown

37151-C9400

2.17 (0.0854)

Black

37152-C9400

2.20 (0.0866)

Black

37153-C9400

SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft (Cont’d)
2F100H
Thickness mm (in)

Color

Part number

1.95 (0.0768)

White

37146-61502

1.98 (0.0780)

Yellow

37147-61502

2.01 (0.0791)

Red

37148-61502

2.04 (0.0803)

Green

37149-61502

2.07 (0.0815)

Blue

37150-61502

2.10 (0.0827)

Light Brown

37151-61502

2.13 (0.0839)

Pink

37146-61503

2.16 (0.0850)

Gold

37147-61503

2.19 (0.0862)

Black

37148-61503

2.22 (0.0874)

Color less

37149-61503

Final Drive
GENERAL SPECIFICATIONS
Body type

Wagon

Hardtop

Engine

RD28ETi

Transmission

M/T
Standard

Front final drive [All]

H233B
2-pinion

Gear ratio

4.625

Number of teeth (Ring
gear/drive pinion)

37/8

Oil capacity (Approx.)
! (Imp pt)

5.4 (9-1/2)
Optional

Rear final drive
[Grade]

Standard

Optional

H233B
Diff. lock

H233B
4 pinion

4 pinion

Diff. lock

Gear ratio

4.625

Number of teeth (Ring
gear/drive pinion)

37/8

Without diff.
lock

2.4 (4-1/4)

With diff.
lock

3.0 (5-1/4)

Oil capacity
(Approx.)
! (Imp pt)

With LSD model
Body type

INSPECTION AND ADJUSTMENT
Wagon

Engine
Transmission

Hardtop
RD28ETi

All

Ring gear runout limit

mm (in)

0.08 (0.0031)

M/T

Rear final drive
[Grade]

H233B

Gear ratio

4,625

Number of teeth
(ring gear/drive
pinion)

37/8

Oil capacity
(Approx.)
! (Imp pt)

Ring gear runout

LSD

Side gear adjustment (without LSD)
Side gear backlash
(Clearance between side gear to
differential case)
mm (in)

0.15 — 0.20 (0.0059 — 0.0079)

Available side gear thrust washers
Thickness

2.1 (3-3/4)

1.75 (0.0689)
1.80 (0.0709)
1.85 (0.0728)

PD-52

mm (in)

Part number
38424-T5000
38424-T5001
38424-T5002

SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont’d)
— Additional service for LSD model —
Differential torque adjustment
Differential torque

Drive pinion bearing preload adjusting method

108 — 137
(11 — 14, 80 — 101)

Nzm (kg-m, ft-lb)

Drive pinion preload adjustment

Number of discs and plates

Drive pinion preload
Nzm (kg-cm, in-lb)

4
4
4

Friction disc
Friction plate
Spring plate
Wear limit of plate and disc

0.1 (0.004)

mm (in)
Allowable warpage of friction disc
and plate
mm (in)

Adjusting shim and spacer

With front oil seal

1.4 — 1.7
(14 — 17, 12 — 15)

Without front oil seal

1.2 — 1.5
(12 — 15, 10 — 13)

Available drive pinion preload adjusting shims

0.08 (0.0031)

Thickness

mm (in)

Part number

Available discs and plates
Part name

Thickness

mm (in)

1.48 — 1.52
(0.0583 — 0.0598)

38433-C6000
(Standard type)

1.58 — 1.62
(0.0622 — 0.0638)

38433-C6001
(Adjusting type)

Friction plate

1.48 — 1.52
(0.0583 — 0.0598)

38432-C6000

Spring disc

1.48 — 1.52
(0.0583 — 0.0598)

38436-C6000

Spring plate

1.48 — 1.52
(0.0583 — 0.0598)

38435-C6010

Friction disc

2.31
2.33
2.35
2.37
2.39
2.41
2.43
2.45
2.47
2.49
2.51
2.53
2.55
2.57
2.59

Part number

Drive pinion height adjustment
mm (in)
2.58 (0.1016)
2.61 (0.1028)
2.64 (0.1039)
2.67 (0.1051)
2.70 (0.1063)
2.73 (0.1075)
2.76 (0.1087)
2.79 (0.1098)
2.82 (0.1110)
2.85 (0.1122)
2.88 (0.1134)
2.91 (0.1146)
2.94 (0.1157)
2.97 (0.1169)
3.00 (0.1181)
3.03 (0.1193)
3.06 (0.1205)
3.09 (0.1217)
3.12 (0.1228)
3.15 (0.1240)
3.18 (0.1252)
3.21 (0.1264)
3.24 (0.1276)
3.27 (0.1287)
3.30 (0.1299)
3.33 (0.1311)
3.36 (0.1323)
3.39 (0.1335)
3.42 (0.1346)
3.45 (0.1358)
3.48 (0.1370)
3.51 (0.1382)
3.54 (0.1394)
3.57 (0.1406)
3.60 (0.1417)
3.63 (0.1429)
3.66 (0.1441)

38125-82100
38126-82100
38127-82100
38128-82100
38129-82100
38130-82100
38131-82100
38132-82100
38133-82100
38134-82100
38135-82100
38136-82100
38137-82100
38138-82100
38139-82100

Available drive pinion preload adjusting spacers

Available pinion height adjusting washers
Thickness

(0.0909)
(0.0917)
(0.0925)
(0.0933)
(0.0941)
(0.0949)
(0.0957)
(0.0965)
(0.0972)
(0.0980)
(0.0988)
(0.0996)
(0.1004)
(0.1012)
(0.1020)

Length

Part number
38151-01J00
38151-01J01
38151-01J02
38151-01J03
38151-01J04
38151-01J05
38151-01J06
38151-01J07
38151-01J08
38151-01J09
38151-01J10
38151-01J11
38151-01J12
38151-01J13
38151-01J14
38151-01J15
38151-01J16
38151-01J17
38151-01J18
38151-01J19
38151-01J60
38151-01J61
38151-01J62
38151-01J63
38151-01J64
38151-01J65
38151-01J66
38151-01J67
38151-01J68
38151-01J69
38151-01J70
38151-01J71
38151-01J72
38151-01J73
38151-01J74
38151-01J75
38151-01J76

mm (in)
4.50
4.75
5.00
5.25
5.50

Part number

(0.1772)
(0.1870)
(0.1969)
(0.2067)
(0.2165)

38165-76000
38166-76000
38167-76000
38166-01J00
38166-01J10

Total preload adjustment
Total preload
Drive pinion
Nzm (kg-cm, in-lb)
bearing
With front oil seal

Ring gear backlash
Side bearing adjusting method

PD-53

New

1.7 — 2.5
(17 — 25, 15 — 22)

Old

1.5 — 1.7
(15 — 17, 13 — 15)

mm (in)

0.15 — 0.20
(0.0059 — 0.0079)
Side adjuster

REAR AXLE &
REAR SUSPENSION
SECTION

CONTENTS
PRECAUTIONS AND PREPARATION……………………….1
Precautions …………………………………………………………1
Special Service Tools …………………………………………..1
Commercial Service Tools …………………………………….2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ……………………………………………..3
NVH Troubleshooting Chart…………………………………..3
REAR AXLE AND REAR SUSPENSION……………………4
ON-VEHICLE SERVICE …………………………………………..5
Rear Axle and Rear Suspension Parts …………………..5
Rear Wheel Bearing …………………………………………….5
REAR AXLE……………………………………………………………6
Components………………………………………………………..6
Removal……………………………………………………………..7
Inspection……………………………………………………………9

Installation…………………………………………………………..9
REAR SUSPENSION……………………………………………..12
Removal and Installation …………………………………….13
Coil Spring and Shock Absorber ………………………….14
Upper Link, Lower Link and Panhard Rod…………….14
Stabilizer Bar …………………………………………………….15
STABILIZER RELEASE DEVICE…………………………….16
System Components ………………………………………….16
System Description…………………………………………….16
Removal and Installation …………………………………….17
Wiring Diagram ………………………………………………….18
Trouble Diagnoses……………………………………………..20
SERVICE DATA AND SPECIFICATIONS (SDS) ……….25
General Specifications………………………………………..25
Inspection and Adjustment ………………………………….25

PRECAUTIONS AND PREPARATION
Precautions
+

+
+
+

When installing rubber parts, final tightening must be carried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
Use flare nut wrench when removing and installing brake
tubes.
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Always torque brake lines when installing.

SBR820BA

Special Service Tools
Tool number
Tool name

Description

KV40101000
Axle stand

Removing rear axle shaft

NT159

ST36230000
Sliding hammer

Removing rear axle shaft

NT126

ST38080001
Bearing lock nut wrench

Removing wheel bearing lock nut

a: 58 mm (2.28 in)

NT507

KV40106500
Wheel bearing puller

Removing wheel bearing

NT724

GG94310000
Flare nut torque
wrench

Removing and installing brake piping

a: 10 mm (0.39 in)

NT406

RA-1

PRECAUTIONS AND PREPARATION
Commercial Service Tools
Tool name

Description

Equivalent to GG94310000
j
1 Flare nut crowfoot
j
2 Torque wrench

Removing and installing each brake piping

a: 10 mm (0.39 in)

NT360

Rear axle oil seal drift

Installing oil seal

a: 74 mm (2.91 in) dia.
b: 68 mm (2.68 in) dia.
c: 10 mm (0.39 in)

NT163

RA-2

Symptom

Vibration

Shimmy

Judder

Poor quality ride or handling

X: Applicable

RA-3

NVH in FA section
NVH in FA section
NVH in FA section
NVH in BR section
NVH in ST section

TIRES
ROAD WHEEL
AXLE SHAFT
BRAKES
STEERING

Refer to REAR AXLE AND REAR SUSPENSION in this chart.

X
REAR AXLE AND REAR SUSPENSION

NVH in FA section

FRONT AXLE AND FRONT SUSPENSION

NVH in PD section

X
DIFFERENTIAL

NVH in PD section

X
PROPELLER SHAFT

RA-5

Shake
Wheel bearing damage

RA-15

X
Stabilizer bar fatigue

—

RA-12

—

Parts interference

X
Suspension looseness

—

Bushing or mounting deterioration

Noise
Spring fatigue

RA-14

REAR
AXLE AND
REAR
SUSPENSION
Shock absorber deformation, damage or deflection

Possible cause and SUSPECTED PARTS
RA-4

Reference page

Improper installation, looseness

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X
X
X
X
X
X
X

REAR AXLE AND REAR SUSPENSION

SRA813A

RA-4

ON-VEHICLE SERVICE
Rear Axle and Rear Suspension Parts
Check rear axle and rear suspension parts for excessive play, wear
or damage.
+ Shake each rear wheel to check for excessive play.
+ Retighten all nuts and bolts to the specified torque.
Tightening torque:
Refer to REAR SUSPENSION, RA-12.

SMA525A

+
+

Check shock absorber for oil leakage or other damage.
Check shock absorber bushing for excessive wear or other
damage.

SRA814A

Rear Wheel Bearing
+
+

Check that wheel bearings operate smoothly.
Check axial end play.
Axial end play:
0 mm (0 in)

SRA755A

RA-5

REAR AXLE
Components

SRA816A

RA-6

REAR AXLE
Removal
CAUTION:
+ Before removing the rear axle, disconnect the ABS wheel
sensor from the assembly. Then move it away from the
axle. Failure to do so may result in damage to the sensor
wires and the sensor becoming inoperative.
+ Wheel bearing does not require maintenance.
+ If growling noise is emitted from wheel bearing during
operation, replace wheel bearing assembly.
+ If the wheel bearing assembly is removed, it must be renewed.
The old assembly must not be re-used.
1. Disconnect parking brake cable and brake tube.
2. Remove nuts securing wheel bearing cage with baffle plate.

SRA757A

3. Draw out axle shaft with Tool.
When drawing out axle shaft, be careful not to damage oil seal.
4. Remove O-ring.

SRA845A

5. Remove oil seal with a screwdriver.
Do not reuse oil seal once it is removed.
Always install new one.

SRA846A

6. Remove ABS sensor rotor. — Models with ABS —

SRA799A

RA-7

REAR AXLE
Removal (Cont’d)
7. Unbend lock washer with a screwdriver.
Do not reuse lock washer once removed. Always install new
one.

SRA847A

8. Remove bearing lock nut with Tool.

SRA817A

9. Remove wheel bearing together with bearing cage and baffle
plate from axle shaft.

SRA800A

10. Remove grease seal in bearing cage with suitable bar.

SRA595C

11. Remove wheel bearing assembly.

SRA801AA

RA-8

REAR AXLE
Inspection
AXLE SHAFT
Check axle shaft for straightness, cracks, damage, wear or distortion. Replace if necessary.

BEARING CAGE
Check bearing cage for deformation or cracks. Replace if necessary.

REAR AXLE HOUSING
Check rear axle housing for yield, deformation or cracks. Replace
if necessary.

Installation
1. Press new wheel bearing until it bottoms end face of bearing
cage.
Always press outer race of wheel bearing during installation.

SRA288A

2. Press new grease seal until it bottoms end face of bearing
cage.
After installing new grease seal, coat sealing lip with multipurpose grease.
3. Install bearing spacer with chamfer side facing axle shaft
flange.
4. Install caliper adapter and baffle plate to bearing cage.

SRA289A

5. Press axle shaft into inner race of wheel bearing.
Be careful not to damage or deform grease seal.

SRA849A

RA-9

REAR AXLE
Installation (Cont’d)
6. Install a new wheel bearing lock washer.
7. Tighten wheel bearing lock nut to specified torque.
: 441 — 490 Nzm (45 — 50 kg-m, 325 — 362 ft-lb)
Be sure to bend bearing lock washer up.

SRA828A

8. Check wheel bearing preload.
a. Turn bearing cage (with respect to axle shaft) two or three
times. It must turn smoothly.
b. Attach spring gauge to bearing cage bolt (as shown at left) and
pull it at a speed of 10 rpm to measure preload.
Spring gauge indication:
8.8 — 42.2 N (0.9 — 4.3 kg, 2.0 — 9.5 lb)

SRA821A

9. Install new oil seal to rear axle housing using a suitable tool.
After installing new oil seal, coat sealing lip with multi-purpose
grease.
10. Install new O-ring to rear axle housing.

SRA850A

11. Press ABS sensor rotor onto axle shaft until it contacts wheel
bearing lock nut.

SRA822A

12. Install axle shafts in rear axle housing.
Be careful not to damage oil seal.

SRA823A

RA-10

REAR AXLE
Installation (Cont’d)
13. Check axial end play.
a. Check that wheel bearings operate smoothly.
b. Check axial end play.
Axial end play:
0 mm (0 in)

SRA824A

RA-11

REAR SUSPENSION

SRA819A

RA-12

REAR SUSPENSION
Removal and Installation

SRA825A

Support axle and suspension components with a suitable jack
and block.
+ Disconnect brake hydraulic line and parking brake cables at
back plates.
CAUTION:
+ Use flare nut wrench when removing or installing brake
tubes.
+ Before removing the rear suspension assembly, disconnect the ABS wheel sensor from the assembly. Then move
it away from the rear suspension assembly. Failure to do
so may result in damage to the sensor wires and the sensor becoming inoperative.
+ Remove stabilizer bar from body.
+ Remove upper links and lower links from body.
+ Remove panhard rod from body.
+ Disconnect rear end of propeller shaft. Refer to PD section.
+ Remove upper end nuts of shock absorber.
+

SBR820BA

RA-13

REAR SUSPENSION
Removal and Installation (Cont’d)
Final tightening for rubber parts requires to be carried out
under unladen condition with tires on ground.

SRA851A

Coil Spring and Shock Absorber
REMOVAL AND INSTALLATION
Refer to ‘‘Removal and Installation’’, ‘‘REAR SUSPENSION’’,
RA-13.
When installing coil spring, pay attention to its direction.
Be sure spring rubber seat is not twisted and has not slipped
off when installing coil spring.

SRA852A

INSPECTION
+
+
+

Check coil spring for yield, deformation or cracks.
Check shock absorber for oil leakage, cracks or deformation.
Check all rubber parts for wear, cracks or deformation. Replace
if necessary.

Upper Link, Lower Link and Panhard Rod
INSPECTION
Check for cracks, distortion or other damage. Replace if necessary.

BUSHING REPLACEMENT
Check for cracks or other damage. Replace with suitable tool if
necessary.
+ Remove bushing with suitable tool.

SRA898

When installing bushing, apply a coat of 1% soapy water to
outer wall of bushing.
Always install new bushing.
Do not tap end face of bushing directly with a hammer.

SRA900

RA-14

REAR SUSPENSION
Upper Link, Lower Link and Panhard Rod
(Cont’d)
INSTALLATION
When installing each link, pay attention to direction of nuts
and bolts.
When installing each rubber part, final tightening must be carried out under unladen condition with tires on ground.

Stabilizer Bar
REMOVAL AND INSTALLATION
+

When removing and installing stabilizer bar, fix portion A.

Install stabilizer bar with ball joint socket properly placed.

SRA766A

SFA449BA

RA-15

STABILIZER RELEASE DEVICE
System Components

SRA832A

Roll rigidity is increased by activating the stabilizer function (turning the stabilizer ON) on good roads. On rough
roads, deactivating the stabilizer function (turning the stabilizer OFF) reduces stabilizer swing-back behavior.
As a result, the stabilizer release device serves to increase driving capability and riding comfort on rough roads.
The stabilizer release device is electrically activated (turned ON) or deactivated (turned OFF) by the stabilizer
switch in the driver’s compartment.

System Description
CONTROL UNIT

SRA833A

The stabilizer control unit controls the actuator motor using the
stabilizer switch and a signal sent from the vehicle speed sensor.
When vehicle speed exceeds 20 km/h (12 MPH), the stabilizer
control unit maintains the clutch cylinder position and activates the
stabilizer function, regardless of the position of the stabilizer switch.
The system is provided with a timer function to cut the actuator
activating power output in about 15 seconds, in consideration of a
possible system abnormality.

ACTUATOR
The actuator motor is turned on by a signal sent from the control
unit. When the motor operates, the cable moves to activate the
stopper pin at the end of the cable.

CLUTCH CYLINDER
The stopper pin (at the end of the cable) moves in and out of the
cylinder (toward the piston rod or away from the piston rod) to turn
the stabilizer ON or OFF.

SRA834A

RA-16

STABILIZER RELEASE DEVICE
Removal and Installation

SRA835A

1. Loosen the lock nut C, and loosen the A nut. Remove the cable
from the clutch cylinder.
CAUTION:
+ Do not remove the B nut because this requires the inner
cable extension adjustment.
+ Before installing the A and C nuts, use seal tape to wrap
the clutch cylinder thread area and cable thread area.
2. Remove the clamp and other fasteners which secure the cable.
3. Remove the stabilizer actuator connector.
4. Remove the stabilizer actuator.
5. Remove the clutch cylinder.
SRA836A

6. Before removing the stabilizer control unit, remove cluster lid C
and audio equipment. Refer to the BT section ‘‘INSTRUMENT
PANEL’’.

SRA837A

RA-17

STABILIZER RELEASE DEVICE
Wiring Diagram

TRA001

RA-18

STABILIZER RELEASE DEVICE
Wiring Diagram (Cont’d)

TRA002

RA-19

STABILIZER RELEASE DEVICE
Trouble Diagnoses
DIAGNOSTIC PROCEDURE 1
(POWER SUPPLY AND GROUND CIRCUIT CHECK)

SRA838A

CHECK POWER SUPPLY CIRCUIT FOR
STABILIZER CONTROL UNIT.
1. Turn ignition switch ON.
2. Check voltage between control unit
connector terminals V
4 , V
5 and
ground.
Battery voltage should exist.

NG
c

Check the following.
+ 7.5A fuse 24 , 10A fuse

28
+ Harness connector M44
+ Harness for open or
short between control
unit and fuse
If NG, repair fuse, harness
or connectors.

SRA839A

CHECK GROUND CIRCUIT FOR STABILIZER CONTROL UNIT.
1. Disconnect control unit connector.
2. Check continuity between control unit
connector terminal V
10 and ground.
Continuity should exist.
OK
.

Power supply and ground circuit is OK.

RA-20

NG
c

Check the following.
+ Harness connector M44
+ Harness for open or
short between control
unit and ground
If NG, repair harness or
connectors.

STABILIZER RELEASE DEVICE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 2
(VEHICLE SPEED SENSOR CIRCUIT CHECK)

SRA840A

CHECK VEHICLE SPEED SENSOR CIRCUIT.
1. Jack up drive wheels.
2. Connect voltmeter between control unit
connector terminal V
9 and ground.
3. Slowly turn wheels.
4. Check deflection of voltmeter vary from
0 to 5 volts.

OK
c

Vehicle speed sensor is
OK.

NG
.

Does speedometer operate normally?
Yes
.

Check the following.
+ Harness connector M44
+ Harness for open or short between control unit and combination meter
If NG, repair harness or connectors.

RA-21

No
c

Check speedometer and
vehicle speed sensor circuit.

STABILIZER RELEASE DEVICE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 3
(STABILIZER SWITCH CIRCUIT CHECK)
1. Turn ignition switch ON.
2. Turn stabilizer switch ‘‘OFF’’ to make
sure stabilizer OFF illuminate.

NG
c

OK
.
SRA841A

OK
.

CHECK POWER SUPPLY FOR STABILIZER SWITCH.
1. Turn ignition switch ON.
2. Check voltage between control unit
connector terminals V
1 , V
2 , V
3 , V
4
and ground.
Stabilizer
switch

SRA842A

OFF

Terminal
1
V
2
V
3
V
4
V
1
V
2
V
3
V
4
V

—

Check the following.
+ 10A fuse 28
+ Stabilizer off lamp bulb

OK
c

Stabilizer switch circuit is
OK.

Volt

Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground

Battery voltage
Battery voltage
0
Battery voltage
0
0
Battery voltage
Battery voltage

NG
.

STABILIZER SWITCH CHECK.
Switch condition
ON
OFF

Continuity between terminals
1 — V
3
2 — V
3
V
V
No
Yes
Yes
No

OK
.

Check the following.
+ Harness connectors M32 , M44 , M100
+ Harness for open or short between control unit and stabilizer switch, combination meter
+ Combination meter
If NG, repair harness or connectors.

RA-22

NG
c

Replace stabilizer switch.

STABILIZER RELEASE DEVICE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 4
(STABILIZER ACTUATOR CIRCUIT CHECK)
CHECK STABILIZER ACTUATOR CIRCUIT.
1. Turn ignition switch ON.
2. Check voltage between control unit
connector terminals V
6 , V
7 , V
8 and
ground.

OK
c

Stabilizer actuator circuit is
OK.

SRA843A

Stabilizer
switch

Terminal

Volt

6
V

— Ground

7
V

— Ground

8
V

— Ground

6
V

— Ground

7
V
8
V

— Ground
— Ground

SRA844A

OFF

0
After turning stabilizer switch
‘‘ON’’, battery
voltage will exist
for about 15
seconds, then
drop to 0 volts.
Approximately 4
After turning stabilizer switch
‘‘OFF’’, battery
voltage will exist
for about 15
seconds, then
drop to 0 volts.
0
Approximately 4

NG
.

CHECK STABILIZER ACTUATOR
CHECK.
1. Disconnect stabilizer actuator connector.
2. Check stabilizer actuator by listening for
its operating sound while applying battery voltage to the terminals V
1 and
2 .
V
Terminal

Clutch cylinder

Operating
sound

1 — V
2
V

OFF → ON

Yes

ON → OFF

Yes

⊕

1 — V
2
V

⊕

OK
.

Check the following.
+ Harness connectors
M44 , C4
+ Harness for open or short between control unit and stabilizer actuator
If NG, repair harness or connectors.

RA-23

NG
c

Replace stabilizer actuator.

STABILIZER RELEASE DEVICE
Trouble Diagnoses (Cont’d)
INSPECTION OF STABILIZER RELEASE DEVICE
CONTROL UNIT

SRA853A

Terminal No.
Parts of check
+

Specifications

−

Key switch ON,

Stabilizer switch
ON: 0 volts
OFF: Approx. 0.6 volts

Key switch ON

Stabilizer switch
ON: Battery voltage (Approx. 12 volts)
OFF: 0 volts

Key switch ON

Stabilizer switch
ON: 0 volts
OFF: Battery voltage (Approx. 12 volts)

Stabilizer off indicator

Stabilizer switch

Key switch

4
5

Power supply

ON: Battery voltage (Approx. 12 volts)
OFF: volts

Always battery voltage (Approx. 12 volts)
Key switch ON

Stabilizer switch
ON: 0 volts
OFF: After turning stabilizer switch
‘‘OFF’’, battery voltage (Approx. 12
volts) will exist for about 15
seconds, then drop to 0 volts.

Key switch ON

Stabilizer switch
ON: After turning stabilizer switch ‘‘ON’’,
battery voltage (Approx. 12 volts)
will exist for about 15 seconds, then
drop to 0 volts.
OFF: 0 volts

Body ground
6

Stabilizer actuator
7

8
9

Vehicle speed sensor

Ground

Key switch

ON: Approx. 4 volts
OFF: 0 volts

During extremely low
speeds

Varies from 0 volts to 5 volts
—

RA-24

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Suspension type

5-link type rigid with coil spring

Shock absorber type

Double-acting hydraulic

Stabilizer

Standard equipment

Inspection and Adjustment
WHEEL BEARING
Total end play

mm (in)

Wheel bearing preload at bearing
cage bolt
N (kg, lb)

0 (0)
8.8 — 42.2 (0.9 — 4.3, 2.0 — 9.5)

RA-25

RESTRAINT SYSTEM
SECTION

CONTENTS
PRECAUTION…………………………………………………………1
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’……………1
SEAT BELTS ………………………………………………………….2
Front Seat Belt…………………………………………………….3
Rear Seat Belt …………………………………………………….5
3rd Seat Belt……………………………………………………….7
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)…………8
Precautions for SRS ‘‘AIR BAG’’ and ‘‘Seat Belt
Pre-tensioner’’ Service………………………………………….8
Special Service Tools …………………………………………..8
Description ………………………………………………………..10
SRS Component Parts Location ………………………….10
Maintenance Items …………………………………………….11
Removal and Installation — Diagnosis Sensor
Unit and Seat Belt Pre-tensioner………………………….12
Removal and Installation — Air Bag Module and
Spiral Cable ………………………………………………………13
Removal — Air Bag Module and Spiral Cable……….13
Removal — Front Passenger Air Bag Module ……….14
Installation — Air Bag Module and Spiral Cable…….16

Installation — Front Passenger Air Bag Module …….16
Disposal of Air Bag Module and Seat Belt Pretensioner …………………………………………………………..17
TROUBLE DIAGNOSES — Supplemental
Restraint System (SRS) ………………………………………..22
Trouble Diagnoses Introduction……………………………22
How to Perform Trouble Diagnoses for Quick
and Accurate Repair …………………………………………..24
Schematic …………………………………………………………26
Wiring Diagram — SRS —………………………………….27
SRS Operation Check ………………………………………..30
Trouble Diagnoses with CONSULT ………………………32
Trouble Diagnoses without CONSULT ………………….39
Trouble Diagnoses: ‘‘AIR BAG’’ Warning Lamp
Does Not Turn Off ……………………………………………..43
Trouble Diagnoses: ‘‘AIR BAG’’ Warning Lamp
Does Not Turn On ……………………………………………..43
Trouble Diagnoses: SRS Does Not Enter
Diagnosis Mode Using Door Switch……………………..44
COLLISION DIAGNOSIS………………………………………..45

RS
When you read wiring diagrams:
+ Read GI section, ‘‘HOW TO READ WIRING DIAGRAMS’’.
+ See EL section, ‘‘POWER SUPPLY ROUTING’’ for power distribution circuit.
When you perform trouble diagnoses, read GI section, ‘‘HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES’’ and ‘‘HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT’’.

PRECAUTION
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’
The Supplemental Restraint System such as ‘‘AIR BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’ used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS composition which is available to NISSAN MODEL Y61 is as follows (The composition varies
according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.

RS-1

SEAT BELTS
CAUTION:
+ Before removing the seat belt pre-tensioner assembly (if equipped), turn the ignition switch off,
disconnect both battery cables and wait at least 3 minutes.
+ After replacing or reinstalling seat belt pre-tensioner assembly, or reconnecting seat belt pre-tensioner connector, check the system function. Refer to ‘‘SRS Operation Check’’ (RS-30) for details.
+ Do not disassemble buckle or seat belt assembly.
+ Replace anchor bolts if they are deformed or worn out.
+ Never oil tongue and buckle.
+ If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt
assembly.
+ If webbing is cut, frayed, or damaged, replace seat belt assembly.
+ When replacing seat belt assembly, use a genuine seat belt assembly.
+ After any collision, inspect all seat belt assemblies, including retractors and other attached hardwares (i.e., guide rail set).

RS-2

SEAT BELTS
Front Seat Belt
REMOVAL (WAGON)
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V
9
V

Remove front seat. Refer to ‘‘SEAT’’ in BT section for details.
Remove adjuster cover.
Slide floor anchor cover.
Remove floor anchor bolt.
Remove shoulder anchor bolt.
Remove center pillar upper and lower garnish. Refer to ‘‘Side and Floor Trim’’ in BT section for details.
Remove bolts securing second sash guide, then remove second sash guide.
Remove the bolt securing seat belt pre-tensioner retractor, then remove seat belt and seat belt pre-tensioner retractor.
Remove bolts securing seat belt adjuster, then remove seat belt adjuster.

SRS446

RS-3

SEAT BELTS
Front Seat Belt (Cont’d)
REMOVAL (HARDTOP)
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V
9
V

Remove front seat. Refer to ‘‘SEAT’’ in BT section for details.
Remove adjuster cover.
Remove lap outer cover. Refer to ‘‘Side and Floor Trim’’ in BT section for details.
Slide floor anchor cover.
Remove floor anchor bolt.
Remove shoulder anchor bolt.
Remove luggage side upper and lower finisher. Refer to ‘‘Side and Floor Trim’’ in BT section for details.
Remove the bolt securing seat belt pre-tensioner retractor, then remove seat belt and seat belt pre-tensioner retractor.
Remove bolts securing seat belt adjuster, then remove seat belt adjuster.

SRS447

RS-4

SEAT BELTS
Rear Seat Belt
REMOVAL (WAGON)
1
V
2
V
3
V
4
V
5
V
6
V

Remove rear and 3rd seats. Refer to ‘‘SEAT’’ in BT section for details.
Slide anchor cover.
Remove anchor bolt.
Remove luggage upper and lower finishers. Refer to ‘‘Side and Floor Trim’’ in BT section for details.
Remove shoulder anchor bolt.
Remove the bolt and anchor bolt securing seat belt retractor, then remove seat belt and seat belt retractor.

SRS448

RS-5

SEAT BELTS
Rear Seat Belt (Cont’d)
REMOVAL (HARDTOP)
1
V
2
V
3
V
4
V
5
V
6
V
7
V

Fold the rear seat forward.
Slide anchor cover.
Remove shoulder anchor cover.
Remove anchor bolt.
Remove shoulder anchor bolt.
Remove luggage upper and lower finishers. Refer to ‘‘Side and Floor Trim’’ in BT section for details.
Remove anchor bolt securing seat belt retractor, then remove seat belt and seat belt retractor.

SRS449

RS-6

SEAT BELTS
3rd Seat Belt
REMOVAL (WAGON)
1
V
2
V
3
V
4
V
5
V
6
V

Remove rear and 3rd seats. Refer to ‘‘SEAT’’ in BT section for details.
Slide anchor cover.
Remove anchor bolt.
Remove luggage upper and lower finishers. Refer to ‘‘Side and Floor Trim’’ in BT section for details.
Remove shoulder anchor bolt.
Remove anchor bolt securing seat belt retractor, then remove seat belt and seat belt retractor.

SRS450

RS-7

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Precautions for SRS ‘‘AIR BAG’’ and ‘‘Seat Belt
Pre-tensioner’’ Service
+
+

+
+
+
+
+

Do not use a circuit tester to check SRS circuits unless instructed to in this Service Manual.
Before servicing the SRS, turn ignition switch ‘‘OFF’’, disconnect both battery cables and wait for at least
3 minutes.
For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt
pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes
have passed.
Diagnosis sensor unit must always be installed with their arrow marks ‘‘S’’ pointing towards the front of
the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before
installation and replace as required.
The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt to
turn steering wheel or column after removal of steering gear.
Handle air bag module carefully. Always place it with the pad side facing upward.
Conduct self-diagnosis to check entire SRS for proper function after replacing any components.
Instrument panel assembly should be replaced after air bag inflates if damaged.

Special Service Tools
Application
Tool number
Tool name

Description

KV99106400
Deployment tool

Seat belt
pre-tensioner

Air Bag
System

—

Disposing of air bag module

NT357

KV99105300
Air bag module
bracket

Anchoring air bag module

NT354

Special torx bit

Use for special bolts
[TAMPER RESISTANT
TORX (Size T50)]
a: 3.5 (0.138) dia.
b: 8.5 — 8.6
(0.335 — 0.339) dia.
c: approx. 10 (0.39) sq.
Unit: mm (in)

NT361

KV999R0020
Deployment tool
adapters for seat
belt pre-tensioner

NT721

RS-8

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Special Service Tools (Cont’d)
Application
Tool number
Tool name

Description

Seat belt
pre-tensioner

Air Bag
System

—

KV99108300
Deployment tool
adapters for passenger air bag

NT722

RS-9

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Description
The air bag deploys if the diagnosis sensor unit activates while the ignition switch is in the ‘‘ON’’ or ‘‘START’’
position.

SBF564HA

SRS Component Parts Location

SRS452

RS-10

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Maintenance Items

SRS451

CAUTION:
Do not use a circuit tester to check SRS circuit.
1. Check operation of ‘‘AIR BAG’’ warning lamp.
After turning ignition key to ‘‘ON’’ position, both warning lamps
illuminate. The ‘‘AIR BAG’’ warning lamp will go off after about
7 seconds if no malfunction is detected.
If any of the following warning lamp conditions occur, immediately check the air bag or seat belt pre-tensioner system. Refer
to RS-30 for details.
+ The ‘‘AIR BAG’’ warning lamp does not illuminate when the
ignition switch is turned ‘‘ON’’.
+ The ‘‘AIR BAG’’ warning lamp does not go off about 7 seconds
after the ignition switch is turned ‘‘ON’’.
+ The ‘‘AIR BAG’’ warning lamp blinks about 7 seconds after the
ignition switch is turned ‘‘ON’’.
2. Visually check SRS components.
(1) Diagnosis sensor unit
+ Check diagnosis sensor unit and bracket for dents, cracks or
deformities.
+ Check connectors for damage, and terminals for deformities.
(2) Air bag module and steering wheel
+ Remove air bag module from steering wheel or instrument
panel. Check harness cover and connectors for damage, terminals for deformities, and harness for binding.
+ Install driver air bag module to steering wheel to check fit or
alignment with the wheel.
+ Check steering wheel for excessive free play.
+ For dual air bag system, install passenger air bag module to
instrument panel to check fit or alignment with the instrument
panel.
(3)
+
+
+

Spiral cable
Check spiral cable for dents, cracks, or deformities.
Check connectors and protective tape for damage.
Check steering wheel for noise, binding or heavy operation.

(4) Harness related to SRS
+ Check connectors for poor connections, damage, and terminals
for deformities.
+ Check harnesses for binding, chafing or cut.
(5) Seat belt pre-tensioner
+ Check harness cover and connectors for damage, terminals for
deformities, and harness for binding.
+ Check belts for damage and anchors for loose mounting.
+ Check retractor for smooth operation.
+ Perform self-diagnosis for seat belt pre-tensioner using
bulb or CONSULT. Refer to ‘‘SRS Operation Check’’ for details.
(RS-30)
CAUTION:
Replace previously used special bolts, ground bolt and anchor
bolt with new ones.

RS-11

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal and Installation — Diagnosis Sensor
Unit and Seat Belt Pre-tensioner
CAUTION:
+ Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait for at
least 3 minutes.
+ The special bolts are coated with bonding agent while the other bolt is for ground. Do not use old
bolts after removal; replace with new ones.
+ Check diagnosis sensor unit and seat belt pre-tensioner for proper installation.
+ Check diagnosis sensor unit to ensure they are free of deformities, dents, cracks or rust. If they
show any visible signs of damage, replace them with new ones.
+ Check diagnosis sensor unit brackets to ensure they are free of deformities or rust.
+ Replace diagnosis sensor unit and seat belt pre-tensioner if they have been dropped or sustained
an impact.
+ After replacement of diagnosis sensor unit and seat belt pre-tensioner, check SRS function and
perform self-diagnosis for SRS. Refer to ‘‘SRS Operation Check’’ for details (RS-30).
+ Do not attempt to disassemble diagnosis sensor unit and seat belt pre-tensioner.
+ Do not expose seat belt pre-tensioner to temperatures exceeding 80°C (176°F).

REMOVAL OF DIAGNOSIS SENSOR UNIT

SRS453

1. Disconnect driver and passenger air bag module connectors.
Also, disconnect seat belt pre-tensioner connector.
2. Remove console finisher, console box assembly and instrument panel stay cover. Refer to ‘‘INSTRUMENT PANEL’’ in BT
section.
3. Remove rear heater duct and foot duct. (If equipped with rear
heater duct and foot duct.)
4. Remove bolt and also remove special bolts using the TAMPER
RESISTANT TORX (Size T50), from diagnosis sensor unit.
5. Disconnect diagnosis sensor unit connector. Then remove the
diagnosis sensor unit.
NOTE:
+ To install, reverse the removal procedure sequence.

REMOVAL OF SEAT BELT PRE-TENSIONER
For removal of seat belt pre-tensioner, refer to ‘‘Front Seat Belt’’ for
details. (RS-3)
NOTE:
+ To install, reverse the removal procedure sequence.

SRS454

RS-12

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal and Installation — Air Bag Module
and Spiral Cable

SRS455

Removal — Air Bag Module and Spiral Cable
CAUTION:
+ Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait for at least 3 minutes.
+ Always work from the side of air bag module.
1. Remove lower lid from steering wheel, and disconnect air bag
module connector.

SBF811E

2. Remove side lids. Using the TAMPER RESISTANT TORX (Size
T50), remove left and right special bolts. Air bag module can
then be removed.

SBF812E

RS-13

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal — Air Bag Module and Spiral Cable
(Cont’d)
CAUTION:
+ Always place air bag module with pad side facing upward.
+ Do not attempt to disassemble air bag module.
+ The special bolts are coated with bonding agent. Do not
use old bolts after removal; replace with new ones.

MRS120A

+
+
+

Replace air bag module if it has been dropped or sustained
an impact.
Do not expose the air bag module to temperatures exceeding 90°C (194°F).
Do not allow oil, grease or water to come in contact with
the air bag module.

SBF814E

3. Set steering wheel in the neutral position.
4. Disconnect horn connector and remove nuts.
5. Using steering wheel puller, remove steering wheel. Be careful
not to over-tighten puller bolt on steering wheel.
CAUTION:
Do not tap or bump the steering wheel.
6. Remove steering column cover.

SBF239F

7. Remove four screws securing the spiral cable. Unlock the spiral cable connector. Then disconnect the spiral cable connector. The spiral cable can then be removed.
CAUTION:
+ Do not attempt to disassemble spiral cable.
+ Do not apply lubricant to the spiral cable.

SRS384

Removal — Front Passenger Air Bag Module
CAUTION:
+ Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait for at least 3 minutes.
+ Always work from the side of or under air bag module.
1. Remove glove box assembly. Refer to ‘‘INSTRUMENT PANEL’’
in BT section for details.

SRS456

RS-14

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal — Front Passenger Air Bag Module
(Cont’d)
2. Remove clips securing inflator connector.
3. Disconnect inflator connector from body harness air bag connector.
4. Remove the nuts and special bolts using the TAMPER RESISTANT TORX (Size T50) from front passenger air bag module.
Take out the air bag module from the instrument panel.
+ The air bag module is heavy and should be supported using
bolt hands during removal.
SRS457

CAUTION:
+ Always place air bag module with pad side facing upward.
+ Do not attempt to disassemble air bag module.
+ The special bolts are coated with bonding agent. Do not
use old bolts after removal; replace with new coated bolts.
+ Do not insert foreign objects (screwdriver, etc.) into air bag
module connector.
+ Do not use a circuit tester to check the air bag module
harness connector.
SBF579H

+
+
+

SBF814E

RS-15

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Installation — Air Bag Module and Spiral Cable

SRS276

SRS166

1. Set the front wheels in the straight-ahead position.
2. Make sure that the spiral cable is in the neutral position. The
neutral position is detected by turning left about 2.5 revolutions
from the right end position. Align the two marks (,
m ).
CAUTION:
+ The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
+ Also, with the steering linkage disconnected, the cable
may snap by turning the steering wheel beyond the limited
number of turns. The spiral cable can be turned to the left
about 2.5 turns from the right end position.
3. Connect and lock spiral cable connector and tighten with
screws. Install steering column cover.
4. Install steering wheel, aligning with spiral cable pin guides, and
pull spiral cable through.
5. Connect horn connector and engage spiral cable with pawls in
steering wheel. Move air bag module connector away from
steering wheel lower lid opening.
6. Tighten nut.
: 29 — 39 Nzm (3.0 — 4.0 kg-m, 22 — 29 ft-lb)
7. Position air bag module and tighten with new special bolts.
8. Connect air bag module connector.
9. Install all lids.
10. Conduct self-diagnosis to ensure entire SRS operates properly.
(Use CONSULT or warning lamp check.)
Before performing self-diagnosis, connect both battery cables.
11. Turn steering wheel to the left end and then to the right end fully
to make sure that spiral cable is set in the neutral position.
If air bag warning lamp blinks or stays ON (at the User mode),
it shows the spiral cable may be snapped due to its improper
position. Perform self-diagnosis again (use CONSULT or warning lamp). If a malfunction is detected, replace the spiral cable
with a new one.
12. Perform self-diagnosis again to check that no malfunction is
detected.

SBF812EB

Installation — Front Passenger Air Bag Module
+ Always work from the side of air bag module.
1. Install front passenger air bag module on steering member.
+ Ensure harness is not caught between rear of air bag module
and steering member.
2. Connect inflator connector to body harness connector.
3. Install inflator connector on steering member.

SRS457

RS-16

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Installation — Front Passenger Air Bag Module
(Cont’d)
4. Install glove box assembly. (Glove box lid is open.)
5. Close the glove box lid.

SRS456

Disposal of Air Bag Module and Seat Belt Pretensioner
+
+
+
+
+
+
+
+
+
+
+
+

Before disposing of air bag module and seat belt pre-tensioner, or vehicles equipped with such systems,
deploy the systems. If such systems have already been deployed due to an accident, dispose of as indicated in ‘‘DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER’’ (RS-21).
When deploying the air bag module, always use the Special Service Tool; Deployment tool KV99106400,
KV99108200 and KV99108300.
When deploying the air bag module and seat belt pre-tensioner, stand at least 5 m (16 ft) away from the
deployment component.
When deploying air bag module and seat belt pre-tensioner, a fairly loud noise is made, followed by smoke
being released. The smoke is not poisonous, however, be careful not to inhale smoke since it irritates throat
and can cause choking.
Always activate one air bag module at a time.
Due to heat, leave air bag module unattended for more than 30 minutes after deployment. Also leave seat
belt pre-tensioner unattended for more than 10 minutes after deployment.
Be sure to wear gloves when handling a deployed air bag module.
Never apply water to a deployed air bag module.
Wash your hands clean after finishing work.
Do not dispose of the air bag module un-deployed.
Place the vehicle outdoors with an open space of at least 6 m (20 ft) on all sides when deploying the air
bag module while mounted in vehicle.
Use a voltmeter to make sure the vehicle battery is fully charged.

CHECKING DEPLOYMENT TOOL
Connecting to battery

SRS005-B

CAUTION:
The battery must show voltage of 9.6V or more.
Remove the battery from the vehicle and place it on dry wood
blocks approximately 5 m (16 ft) away from the vehicle.
+ Wait 3 minutes after the vehicle battery is disconnected before
proceeding.
+ Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
Make sure the polarity is correct. The right side lamp in the
tool, marked ‘‘deployment tool power’’, should glow with a
green light. If the right side lamp glows red, reverse the connections to the battery.

RS-17

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt Pretensioner (Cont’d)
Deployment tool check
Press the deployment tool switch to the ‘‘ON’’ position. The left side
lamp in the tool, marked ‘‘air bag connector voltage’’ should illuminate. If it does not illuminate, replace the tool.

Air bag deployment tool lamp illumination chart
(Battery connected)
SBF266H

Switch operation

Left side lamp, green*
‘‘AIR BAG CONNECTOR
VOLTAGE’’

Right side lamp, green*
‘‘DEPLOYMENT TOOL
POWER’’

OFF

*: If this lamp glows red, the tool is connected to the battery incorrectly.
Reverse the connections and make sure the lamp glows green.

DEPLOYMENT PROCEDURES FOR AIR BAG MODULE
(OUTSIDE OF VEHICLE)
Unless the vehicle is being scrapped, deploying the air bag in the
vehicle is not recommended. This may cause damage to the
vehicle interior.
Anchor air bag module in a vise secured to a firm foundation during deployment.

Deployment of driver’s air bag module (outside of
vehicle)
SRS232-B

1. Using wire, secure air bag module to air bag module bracket
(SST: KV99105300).
CAUTION:
Use wire of at least 1 mm (0.04 in) diameter.
2. Firmly secure air bag module bracket (SST: KV99105300) with
air bag module attached, in a vise.

SRS233-B

3. Connect deployment tool (SST: KV99106400) to air bag module connector.

SRS234-B

RS-18

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt Pretensioner (Cont’d)

SRS235-B

4. Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
5. The lamp on the right side of the tool, marked ‘‘deployment tool
power’’, should glow green, not red.
6. Press the button on the deployment tool. The left side lamp on
the tool, marked ‘‘air bag connector voltage’’, will illuminate and
the air bag module will deploy.
CAUTION:
When deploying the air bag module, stand at least 5 m (16 ft)
away from the air bag module.

Deployment of passenger air bag module (outside of
vehicle)
1. Make an 8.5 mm (0.335 in) diameter hole in air bag module
bracket (SST: KV99105300) at the position shown in figure at
left.

SRS236-B

2. Firmly secure air bag module bracket (SST: KV99105300) in a
vise.

SRS310

3. Match the two holes in air bag module bracket (held in vise) and
passenger air bag module and fix them with two bolts [M8 x 25
— 30 mm (0.98 — 1.18 in)].
CAUTION:
If a gap exists between passenger air bag module and air bag
module bracket, use a piece of wood inserted in the gap to
stabilize the air bag module.

SRS311

4. Connect deployment tool adapter (SST: KV99108300) to
deployment tool (SST: KV99106400) connector and connector
on either side of air bag module.
5. Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
6. The lamp on the right side of the tool, marked ‘‘deployment tool
power’’, should glow green, not red.
7. Press the button on the deployment tool. The left side lamp on
the tool, marked ‘‘air bag connector voltage’’, will illuminate and
the air bag module will deploy.
SRS313-A

RS-19

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt Pretensioner (Cont’d)
CAUTION:
+ When deploying the air bag module, do not stand on the
deploying side.
+ Stand at least 5 m (16 ft) away from the air bag module.

SRS020-A

Deployment of seat belt pre-tensioner (outside of
vehicle)
1. Firmly anchor seat belt pre-tensioner in a vise.
CAUTION:
Ensure bracket and webbing are placed in the vise.

SRS240

2. Connect deployment tool adapter (SST: KV999R0020) to
deployment tool (SST: KV99106400) connector and seat belt
pre-tensioner connector.

SRS241-D

3. Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
4. The lamp on the right side of the tool, marked ‘‘deployment tool
power’’, should glow green, not red.
5. Press the button on the deployment tool. The left side lamp on
the tool, marked ‘‘seat belt pre-tensioner connector voltage’’,
will illuminate and the seat belt pre-tensioner will deploy.
CAUTION:
When deploying the seat belt pre-tensioner, stand at least 5 m
(16 ft) away from the seat belt pre-tensioner.
SRS242-B

RS-20

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt Pretensioner (Cont’d)
DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT
PRE-TENSIONER WHILE MOUNTED IN VEHICLE

SRS006-D

When disposing of a vehicle, deploy air bag modules and seat belt
pre-tensioners while they are mounted in vehicle.
CAUTION:
When deploying air bag module or seat belt pre-tensioner,
ensure vehicle is empty.
1. Disconnect both the vehicle battery cables and wait 3 minutes.
2. Disconnect air bag modules and seat belt pre-tensioners connector.
3. Connect deployment tool (SST: KV99106400) to air bag module or seat belt pre-tensioner.
For front passenger air bag module and seat belt pre-tensioner,
attach deployment tool adapter (SST: KV99108300 and
KV999R0020) to the tool connector.
4. Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
5. The lamp on the right side of the tool, marked ‘‘deployment tool
power’’, should glow green, not red.
6. Press the button on the deployment tool. The left side lamp on
the tool, marked ‘‘air bag connector voltage’’, will illuminate and
the air bag module or seat belt pre-tensioner will deploy.
CAUTION:
Activate only one passenger air bag module or seat belt pretensioner at a time.

DISPOSING OF AIR BAG MODULE AND SEAT BELT
PRE-TENSIONER

SBF276H

Deployed air bag modules and seat belt pre-tensioners are very
hot. Before disposing of air bag module, and seat belt pretensioner, wait at least 30 minutes, and 10 minutes, respectively.
Seal them in a plastic bag before disposal.
CAUTION:
+ Never apply water to a deployed air bag module and seat
belt pre-tensioner.
+ Be sure to wear gloves when handling a deployed air bag
module and seat belt pre-tensioner.
+ No poisonous gas is produced upon air bag module
deployment. However, be careful not to inhale gas since it
irritates throat and can cause choking.
+ Do not attempt to disassemble air bag module and seat
belt pre-tensioner.
+ Air bag module and seat belt pre-tensioner cannot be reused.
+ Wash your hands clean after finishing work.

RS-21

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction
CAUTION:
+ Do not use a circuit tester to check SRS harness connectors unless instructed to in this Service
Manual. SRS wiring harnesses except for ‘‘SEAT BELT PRE-TENSIONER’’ can be identified with
yellow harness protector or yellow insulation tape before the harness connectors.
+ Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged,
replace it with a new one.
+ Keep ground portion clean.

DIAGNOSIS FUNCTION
The SRS self-diagnosis results can be read by using ‘‘AIR BAG’’ warning lamp and/or CONSULT.
System

Using CONSULT

Using warning lamp

Seat belt pre-tensioner

—

Air bag

Driver air bag

Front passenger air bag

The reading of these results is accomplished using one of two modes — ‘‘User mode’’ and ‘‘Diagnosis mode’’.
The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a system
malfunction through the operation of the ‘‘AIR BAG’’ warning lamp.
The Diagnosis mode allows the technician to locate and inspect the malfunctioning part.
The mode applications for the ‘‘AIR BAG’’ warning lamp and CONSULT are as follows:
User mode

Diagnosis mode

Display type

‘‘AIR BAG’’ warning lamp

ON-OFF operation

CONSULT

—

Monitoring

DIAGNOSIS MODE FOR CONSULT
+
+
+

‘‘SELF-DIAG [CURRENT]’’
A current Self-diagnosis result (also indicated by the warning lamp flashes in the Diagnosis mode) is displayed on the CONSULT screen in real time. This refers to a malfunctioning part requiring repairs.
‘‘SELF-DIAG [PAST]’’
Diagnosis results previously stored in the memory are displayed on the CONSULT screen. The stored
results are not erased until memory erasing is executed.
‘‘TROUBLE DIAG RECORD’’
With ‘‘TROUBLE DIAG RECORD’’, diagnosis results previously erased by a reset operation can be displayed on the CONSULT screen.

‘‘ECU DISCRIMINATED NO.’’
The diagnosis sensor unit for each vehicle model is assigned
with its own, individual classification number. This number will
be displayed on the CONSULT screen, as shown at left. When
replacing the diagnosis sensor unit, refer to the part number for
the compatibility. After installation, replacement with a correct
unit can be checked by confirming this classification number on
the CONSULT screen.
For NISSAN MODEL Y61, the diagnosis sensor unit classification numbers assigned are C2 (Hardtop models) and 27 (Models except Hardtop).
+

SRS504

RS-22

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction (Cont’d)
HOW TO CHANGE SELF-DIAGNOSIS MODE
With CONSULT
From User mode to Diagnosis mode
After selecting AIR BAG on the ‘‘SELECT SYSTEM’’ screen, User mode automatically changes to Diagnosis
mode.

SRS391

From Diagnosis mode to User mode
To return to User mode from diagnosis mode, touch ‘‘BACK’’ key of CONSULT until ‘‘SELECT SYSTEM’’
appears. Diagnosis mode automatically changes to User mode.

SRS392

Without CONSULT
From User mode to Diagnosis mode
Diagnosis mode activates only when a malfunction is detected, by
pressing the driver’s door switch at least 5 times within 7 seconds
after turning the ignition ‘‘ON’’. SRS will not enter Diagnosis mode
if no malfunction is detected.

SRS465

From Diagnosis mode to User mode
After a malfunction is repaired, switch the ignition ‘‘OFF’’ for at least 1 second, then back ‘‘ON’’. Diagnosis
mode returns to User mode. If switching from Diagnosis mode to User mode is required while malfunction is
being detected, switch the ignition ‘‘OFF’’, then back ‘‘ON’’ and press the driver’s door switch at least 5 times
within 7 seconds.

RS-23

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction (Cont’d)
HOW TO ERASE SELF-DIAGNOSIS RESULTS
With CONSULT
+

‘‘SELF-DIAG [CURRENT]’’
A current Self-diagnosis result is displayed on the CONSULT screen in real time. After the malfunction is
repaired completely, no malfunction is detected on ‘‘SELF-DIAG [CURRENT]’’.

‘‘SELF-DIAG [PAST]’’
Return to the ‘‘SELF-DIAG [CURRENT]’’ CONSULT screen by
pushing ‘‘BACK’’ key of CONSULT and select ‘‘SELF-DIAG
[CURRENT]’’ in ‘‘SELECT DIAG MODE’’. Touch ‘‘ERASE’’ in
‘‘SELF-DIAG [CURRENT]’’ mode.
NOTE:
If the memory of the malfunction in ‘‘SELF-DIAG [PAST]’’ is not
erased, the User mode shows the system malfunction by the
operation of the warning lamp even if the malfunction is
repaired completely.
+

SRS357

‘‘TROUBLE DIAG RECORD’’
The memory of ‘‘TROUBLE DIAG RECORD’’ cannot be erased.

Without CONSULT
After a malfunction is repaired, return to User mode from Diagnosis mode by switching the ignition ‘‘OFF’’ for
at least 1 second, then back ‘‘ON’’. At that time, the problem code is cleared.

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is important to fully understand the symptoms
or conditions for a customer complaint.

INFORMATION FROM CUSTOMER
WHAT ………… Vehicle model
WHEN ……….. Date, Frequencies
WHERE ……… Road conditions
HOW ………….. Operating conditions, Symptoms

PRELIMINARY CHECK
Check that the following parts are in good order.
+ Battery [Refer to EL section (‘‘BATTERY’’).]
+ Fuse [Refer to EL section (‘‘Fuse’’, ‘‘POWER SUPPLY ROUTING’’).]
+ System component-to-harness connections

RS-24

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont’d)
WORK FLOW
ACTION ITEM

REFERENCE ITEM

Check in

Listen to customer complaints and requests.

Perform preliminary check.

Preliminary check (RS-24)

Check for any Service Bulletin.

Check air bag system operation by using ‘‘AIR BAG’’ warning lamp.
— User mode
Check seat belt pre-tensioner system operation by using a bulb.

SRS Operation Check
DIAGNOSTIC PROCEDURE 1
(RS-30)

.
c

Inspect malfunctioning part. — Diagnosis mode

Perform self-diagnosis using CONSULT.
—————————————————————————————————————— OR —————————————————————————————————————-Perform self-diagnosis using ‘‘AIR BAG’’ warning lamp.

DIAGNOSTIC PROCEDURE 2:
Using CONSULT (RS-32)
DIAGNOSTIC PROCEDURE 6:
Using ‘‘AIR BAG’’ warning lamp
(RS-39)

Repair/Replace

Final check — Diagnosis mode and User mode
CONSULT can only show one seat belt pre-tensioner malfunction as
self-diagnosis result at a time. Check self-diagnosis result with CONSULT whether other malfunctions are detected after repairing one
seat belt pre-tensioner malfunction.
OK
.

Check out

RS-25

DIAGNOSTIC PROCEDURE 3:
Using CONSULT (RS-34)
DIAGNOSTIC PROCEDURE 7:
Using ‘‘AIR BAG’’ warning lamp
(RS-40)

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Schematic

TRS073

RS-26

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —

TRS061

RS-27

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (Cont’d)

TRS062

RS-28

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (Cont’d)

TRS063

RS-29

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
SRS Operation Check
DIAGNOSTIC PROCEDURE 1
Checking SRS operation by using ‘‘AIR BAG’’ warning lamp —
User mode
1. After turning ignition switch from ‘‘OFF’’ to ‘‘ON’’, ‘‘AIR BAG’’
warning lamp operates.
2. Compare ‘‘AIR BAG’’ warning lamp operation to the chart
below.
SRS466

‘‘AIR BAG’’ warning lamp operation — User mode —

SRS condition

Reference item

No malfunction is
detected. No further action
is necessary.
—

MRS095A

The system has problem
and needs to be repaired
as indicated.

Go to DIAGNOSTIC
PROCEDURE 2 or 6
(RS-32 or RS-39).

Air bag is deployed.

Go to COLLISION
DIAGNOSIS (RS-45).

Air bag fuse, diagnosis
sensor unit or harness is
malfunctioning and needs
to be repaired.

Go to DIAGNOSTIC
PROCEDURE 9 (RS-43).

One of the following has
occurred and needs to be
repaired.
+ Meter fuse is blown.
+ ‘‘AIR BAG’’ warning
lamp circuit has open or
short.
+ Diagnosis sensor unit is
malfunctioning.

Go to DIAGNOSTIC
PROCEDURE 10 (RS-43).

MRS096A

MRS097A

MRS098A

NOTE:
If ‘‘AIR BAG’’ warning lamp operates differently from the
operations shown above, refer to ‘‘AIR BAG’’ warning lamp
operation — Diagnosis mode —, DIAGNOSTIC PROCEDURE 6
(step 4), RS-39.

RS-30

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
SRS Operation Check (Cont’d)
Checking seat belt pre-tensioner system operation
Check seat belt pre-tensioner system operation using a bulb as
follows:
1. Connect a bulb of less than 3.4W between data link connector
terminals V
7 and V
11 .
2. After turning ignition switch from ‘‘OFF’’ to ‘‘ON’’, the bulb operates.
3. Compare the bulb operation to the chart below.

MRS054AB

Lighting condition of the bulb

SRS condition

Reference item

No malfunction is
detected.
No further action is necessary.
—

MRS095A

+ Seat belt pre-tensioner
circuit is opened, or
+ Seat belt pre-tensioner
power supply or ground
circuit is shorted.

+ If CONSULT is
available, go to DIAGNOSTIC PROCEDURE
2 (RS-32).
+ If CONSULT is not
available, repair the system as follows.*
1. Visually check the wiring harness connections.
2. Replace the harness if it
has visible damage.
3. Replace driver’s and
front passenger seat
belt assemblies.
(Before disposing, they
must be deactivated.)
4. Replace diagnosis sensor unit.

Seat belt pre-tensioner
(and air bag) is deployed.

Go to COLLISION DIAGNOSIS (RS-45).

MRS096A

MRS097A

* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated
using a bulb or CONSULT each time repair is finished. If malfunction is still observed, proceed to the next step. When malfunction is eliminated, further repair work is not required.

RS-31

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses with CONSULT
DIAGNOSTIC PROCEDURE 2
Inspecting SRS malfunctioning parts by using CONSULT —
Diagnosis mode
1. Turn ignition switch ‘‘OFF’’.
2. Connect ‘‘CONSULT’’ to Data link connector.

SRS468

3. Turn ignition switch ‘‘ON’’.
4. Touch ‘‘START’’.

SRS046

5. Touch ‘‘AIRBAG’’.

SRS074

6. Touch ‘‘SELF-DIAG [CURRENT]’’.

SRS047

7. Diagnostic codes are displayed on ‘‘SELF-DIAG [CURRENT]’’.

SRS048

RS-32

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses with CONSULT (Cont’d)
If no self-diagnostic failure is detected on ‘‘SELF-DIAG [CURRENT]’’ even though malfunction is detected in SRS Operation
Check (User mode), check the battery voltage. If the battery voltage is less than 9V, charge the battery. Then go to DIAGNOSTIC
PROCEDURE 3, page RS-34. If the battery voltage is OK, go to
DIAGNOSTIC PROCEDURE 4, page RS-36, to diagnose the following cases:
+ Self-diagnostic failure ‘‘SELF-DIAG [PAST]’’ (previously stored
in the memory) might not be erased after repair.
+ The SRS system malfunctions intermittently.
SRS049

8. Touch ‘‘PRINT’’.
9. Compare diagnostic codes to ‘‘CONSULT DIAGNOSTIC CODE
CHART’’, page RS-33.
10. Touch ‘‘BACK’’ key of CONSULT until ‘‘SELECT SYSTEM’’
appears in order to return to User mode from Diagnosis mode,
then turn off CONSULT.
11. Turn ignition switch ‘‘OFF’’, then disconnect CONSULT and
both battery cables.
12. Repair the system as outlined by the ‘‘Repair order’’ in ‘‘CONSULT DIAGNOSTIC CODE CHART’’, that corresponds to the
problem code. For replacement procedure of component parts,
refer to RS-12.
13. After repairing the system, go to DIAGNOSTIC PROCEDURE
3, page RS-34 for final checking.
CONSULT can only show one seat belt pre-tensioner malfunction as self-diagnosis result at a time. Check self-diagnosis
result with CONSULT whether other malfunctions are detected
after repairing one seat belt pre-tensioner malfunction.

CONSULT DIAGNOSTIC CODE CHART (‘‘SELF-DIAG
[CURRENT]’’)
Diagnostic item
NO SELF DIAGNOSTIC
FAILURE INDICATED.

Repair order
‘‘Recheck SRS at each replacement.’’

Explanation
When malfunction is
indicated by the ‘‘AIR
BAG’’ warning lamp in
User mode

+ Low battery voltage
(Less than 9V)

+ Go to DIAGNOSTIC PROCEDURE 3 (RS-34)
after charging battery.

+ Self-diagnostic failure ‘‘SELF-DIAG
[PAST]’’ (previously
stored in the
memory) might not
be erased after
repair.
+ Intermittent problem
has been detected
in the past.

+ Go to DIAGNOSTIC PROCEDURE 4 (RS-36).

+ No malfunction is detected.

+ Go to DIAGNOSTIC PROCEDURE 3 (RS-34).

AIRBAG MODULE
[OPEN]

+ Driver’s air bag module circuit is open.
(including the spiral cable)

AIRBAG MODULE
[VB-SHORT]

+ Driver’s air bag module circuit is shorted to
some power supply circuit. (including the spiral cable)

1.
2.
3.
4.

AIRBAG MODULE
[GND-SHORT]

+ Driver’s air bag module circuit is shorted to
ground. (including the spiral cable)

AIRBAG MODULE
[SHORT]

+ Driver’s air bag module circuits are shorted to
each other.

RS-33

Visually check the wiring harness connection.
Replace the harness if it has visible damage.
Replace the spiral cable.
Replace driver’s air bag module. (Before disposal
of it, it must be deployed.)
5. Replace the diagnosis sensor unit.
6. Replace the harness.

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses with CONSULT (Cont’d)
Diagnostic item

Repair order
‘‘Recheck SRS at each replacement.’’

Explanation

ASSIST A/B MODULE
[VB-SHORT]

+ Front passenger air bag module circuit is
shorted to some power supply circuit.

ASSIST A/B MODULE
[OPEN]

+ Front passenger air bag module circuit is
open.

ASSIST A/B MODULE
[GND-SHORT]

+ Front passenger air bag module circuit is
shorted to ground.

ASSIST A/B MODULE
[SHORT]

+ Front passenger air bag module circuits are
shorted to each other.

DRIVE PRE-TENSIONER
[OPEN/VB-SHORT]

+ The circuit for the driver’s pre-tensioner is
open or shorted to some power supply circuit.

DRIVE PRE-TENSIONER
[GND-SHORT]

+ The circuit for the driver’s pre-tensioner is
shorted to ground.

ASSIST
PRE-TENSIONER
[OPEN/VB-SHORT]

+ The circuit for the front passenger pre-tensioner is open or shorted to some power supply circuit.

ASSIST
PRE-TENSIONER
[GND-SHORT]

+ The circuit for the front passenger pre-tensioner is shorted to ground.

CONTROL UNIT

+ Diagnosis sensor unit is malfunctioning.

1. Visually check the wiring harness connections.
2. Replace the harness if it has visible damage.
3. Replace the driver’s seat belt.
(Before disposing, it must be deactivated.)
4. Replace the diagnosis sensor unit.
5. Replace the harness.
1. Visually check the wiring harness connections.
2. Replace the harness if it has visible damage.
3. Replace the front passenger seat belt.
(Before disposing, it must be deactivated.)
4. Replace the diagnosis sensor unit.
5. Replace the harness.
1.
2.
3.
4.

Visually check the wiring harness connections.
Replace the harness if it has visible damage.
Replace the diagnosis sensor unit.
Replace the harness.

* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated
using the air bag warning lamp or CONSULT each time repair is finished. If malfunction is still observed, proceed to the next
step. When malfunction is eliminated, further repair work is not required.
CONSULT can only show one seat belt pre-tensioner malfunction as self-diagnosis result at a time. Check self-diagnosis
result with CONSULT whether other malfunctions are detected after repairing one seat belt pre-tensioner malfunction.

DIAGNOSTIC PROCEDURE 3
Final checking after repairing SRS by using CONSULT — Diagnosis mode
1. After repairing SRS, connect both battery cables.
2. Connect CONSULT to Data link connector.
3. Turn ignition switch from ‘‘OFF’’ to ‘‘ON’’.

SRS468

4. Touch ‘‘START’’.

SRS046

RS-34

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses with CONSULT (Cont’d)
5. Touch ‘‘AIRBAG’’.

SRS074

6. Touch ‘‘SELF-DIAG [CURRENT]’’.

SRS047

7. If no malfunction is detected on ‘‘SELF-DIAG [CURRENT]’’,
repair of SRS is completed.
If any problem code is displayed on ‘‘SELF-DIAG [CURRENT]’’,
the malfunctioning part is not repaired completely or another
malfunctioning part is detected. Go to DIAGNOSTIC PROCEDURE 2, page RS-32, and repair malfunctioning part completely.

SRS049

8. Touch ‘‘ERASE’’.
NOTE:
Touch ‘‘ERASE’’ to clear the memory of the malfunction
(‘‘SELF-DIAG [PAST]’’).
If the memory of the malfunction in ‘‘SELF-DIAG [PAST]’’ is not
erased, the User mode shows the system malfunction by the
operation of the warning lamp even if the malfunction is
repaired completely.

SRS365

9. Touch ‘‘BACK’’ key of CONSULT to ‘‘SELECT DIAG MODE’’
screen. Touch ‘‘SELF-DIAG [PAST]’’.

SRS050

RS-35

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses with CONSULT (Cont’d)
10. Check that no self-diagnostic failure is detected on ‘‘SELFDIAG [PAST]’’.
NOTE:
Past malfunction for seat belt pre-tensioner system will not be
displayed on ‘‘SELF-DIAG [PAST]’’.

SRS062

11. Touch ‘‘BACK’’ key of CONSULT until ‘‘SELECT SYSTEM’’
appears in order to return to User mode from Diagnosis mode,
turn off CONSULT, then disconnect CONSULT.
12. Turn ignition switch ‘‘OFF’’.
13. Go to ‘‘SRS Operation Check’’, page RS-30 to check SRS
operation by using ‘‘AIR BAG’’ warning lamp with User mode.

DIAGNOSTIC PROCEDURE 4 (Continued from
with CONSULT)
DIAGNOSTIC PROCEDURE 2) (
Inspecting SRS malfunctioning record
Is it the first time for maintenance of
SRS?
Yes

No
c

Self-diagnostic failure
‘‘SELF-DIAG [PAST]’’ (previously stored in the
memory) might not be
erased after repair.
Go to DIAGNOSTIC PROCEDURE 3, step 8 (RS34).

GO TO DIAGNOSTIC PROCEDURE 5
(RS-36).

DIAGNOSTIC PROCEDURE 5
Inspecting SRS intermittent problem by using CONSULT —
Diagnosis mode
1. Turn ignition switch ‘‘OFF’’.
2. Connect ‘‘CONSULT’’ to Data link connector.

SRS468

3. Turn ignition switch ‘‘ON’’.
4. Touch ‘‘START’’.

SRS046

RS-36

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses with CONSULT (Cont’d)
5. Touch ‘‘AIRBAG’’.

SRS074

6. Touch ‘‘SELF-DIAG [PAST]’’.

SRS050

7. If diagnostic codes are displayed on ‘‘SELF-DIAG [PAST]’’, go
to step 10.

SRS054

If no self-diagnostic failure is detected on ‘‘SELF-DIAG
[PAST]’’, touch ‘‘BACK’’ and go back to ‘‘SELECT DIAG
MODE’’.
NOTE:
Past malfunction for seat belt pre-tensioner system will not be
displayed on ‘‘SELF-DIAG [PAST]’’.

SRS062

8. Touch ‘‘TROUBLE DIAG RECORD’’.
NOTE:
With ‘‘TROUBLE DIAG RECORD’’, diagnosis results previously erased by a reset operation can be displayed.

SRS055

RS-37

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses with CONSULT (Cont’d)
9. Diagnostic code is displayed on ‘‘TROUBLE DIAG RECORD’’.

SRS056

10. Touch ‘‘PRINT’’.
11. Compare diagnostic codes to ‘‘INTERMITTENT PROBLEM
DIAGNOSTIC CODE CHART’’, page RS-38.
12. Touch ‘‘BACK’’ key of CONSULT until ‘‘SELECT SYSTEM’’
appears, then turn off CONSULT.
13. Turn ignition switch ‘‘OFF’’, then disconnect CONSULT and
both battery cables.
14. Repair the system as outlined by the ‘‘Repair order’’ in ‘‘INTERMITTENT PROBLEM DIAGNOSTIC CODE CHART’’, that corresponds to the problem code. For replacement procedure of
component parts, refer to RS-12.
15. Go to DIAGNOSTIC PROCEDURE 3, page RS-34, for final
checking.

INTERMITTENT PROBLEM DIAGNOSTIC CODE CHART
(‘‘SELF-DIAG [PAST]’’ or ‘‘TROUBLE DIAG RECORD’’)
Diagnostic item
NO SELF DIAGNOSTIC
FAILURE INDICATED.

Explanation
When malfunction is
indicated by the ‘‘AIR
BAG’’ warning lamp in
User mode

Repair order

+ Low battery voltage
(Less than 9V)

+ Go to DIAGNOSTIC PROCEDURE 3 (RS-34)
after charging battery.

+ No malfunction is detected.

+ Go to DIAGNOSTIC PROCEDURE 3 (RS-34).

AIRBAG MODULE
[OPEN]

+ Driver’s air bag module circuit is open.
(including the spiral cable)

AIRBAG MODULE
[VB-SHORT]

+ Driver’s air bag module circuit is shorted to
some power supply circuit. (including the spiral cable)

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check result is OK, replace driver’s
air bag module (Before disposal of it, it must be
deployed.), diagnosis sensor unit and spiral
cable.

AIRBAG MODULE
[GND-SHORT]

+ Driver’s air bag module circuit is shorted to
ground. (including the spiral cable)

AIRBAG MODULE
[SHORT]

+ Driver’s air bag module circuits are shorted to
each other.

ASSIST A/B MODULE
[VB-SHORT]

+ Front passenger air bag module circuit is
shorted to some power supply circuit.

ASSIST A/B MODULE
[OPEN]

+ Front passenger air bag module circuit is
open.

ASSIST A/B MODULE
[GND-SHORT]

+ Front passenger air bag module circuit is
shorted to ground.

ASSIST A/B MODULE
[SHORT]

+ Front passenger air bag module circuits are
shorted to each other.

CONTROL UNIT

+ Diagnosis sensor unit is malfunctioning.

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check result is OK, replace front
air bag module (Before disposal of it, it must be
deployed.), and diagnosis sensor unit.

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check result is OK, replace diagnosis sensor unit.

*Intermittent problem areas cannot be easily located. For this reason, perform the procedures outlined under the repair order, then
make the final system check.

RS-38

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses without CONSULT
DIAGNOSTIC PROCEDURE 6

SRS465

No.

Inspecting SRS malfunctioning parts by using ‘‘AIR BAG’’
warning lamp — Diagnosis mode
NOTE:
SRS will not enter Diagnosis mode if no malfunction is
detected in User mode.
1. Open driver’s door.
2. Turn ignition switch from ‘‘OFF’’ to ‘‘ON’’.
3. Press driver’s door switch at least 5 times within 7 seconds
after turning ignition switch ‘‘ON’’.
SRS is now in Diagnosis mode.
4. ‘‘AIR BAG’’ warning lamp operates in Diagnosis mode as follows:
NOTE:
If SRS does not enter Diagnosis mode even though malfunction is detected in User mode, go to DIAGNOSTIC PROCEDURE 11, page RS-44.

‘‘AIR BAG’’ warning lamp operation — Diagnosis mode —
j
a through j
b are repeated.

MRS100A

j
a through j
b are repeated.
NOTE:
j
a — Interval I
j
b — Start signal (Start signal
identifies display modes)
j
c — Interval II
j
d — Indicates
malfunctioning part (0.5
sec. ON and 0.5 sec. OFF
MRS099A
is counted as one flash.)

SRS condition
+ Diagnosis
results (previously
stored in the
memory)
might not be
erased after
repair.
+ Intermittent
problem has
been
detected in
the past.
Go to DIAGNOSTIC PROCEDURE 8
(RS-42).
The system
has a problem
and needs to
be repaired.

5. Malfunctioning part is indicated by the number of flashes (part
j
d ). Compare the number of flashes to ‘‘AIR BAG WARNING
LAMP FLASH CODE CHART’’, page RS-40, and locate malfunctioning part.
6. Turn ignition switch ‘‘OFF’’, and disconnect both battery cables.
7. Repair the system as outlined by the ‘‘Repair order’’ in ‘‘AIR
BAG WARNING LAMP FLASH CODE CHART’’ that corresponds to the flash code. For replacement procedure of component parts, refer to RS-12.
8. After repairing the system, go to DIAGNOSTIC PROCEDURE
7, page RS-40.

RS-39

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses without CONSULT (Cont’d)
AIR BAG WARNING LAMP FLASH CODE CHART

‘‘AIR BAG’’ warning lamp

Warning
lamp

d
Flash code j
(# of flashes)

Repair order
‘‘Recheck SRS at each replacement.’’

Explanation

+ Diagnosis results (previously stored in the
memory) might not be erased after repair.
+ Intermittent problem has been detected in the
past.

Go to DIAGNOSTIC PROCEDURE 8 (RS-42).

The driver’s air bag module circuit is malfunction- 1.
ing.
2.
3.
4.

The diagnosis sensor unit is malfunctioning.

1.
2.
3.
4.

The front passenger air bag module circuit is
malfunctioning.

1. Visually check the wiring harness connections.
2. Replace the harness if it has visible damage.
3. Replace the front passenger air bag module.
(Before disposing of it, it must be deployed.)
4. Replace the diagnosis sensor unit.
5. Replace the harness.

Visually check the wiring harness connections.
Replace the harness if it has visible damage.
Replace the spiral cable.
Replace the driver’s air bag module. (Before
disposing of it, it must be deployed.)
5. Replace the diagnosis sensor unit.
6. Replace the harness.
Visually check the wiring harness connections.
Replace the harness if it has visible damage.
Replace the diagnosis sensor unit.
Replace the harness.

DIAGNOSTIC PROCEDURE 7
Final checking after repairing SRS by using ‘‘AIR BAG’’ warning lamp — Diagnosis mode and User mode
1. After repairing SRS connect both battery cables.
2. Open driver’s door.
3. Turn ignition switch from ‘‘OFF’’ to ‘‘ON’’.
4. ‘‘AIR BAG’’ warning lamp operates in Diagnosis mode as follows:

SRS465

RS-40

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses without CONSULT (Cont’d)
No.

‘‘AIR BAG’’ warning lamp operation — Diagnosis mode —

SRS condition

j
a through j
b are repeated.

No malfunction is
detected or
repair is completed.
No further
action is necessary.

MRS100A

j
a through j
d are repeated.
NOTE:
j
a — Interval I
j
b — Start signal (Start signal
identifies display modes)
j
c — Interval II
j
d — Indicates malfunctioning
part (0.5 sec. ON and 0.5
sec. OFF is counted as one
MRS099A
flash.)

The system
has a problem
and needs to
be repaired.

NOTE:
When diagnosis sensor unit is replaced with new one, ‘‘AIR
BAG’’ warning lamp will operate in User mode. Checking ‘‘AIR
BAG’’ warning lamp operation in Diagnosis mode is not
required. Go to step 6.
5. If ‘‘AIR BAG’’ warning lamp operates as shown in No. 1 in chart
above, turn ignition switch ‘‘OFF’’ to reset from Diagnosis mode
to User mode and to erase the memory of the malfunction.
Then go to step 6.
If ‘‘AIR BAG’’ warning lamp operates as shown in No. 2 in chart
above, the malfunctioning part is not repaired completely, or
another malfunctioning part is detected. Go to DIAGNOSTIC
PROCEDURE 6, page RS-39, and repair malfunctioning part
completely.
6. Turn ignition switch ‘‘ON’’. ‘‘AIR BAG’’ warning lamp operates
in User mode. Compare ‘‘AIR BAG’’ warning lamp operation to
the chart below.
NOTE:
If switching Diagnosis mode to User mode is required while
malfunction is being detected, turn ignition switch from ‘‘OFF’’
to ‘‘ON’’. Then press driver’s door switch at least 5 times
within 7 seconds after turning ignition switch ‘‘ON’’. SRS is
now in User mode.
‘‘AIR BAG’’ warning lamp operation — User mode —

SRS condition
No malfunction is
detected.
No further action is necessary.

MRS095A

RS-41

Reference item

—

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses without CONSULT (Cont’d)
‘‘AIR BAG’’ warning lamp operation — User mode —

SRS condition

Reference item

The system has a problem Go to DIAGNOSTIC PROCEDURE 2 or 6 (RS-32 or
and needs to be repaired
RS-39).
as indicated.

MRS096A

Air bag is deployed.

Go to COLLISION DIAGNOSIS (RS-45).

Air bag fuse, diagnosis
sensor unit or harness is
malfunctioning and needs
to be repaired.

Go to DIAGNOSTIC PROCEDURE 9 (RS-43).

MRS097A

One of the following has
occurred and needs to be
repaired.
+ Meter fuse is blown.
+ ‘‘AIR BAG’’ warning
lamp circuit has open or
short.
+ Diagnosis sensor unit is
MRS098A
malfunctioning.

Go to DIAGNOSTIC PROCEDURE 10 (RS-43).

DIAGNOSTIC PROCEDURE 8 (Continued from
without CONSULT)
DIAGNOSTIC PROCEDURE 6) (
Inspecting SRS malfunctioning record
Is it the first time for maintenance of
SRS?
Yes

GO TO DIAGNOSTIC PROCEDURE 5
(RS-36). Further inspection cannot be performed without CONSULT.

RS-42

No
c

Diagnosis results (previously stored in the
memory) might not be
erased after repair.
Go to DIAGNOSTIC PROCEDURE 7, step 5 (RS40).

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses: ‘‘AIR BAG’’ Warning Lamp
Does Not Turn Off
DIAGNOSTIC PROCEDURE 9
Yes

Is air bag deployed?

Refer to COLLISION DIAGNOSIS (RS-45).

Is SRS ‘‘Air Bag’’ fuse OK?

Replace fuse.
c

Yes
SRS307

Connect CONSULT and touch
‘‘START’’.
+ Is ‘‘AIRBAG’’ displayed on
CONSULT?

No
c

Yes

Visually check the wiring
harness connection of diagnosis sensor unit. If the harness connection check is
OK, replace diagnosis sensor unit.

Is harness connection between warning
lamp and diagnosis sensor unit OK?

No
c

Yes
SRS180

Connect warning lamp and
diagnosis sensor unit connector properly. If warning
lamp still does not go off,
replace harness.

Replace diagnosis sensor unit.

Trouble Diagnoses: ‘‘AIR BAG’’ Warning Lamp
Does Not Turn On
DIAGNOSTIC PROCEDURE 10
No

Is meter fuse OK?

Replace fuse.
c

Yes
.

Is warning lamp LED OK?

Replace warning lamp LED.
c

Yes
.
SRS469

1. Disconnect diagnosis sensor unit connector.
2. Turn the ignition key to ON position.
+ Does warning lamp turn on?
Yes
.

Replace diagnosis sensor unit.

RS-43

No
c

Check the ground circuit of
‘‘AIR BAG’’ warning lamp.

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses: SRS Does Not Enter
Diagnosis Mode Using Door Switch
DIAGNOSTIC PROCEDURE 11
Disconnect both battery cables and check
battery voltage using circuit tester.
+ Is battery voltage more than 9V?

Charge battery.
c

Yes
.

SRS263

Remove driver’s door switch and check
continuity between driver’s door switch
connector terminals V
1 and V
3 under the
following conditions.
Condition

No
c

Replace driver’s door
switch.

Continuity

Door switch is depressed
(Door is closed).

Door switch is released
(Door is open).

YES

SRS470

Yes
.

Check harness continuity between driver’s
door switch connector terminal V
3 and
body ground.
+ Does continuity exist?
Yes
.

Replace diagnosis sensor unit.
.
SRS265-D

Go to SRS Operation Check (RS-30).

RS-44

Replace or repair harness.
c

COLLISION DIAGNOSIS
To repair the SRS for a frontal collision, perform the following steps.
When SRS (except the side air bag) is activated in a collision:
1 Replace the diagnosis sensor unit.
V
2 Remove the air bag modules.
V
3 Check the SRS components using the table shown below:
V
+ Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
4 Install new air bag modules.
V
5 Conduct self-diagnosis using CONSULT and ‘‘AIR BAG’’ warning lamp. Refer to ‘‘SRS Operation Check’’
V
for details (RS-30). Ensure entire SRS operates properly.
When SRS is not activated in a collision:
1 Check the SRS components using the table shown below:
V
+ Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
2 Conduct self-diagnosis using CONSULT and ‘‘AIR BAG’’ warning lamp. Refer to ‘‘SRS Operation Check’’
V
for details (RS-30). Ensure entire SRS operates properly.

SRS inspection
Part

SRS (except the
side air bag) is activated

SRS is NOT activated

Air bag module
(driver and passenger side)

REPLACE
Install air bag module with new bolts
coated with bonding
agent.

1. Remove air bag module. Check harness cover and connectors for damage, terminals for deformities, and harness for binding.
2-1. Install driver air bag module into the steering wheel to check fit and alignment
with the wheel.
2-2. Install passenger air bag module into the instrument panel to check fit with the
instrument panel.
3. No damage found, reinstall with new bolts coated with bonding agent.
4. If damaged—REPLACE. Air bag must be deployed before discarding.

Diagnosis sensor
unit

REPLACE
Install diagnosis sensor unit with new
bolts coated with
bonding agent.

1.
2.
3.
4.

Seat belt pre-tensioner assembly

REPLACE
Install seat belt pretensioner with new
bolts coated with
bonding agent.

1. Remove seat belt pre-tensioners.
Check harness cover and connectors for damage, terminals for deformities, and
harness for binding.
2. Check belts for damage and anchors for loose mounting.
3. Check retractor for smooth operation.
4. If no damage is found, reinstall with new bolts coated with bonding agent.
5. If damaged—REPLACE. Install the seat belt pre-tensioners with new bolts coated
with bonding agent. Seat belt pre-tensioners must be deployed before discarding.

Steering wheel

1.
2.
3.
4.
5.
6.

Visually check steering wheel for deformities.
Check harness (built into steering wheel) and connectors for damage, and terminals for deformities.
Install air bag module to check fit or alignment with steering wheel.
Check steering wheel for excessive free play.
If no damage is found, reinstall the steering wheel.
If damaged—REPLACE.

Spiral cable

1.
2.
3.
4.
5.

Visually check spiral cable and combination switch for damage.
Check connectors, flat cable and protective tape for damage.
Check steering wheel for noise, binding or heavy operation.
If no damage is found, reinstall the spiral cable.
If damaged—REPLACE.

Harness and Connectors

1.
2.
3.
4.

Check connectors for poor connection, damage, and terminals for deformities.
Check harness for binding, chafing, cuts, or deformities.
If no damage is found, reinstall harness and connectors.
Damaged—REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS
harness.

Instrument panel

Refer to the table on the next page.

Check case and bracket for dents, cracks or deformities.
Check connectors for damage, and terminals for deformities.
If no damage is found, reinstall with new bolts coated with bonding agent.
If damaged—REPLACE. Install diagnosis sensor unit with new bolts coated with
bonding agent.

RS-45

COLLISION DIAGNOSIS
Part

Instrument panel

SRS is NOT activated

SRS (except the
side air bag) is activated

1. When passenger air bag inflates, check the following points for bending, deformities or cracks.
+ Opening portion for passenger air bag

SRS472

+ Passenger air bag module brackets

SRS473

+ The portions securing the instrument panel

SRS474

2. If no damage is found, reinstall the instrument panel.
3. If damaged—REPLACE the instrument panel with bolts.

RS-46

STEERING SYSTEM
SECTION

CONTENTS
PRECAUTIONS AND PREPARATION……………………….1
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’……………1
Precautions for Steering System……………………………1
Special Service Tools …………………………………………..1
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ……………………………………………..3
NVH Troubleshooting Chart…………………………………..3
ON-VEHICLE SERVICE …………………………………………..4
Checking Steering Wheel Play………………………………4
Checking Neutral Position on Steering Wheel …………4
Front Wheel Turning Angle……………………………………4
Checking and Adjusting Drive Belts ……………………….5
Checking Fluid Level ……………………………………………5
Checking Fluid Leakage ……………………………………….5
Bleeding Hydraulic System……………………………………6
Checking Steering Wheel Turning Force ………………..6
Checking Hydraulic System…………………………………..6
STEERING WHEEL AND STEERING COLUMN…………8
Removal and Installation ………………………………………8
Disassembly and Assembly…………………………………10

Inspection………………………………………………………….11
POWER STEERING SYSTEM (Model: PB69K) ……….12
Description ………………………………………………………..12
POWER STEERING GEAR (Model: PB69K)……………13
Removal and Installation …………………………………….13
Inspection………………………………………………………….13
POWER STEERING OIL PUMP………………………………15
Removal and Installation …………………………………….15
Disassembly and Assembly…………………………………16
Pre-disassembly Inspection…………………………………16
Inspection………………………………………………………….17
Disassembly………………………………………………………17
Assembly ………………………………………………………….18
STEERING LINKAGE…………………………………………….19
Removal and Installation …………………………………….19
Disassembly………………………………………………………20
Inspection………………………………………………………….20
SERVICE DATA AND SPECIFICATIONS (SDS) ……….22
General Specifications………………………………………..22
Inspection and Adjustment ………………………………….22

PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’
The Supplemental Restraint System such as ‘‘AIR BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’ used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The composition varies according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.

Precautions for Steering System
+
+
+
+
+
+
+

Before disassembly, thoroughly clean the outside of the unit.
Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
Place disassembled parts in order, on a parts rack, for easier and proper assembly.
Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
Before assembly, apply a coat of recommended ATF* to hydraulic parts. Vaseline may be applied
to O-rings and seals. Do not use any grease.
Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during installation. Perform functional tests whenever designated.
*: Automatic Transmission Fluid type DEXRONTMIII or equivalent

Special Service Tools
Tool number
Tool name

Description

KV48100700
Torque adapter

Measuring turning torque

NT169

ST27180001
Steering wheel puller

Removing steering wheel

NT544

ST-1

PRECAUTIONS AND PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name

Description

ST29020001
Ball joint remover

Removing ball joint

a: 34 mm (1.34 in)
b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)

NT551

ST27091000
Pressure gauge

Measuring oil pressure

NT547

KV48102500
Pressure gauge adapter

Measuring oil pressure

NT542

ST3127S000
GG91030000
Torque wrench
2 HT62940000
V
Socket adapter
3
V HT62900000
Socket adapter

Measuring turning torque

1
V

NT541

KV48100301
Strut and steering gear box
attachment

Disassembling and assembling steering gear

a: 162 mm (6.38 in)
b: 110 mm (4.33 in)
c: 190 mm (7.48 in)
d: 9 mm (0.35 in)

NT688

ST-2

Symptom
ST-20
ST-20
ST-5
ST-4
ST-6

Tie-rod ball joint rotating torque
Tie-rod ball joint end play
Steering gear fluid leakage
Steering wheel play
Steering wheel turning force
Drive belt looseness

X
X
X
X
X
X
X
X

Shake

STEERING Vibration

Shimmy

Judder

X: Applicable

ST-3
X
X

X
X

X
X
X
X

NVH in PD section
NVH in FA, RA section
NVH in FA section
NVH in FA section
NVH in FA section
NVH in BR section

AXLE AND SUSPENSION
TIRES
ROAD WHEEL
AXLE SHAFT
BRAKES

ST-19

Steering linkage looseness

DIFFERENTIAL

ST-10

Improper installation or looseness of steering column

NVH in PD section

ST-11

Steering column deformation

PROPELLER SHAFT

ST-11

—

Improper installation or looseness of tilt lock lever

Improper steering wheel or damage

ST-20

Tie-rod ball joint swinging force

Refer to MA section.

ST-6

Noise
Air in hydraulic system

Possible cause and
SUSPECTED PARTS
ST-5

Reference page

Fluid level

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X
X
X
X
X
X
X

X
X
X
X
X
X

X
X
X

X
X
X
X
X

ON-VEHICLE SERVICE
Checking Steering Wheel Play
+

SST489B

With wheels in a straight-ahead position, check steering wheel
play.
Steering wheel play:
35 mm (1.38 in) or less
If it is not within specification, check the following for loose and
worn components.
Steering gear assembly
Steering linkage
Steering column
Front suspension and axle

Checking Neutral Position on Steering Wheel
Pre-checking
+
+

Make sure that wheel alignment is correct.
Wheel alignment:
Refer to SDS in FA section.
Verify that the steering gear is centered before removing the
steering wheel.

Checking
SST490BA

1. Check that the steering wheel is in the neutral position when
driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel and
reinstall it correctly.
3. If the neutral position is between two teeth, loosen drag link lock
nuts. Adjust neutral position by turning drag link adjuster.

SST756C

Front Wheel Turning Angle
1. Rotate steering wheel all the way right and left; measure turning angle.
Turning angle of full turns:
Refer to SDS in FA section.

SMA127

2. If not within specification, adjust using stopper bolt.

SST773C

ST-4

ON-VEHICLE SERVICE
Checking and Adjusting Drive Belts
Refer to MA section (‘‘Checking Drive Belts’’, ‘‘ENGINE MAINTENANCE’’).

Checking Fluid Level
Check fluid level.
Use the correct range of the dipstick depending on the fluid temperature. Use the ‘‘HOT’’ range at 50 to 80°C (122 to 176°F), or the
‘‘COLD’’ range at 0 to 30°C (32 to 86°F).
CAUTION:
+ Do not overfill.
+ Recommended fluid is Automatic Transmission Fluid type
DEXRONTMIII or equivalent.
SST280BA

Checking Fluid Leakage

SST757C

Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing and deterioration.
1. Run engine between idle speed and 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 60 to 80°C
(140 to 176°F).
2. Turn steering wheel right-to-left several times.
3. Hold steering wheel at each ‘‘lock’’ position for five seconds and
carefully check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
4. If fluid leakage at connectors is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.

ST-5

ON-VEHICLE SERVICE
Bleeding Hydraulic System
1. Raise front end of vehicle until wheels are clear of the ground.
2. Add fluid into oil tank to specified level. Then, quickly turn steering wheel fully to right and left and lightly touch steering stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2 above.
+ Incomplete air bleeding will cause the following to occur. When
this happens, bleed air again.
a. Air bubbles in reservoir tank
b. Clicking noise in oil pump
c. Excessive buzzing in oil pump
Fluid noise may occur in the valve or oil pump. This is common
when the vehicle is stationary or while turning steering wheel
slowly. This does not affect performance or durability of the system.

Checking Steering Wheel Turning Force

SST491B

1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is approximately 60 to
80°C (140 to 176°F).]
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel has
been turned 360° from the neutral position.
Steering wheel turning force:
39 N (4 kg, 9 lb) or less

Checking Hydraulic System

SST834-E

Before starting, check belt tension, driving pulley and tire pressure.
1. Set Tool. Open shut-off valve. Then bleed air. Refer to ‘‘Bleeding Hydraulic System’’, ST-6.
2. Run engine at idle speed or 1,000 rpm.
Make sure fluid temperature in reservoir tank rises to 60 to
80°C (140 to 176°F).
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, fluid pressure in the power
steering pump increases to maximum. This will raise fluid temperature abnormally.
3. Check pressure with steering wheel fully turned to left and right
positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Power steering pump maximum operating pressure:
8,140 — 8,728 kPa (81.4 — 87.3 bar, 83 — 89 kg/cm2,
1,180 — 1,266 psi)
+ If pressure reaches maximum operating pressure, system is
OK.
+ If pressure increases above maximum operating pressure,
check power steering pump flow control valve. Refer to ST-16.

ST-6

ON-VEHICLE SERVICE
Checking Hydraulic System (Cont’d)
4. If power steering pressure is below the maximum operating
pressure, slowly close shut-off valve and check pressure again.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
+ If pressure increases to maximum operating pressure, gear is
damaged. Refer to ‘‘Removal and Installation’’, ST-13.
+ If pressure remains below maximum operating pressure, pump
is damaged. Refer to ‘‘Disassembly’’, ST-17.
5. After checking hydraulic system, remove Tool and add fluid as
necessary. Then completely bleed air out of system. Refer to
ST-6.

ST-7

STEERING WHEEL AND STEERING COLUMN
Removal and Installation

SST758C

1
V
2
V
3
V

Air bag module
Steering wheel
Spiral cable

4
V
5
V
6
V

Combination switch
Steering column assembly
Column cover

7
V
8
V

Lower shaft
Coupling

CAUTION:
+ The rotation of the spiral cable (SRS ‘‘Air bag’’ component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rotate the steering column while the steering gear is
removed.
+ Remove the steering wheel before removing the steering
lower joint to avoid damaging the SRS spiral cable.

STEERING WHEEL
+

Remove air bag module and spiral cable. Refer to RS section
(‘‘Removal — Air Bag Module and Spiral Cable’’, ‘‘SUPPLEMENTAL RESTRAINT SYSTEM’’).

SBF812E

ST-8

STEERING WHEEL AND STEERING COLUMN
Removal and Installation (Cont’d)
+ Align spiral cable correctly when installing steering wheel.
a. Set the front wheels in the straight-ahead position.
b. Make sure that the spiral cable is in the neutral position.
The neutral position is detected by turning left 2.5 revolutions
from the right end position. Align the two marks (,
m ).
CAUTION:
The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
Also, with the steering linkage disconnected, the cable may
snap by turning the steering wheel beyond the limited number
of turns. (The spiral cable can be turned up to 2.5 turns from
the neutral position to both the right and left.)

SRS276

Remove steering wheel with Tool.

SST777C

STEERING COLUMN
+
+

When installing steering column, fingertighten all lower bracket
and clamp retaining bolts; then tighten them securely. Do not
apply undue stress to steering column.
When attaching coupling joint, be sure tightening bolt faces
cutout portion.

SST759C

ST-9

STEERING WHEEL AND STEERING COLUMN
Disassembly and Assembly

SST760C

1
V
2
V
3
V

Combination switch
Lock nut
Jacket tube assembly

4
V
5
V
6
V

Tilt lever
Tilt spring
Steering column shaft assembly

+
+

7
V
8
V
9
V

Band
Column cover
Coupling

When disassembling and assembling, unlock steering lock with
key.
Install lock nut on steering column shaft and tighten the nut to
specification.
: 25 — 34 Nzm (2.5 — 3.5 kg-m, 18 — 25 ft-lb)

SST490C

+ Steering lock
a. Break self-shear type screws with a drill or other appropriate
tool.
b. Install new self-shear type screws and then cut off self-shear
type screw heads.

SST742A

ST-10

STEERING WHEEL AND STEERING COLUMN
Inspection
When steering wheel does not turn smoothly, check the steering column as follows and replace damaged parts.
a. Check column bearings for damage and unevenness. Lubricate
with recommended multi-purpose grease or replace steering
column as an assembly, if necessary.
b. Check steering column lower shaft for deformation and breakage. Replace if necessary.
+ When the vehicle comes into a light collision, check length ‘‘L1’’
and ‘‘L2’’.
Steering column length ‘‘L1’’:
679.9 — 681.5 mm (26.77 — 26.83 in)
Steering column lower shaft length ‘‘L2’’:
489.3 — 493.3 mm (19.26 — 19.42 in)
If out of the specifications, replace steering column shaft or
steering column as an assembly.
+

SST761C

Tilt mechanism
After installing steering column, check tilt mechanism operation.

SST582BD

ST-11

POWER STEERING SYSTEM (Model: PB69K)
Description

SST762C

CAUTION:
+ Parts which can be disassembled are strictly limited. Never
disassemble parts other than those specified.
+ Disassemble in as clean a place as possible.
+ Clean your hands before disassembly.
+ Do not use rags; use nylon cloths or paper towels.
+ Follow the procedures and cautions indicated in the Service Manual.

ST-12

POWER STEERING GEAR (Model: PB69K)
Removal and Installation
Before removal, clean gear housing and oil pump exteriors
using a steam cleaner. Then dry with compressed air.

SST774C

+
+
+

Plug openings of gear housing, and securely locate hose connectors at a position higher than oil pump and cover with paper
towels.
Be extremely careful to prevent entry of foreign matter into
hoses through connectors.
When installing pitman arm, align four grooves of pitman arm
serrations with four projections of sector shaft serrations, and
install and tighten lock washer and nut.

Inspection
Do not disassemble for power steering gear assembly.

TURNING TORQUE MEASUREMENT
1. Measure turning torque at 360° position.
a. Install steering gear on Tool.

SST040-A

ST-13

POWER STEERING GEAR (Model: PB69K)
Inspection (Cont’d)

SST652AA

b. Turn stub shaft all the way to right and left several times.
c. Measure turning torque at 360° position from straight-ahead
position with Tools.
Turning torque at 360°
0.15 — 0.78 Nzm (1.5 — 8.0 kg-cm, 1.3 — 6.9 in-lb)
2. Measure turning torque at straight-ahead position.
Straight-ahead position is a position where stub shaft is
turned 2.14 turns (two full turns and 50°) from lock position.
Turning torque at straight-ahead position:
0.2 — 0.5 Nzm (2 — 5 kg-cm, 1.7 — 4.3 in-lb)
higher than turning torque at 360°
Maximum turning torque:
0.44 — 1.18 Nzm (4.5 — 12 kg-cm, 3.9 — 10.4 in-lb)
3. Check sector shaft end play in neutral position.
End play:
Less than 0.1 mm (0.004 in)
If turning torque and end play are not within specifications,
replace power steering gear assembly.

ST-14

POWER STEERING OIL PUMP
Removal and Installation

YST001

ST-15

POWER STEERING OIL PUMP
Disassembly and Assembly

YST002

Pre-disassembly Inspection
Disassemble the power steering oil pump only if the following items
are found.
+ Oil leak from any point shown in the figure.
+ Deformed or damaged pulley.
+ Poor performance.

SST984A

ST-16

POWER STEERING OIL PUMP
Inspection
PULLEY AND PULLEY SHAFT
+
+

If pulley is cracked or deformed, replace it.
If fluid leak is found around the pulley shaft, replace the oil seal.

Disassembly
CAUTION:
+ Parts which can be disassembled are strictly limited. Never
disassemble parts other than those specified.
+ Disassemble in as clean a place as possible.
+ Clean your hands before disassembly.
+ Do not use rags; use nylon cloths or paper towels.
+ When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

+
+

Remove snap ring, then draw drive shaft out.
Be careful not to drop drive shaft.

+
+

Remove oil seal.
Be careful not to damage front housing.

+
+

Remove connector.
Be careful not to drop control valve.

SST010B

SST034A

SST036AA

ST-17

POWER STEERING OIL PUMP
Assembly
Assemble oil pump, noting the following instructions.
+ Make sure O-rings and oil seal are properly installed.
+ Always install new O-rings and oil seal.
+ Be careful of oil seal direction.
+ Cam ring, rotor and vanes must be replaced as a set if necessary.
+ When assembling, coat each part with ATF.

SST038A

Pay attention to the direction of rotor.

When assembling vanes to rotor, rounded surfaces of vanes
must face cam ring side.

2 into pin groove V
1 of front housing and front side
Insert pin V
plate. Then install cam ring V
3 as shown at left.
Cam ring:
D1 is less than D2

SST289A

SST843A

SST497A

ST-18

STEERING LINKAGE
Removal and Installation

SST766C

+
+

Remove pitman arm with tool.
Remove steering damper.

Remove tie-rod and drag link with Tool.

SST100-B

SST767C

ST-19

STEERING LINKAGE
Disassembly
TIE-ROD

SST768C

When tie-rod ball joints and tie-rod bar are separated, adjust tie-rod
length correctly.
Adjustment should be done between ball stud centers.
L: Standard
1,302 mm (51.26 in)
CAUTION:
+ Make sure that tie-rod ball joints are the same length as to
the left and right.
+ The toe-in must be adjusted to within dimension ‘‘L’’±5 mm
(0.20 in).

DRAG LINK

SST769C

When drag link ball joints and drag link bar are separated, adjust
drag link length correctly.
Adjustment should be done between ball stud centers.
L: Standard
1,123.4 mm (44.23 in)
CAUTION:
+ Make sure that drag link ball joint and adjuster are turned
to the same length.
+ The neutral position must be adjusted to within dimension
‘‘L’’±1 mm (0.04 in).

Inspection
BALL JOINT

SST827CA

1. Check joints for play. If ball is worn and play in axial direction
is excessive or joint is hard to swing, replace as a complete
unit.
Swinging force (Measure point: Cotter pin hole) ‘‘A’’:
4.9 — 49.0 N (0.5 — 5.0 kg, 1.1 — 11.0 lb)
Rotating torque ‘‘B’’:
0.3 — 2.9 Nzm (3 — 30 kg-cm, 2.6 — 26.0 in-lb)
Axial end play ‘‘C’’:
0 mm (0 in)
2. Check condition of dust cover. If it is cracked excessively,
replace as a complete unit.
CAUTION:
Be careful not to apply grease or oil to taper of joint.

ST-20

STEERING LINKAGE
Inspection (Cont’d)
TIE-ROD AND DRAG LINK
Check tie-rod and drag link for breakage, bends and cracks, and
replace with a new one if necessary.

FIXING LOCATION
+
+
+

Check fixing location (nuts and cotter pins) for looseness, play
and breakage.
When looseness or play is found, check for wear and tapered
portion of ball joints, pitman arm and knuckle arms.
When reassembling each joint, use new cotter pins.

STEERING DAMPER
Check for oil leakage and measure damping force. Replace if necessary.
Damping force:
at 0.3 m (1.0 ft)/sec
4,443 N (453 kg, 999 lb)
… Extended direction
3,315 N (338 kg, 745 lb)
… Compressed direction

ST-21

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Power steering
Steering gear type

Steering wheel axial play
mm (in)

PB69K

Steering wheel play

Turns of steering wheel on the vehicle
(Lock-to-lock)

3.4

Steering gear ratio

17.0

mm (in)
Steering damper
[at 0.3 m (1.0 ft)/sec.]
N (kg, lb)

0 (0)
35 (1.38) or less
4,443 (453, 999) …
Extended direction
3,315 (338, 745) …
Compressed direction

Inspection and Adjustment
STEERING COLUMN

STEERING LINKAGE
Unit: mm (in)

Steering column

(L1)

679.9 — 681.5 (26.77 — 26.83)

Steering column lower shaft

(L2)

489.3 — 493.3 (19.26 — 19.42)

Tie-rod & drag link ball joint
Swinging force at cotter pin hole N (kg, lb)
Rotating torque
Nzm (kg-cm, in-lb)
Axial end play

mm (in)

Tie-rod standard length (L)
mm (in)
Drag link standard length (L)
mm (in)

4.9 — 49.0
(0.5 — 5.0, 1.1 — 11.0)
0.3 — 2.9
(3 — 30, 2.6 — 26.0)
0 (0)
1,302 (51.26)
1,123.4 (44.23)

SST761C

SST768C

SST769C

ST-22

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
POWER STEERING SYSTEM
(Model: PB69K)
Steering wheel turning force
(at 360° from neutral position and circumference of
steering wheel)
N (kg, lb)
Oil pump pressure
kPa (bar, kg/cm2, psi)
Fluid capacity
m! (Imp fl oz)
Normal operating temperature
°C (°F)

39 (4, 9) or less

8,140 — 8,728
(81.4 — 87.3, 83 — 89, 1,180 — 1,266)
at idling
Approximately 1,000 (35.2)
60 — 80 (140 — 176)

Steering gear turning torque
Nzm (kg-cm, in-lb)
360° position from
straight-ahead position

0.15 — 0.78 (1.5 — 8.0, 1.3 — 6.9)

Straight-ahead position
(As compared with steering wheel turned 360°)

0.2 — 0.5 (2 — 5, 1.7 — 4.3) higher

Maximum turning torque

0.44 — 1.18 (4.5 — 12, 3.9 — 10.4)

Backlash at pitman arm top
end (in a straightahead position)
mm (in)

0 — 0.1 (0 — 0.004)

End play (at sector shaft
end in neutral position)
mm (in)

0.1 (0.004) or less

ST-23

TRANSFER
SECTION

CONTENTS
PREPARATION……………………………………………………….1
Special Service Tools …………………………………………..1
Commercial Service Tools …………………………………….2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ……………………………………………..3
NVH Troubleshooting Chart…………………………………..3
DESCRIPTION ………………………………………………………..4
Cross-sectional View ……………………………………………4
ON-VEHICLE SERVICE …………………………………………..5
Replacing Oil Seal ……………………………………………….5
Checking Position Switch ……………………………………..7
REMOVAL AND INSTALLATION ………………………………8
Removal……………………………………………………………..8
Installation…………………………………………………………..8
TRANSFER GEAR CONTROL …………………………………9
MAJOR OVERHAUL ……………………………………………..10
Case Components ……………………………………………..10
Gear Components ……………………………………………..11

Shift Control Components …………………………………..12
DISASSEMBLY……………………………………………………..13
REPAIR FOR COMPONENT PARTS……………………….19
Mainshaft ………………………………………………………….19
Front Drive Shaft ……………………………………………….20
Counter Gear …………………………………………………….21
Main Gear …………………………………………………………22
Front Case ………………………………………………………..24
Front Case Cover ………………………………………………24
Center Case………………………………………………………24
Bearing Retainer………………………………………………..25
Rear Case…………………………………………………………25
Shift Control Components …………………………………..26
ASSEMBLY…………………………………………………………..27
SERVICE DATA AND SPECIFICATIONS (SDS) ……….33
General Specifications………………………………………..33
Inspection and Adjustment ………………………………….33

PREPARATION
Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool name
KV38104700*
Flange wrench

Description
Removing front companion flange nut
Installing front companion flange nut

NT428

ST30021000*
Puller

Removing counter gear front bearing

NT411

ST30031000*
Puller

Removing counter gear rear bearing

NT411

ST33290001*
Puller

Removing center case oil seal
Removing rear oil seal

NT414

ST22452000*
Drift

Installing mainshaft rear bearing

a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.

NT065

ST33061000*
Drift

Removing main gear bearing

a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.

NT116

ST30613000*
Drift

Installing counter gear rear bearing
Installing main gear bearing
Installing cover oil seal
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.

NT073

ST33200000*
Drift

Installing counter gear front bearing
Removing cover oil seal

a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

NT091

ST30720000*
Drift

Installing counter case oil seal

a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

NT115

TF-1

PREPARATION
Commercial Service Tools
Tool name
Puller

Description
Removing front and rear companion flanges
Removing mainshaft rear bearing and clutch
gear
Removing L & H hub
Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Removing main gear bearing
Installing shift shaft oil seal

NT077

Drift

a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
c: 40 mm (1.57 in)

NT117

Drift

Installing L & H hub

a: 60 mm (2.36 in) dia.
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in)

NT117

Drift

Installing clutch gear

a: 55 mm (2.17 in) dia.
b: 45 mm (1.77 in) dia.
c: 160 mm (6.30 in)

NT117

Drift

Installing rear oil seal

a: 75 mm (2.95 in) dia.
b: 67 mm (2.64 in) dia.
c: 60 mm (2.36 in)

NT117

TF-2

1
2

Symptom
Fluid leakage
3
1

Hard to shift or will not shift

Jumps out of gear

TF-3
2

TF-12

TF-11

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged)

SHIFTING INSERT (Damaged)

2
SHIFT FORK (Worn)

TF-10, TF-12

TF-10

OIL SEAL (Worn or damaged)

CHECK SPRING AND CHECK BALL (Worn or damaged)

TF-10

SUSPECTED PARTS (Possible cause)
LIQUID GASKET (Damaged)

Refer to MA section (‘‘Checking Transfer Fluid’’,
‘‘CHASSIS AND BODY MAINTENANCE’’).

Reference page

FLUID (Level too high)

FLUID (Wrong)

Noise
FLUID (Level low)

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

TRANSFER

3
3

DESCRIPTION
Cross-sectional View

SMT248D

TF-4

ON-VEHICLE SERVICE
Replacing Oil Seal
CENTER CASE OIL SEAL
1. Remove front propeller shaft. Refer to PD section (‘‘Removal
and Installation’’, ‘‘PROPELLER SHAFT’’).
2. Remove companion flange nut.

SMT091B

3. Remove front companion flange.

SMT092B

4. Remove center case oil seal.

SMT093B

5. Install center case oil seal.
+ Before installing, apply multi-purpose grease to seal lip.
6. Reinstall any part removed.

SMT094B

SHIFT SHAFT OIL SEAL
1. Remove transfer control lever from transfer cross shaft.

SMT251D

TF-5

ON-VEHICLE SERVICE
Replacing Oil Seal (Cont’d)
2. Remove shift shaft oil seal.
+ Be careful not to damage inner shift lever.

SMT097B

3. Install shift shaft oil seal.
+ Before installing, apply multi-purpose grease to seal lip.
4. Install transfer control lever.

SMT096B

REAR OIL SEAL
1. Remove rear propeller shaft. Refer to PD section (‘‘Removal
and Installation’’, ‘‘PROPELLER SHAFT’’).
2. Remove brake drum.
3. Remove companion flange nut.
4. Remove rear companion flange.
5. Remove center brake assembly.

SMT323B

6. Remove rear oil seal.

SMT324B

7. Install rear oil seal.
+ Before installing, apply multi-purpose grease to seal lip.
8. Reinstall any part removed.

SMT325B

TF-6

ON-VEHICLE SERVICE
Checking Position Switch
4WD SWITCH
Transfer control lever position

Continuity

4H, 4L

Yes

Except above

SMT252D

NEUTRAL POSITION SWITCH
Transfer control lever position

Continuity

Between 4H and 4L
(‘‘PUSH’’ position)

Yes

Except above

SMT253D

TF-7

REMOVAL AND INSTALLATION
Removal

SMT251D

1. Drain fluid and oil from transfer and transmission (M/T model
only).
2. Remove exhaust front and rear tubes. Refer to FE section
(‘‘EXHAUST SYSTEM’’).
3. Remove front and rear propeller shaft. Refer to PD section
(‘‘Removal and Installation’’, ‘‘PROPELLER SHAFT’’).
4. Disconnect neutral position switch and 4WD switch harness
connectors.
5. Remove transfer control lever from transfer cross shaft.
6. Remove transfer from transmission.
WARNING:
Support transfer while removing it.

SMT268D

Installation
+

Apply recommended sealant to mating surface to transmission.
(M/T models only)
Recommended sealant:
Genuine anaerobic liquid gasket, Three Bond
TB1215, Loctite Part No. 51813 or equivalent
Tighten transfer bolts.
Transfer fixing bolts:
: 32 — 42 Nzm (3.3 — 4.3 kg-m, 24 — 31 ft-lb)

SMT176BA

TF-8

TRANSFER GEAR CONTROL

SMT254D

TF-9

MAJOR OVERHAUL
Case Components

SMT255D

TF-10

MAJOR OVERHAUL
Gear Components

SMT256D

TF-11

MAJOR OVERHAUL
Shift Control Components

SMT257D

TF-12

DISASSEMBLY
1. Remove nut of front companion flange.

SMT101B

2. Remove center brake components.
a. Remove rear companion flange nut.
b. Remove brake drum.

SMT258D

c. Remove rear companion flange.
d. Remove center brake components.

SMT103B

3. Remove rear case.
+ Be careful not to damage the mating surface.

SMT104B

4. Remove front companion flange.

SMT105B

TF-13

DISASSEMBLY
5. Remove speedometer drive gear and oil gutter.

SMT106B

6. Remove snap ring from 2-4 shift rod.

SMT107B

7. Check front drive sprocket end play.
a. While holding front drive sprocket forward as far as it will go,
measure distance ‘‘A’’ between rear surface of front drive
sprocket and front surface of 2-4 coupling sleeve.
b. While holding front drive sprocket back as far as it will go,
measure distance ‘‘B’’ as same as step a.
c. Determine front drive sprocket end play to be used by the following equation.
Front drive sprocket end play = A − B
Standard:
0.20 — 0.35 mm (0.0079 — 0.0138 in)
+ If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.

SMT108B

8. Shift 2-4 coupling sleeve to 2WD position.

SMT110B

TF-14

DISASSEMBLY
9. Pull out clutch gear and mainshaft rear bearing.

SMT111B

10. Remove 2-4 coupling sleeve with 2-4 shift fork.

SMT112B

11. Remove front drive shaft assembly, drive chain and front drive
sprocket by tapping front end of front drive shaft.

SMT113B

12. Remove bolts securing bearing retainer and then remove bearing retainer.

SMT115B

TF-15

DISASSEMBLY
13. Remove bolts securing center case to front case and then
separate center case and front case.

SMT116B

14. Measure end play of low gear.
Standard:
0.20 — 0.35 mm (0.0079 — 0.0138 in)
Refer to SDS, TF-33.
+ If end play is beyond the maximum value, check low gear and
L & H hub for wear.

SMT117B

15. Disassemble center case assembly.
a. Remove snap ring from mainshaft.

SMT118B

b. Pull out low gear with L & H hub.

SMT119B

c. Remove mainshaft by tapping front end of mainshaft.

SMT120B

TF-16

DISASSEMBLY
16.
a.
+
+
+
+
+
+

Disassemble front case assembly.
Remove the following parts.
4WD switch
Neutral position switch
Check plugs
Check springs
Check balls
Be careful not to lose the check balls.

SMT259D

b. Remove 2-4 shift rod.

SMT122B

c. Remove L & H shift rod and fork assembly with coupling sleeve.

SMT260D

d. Remove needle bearing from main gear.

SMT124B

e. Remove bolts securing front case cover and then remove it.

SMT125B

TF-17

DISASSEMBLY
f.

Remove counter gear by tapping it lightly with a soft hammer.

SMT261D

g. Remove main gear by tapping it lightly with a soft hammer.

SMT262D

TF-18

REPAIR FOR COMPONENT PARTS
Mainshaft
DISASSEMBLY
1. Remove snap ring and spacer.

SMT129B

2. Press out mainshaft front bearing from mainshaft.

SMT130B

INSPECTION
Gear and shaft
+
+
+

Check gears for excessive wear, chips or cracks.
Check shaft for cracks, wear or bending.
Check coupling sleeve for wear or damage.

SMT180B

Baulk ring
+

Check baulk ring for cracks or deformation.

SMT349A

+ Measure clearance between baulk ring and gear.
Baulk ring to gear clearance:
Unit: mm (in)

Standard

Wear limit

1.0 — 1.5 (0.039 — 0.059)

0.5 (0.020)

If not within wear limit, replace baulk ring.

SMT350A

TF-19

REPAIR FOR COMPONENT PARTS
Mainshaft (Cont’d)
Bearing
+

Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

SMT351A

ASSEMBLY
1. Press mainshaft front bearing onto mainshaft.
+ Pay special attention to its direction.

SMT294A

2. Install spacer.
3. Select mainshaft front bearing snap ring with proper thickness
and install it.
Allowable clearance between mainshaft front bearing
snap ring and groove:
0 — 0.15 mm (0 — 0.0059 in)
Mainshaft front bearing snap ring:
Refer to SDS, TF-33.

SMT295A

Front Drive Shaft
DISASSEMBLY
+

Front drive shaft front bearing

Front drive shaft rear bearing

SMT296A

SMT297A

TF-20

REPAIR FOR COMPONENT PARTS
Front Drive Shaft (Cont’d)
INSPECTION
Sprocket and shaft
+
+

Check sprocket for excessive wear, chips or cracks.
Check shaft for cracks or wear.

Bearing
+

Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

SMT357A

ASSEMBLY
+

Press front drive shaft front bearing.

Press front drive shaft rear bearing.

SMT298A

SMT299A

Counter Gear
DISASSEMBLY
1. Press out counter gear front bearing and then remove front
sub-gear, spacer and dish spring.

SMT134B

2. Press out counter gear rear bearing and then remove rear
sub-gear, spacer and dish spring.

SMT135B

TF-21

REPAIR FOR COMPONENT PARTS
Counter Gear (Cont’d)
INSPECTION
Gear and shaft
+
+

Check gears for excessive wear, chips or cracks.
Check shaft for cracks or wear.

Bearing
+

Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

SMT266D

ASSEMBLY
1. Press on counter gear rear bearing.

SMT267D

2. Install front sub-gear, dish spring and spacer, and then press on
counter gear front bearing.
+ Pay attention to direction of dish spring.

SMT137B

Main Gear
DISASSEMBLY
Main gear bearing
1. Remove snap ring and spacer.

SMT304A

2. Pull out main gear bearing.

SMT305AA

TF-22

REPAIR FOR COMPONENT PARTS
Main Gear (Cont’d)
Plug
+

Always replace it with new one whenever it is removed.

SMT306A

INSPECTION
Gear and shaft
+
+

Check gears for excessive wear, chips or cracks.
Check shaft for cracks or wear.

Bearing
+

Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

SMT359A

ASSEMBLY
Main gear bearing
1. Press on main gear bearing.
+ Pay attention to its direction.
2. Install spacer.

SMT307AA

3. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove:
0 — 0.15 mm (0 — 0.0059 in)
Snap ring (main gear bearing):
Refer to SDS, TF-33.

SMT308A

Plug
+

Apply sealant to plug and install it.

SMT309A

TF-23

REPAIR FOR COMPONENT PARTS
Front Case
SHIFT SHAFT OIL SEAL
Removal
+
+
+

Use a screwdriver to pry out old seal.
Be careful not to damage case.
Always replace with a new one whenever it has been removed.

SMT138B

Installation
+
+

Install new shift shaft oil seal until flush with case.
Before installing, apply multi-purpose grease to seal lip.

SMT139B

Front Case Cover
Removal
+
+

Take out old seal from inside of front case cover.
Be careful not to damage front case cover.

SMT263D

Installation
+
+

Install new front case cover oil seal until it stops.
Before installing, apply multi-purpose grease to seal lip.

SMT141B

Center Case
CENTER CASE OIL SEAL
Removal
+

Remove center case oil seal.

SMT146B

TF-24

REPAIR FOR COMPONENT PARTS
Installation
+

Install center case oil seal.

SMT147B

Bearing Retainer
OIL CATCHER
Removal
+
+

Drive out oil catcher from inside of bearing retainer.
Be careful not to damage bearing retainer.

SMT142B

Installation
+
+
+

Install oil catcher until it stops.
Be careful not to damage or distort oil catcher or bearing
retainer.
Before installing, apply multi-purpose grease to seal lip.

SMT143B

Rear Case
REAR OIL SEAL
Removal
+

Pull out rear oil seal.

SMT144B

Installation
+
+

Install new rear oil seal until it stops.
Before installing, apply multi-purpose grease to seal lip.

SMT145B

TF-25

REPAIR FOR COMPONENT PARTS
AIR BREATHER
+

Install as shown in illustration.
Thread locker:
Refer to TF-10.

SMT148B

Shift Control Components
INSPECTION
+

Check contact surface and sliding surface for wear, scratches,
projections or other faulty conditions.

SMT360A

L & H SHIFT ROD & FORK
+ Assemble as shown in illustration.
* This pin is the same size as the one for 2-4 shift rod.

SMT149B

2-4 SHIFT ROD & FORK
+ Assemble as shown in illustration.
* These pins are the same size.

SMT150B

Pay attention to the direction of fork guide collar.

SMT033B

TF-26

ASSEMBLY
1. Install cross shaft.

SMT151B

2. Assemble front case.
a. Install main gear assembly by tapping it lightly with a soft hammer.

SMT152B

b. Apply sealant to the mating surface and bolts of front case
cover and install it on front case.
+ Apply recommended sealant to these ten bolts.
+ Tightening torque
A:
: 16 — 21 Nzm (1.6 — 2.1 kg-m, 12 — 15 ft-lb)
B:
: 19 — 24 Nzm (1.9 — 2.4 kg-m, 14 — 17 ft-lb)

SMT153B

c. Apply gear oil to needle bearing and install it into main gear.

SMT326A

d. Install counter gear assembly by tapping it lightly with a soft
hammer.

SMT264D

TF-27

ASSEMBLY
e. Insert interlock plunger into front case.

SMT090B

Install L & H shift rod and fork assembly with coupling sleeve.

SMT155B

g. Install 2-4 shift rod.

SMT265D

h. Install switches, check balls, check springs and plugs.
+ Apply sealant to switches and plugs.

SMT259D

3. Select counter gear rear bearing shim.
Counter gear end play:
0 — 0.2 mm (0 — 0.008 in)
a. Measure distance ‘‘A’’ between upper surface of counter gear
rear bearing and mating surface of front case.

SMT335A

TF-28

ASSEMBLY
b. Select suitable shim using SDS table as a guide.
Counter gear rear bearing shim:
Refer to SDS, TF-33.

SMT157B

4. Place suitable shim on counter gear rear bearing with grease.
5. Apply gear oil to each part in front case.

SMT158B

6. Install mainshaft on center case.
a. Install mainshaft on center case by tapping it lightly.
+ Apply gear oil to mainshaft front bearing.

SMT159B

b. Install bearing retainer.

SMT407A

c. Install low gear and its bearing to mainshaft.
+ Apply gear oil to needle bearing.

SMT160B

TF-29

ASSEMBLY
d. Install L & H hub and snap ring to mainshaft.
+ Pay attention to direction of L & H hub.

SMT161B

e. Measure end play of low gear.
Standard:
0.20 — 0.35 mm (0.0079 — 0.0138 in)

SMT117B

7. Apply sealant to mating surface and put center case assembly
onto front case and tighten bolts.

SMT163B

8. Assemble center case assembly.
a. Put drive chain onto front drive sprocket and front drive shaft,
and then put them in center case.

SMT164B

b. Install front drive shaft by tapping it lightly with a soft hammer.
+ Make sure shafts are lined up in case.

SMT165B

TF-30

ASSEMBLY
c. Apply gear oil to needle bearings and install them into front
drive sprocket.
+ These needle bearings can be easily installed if front drive
sprocket is rotated during their installation.

SMT166B

d. Install 2-4 coupling sleeve with 2-4 shift fork.
+ Pay attention to direction of coupling sleeve.

SMT167B

e. Install shifting inserts and spread spring.
+ Pay attention to direction of shifting inserts.

SMT168B

Install baulk ring and then install clutch gear.

SMT169B

g. Install mainshaft rear bearing.
+ Pay attention to its direction.

SMT170B

TF-31

ASSEMBLY
h. Install snap ring to 2-4 shift rod.

SMT107B

i.
j.

Install speedometer drive gear and oil gutter.
Apply gear oil to each part in center case.

SMT106B

9. Apply sealant to mating surface. Set center case assembly onto
front case, then tighten bolts.
10. Install front and rear companion flanges and center brake components.

SMT171B

TF-32

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Transfer model

TX12A
High

1.000

Low

2.020

Gear ratio

Number of teeth

Main gear

Low gear

Counter
gear

High

Low

Front drive sprocket

Front drive shaft

Fluid capacity

liters (Imp qt)

1.9 (1-5/8)

Inspection and Adjustment
GEAR END PLAY

AVAILABLE SHIM
Unit: mm (in)

Front drive sprocket

0.20 — 0.35 (0.0079 — 0.0138)

Low gear

0.20 — 0.35 (0.0079 — 0.0138)

Counter gear

Counter gear rear bearing
Distance ‘‘A’’
mm (in)

0 — 0.2 (0 — 0.008)

CLEARANCE BETWEEN BAULK RING AND
CLUTCH GEAR

40.6 — 40.5
(1.598 — 1.594)

Shim(s)
Thickness mm (in)

Part number

Not necessary

40.5 — 40.4
(1.594 — 1.591)

0.1 (0.004)

33112-C6900

40.4 — 40.3
(1.591 — 1.587)

0.2 (0.008)

33112-C6901

40.3 — 40.2
(1.587 — 1.583)

0.3 (0.012)

33112-C6902

AVAILABLE SNAP RING

40.2 — 40.1
(1.583 — 1.579)

0.4 (0.016)

33112-C6903

Mainshaft front bearing

40.1 — 40.0
(1.579 — 1.575)

0.5 (0.020)

33112-33G00

40.0 — 39.9
(1.575 — 1.571)

0.6 (0.024)

33112-33G01

Unit: mm (in)
Standard

Wear limit

1.0 — 1.5 (0.039 — 0.059)

0.5 (0.020)

Unit: mm (in)
Allowable clearance

0 — 0.15 (0 — 0.0059)

Thickness

Part number

3.0 (0.118)
3.1 (0.122)
3.2 (0.126)

33138-73P10
33138-73P11
33138-73P12

Main gear bearing
Unit: mm (in)
Allowable clearance

0 — 0.15 (0 — 0.0059)

Thickness

Part number

2.6 (0.102)
2.7 (0.106)
2.8 (0.110)

33114-73P00
33114-73P01
33114-73P02

SMT335A

TF-33

AUTOMATIC TRANSMISSION
SECTION

CONTENTS
PREPARATION AND PRECAUTIONS …………… 1003
Special Service Tools ……………………………….. 1003
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 1004
Precautions ……………………………………………… 1004
Service Notice or Precautions ……………………. 1006
OVERALL SYSTEM …………………………………….. 1007
A/T Electrical Parts Location ……………………… 1007
Circuit Diagram ………………………………………… 1008
Wiring Diagram — A/T —………………………….. 1009
Cross-sectional View ………………………………… 1022
Hydraulic Control Circuits ………………………….. 1023
Shift Mechanism ………………………………………. 1024
Control System ………………………………………… 1026
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION …………………………………………….. 1028
Self-diagnosis…………………………………………… 1028
Diagnosis by CONSULT-II…………………………. 1034
TROUBLE DIAGNOSIS — Introduction………… 1036
Introduction ……………………………………………… 1036
Diagnostic Worksheet ……………………………….. 1037
Work Flow ……………………………………………….. 1040
TROUBLE DIAGNOSIS — Basic Inspection …. 1041
A/T Fluid Check ……………………………………….. 1041
Stall Test …………………………………………………. 1041
Line Pressure Test……………………………………. 1044
Road Test ……………………………………………….. 1046
TROUBLE DIAGNOSIS — General
Description…………………………………………………. 1057
Symptom Chart ………………………………………… 1057
TCM Terminals and Reference Value …………. 1060
TROUBLE DIAGNOSIS FOR VHCL SPEED
SENzA/T………………………………………………………. 1064

Vehicle Speed SensorzA/T (Revolution
sensor) ……………………………………………………. 1064
TROUBLE DIAGNOSIS FOR VHCL SPEED
SENzMTR…………………………………………………….. 1066
Vehicle Speed SensorzzMTR………………………. 1066
TROUBLE DIAGNOSIS FOR THROTTLE POSI
SEN ……………………………………………………………. 1068
Accelerator Position Sensor ………………………. 1068
TROUBLE DIAGNOSIS FOR SHIFT
SOLENOID/V A……………………………………………. 1070
Shift Solenoid Valve A ………………………………. 1070
TROUBLE DIAGNOSIS FOR SHIFT
SOLENOID/V B……………………………………………. 1072
Shift Solenoid Valve B ………………………………. 1072
TROUBLE DIAGNOSIS FOR OVERRUN
CLUTCH S/V……………………………………………….. 1074
Overrun Clutch Solenoid Valve ………………….. 1074
TROUBLE DIAGNOSIS FOR T/C CLUTCH
SOL/V…………………………………………………………. 1076
Torque Converter Clutch Solenoid Valve …….. 1076
TROUBLE DIAGNOSIS FOR BATT/FLUID
TEMP SEN ………………………………………………….. 1079
A/T Fluid Temperature Sensor and TCM
Power Source ………………………………………….. 1079
TROUBLE DIAGNOSIS FOR ENGINE SPEED
SIG …………………………………………………………….. 1082
Engine Speed Signal ………………………………… 1082
TROUBLE DIAGNOSIS FOR LINE PRESSURE
S/V……………………………………………………………… 1084
Line Pressure Solenoid Valve ……………………. 1084
TROUBLE DIAGNOSIS FOR CONTROL UNIT
(RAM), CONTROL UNIT (ROM) ……………………. 1087
Description ………………………………………………. 1087

Diagnostic Procedure………………………………… 1088
TROUBLE DIAGNOSIS FOR CONTROL UNIT
(EFP ROM)………………………………………………….. 1089
Description ………………………………………………. 1089
Diagnostic Procedure………………………………… 1090
TROUBLE DIAGNOSIS FOR
NON-DETECTABLE ITEMS ………………………….. 1091
PNP, Overdrive Control, A/T Mode or
Accelerator Position Switches ……………………. 1091
DIAGNOSTIC PROCEDURES FOR
SYMPTOMS ………………………………………………… 1097
1. SPORT Indicator Lamp Does Not
Come On…………………………………………………. 1097
2. SPORT Indicator Lamp Does Not
Come On…………………………………………………. 1098
3. O/D OFF Indicator Lamp Does Not Come
On ………………………………………………………….. 1098
4. SPORT Indicator Lamp Does Not
Come On…………………………………………………. 1099
5. Engine Cannot Be Started In “P” and “N”
Position …………………………………………………… 1100
6. In “P” Position, Vehicle Moves Forward Or
Backward When Pushed …………………………… 1100
7. In “N” Position, Vehicle Moves ……………….. 1101
8. Large Shock. “N” → “R” Position ……………. 1102
9. Vehicle Does Not Creep Backward In “R”
Position …………………………………………………… 1103
10. Vehicle Does Not Creep Forward In “D”,
“2” Or “1” Position …………………………………….. 1104
11. Vehicle Cannot Be Started From D1 ……… 1105
12. A/T Does Not Shift: D1 → D2 Or Does Not
Kickdown: D4 → D2 ………………………………….. 1106
13. A/T Does Not Shift: D2 → D3 ……………….. 1107
14. A/T Does Not Shift: D3 → D4 ……………….. 1108
15. A/T Does Not Perform Lock-up …………….. 1109
16. A/T Does Not Hold Lock-up Condition …… 1110
17. Lock-up Is Not Released ……………………… 1110
18. Engine Speed Does Not Return To Idle
(Light Braking D4 → D3) ……………………………. 1111
19. Vehicle Does Not Start From D1 …………… 1112
20. A/T Does Not Shift: D2 → D1 When
Depressing Accelerator Pedal ……………………. 1113
21. A/T Does Not Shift: D4 → D3, When
Overdrive Control Switch “ON” → “OFF” …….. 1114
22. A/T Does Not Shift: D3 → 22, When
Selector Lever “D” → “2” Position ………………. 1114
23. A/T Does Not Shift: 22 → 11, When

Selector Lever “2” → “1” Position……………….. 1115
24. Vehicle Does Not Decelerate By Engine
Brake………………………………………………………. 1115
TROUBLE DIAGNOSES — A/T Shift Lock
System……………………………………………………….. 1116
Description ………………………………………………. 1116
Wiring Diagram — SHIFT — ……………………… 1117
Diagnostic Procedure………………………………… 1118
Key Interlock Cable…………………………………… 1121
Component Check ……………………………………. 1122
ON-VEHICLE SERVICE ……………………………….. 1124
Control Valve Assembly and Accumulators …. 1124
Revolution Sensor Replacement ………………… 1125
Rear Oil Seal Replacement ……………………….. 1125
Parking Pawl Components Inspection…………. 1125
PNP Switch Adjustment…………………………….. 1125
Manual Control Linkage Adjustment……………. 1126
REMOVAL AND INSTALLATION ………………….. 1127
Removal ………………………………………………….. 1127
Installation ……………………………………………….. 1128
MAJOR OVERHAUL ……………………………………. 1129
Oil Channel ……………………………………………… 1131
Locations of Needle Bearings, Thrust Washers
and Snap Rings ……………………………………….. 1132
DISASSEMBLY……………………………………………. 1133
REPAIR FOR COMPONENT PARTS …………….. 1144
Oil Pump …………………………………………………. 1144
Control Valve Assembly…………………………….. 1148
Control Valve Upper Body …………………………. 1154
Control Valve Lower Body …………………………. 1159
Reverse Clutch ………………………………………… 1161
High Clutch ……………………………………………… 1165
Forward and Overrun Clutches ………………….. 1167
Low & Reverse Brake……………………………….. 1171
Forward Clutch Drum Assembly…………………. 1175
Rear Internal Gear and Forward Clutch Hub .. 1177
Band Servo Piston Assembly …………………….. 1180
Parking Pawl Components ………………………… 1184
ASSEMBLY…………………………………………………. 1186
Assembly (1) ……………………………………………. 1186
Adjustment ………………………………………………. 1190
Assembly (2) ……………………………………………. 1195
A/T FLUID COOLER SYSTEM ……………………… 1205
A/T Fluid Cooler……………………………………….. 1205
SERVICE DATA AND SPECIFICATIONS (SDS)1206
General Specifications ………………………………. 1206
Specifications and Adjustment……………………. 1206

When you read wiring diagrams:
+ Read GI section, “HOW TO READ WIRING DIAGRAMS”.
+ See EL section, “POWER SUPPLY ROUTING” for power distribution circuit.
When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES”.

AT-1002

PREPARATION AND PRECAUTIONS
Special Service Tools
Tool number
Tool name

Description

ST2505S001
Oil pressure gauge set
1 ST25051001
V
Oil pressure gauge
2 ST25052000
V
Hose
3 ST25053000
V
Joint pipe
4 ST25054000
V
Adapter
5 ST25055000
V
Adapter

Measuring line pressure

NT097

KV31101201
Oil pressure gauge
adapter

Measuring line pressure

NT093

ST07870000
Transmission case
stand

Disassembling and assembling
A/T
a: 182 mm (7.17 in)
b: 282 mm (11.10 in)
c: 230 mm (9.06 in)
d: 100 mm (3.94 in)

NT421

KV31102100
Torque converter oneway clutch check tool

Checking one-way clutch in
torque converter

NT098

ST25850000
Sliding hammer

Removing oil pump assembly

a: 179 mm (7.05 in)
b: 70 mm (2.76 in)
c: 40 mm (1.57 in) dia.
d: M12 x 1.75P

NT422

ST33200000
Drift

Installing oil pump housing
oil seal

a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

NT091

ST30720000
Drift

Installing rear oil seal

a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

NT115

AT-1003

PREPARATION AND PRECAUTIONS
Special Service Tools (Cont’d)
Tool number
Tool name

Description

KV31102400
Clutch spring
compressor

Removing and installing clutch
return springs

a: 320 mm (12.60 in)
b: 174 mm (6.85 in)

NT423

Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and
Air Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.

Precautions
+Before proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to
prevent the internal parts from becoming contaminated by dirt or other foreign matter.
+ Disassembly should be done in a clean work area.
+ Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transmission.
+ Place disassembled parts in order for easier and proper assembly.
+ All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection
or reassembly.
+ Gaskets, seals and O-rings should be replaced any time the transmission is disassembled.
+ It is very important to perform functional tests whenever they are indicated.
+ The valve body contains precision parts and requires extreme care when parts are removed and serviced. Place removed parts in a parts rack in order to replace them in correct positions and sequences.
Care will also prevent springs and small parts from becoming scattered or lost.
+ Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
+ Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, and to hold bearings and washers in place during assembly. Do not use grease.

AT-1004

PREPARATION AND PRECAUTIONS
Precautions (Cont’d)
+
+
+

Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
After overhaul, refill the transmission with new ATF.
When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under “Changing A/T Fluid” in the MA section when changing A/T fluid.

AT-1005

PREPARATION AND PRECAUTIONS
Service Notice or Precautions
FAIL-SAFE
The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major
electrical input/output device circuit is damaged.
Under Fail-Safe, the vehicle always runs in third gear even with a shift lever position of “1”, “2” or “D”. Customer may complain of “sluggish or poor acceleration”.
When the Fail-Safe operation occurs the next time the key is turned to the “ON” position, the SPORT indicator lamp will blink for about 8 seconds. (For diagnosis, refer to AT-1029.)
The blinking of the SPORT indicator lamp for about 8 seconds will appear only once and be cleared. The
customer may resume normal driving conditions by chance.
Always follow the “WORK FLOW” (Refer to AT-1040).
The SELF-DIAGNOSIS results will be as follows:
The first SELF-DIAGNOSIS will indicate the damage of the vehicle speed sensor or the revolution
sensor.
During the next SELF-DIAGNOSIS performed after checking the sensor, no damages will be indicated.

AT-1006

OVERALL SYSTEM
A/T Electrical Parts Location

SAT164KA

AT-1007

OVERALL SYSTEM
Circuit Diagram

TAT012M

AT-1008

OVERALL SYSTEM
Wiring Diagram — A/T —

TAT013M

AT-1009

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT014M

AT-1010

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT015M

AT-1011

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT026M

AT-1012

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT016M

AT-1013

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT017M

AT-1014

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT018M

AT-1015

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT019M

AT-1016

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT020M

AT-1017

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT021M

AT-1018

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT022M

AT-1019

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT023M

AT-1020

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT024M

AT-1021

OVERALL SYSTEM
Cross-sectional View

SAT750HA

AT-1022

OVERALL SYSTEM
Hydraulic Control Circuits

SAT208J

AT-1023

OVERALL SYSTEM
Shift Mechanism
The automatic transmission uses compact, dual planetary gear systems to improve power-transmission
efficiency, simplify construction and reduce weight.
It also employs an optimum shift control and superwide gear ratios. They improve starting performance and
acceleration during medium and high-speed operation.
Two one-way clutches are also employed: one is used for the forward clutch and the other for the low clutch.
These one-way clutches, combined with four accumulators, reduce shifting shock to a minimum.

CONSTRUCTION

SAT509I

1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V

9
V
10
V
11
V
12
V
13
V
14
V
15
V
16
V

Torque converter clutch piston
Torque converter
Oil pump
Input shaft
Brake band
Reverse clutch
High clutch
Front pinion gear

Front sun gear
Front internal gear
Front planetary carrier
Rear sun gear
Rear pinion gear
Rear internal gear
Rear planetary carrier
Forward clutch

17
V
18
V
19
V
20
V
21
V
22
V
23
V

Forward one-way clutch
Overrun clutch
Low one-way clutch
Low & reverse brake
Parking pawl
Parking gear
Output shaft

FUNCTION OF CLUTCH AND BRAKE
Control members
6 Reverse clutch
V
7 High clutch
V
16 Forward clutch
V
18 Overrun clutch
V
5 Brake band
V

Abbr.

Function

R/C

9 .
To transmit input power to front sun gear V

H/C

To transmit input power to front planetary carrier V
11 .

F/C

To connect front planetary carrier V
11 with forward one-way clutch V
17 .

O/C

To connect front planetary carrier V
11 with rear internal gear V
14 .

B/B

9 .
To lock front sun gear V

17 Forward one-way clutch
V

F/O.C

When forward clutch is engaged, to stop rear internal gear V
14 from rotating in opposite direction.

19 Low one-way clutch
V

L/O.C

At D1 position, to prevent rear internal gear V
14 from rotating in opposite direction.

20 Low & reverse brake
V

L & R/B

To lock rear internal gear V
14 (2, 12 and 11), to lock front planetary carrier V
11 (R
position).

AT-1024

OVERALL SYSTEM
Shift Mechanism (Cont’d)
CLUTCH AND BAND CHART
Shift position

6
V

7
V

Reverse
clutch

High
clutch

16
V

Band servo

18
V

Forward Overrun
clutch
clutch

2nd
apply

3rd
release

4th
apply

17
V

19
V

Forward
oneway
clutch

Low
oneway
clutch

20
V

Low &
reverse
brake

Lock-up

Remarks

PARK
POSITION

P
R

REVERSE
POSITION

NEUTRAL
POSITION

N
1st

2nd

D*4
3rd

4th

j
*1j
V
*1j
V

1st

2nd

X
V
j
*1j
V

1st

2nd

+
+
+

X
*1 V

^
*3^
*2

^
^

+
Automatic shift
1↔2↔3↔4

+
+
+
+

Automatic shift
1↔2

Locks (held stationary)
in 1st speed
1←2

*1: Operates when overdrive control or A/T mode switch is being set in “OFF” or “SPORT” position.
*2: Oil pressure is applied to both 2nd “apply” side and 3rd “release” side of band servo piston. However, brake band does not contract because oil
pressure area on the “release” side is greater than that on the “apply” side.
*3: Oil pressure is applied to 4th “apply” side in condition *2 above, and brake band contracts.
*4: A/T will not shift to 4th when overdrive control or A/T mode switch is set in “OFF” or “SPORT” position.

j:
V :
j
*:

Operates
Operates when throttle opening is less than 5.5/16, activating engine brake.
Operates during “progressive” acceleration.

: Operates but does not affect power transmission.

:
X
V
j

Operates when throttle opening is less than 5.5/16, but does not affect engine brake.

AT-1025

OVERALL SYSTEM
Control System
OUTLINE
The automatic transmission senses vehicle operating conditions through various sensors. It always controls
the optimum shaft position and reduces shifting and lock-up shocks.
SENSORS

TCM

PNP switch
Accelerator position sensor
Accelerator position switch
(Full accel, off accel position
switch)
Engine speed signal
A/T fluid temperature sensor
Revolution sensor
Vehicle speed sensor
Overdrive control switch
A/T mode switch

Shift control
Line pressure control
Lock-up control
Overrun clutch control
Timing control
Fail-safe control
Self-diagnosis
Duet-EU control
CONSULT-II communication line
control

ACTUATORS

Shift solenoid valve A
Shift solenoid valve B
Overrun clutch solenoid valve
Torque converter clutch
solenoid valve
Line pressure solenoid valve
SPORT indicator lamp

CONTROL SYSTEM

SAT207K

AT-1026

OVERALL SYSTEM
Control System (Cont’d)
TCM FUNCTION
The function of the TCM is to:
+ Receive input signals sent from various switches and sensors.
+ Determine required line pressure, shifting point, lock-up operation, and engine brake operation.
+ Send required output signals to the respective solenoids.

INPUT/OUTPUT SIGNAL OF TCM
Sensors and solenoid valves

Input

Function

PNP switch

Detects select lever position and sends a signal to TCM.

Accelerator position sensor

Detects throttle valve position and sends a signal to TCM.

Accelerator position switch
(Off accel)

Detects throttle valve’s fully-closed position and sends a signal to TCM.

Accelerator position switch
(Full accel)

Detects a throttle valve position of greater than 1/2 of full throttle and sends a
signal to TCM.

Engine speed signal

From ECM.

A/T fluid temperature sensor

Detects transmission fluid temperature and sends a signal to TCM.

Revolution sensor

Detects output shaft rpm and sends a signal to TCM.

Vehicle speed sensor

Used as an auxiliary vehicle speed sensor. Sends a signal when revolution sensor (installed on transmission) malfunctions.

Overdrive control switch
A/T mode switch

Sends a signal, which prohibits a shift to “D4” (overdrive) position, to the TCM.

Shift solenoid valve A/B

Selects shifting point suited to driving conditions in relation to a signal sent from
TCM.

Line pressure solenoid valve

Regulates (or decreases) line pressure suited to driving conditions in relation to
a signal sent from TCM.

Output Torque converter clutch solenoid valve

Regulates (or decreases) lock-up pressure suited to driving conditions in relation
to a signal sent from TCM.

Overrun clutch solenoid valve

Controls an “engine brake” effect suited to driving conditions in relation to a signal sent from TCM.

O/D OFF indicator lamp
SPORT indicator lamp

Shows TCM faults, when A/T control components malfunction.

AT-1027

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Self-diagnosis
After performing this procedure, place check marks for results on
the “DIAGNOSTIC WORKSHEET”, AT-1038. Reference pages
are provided following the items.

SELF-DIAGNOSTIC PROCEDURE (With
CONSULT-II)

SAT014K

1. Turn on CONSULT-II and touch “A/T”.
If A/T is not displayed, check TCM power supply and ground
circuit. Refer to AT-1060. If result is NG, refer to EL section
(“POWER SUPPLY ROUTING”).
2. Touch “SELF-DIAG RESULTS”.
Display shows malfunction experienced since the last erasing operation.
CONSULT-II performs REAL-TIME SELF-DIAGNOSIS.
Also, any malfunction detected while in this mode will be
displayed at real time.

SAT987J

Item
No failure

Display

Description

Remarks

****NO FAILURE****

+ No failure has been detected.

Initial start

*INITIAL START*

+ This is NOT a malfunction message.
Whenever shutting off a power supply to the
TCM, this message appears on the screen.

Vehicle speed sensorzA/T
(Revolution sensor)

VHCL SPEED SENzA/T

+ No signal input from vehicle speed sensorzA/T
(revolution sensor) during traveling due to
disconnection, or input of abnormal signal.

Vehicle speed sensorzMTR
(Meter)

VHCL SPEED SENzMTR

+ No signal input from vehicle speed sensorzMTR
during traveling due to disconnection, or input of
abnormal signal.

[

]

Accelerator position sensor THROTTLE POSI SEN

+ Accelerator position sensor signal voltage is abnormally high.
+ Throttle (accelerator) position sensor signal voltage
is abnormally low with closed throttle position
switch “OFF” or wide open throttle position switch
“ON”.

Shift solenoid valve A

SHIFT SOLENOID/V A

+ Specified voltage is not applied to solenoid valve
due to disconnection or shortcircuit.

Shift solenoid valve B

SHIFT SOLENOID/V B

+ Specified voltage is not applied to solenoid valve
due to disconnection or shortcircuit.

Overrun clutch solenoid
valve

OVERRUN CLUTCH S/V

+ Specified voltage is not applied to solenoid valve
due to disconnection or shortcircuit.

T/C clutch solenoid valve

T/C CLUTCH SOL/V

+ Specified voltage is not applied to solenoid valve
due to disconnection or shortcircuit.

A/T fluid temperature
sensor/TCM power source

BATT/FLUID TEMP SEN

+ Supply voltage to TCM is abnormally low during
traveling.
+ Fluid temperature signal voltage is abnormally high
(fluid temperature is low) during traveling.

Engine speed signal

ENGINE SPEED SIG

+ Engine RPM is abnormally low during traveling.

Line pressure solenoid
valve

LINE PRESSURE S/V

+ Specified voltage is not applied to solenoid valve
due to disconnection or shortcircuit.

TCM (ROM)

CONTROL UNIT (ROM)

+ TCM memory (ROM) is malfunctioning.

TCM (RAM)

CONTROL UNIT (RAM)

+ TCM memory (RAM) is malfunctioning.

TCM (EEP ROM)

CONTROL UNIT (EEP ROM)

+ TCM memory (EEP ROM) is malfunctioning.

AT-1028

To be displayed in case
of abnormality
and no recording is made

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Self-diagnosis (Cont’d)
SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II)
DIAGNOSIS START

1. Start engine and warm it up to normal
engine operating temperature.
2. Turn ignition switch to “OFF” position.
Wait at least 5 seconds.
SAT211JA

1. Set A/T mode switch to “AUTO” position.
2. Set overdrive control switch in “ON”
position.
3. Move selector lever to “P” position.
4. Turn ignition switch to “ON” position.
(Do not start engine.)
5. Does SPORT indicator lamp come on
for about 2 seconds?
SAT879E

Yes
.

1. Turn ignition switch to “ACC” position.
2. Move selector lever to “D” position.

SAT244I

1. Set overdrive control switch in “OFF”
position.
2. Depress accelerator pedal fully and
release it.
3. Turn ignition switch “ON”.
(Do not start engine.)

1. Move selector lever to “2” position.
2. Set overdrive control switch in “ON”
position.

SAT881E

A
V

SAT245I

AT-1029

No
c

Go to 1. SPORT Indicator
Lamp Does Not Come On,
AT-1097.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Self-diagnosis (Cont’d)
A
V

1. Move selector lever to “1” position.
2. Set overdrive control switch in “OFF”
position.

SAT246I

Depress accelerator pedal fully and
release it.

Check SPORT indicator lamp.
Refer to JUDGEMENT OF SELF-DIAGNOSIS CODE, AT-1031.

SAT981F

DIAGNOSIS END

SAT211JA

AT-1030

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Self-diagnosis (Cont’d)
JUDGEMENT OF SELF-DIAGNOSIS CODE
All judgement flickers are same.

SPORT indicator lamps:*1
4th judgement flicker is longer than others.

SAT819H

SAT797H

All circuits that can be confirmed by self-diagnosis are OK.

Shift solenoid valve A circuit is short-circuited or disconnected.
Go to SHIFT SOLENOID VALVE A, AT-1070.

1st judgement flicker is longer than others.

5th judgement flicker is longer than others.

SAT798H

SAT794H

Revolution sensor circuit is short-circuited or disconnected.
Go to VEHICLE SPEED SENSORzA/T (REVOLUTION
SENSOR), AT-1064.

Shift solenoid valve B circuit is short-circuited or disconnected.
Go to SHIFT SOLENOID VALVE B, AT-1072.

2nd judgement flicker is longer than others.

6th judgement flicker is longer than others.

SAT795H

SAT799H

Vehicle speed sensor circuit is short-circuited or disconnected.
Go to VEHICLE SPEED SENSORzMTR, AT-1066.

Overrun clutch solenoid valve circuit is short-circuited or disconnected.
Go to OVERRUN CLUTCH SOLENOID VALVE, AT-1074.

3rd judgement flicker is longer than others.

7th judgement flicker is longer than others.

SAT800H

SAT796H

Throttle (accelerator) position sensor circuit is short-circuited
or disconnected.
Go to ACCELERATOR POSITION SENSOR, AT-1068.

Torque converter clutch solenoid valve circuit is short-circuited or disconnected.
Go to TORQUE CONVERTER CLUTCH SOLENOID
VALVE, AT-1076.

t1 = 2.5 seconds
t2 = 2.0 seconds
t3 = 1.0 second
*1: Refer to applicable indicator lamps for specified areas on next page.

AT-1031

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Self-diagnosis (Cont’d)
SPORT indicator lamps:
8th judgement flicker is longer than others.

Flickers as shown below.

SAT801H

SAT804H

A/T fluid temperature sensor is disconnected or TCM power
source circuit is damaged.
Go to A/T FLUID TEMPERATURE SENSOR AND TCM
POWER SOURCE, AT-1079.

Battery power is low.
Battery has been disconnected for a long time.
Battery is connected conversely.
(When reconnecting TCM connectors. — This is not a problem.)

9th judgement flicker is longer than others.

Does not come on.

SAT805H
SAT802H

PNP, overdrive control, A/T mode or accelerator position
Engine speed signal circuit is short-circuited or disconnected. switches circuit is disconnected or TCM is damaged.
Go to PNP, OVERDRIVE CONTROL, A/T MODE AND
Go to ENGINE SPEED SIGNAL, AT-1082.
ACCELERATOR POSITION SWITCHES, AT-1091.
10th judgement flicker is longer than others.

SAT803H

Line pressure solenoid valve circuit is short-circuited or disconnected.
Go to LINE PRESSURE SOLENOID VALVE, AT-1084.
t4 = 1.0 second

AT-1032

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Self-diagnosis (Cont’d)
HOW TO ERASE SELF-DIAGNOSTIC RESULTS
(With CONSULT-II)
1. If the ignition switch stays “ON” after repair work, be sure to
turn ignition switch “OFF” once. Wait for at least 5 seconds
and then turn it “ON” again.
2. Turn CONSULT-II “ON”, and touch “A/T”.

SAT014K

3. Touch “SELF-DIAG RESULTS”.

SAT971J

4. Touch “ERASE”. (The self-diagnostic results will be erased.)

SAT970J

HOW TO ERASE SELF-DIAGNOSTIC RESULTS
(Without CONSULT-II)
1. If the ignition switch stays “ON” after repair work, be sure to
turn ignition switch “OFF” once. Wait for at least 5 seconds
and then turn it “ON” again.
2. Perform “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)”. Refer to AT-1029.
3. Turn ignition switch “OFF”. (The self-diagnostic results will be
erased.)

AT-1033

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Diagnosis by CONSULT-II
NOTICE
1.The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each
solenoid).
Check for time difference between actual shift timing and the CONSULT-II display. If the difference is
noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical
parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service
Manual may differ slightly. This occurs because of the following reasons:
+ Actual shift schedule has more or less tolerance or allowance,
+ Shift schedule indicated in Service Manual refers to the point where shifts start. Gear position displayed on CONSULT-II indicates the point where shifts are completed.
3. Shift solenoid valve “A” or “B” is displayed on CONSULT-II at the start of shifting. Gear position is displayed upon completion of shifting (which is computed by TCM).
4. Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II
unit.

SELF-DIAGNOSTIC RESULT TEST MODE
Refer to AT-1028.

DATA MONITOR DIAGNOSTIC TEST MODE
Monitor item
Item

Display

Vehicle speed sensor 1 (A/T)
(Revolution sensor)

VHCL/S SEzA/T
[km/h] or [mph]

Vehicle speed sensor 2
(Meter)

VHCL/S SEzMTR
[km/h] or [mph]

+ Vehicle speed computed from
signal of vehicle speed sensor
is displayed.

Vehicle speed display may not be
accurate under approx. 10 km/h
(6 MPH). It may not indicate 0
km/h (0 MPH) when vehicle is
stationary.

—

+ A/T fluid temperature sensor
signal voltage is displayed.
+ Signal voltage lowers as fluid
temperature rises.

—

+ Source voltage of TCM is displayed.

OVERDRIVE SW
[ON/OFF]

—

+ ON/OFF state computed from
signal of overdrive control SW
is displayed.

PN POSI SW
[ON/OFF]

—

+ ON/OFF state computed from
signal of PN position SW is displayed.

R POSITION SW
[ON/OFF]

—

+ ON/OFF state computed from
signal of R position SW is displayed.

D POSITION SW
[ON/OFF]

—

+ ON/OFF state computed from
signal of D position SW is displayed.

2 POSITION SW
[ON/OFF]

—

+ ON/OFF status, computed from
signal of 2 position SW, is displayed.

BATTERY VOLT
[V]

Engine speed

ENGINE SPEED
[rpm]

2 position switch

When racing engine in “N” or “P”
position with vehicle stationary,
CONSULT data may not indicate
0 km/h (0 MPH).

+ Accelerator position sensor signal voltage is displayed.

Battery voltage

Remarks

+ Vehicle speed computed from
signal of revolution sensor is
displayed.

—

FLUID TEMP SE
[V]

D position switch

—

A/T fluid temperature sensor

R position switch

Description

—

THRTL POS SEN
[V]

P/N position switch

Main
signals

Accelerator position sensor

Overdrive control switch

TCM
input
signals

+ Engine speed, computed from
engine speed signal, is displayed.

AT-1034

Engine speed display may not be
accurate under approx. 800 rpm.
It may not indicate 0 rpm even
when engine is not running.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Diagnosis by CONSULT-II (Cont’d)
Monitor item
TCM
input
signals

Main
signals

—

+ ON/OFF status, computed from
signal of 1 position SW, is displayed.

—

+ Status of ASCD cruise signal is
displayed.
ON … Cruising state
OFF … Normal running state

+ This is displayed even when no
ASCD is mounted.

—

+ Status of ASCDzOD release
signal is displayed.
ON … OD released
OFF … OD not released

+ This is displayed even when no
ASCD is mounted.

KICKDOWN SW
[ON/OFF]

—

+ ON/OFF status, computed from
signal of kickdown SW, is displayed.

+ This is displayed even when no
kickdown switch is equipped.

POWER SHIFT SW
[ON/OFF]

—

+ ON/OFF state computed from
signal of POWER shift SW is
displayed.

—

+ ON/OFF status, computed from
signal of closed throttle (accelerator) position SW, is displayed.

—

+ ON/OFF status, computed from
signal of wide open throttle
(accelerator) position SW, is
displayed.

—

+ ON/OFF status, computed from
signal of HOLD shift SW, is
displayed.

—

+ Gear position data used for
computation by TCM, is displayed.

—

+ Selector lever position data,
used for computation by TCM,
is displayed.

VEHICLE SPEED
[km/h] or [mph]

—

+ Vehicle speed data, used for
computation by TCM, is displayed.

THROTTLE POSI
[/8]

—

+ Throttle (accelerator) position
data, used for computation by
TCM, is displayed.

—

+ Control value of line pressure
solenoid valve, computed by
TCM from each input signal, is
displayed.

—

+ Control value of torque converter clutch solenoid valve,
computed by TCM from each
input signal, is displayed.

—

+ Control value of shift solenoid
valve A, computed by TCM
from each input signal, is displayed.

—

+ Control value of shift solenoid
valve B, computed by TCM
from each input signal, is displayed.

—

+ Control value of overrun clutch
solenoid valve computed by
TCM from each input signal is
displayed.

—

+ Control status of SPORT indicator lamp is displayed.

Item

1 position switch

ASCD-cruise signal

ASCD-OD cut signal

Kickdown switch

A/T mode switch

Closed throttle position switch

Wide open throttle position switch

A/T mode switch

Gear position

Selector lever position

Vehicle speed

Accelerator position

Line pressure duty

Display

1 POSITION SW
[ON/OFF]
ASCD-CRUISE
[ON/OFF]

ASCD-OD CUT
[ON/OFF]

CLOSED THL/SW
[ON/OFF]

W/O THRL/P-SW
[ON/OFF]

HOLD SW
[ON/OFF]
GEAR

SLCT LVR POSI

LINE PRES DTY
[%]

Torque converter clutch solenoid
valve duty

TCC S/V DUTY
[%]

Shift solenoid valve A

SHIFT S/V A
[ON/OFF]

Shift solenoid valve B

Overrun clutch solenoid valve

Self-diagnosis display lamp
(SPORT indicator lamp)

SHIFT S/V B
[ON/OFF]

OVERRUN/C S/V
[ON/OFF]

SELF-D DP LMP
[ON/OFF]

Description

X: Applicable
—: Not applicable

AT-1035

Remarks

+ A specific value used for control is displayed if fail-safe is
activated due to error.

Control value of solenoid is displayed even if solenoid circuit is
disconnected.
The “OFF” signal is displayed if
solenoid circuit is shorted.

TROUBLE DIAGNOSIS — Introduction
Introduction

SAT631IA

SAT632I

The TCM receives a signal from the vehicle-speed sensor, accelerator position sensor or PNP switch and provides shift control
or lock-up control via solenoid valves.
Input and output signals must always be correct and stable in the
operation of the A/T system. The A/T system must be in good
operating condition and be free of valve seizure, solenoid valve
malfunction, etc.
It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A
road test with CONSULT-II or a circuit tester connected should
be performed. Follow the “Work Flow”. Refer to AT-1040.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The
customer can supply good information about such problems,
especially intermittent ones. Find out what symptoms are present
and under what conditions they occur. A “Diagnostic Worksheet”
like the example (AT-1038) should be used.
Start your diagnosis by looking for “conventional” problems first.
This will help troubleshoot driveability problems on an electronically controlled engine vehicle.

SEF234G

AT-1036

TROUBLE DIAGNOSIS — Introduction
Diagnostic Worksheet
INFORMATION FROM CUSTOMER
KEY POINTS
WHAT ………………….
WHEN …………………
WHERE ………………
HOW …………………..
Customer name

MR/MS

Vehicle & A/T model
Date, Frequencies
Road conditions
Operating conditions, Symptoms

Model & Year

VIN

Trans. model

Engine

Mileage

Incident Date

Manuf. Date

In Service Date

Frequency

N Continuous

Symptoms

N Vehicle does not move.
N No up-shift

N Intermittent

times a day)

(N Any position

(N 1st → 2nd

N No down-shift

(

N 2nd → 3rd

(N O/D → 3rd

N Particular position)
N 3rd → O/D)

N 3rd → 2nd

N 2nd → 1st)

N Lockup malfunction
N Shift point too high or too low.
N Shift shock or slip

(N N → D

N Lockup

N Any drive position)

N Noise or vibration
N No kickdown
N No pattern select
N Others
(
SPORT indicator lamp

Malfunction indicator (MI)

)

Blinks for about 8 seconds.
N Continuously lit

N Not lit

N Continuously lit

N Not lit

AT-1037

TROUBLE DIAGNOSIS — Introduction
Diagnostic Worksheet (Cont’d)
DIAGNOSTIC WORKSHEET
1.
2.

N Read the Fail-safe and listen to customer complaints.
N A/T FLUID CHECK
N Leakage (Follow specified procedure)
N Fluid condition
N Fluid level
N Perform STALL TEST and LINE PRESSURE TEST.
N Stall test — Mark possible damaged components/others.
N Torque converter one-way clutch
N Low & reverse brake
N Reverse clutch
N Low one-way clutch
N Forward clutch
N Engine
N Overrun clutch
N Line pressure is low
N Forward one-way clutch
N Clutches and brakes except high
clutch and brake band are OK
N Line pressure test — Suspected parts:
N Perform all ROAD TEST and mark required procedures.
4-1. Check before engine is started.
N SELF-DIAGNOSTIC PROCEDURE — Mark detected items.
N Vehicle speed sensorzA/T (Revolution sensor), AT-1064.
N Vehicle speed sensorzMTR, AT-1066.
N Accelerator position sensor, AT-1068.
N Shift solenoid valve A, AT-1070.
N Shift solenoid valve B, AT-1072.
N Overrun clutch solenoid valve, AT-1074.
N Torque converter clutch solenoid valve, AT-1076.
N A/T fluid temperature sensor and TCM power source, AT-1079.
N Engine speed signal, AT-1082.
N Line pressure solenoid valve, AT-1084.
N PNP, overdrive control, A/T mode and accelerator position switches,
AT-1091.
N Battery
N Others
4-2. Check at idle
N 1. SPORT Indicator Lamp Does Not Come On, AT-1097.
N 2. SPORT Indicator Lamp Does Not Come On, AT-1098.
N 3. O/D OFF Indicator Lamp Does Not Come On, AT-1098.
N 4. SPORT Indicator Lamp Does Not Come On AT-1099.
N 5. Engine Cannot Be Started In “P” And “N” Position, AT-1100.
N 6. In “P” Position, Vehicle Moves Forward Or Backward When Pushed,
AT-1100.
N 7. In “N” Position, Vehicle Moves, AT-1101.
N 8. Large Shock. “N” → “R” Position, AT-1102.
N 9. Vehicle Does Not Creep Backward In “R” Position, AT-1103.
N 10. Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position, AT-1104.
4-3. Cruise test
Part-1
N 11. Vehicle Cannot Be Started From D1, AT-1105.
N 12. A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2, AT-1106.
N 13. A/T Does Not Shift: D2 → D3, AT-1107.
N 14. A/T Does Not Shift: D3 → D4, AT-1108.
N 15. A/T Does Not Perform Lock-up, AT-1109.
N 16. A/T Does Not Hold Lock-up Condition, AT-1110.
N 17. Lock-up Is Not Released, AT-1110.
N 18. Engine Speed Does Not Return To Idle (Light Braking D4 → D3), AT-1111.

AT-1038

AT-1006
AT-1041

AT-1041,
AT-1044

AT-1046
AT-1047

AT-1049

AT-1050,
AT-1053

TROUBLE DIAGNOSIS — Introduction
Diagnostic Worksheet (Cont’d)
4.

6.
7.

N
N

Part-2
N 19. Vehicle Does Not Start From D1, AT-1112.
N 12. A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2, AT-1106.
N 13. A/T Does Not Shift: D2 → D3, AT-1107.
N 14. A/T Does Not Shift: D3 → D4, AT-1108.
Part-3
N 20. A/T Does Not Shift: D2 → D1 When Depressing Accelerator Pedal,
AT-1113
N 21. A/T Does Not Shift: D4 → D3 When Overdrive Control Switch “ON” →
“OFF”, AT-1114
N 18. Engine Speed Does Not Return To Idle (Engine Brake In D3), AT-1111.
N 22. A/T Does Not Shift: D3 → 22, When Selector Lever “D” → “2” Position,
AT-1114.
N 18. Engine Speed Does Not Return To Idle (Engine Brake In 22), AT-1111.
N 23. A/T Does Not Shift: 22 → 11, When Selector Lever “2” → “1” Position,
AT-1115.
N 24. Vehicle Does Not Decelerate By Engine Brake, AT-1115.
N SELF-DIAGNOSTIC PROCEDURE — Mark detected items.
N Vehicle speed sensorzA/T (Revolution sensor), AT-1064.
N Vehicle speed sensorzMTR, AT-1066.
N Accelerator position sensor, AT-1068.
N Shift solenoid valve A, AT-1070.
N Shift solenoid valve B, AT-1072.
N Overrun clutch solenoid valve, AT-1074.
N Torque converter clutch solenoid valve, AT-1076.
N A/T fluid temperature sensor and TCM power source, AT-1079.
N Engine speed signal, AT-1082.
N Line pressure solenoid valve, AT-1084.
N PNP, overdrive control, A/T mode and accelerator position switches,
AT-1091.
N Battery
N Others
For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.
Perform all ROAD TEST and re-mark required procedures.
Perform the Diagnostic Procedures for all remaining items marked NG. Repair or
replace the damaged parts.
Refer to the Symptom Chart when you perform the procedures. (The chart also
shows some other possible symptoms and the component inspection orders.)
Erase self-diagnosis code from TCM memories.

AT-1039

AT-1055

AT-1056

AT-1028
AT-1046
AT-1060
AT-1057
AT-1033

TROUBLE DIAGNOSIS — Introduction
Work Flow
HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is important to fully understand the symptoms
or conditions for a customer complaint.
Make good use of the two sheets provided, “INFORMATION FROM CUSTOMER” and “DIAGNOSTIC
WORKSHEET”, to perform the best troubleshooting possible.
CHECK IN
.

LISTEN TO CUSTOMER COMPLAINTS AND FILL OUT
“INFORMATION FROM CUSTOMER”, AT-1037.
Check for any Service Bulletins.

Refer to FAIL-SAFE Service Notice or Precautions, AT-1006.

CHECK A/T FLUID LEVEL AND CONDITION. IF NG, PLACE
CHECK ON THE DIAGNOSTIC WORKSHEET, AT-1038.

Refer to A/T Fluid Check, AT-1041.

PERFORM STALL TEST AND LINE PRESSURE TEST.

Refer to Stall Test and Line Pressure Test, AT-1041, 1044.

PERFORM ROAD TEST WITH SELF-DIAGNOSIS AND
PLACE CHECKS FOR NG ITEMS ON THE DIAGNOSTIC
WORKSHEET.

Follow ROAD TEST procedure, AT-1046.

NG items including
self-diagnostic item
.

+ FOR SELF-DIAGNOSIS NG ITEMS:
−INSPECT EACH COMPONENT.
−REPAIR/REPLACE.
+ PERFORM ROAD TEST AND PLACE CHECKS FOR NG
ITEMS ON THE DIAGNOSTIC WORKSHEET AGAIN.

+ Refer to self-diagnosis, AT-1028.
+ Perform ROAD TEST for all items.

+ FOR ALL REMAINING MALFUNCTIONS:
−INSPECT EACH COMPONENT.
−REPAIR/REPLACE.
+ PERFORM ROAD TEST AND CONFIRM ALL MALFUNCTIONS ARE ELIMINATED.

Refer to
+ ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION,
AT-1028 — AT-1034.
+ TROUBLE DIAGNOSIS FOR SELF-DIAGNOSIS CODE,
AT-1064 — AT-1091.
+ DIAGNOSTIC PROCEDURES FOR SYMPTOMS, AT-1097
— AT-1115.
+ Symptom Chart, AT-1057.

ERASE SELF-DIAGNOSIS CODE FROM TCM MEMORIES.

Refer to HOW TO ERASE SELF-DIAGNOSIS RESULTS,
AT-1033.

Refer to SELF-DIAGNOSIS CONFIRMATION PROCEDURE,
AT-1064 — AT-1089.

PERFORM FINAL CHECK
.

CHECK OUT

AT-1040

TROUBLE DIAGNOSIS — Basic Inspection
A/T Fluid Check
FLUID LEAKAGE CHECK
1. Clean area suspected of leaking. — for example, mating
surface of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in “D”
position and wait a few minutes.
3. Stop engine.
4. Check for fresh leakage.
SAT801A

FLUID CONDITION CHECK
Fluid color
Dark or black with burned odor
Milky pink
Varnished fluid, light to dark brown
and tacky

Suspected problem
Wear of frictional material
Water contamination — Road water
entering through filler tube or breather
Oxidation — Over or under filling, —
Overheating

FLUID LEVEL CHECK
SAT638A

Refer to MA section (“Checking A/T Fluid”, “CHASSIS AND
BODY MAINTENANCE”).

Stall Test
STALL TEST PROCEDURE
1. Check A/T and engine fluid levels. If necessary, add.
2. Drive vehicle for approx. 10 minutes or until engine oil and
ATF reach operating temperature.
ATF operating temperature:
50 — 80°C (122 — 176°F)

SAT647B

3. Set parking brake and block wheels.
4. Install a tachometer where it can be seen by driver during
test.
+ It is good practice to put a mark on point of specified
engine rpm on indicator.

SAT513G

5. Start engine, apply foot brake, and place selector lever in “D”
position.
6. Accelerate to wide open throttle gradually while applying foot
brake.
7. Quickly note the engine stall revolution and immediately
release throttle.
+ During test, never hold throttle wide open for more than
5 seconds.
Stall revolution:
2,480 — 2,680 rpm
SAT514G

AT-1041

TROUBLE DIAGNOSIS — Basic Inspection
Stall Test (Cont’d)
8. Move selector lever to “N” position.
9. Cool off ATF.
+ Run engine at idle for at least one minute.
10. Repeat steps 5 through 9 with selector lever in “2”, “1” and
“R” positions.

SAT771B

JUDGEMENT OF STALL TEST
The test result and possible damaged components relating to each result are shown in the illustration.
In order to pinpoint the possible damaged components, follow the WORK FLOW shown in AT-1040.

Note
Stall revolution is too high in “D” or “2” position:
+Slippage occurs in 1st gear but not in 2nd and 3rd gears. ….. Low one-way clutch slippage
+ Slippage occurs at the following gears:
1st through 3rd gears in “D” position and engine brake functions.
1st and 2nd gears in “2” position and engine brake functions with accelerator pedal released (fully closed
throttle). ….. Forward clutch or forward one-way clutch slippage
Stall revolution is too high in “R” position:
+Engine brake does not function in “1” position. ….. Low & reverse brake slippage
+ Engine brake functions in “1” position. ….. Reverse clutch slippage
Stall revolution within specifications:
+Vehicle does not achieve speed of more than 80 km/h (50 MPH). ….. One-way clutch seizure in torque
converter housing
CAUTION:
Be careful since automatic fluid temperature increases abnormally.
+Slippage occurs in 3rd and 4th gears in “D” position. ….. High clutch slippage
+ Slippage occurs in 2nd and 4th gear in “D” position. ….. Brake band slippage
Stall revolution less than specifications:
+Poor acceleration during starts. ….. One-way clutch seizure in torque converter

AT-1042

TROUBLE DIAGNOSIS — Basic Inspection
Stall Test (Cont’d)
JUDGEMENT OF STALL TEST

SAT392H

AT-1043

TROUBLE DIAGNOSIS — Basic Inspection
Line Pressure Test
LINE PRESSURE TEST PORTS
+ Location of line pressure test ports.
+ Always replace line pressure plugs as they are self-sealing bolts.

SAT889HC

LINE PRESSURE TEST PROCEDURE
1. Check A/T and engine fluid levels. If necessary, add fluid.
2. Drive vehicle for approx. 10 minutes or until engine oil and
ATF reach operating temperature.
ATF operating temperature:
50 — 80°C (122 — 176°F)

SAT647B

3. Install pressure gauge to corresponding line pressure port.

SAT890HC

SAT519GA

AT-1044

TROUBLE DIAGNOSIS — Basic Inspection
Line Pressure Test (Cont’d)
4. Set parking brake and block wheels.
+ Continue to depress brake pedal fully while line pressure
test is being performed at stall speed.

SAT513G

5. Start engine and measure line pressure at idle and stall
speed.
+ When measuring line pressure at stall speed, follow the
stall test procedure.
Line pressure:
Refer to SDS, AT-1207.

SAT493G

JUDGEMENT OF LINE PRESSURE TEST
Judgement
+
+
+
+
+
+

Line pressure is low in particular position.

+ Fluid pressure leakage between manual valve and particular clutch
+ For example, line pressure is:
— Low in “R” and “1” positions, but
— Normal in “D” and “2” positions.
Then, fluid leakage exists at or around low and reverse brake circuit.
Refer to “CLUTCH AND BAND CHART”, AT-1025.

Line pressure is high.

+
+
+
+
+
+
+

Mal-adjustment of throttle position sensor
A/T fluid temperature sensor damaged
Line pressure solenoid valve sticking
Short circuit of line pressure solenoid valve circuit
Pressure modifier valve sticking
Pressure regulator valve or plug sticking
Open in dropping resistor circuit

Line pressure is low.

+
+
+
+
+
+

Mal-adjustment of throttle position sensor
Line pressure solenoid valve sticking
Short circuit of line pressure solenoid valve circuit
Pressure regulator valve or plug sticking
Pressure modifier valve sticking
Pilot valve sticking

At idle

At stall speed

Suspected parts

Line pressure is low in all
positions.

Oil pump wear
Control piston damage
Pressure regulator valve or plug sticking
Spring for pressure regulator valve damaged
A/T fluid pressure leakage between oil strainer and pressure regulator valve
Clogged strainer

AT-1045

TROUBLE DIAGNOSIS — Basic Inspection
Road Test
DESCRIPTION
+ The purpose of the test is to determine overall performance
of A/T and analyze causes of problems.
+ The road test consists of the following three parts:
1. Check before engine is started
2. Check at idle
3. Cruise test
SAT786A

+ Before road test, familiarize yourself with all test procedures
and items to check.
+ Conduct tests on all items until specified symptom is found.
Troubleshoot items which check out No Good after road test.
Refer to “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”
and
“DIAGNOSTIC
PROCEDURES
FOR
SYMPTOMS”, AT-1028 — AT-1034 and AT-1097 — AT-1115.

SAT496G

AT-1046

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
1. CHECK BEFORE ENGINE IS STARTED
1. Park vehicle on flat surface.
2. Turn ignition switch to “OFF” position.

SAT211JA

1. Set A/T mode switch to “AUTO” position.
2. Move selector lever to “P” position.
3. Turn ignition switch to “ON” position.
(Do not start engine.)
4. Does SPORT indicator lamp come on
for about 2 seconds?

No
c

Go to 1. SPORT Indicator
Lamp Does Not Come On,
AT-1097.

Yes
.

Does SPORT indicator lamp flicker for
about 8 seconds?

Yes
c

Perform self-diagnosis.
Refer to SELF-DIAGNOSIS PROCEDURE,
AT-1028.

SAT853E
.

1. Set A/T mode switch to “SPORT” position.
2. Does SPORT indicator lamp come on?

No
c

Go to 2. SPORT Indicator
Lamp Does Not Come On,
AT-1098.

Yes
.

Set overdrive control switch to “OFF”
position.

SAT211JA
.

Does O/D OFF indicator lamp come on?
Yes
.

A
V

(Go to next page)

SAT857E

SAT210J

AT-1047

No
c

Go to 3. O/D OFF Indicator Lamp Does Not Come
On, AT-1098.

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
A
V

Depress brake pedal and move selector
lever to “D” position.

SAT869E

1. Set A/T mode switch to “AUTO” position.
2. Depress and release accelerator pedal
quickly.

Does SPORT indicator lamp come on for
about 3 seconds after accelerator pedal is
depressed?
Yes

SAT754A
.

Turn ignition switch to “OFF” position.

Perform self-diagnosis and note NG
items:
Refer to SELF-DIAGNOSIS
PROCEDURE, AT-1028.

.
SAT211JA

Go to “2. Check at idle”, AT-1049.

AT-1048

No
c

Go to 4. SPORT Indicator
Lamp Does Not Come On,
AT-1099.

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
2. CHECK AT IDLE
1. Park vehicle on flat surface.
2. Turn ignition switch to “OFF” position.
3. Move selector lever to “P” or “N” position.
4. Turn ignition switch to start position.
5. Is engine started?

No
c

Go to “5. Engine Cannot
Be Started In “P” and “N”
Position”, AT-1100.

Yes
.

SAT796A

1. Turn ignition switch to “OFF” position.
2. Move selector lever to “D”, “1”, “2” or
“R” position.
3. Turn ignition switch to start position.
4. Is engine started?

Yes
c

Go to “5. Engine Cannot
Be Started In “P” and “N”
Position”, AT-1100.

SAT797A

1.
2.
3.
4.
5.

Turn ignition switch to “OFF” position.
Move selector lever to “P” position.
Release parking brake.
Push vehicle forward or backward.
Does vehicle move when it is pushed
forward or backward?

Yes
c

Go to “6. In “P” Position,
Vehicle Moves Forward Or
Backward When Pushed”,
AT-1100.

No
.

1. Apply parking brake.
2. Move selector lever to “N” position.
3. Turn ignition switch to “START” position and start engine.
4. Release parking brake.
5. Does vehicle move forward or backward?

Yes
c

Go to “7. In “N” Position,
Vehicle Moves”, AT-1101.

Go to “8. Large Shock. “N”
→ “R” Position”, AT-1102.

No
.

1. Apply foot brake.
2. Move selector lever to “R” position.
3. Is there large shock when changing
from “N” to “R” position?

Yes

No
.

1. Release foot brake for several seconds.
2. Does vehicle creep backward when
foot brake is released?

No
c

Go to “9. Vehicle Does
Not Creep Backward In
“R” Position”, AT-1103.

Yes
.

1. Move selector lever to “D”, “1” and “2”
position and check if vehicle creeps
forward.
2. Does vehicle creep forward in all three
positions?
Yes
.

Go to “3. Cruise test”, AT-1050.

AT-1049

No
c

Go to “10. Vehicle Does
Not Creep Forward In “D”,
“2” Or “1” Position”,
AT-1104.

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
3. CRUISE TEST
+ Check all items listed in Parts 1 through 3.

With CONSULT-II
+ Using CONSULT-II, conduct a cruise test and record the
result.
+ Print the result and ensure that shifts and lock-ups take place
as per Shift Schedule.

SAT601J

CONSULT-II Setting Procedure
1. Turn ignition switch OFF.
2. Connect CONSULT-II to data link connector, which is located
in instrument lower panel on driver side.

SAT165K

3. Turn ignition switch ON.
4. Touch “START”.

SAT586J

5. Touch “A/T”.

SAT014K

6. Touch “DATA MONITOR”.

SAT971J

AT-1050

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
7. Touch “MAIN SIGNALS” or “TCM INPUT SIGNALS”.
8. See “Numerical Display”, “Barchart Display” or “Line Graph
Display”.

SAT175K

9. Touch “SETTING” to set recording condition (“AUTO TRIG”
or “MANU TRIG”) and touch “BACK”.
10. Touch “Start”.

SAT973J

11. When performing cruise test, touch “Store Data”.

SAT985J

12. After finishing cruise test part 1, touch “STOP”.

SAT986J

13. Touch “STORE” and touch “BACK”.

SAT987J

AT-1051

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
14. Touch “DISPLAY”.
15. Touch “PRINT”.
16. Check the monitor data printed out.
17. Continue cruise test part 2 and 3.

SAT974J

SAT975J

Without CONSULT-II
+ Throttle position can be checked by voltage across terminals
41 and V
42 of TCM.
V

SAT215J

AT-1052

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
CRUISE TEST — Part 1
Drive vehicle for approx. 10 minutes to
warm engine oil and ATF up to operating
temperature.
ATF operating temperature:
50 — 80°C (122 — 176°F)

.
SAT774B

1. Park vehicle on flat surface.
2. Set overdrive control switch to “ON”
position.
3. Move selector lever to “P” position.
4. Start engine.

Move selector lever to “D” position.

SAT775B

Accelerate vehicle by constantly depressing accelerator pedal halfway.

Does vehicle start from D1?
Read gear position.

No
c

Go to “11. Vehicle Cannot
Be Started From D1”,
AT-1105.

Yes
.
SAT495G

Does A/T shift from D1 to D2 at the specified speed?
Read gear position,
throttle opening and
vehicle speed.
Specified speed when shifting from
D1 to D2:
Refer to Shift schedule, AT-1206.

No
c

Go to “12. A/T Does Not
Shift: D1 → D2 Or Does
Not Kickdown: D4 → D2”,
AT-1106.

Yes
.
SAT401H

Does A/T shift from D2 to D3 at the specified speed?
Read gear position,
throttle position and
vehicle speed.
Specified speed when shifting from
D2 to D3:
Refer to Shift schedule, AT-1206.
Yes
.

A
V

(Go to next page.)

AT-1053

No
c

Go to “13. A/T Does Not
Shift: D2 → D3”, AT-1107.

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
A
V

SAT402H

Does A/T shift from D3 to D4 at the specified speed?
Read gear position,
throttle position and
vehicle speed.
Specified speed when shifting from
D3 to D4:
Refer to Shift schedule, AT-1206.

No
c

Go to “14. A/T Does Not
Shift: D3 → D4”, AT-1108.

Yes
.

Does A/T perform lock-up at the specified
speed?
Read vehicle speed, throttle position when lock-up
duty becomes 94%.
Specified speed when lock-up
occurs:
Refer to Shift schedule, AT-1206.
SAT403H

No
c

Go to “15. A/T Does Not
Perform Lock-up”,
AT-1109.

Yes
.

Does A/T hold lock-up condition for more
than 30 seconds?

No
c

Yes
.

1. Release accelerator pedal.
2. Is lock-up released when accelerator
pedal is released?

No
c

Go to “16. A/T Does Not
Hold Lock-up Condition”,
AT-1110.

Go to “17. Lock-up Is Not
Released”, AT-1110.

Yes
.

1. Decelerate vehicle by applying foot
brake lightly.
2. Does engine speed return to idle
smoothly when A/T is shifted from D4
to D3?
Read gear position and
engine speed.
Yes
.

1. Stop vehicle.
2. Go to “Cruise test — Part 2”, AT-1055.

AT-1054

No
c

Go to “18. Engine Speed
Does Not Return To Idle
(Light Braking D4 → D3)”,
AT-1111.

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
CRUISE TEST — Part 2
1. Confirm overdrive control switch is in
“ON” position.
2. Confirm selector lever is in “D” position.
3. Accelerate vehicle by half throttle
again.
4. Does vehicle start from D1?
Read gear position.
SAT495G

No
c

Go to “19. Vehicle Does
Not Start From D1”,
AT-1112.

Yes
.

1. Accelerate vehicle to 80 km/h (50
MPH) as shown in illustration.
2. Release accelerator pedal and then
quickly depress it fully.
3. Does A/T shift from D4 to D2 as soon
as accelerator pedal is depressed
fully?
Read gear position and
throttle position.

No
c

Go to “12. A/T Does Not
Shift: D1 → D2 Or Does
Not Kickdown: D4 → D2”,
AT-1106.

SAT404H

Yes
.

Does A/T shift from D2 to D3 at the specified speed?
Read gear position,
throttle position and
vehicle speed.
Specified speed when shifting from
D2 to D3:
Refer to Shift schedule, AT-1206.
SAT405H

No
c

Go to “13. A/T Does Not
Shift: D2 → D3”, AT-1107.

Go to “14. A/T Does Not
Shift: D3 → D4”, AT-1108.

Yes
.

1. Release accelerator pedal after shifting
from D2 to D3.
2. Does A/T shift from D3 to D4 and does
vehicle decelerate by engine brake?
Read gear position,
throttle position and
vehicle speed.

Yes
SAT124I

1. Decelerate to 10 km/h (6 MPH) with
accelerator pedal released and then
quickly depress it fully.
2. Does A/T shift from D2 to D1 as soon
as accelerator pedal is depressed
fully?
Yes
.

1. Stop vehicle.
2. Go to “Cruise test — Part 3”, AT-1056.

AT-1055

No
c

Go to “20. A/T Does Not
Shift: D2 → D1 When
Depressing Accelerator
Pedal”, AT-1113.

TROUBLE DIAGNOSIS — Basic Inspection
Road Test (Cont’d)
CRUISE TEST — Part 3
1. Confirm overdrive control switch is in
“ON” position.
2. Confirm selector lever is in “D” position.

Accelerate vehicle using half-throttle to D4.
.
SAT812A

Release accelerator pedal.

Set overdrive control switch to “OFF” position while driving in D4.
.

Does A/T shift from D4 to D3 (O/D OFF)?
Read gear position and
vehicle speed.

No
c

Yes
.
SAT813A

Does vehicle decelerate by engine brake?

No
c

Yes

Go to “21. A/T Does Not
Shift: D4 → D3, When
Overdrive Control Switch
“ON” → “OFF””, AT-1114.

Go to “18. Engine Speed
Does Not Return To Idle
(Light Braking D4 → D3)”,
AT-1111.

Move selector lever from “D” to “2” position while driving in D3 (O/D OFF).
.

Does A/T shift from D3 (O/D OFF) to 22?
Read gear position.
SAT776BA

No
c

Yes
.

Does vehicle decelerate by engine brake?

No
c

Yes

1. Move selector lever from “2” to “1” position while driving in 22.
2. Does A/T shift from 22 to 11 position?
Read gear position.

SAT791GA

No
c

Go to “22. A/T Does Not
Shift: D3 → 22, When
Selector Lever “D” → “2”
Position”, AT-1114.

Go to “18. Engine Speed
Does Not Return To Idle
(Light Braking D4 → D3)”,
AT-1111.

Go to “23. A/T Does Not
Shift: 22 → 11, When
Selector Lever “2” → “1”
Position”, AT-1115.

Yes
.

Does vehicle decelerate by engine brake?
Yes
.

1. Stop vehicle.
2. Perform self-diagnosis. Refer to SELFDIAGNOSTIC PROCEDURE, AT-1028.

SAT778B

AT-1056

No
c

Go to “24. Vehicle Does
Not Decelerate By Engine
Brake”, AT-1115.

TROUBLE DIAGNOSIS — General Description
Symptom Chart
b

Accumulator 3-4 (N-R)
Ignition switch and starter

Low & reverse brake
Brake band

Parking pawl components

Transmission noise in “P” and “N” positions.

1100

Vehicle moves when changing into “P” position
or parking gear does not disengage when .
shifted out of “P” position.

2
V

1101

Vehicle runs in “N” position.

4
V

3
V

5
V

1103

Vehicle will not run in “R” position (but runs in
“D”, “2” and “1” positions). Clutch slips.
.
Very poor acceleration.

5 V
6 V
7
V

8
V

6 V
8
V
10
. V

9
V

2
V

. 10

Fluid level
Control linkage

Reference page (AT—

Overrun clutch
Low one-way clutch

Accumulator 1-2
Accumulator 2-3

2
1

Forward clutch
Forward one-way clutch

A/T fluid temperature sensor
Accumulator N-D

Engine starts in position other than “N” and “P”. .

Reverse clutch
High clutch

Torque converter clutch solenoid valve
Overrun clutch solenoid valve

Engine does not start in “N”, “P” positions.

1100

Numbers are arranged in order of probability.
Perform inspections starting with number one
and work up. Circled numbers indicate that the
transmission must be removed from the
vehicle.

Torque converter
Oil pump

Shift solenoid valve B
Line pressure solenoid valve

1100

)

Control valve assembly
Shift solenoid valve A

1133, 1161, 1167, 1167, 1171,
1184
1144 1165 1177 1175 1137

Engine idling speed
Line pressure

1124

OFF vehicle

Revolution sensor and vehicle speed sensor
Engine speed signal

)

1064,
1041,
1070, 1072, 1076, 1079,
1125 1066 1044
1124
1126
1148 1084 1074 1124
1082

PNP switch
Accelerator position sensor (Adjustment)

Reference page (AT-

c b

ON vehicle

9
V

7
V

—

Vehicle braked when shifting into “R” position. 1

—

Sharp shock in shifting from “N” to “D” position. .

—

Vehicle will not run in “D” and “2” positions (but
.
runs in “1” and “R” position).

1104

Vehicle will not run in “D”, “1” and “2” positions
(but runs in “R” position). Clutch slips.
1
Very poor acceleration.

—

Clutches or brakes slip somewhat in starting.

. 13 12 10

. 11

—

Excessive creep.

1103 No creep at all.
1104

.
.

—

Failure to change gear from “D1” to “D2”.

—

Failure to change gear from “D2” to “D3”.

—

Failure to change gear from “D3” to “D4”.

1106 Too high a gear change point from “D1” to “D2”,
.
1107,
from “D2” to “D3”, from “D3” to “D4”.
1108

—

Gear change directly from “D1” to “D3” occurs. 1

—

Engine stops when shifting lever into “R”, “D”,
.
“2” and “1”.

4
V

6
V
7
V
6
V

—

Too sharp a shock in change from “D1” to “D2”. .

Too sharp a shock in change from “D2” to “D3”. .

9
V

—

AT-1057

6 V
7 V
8 V
9
V

VVV

6
V

.
5
V

.
3
V

V
6
V

.
.
.
.
.

TROUBLE DIAGNOSIS — General Description
Symptom Chart (Cont’d)
b

A/T fluid temperature sensor
Accumulator N-D

Accumulator 1-2
Accumulator 2-3

Accumulator 3-4 (N-R)
Ignition switch and starter

Torque converter
Oil pump

Reverse clutch
High clutch

Forward clutch
Forward one-way clutch

6
V

5
V

—

Almost no shock or clutches slipping in change
from “D1” to “D2”.

6
V

—

Almost no shock or slipping in change from
“D2” to “D3”.

6
V

7
V

—

Almost no shock or slipping in change from
“D3” to “D4”.

6
V

7
V

—

Vehicle braked by gear change from “D1” to
“D2”.

2 V
4
V

—

Vehicle braked by gear change from “D2” to
“D3”.

—

Vehicle braked by gear change from “D3” to
“D4”.

4
V

—

Maximum speed not attained. Acceleration
poor.

—

Failure to change gear from “D4” to “D3”.

—

Failure to change gear from “D3” to “D2” or
from “D4” to “D2”.

—

Failure to change gear from “D2” to “D1” or
from “D3” to “D1”.

—

Gear change shock felt during deceleration by
releasing accelerator pedal.

—

Too high a change point from “D4” to “D3”, from
“D3” to “D2”, from “D2” to “D1”.

—

Kickdown does not operate when depressing
pedal in “D4” within kickdown vehicle speed.

—

Kickdown operates or engine overruns when
depressing pedal in “D4” beyond kickdown
vehicle speed limit.

—

Races extremely fast or slips in changing from
“D4” to “D3” when depressing pedal.

—

Races extremely fast or slips in changing from
“D4” to “D2” when depressing pedal.

—

Races extremely fast or slips in changing from
“D3” to “D2” when depressing pedal.

—

Races extremely fast or slips in changing from
“D4” or “D3” to “D1” when depressing pedal.

—

Vehicle will not run in any position.

—

Transmission noise in “D”, “2”, “1” and “R”
positions.

AT-1058

6 V
7
11 V
10 V
V

3 V
2
V

5 V
3
V

Reference page (AT-

Parking pawl components

Torque converter clutch solenoid valve
Overrun clutch solenoid valve

Low & reverse brake
Brake band

Shift solenoid valve B
Line pressure solenoid valve

Too sharp a shock in change from
“D3” to “D4”.

Numbers are arranged in order of probability.
Perform inspections starting with number one
and work up. Circled numbers indicate that the
transmission must be removed from the
vehicle.

Overrun clutch
Low one-way clutch

Control valve assembly
Shift solenoid valve A

—

)

Engine idling speed
Line pressure

1133, 1161, 1167, 1167, 1171,
1184
1144 1165 1177 1175 1137

Revolution sensor and vehicle speed sensor
Engine speed signal

1124

PNP switch
Throttle (accelerator) position sensor (Adjustment)

)

OFF vehicle

Fluid level
Control linkage

Reference page (AT-

ON vehicle

1064,
1041,
1070, 1072, 1076, 1079,
1125 1066 1044
1124
1126
1148 1084 1074 1124
1082

2
V

9 V
8
V

8
V

7
V

6
V

8
V

6 V
7
V

8
V

7
V

9
10 V
V

8
V

9 V
5
V

6
V

2
V

6 V
7
V

8 V
7
10
V
V

TROUBLE DIAGNOSIS — General Description
Symptom Chart (Cont’d)
b

Shift solenoid valve B
Line pressure solenoid valve

Torque converter clutch solenoid valve
Overrun clutch solenoid valve

A/T fluid temperature sensor
Accumulator N-D

Accumulator 1-2
Accumulator 2-3

Accumulator 3-4 (N-R)
Ignition switch and starter

Torque converter
Oil pump

Reverse clutch
High clutch

Forward clutch
Forward one-way clutch

9
V

8
V

Parking pawl components

Control valve assembly
Shift solenoid valve A

Low & reverse brake
Brake band

Engine idling speed
Line pressure

Reference page (AT1111

Numbers are arranged in order of probability.
Perform inspections starting with number one and
work up. Circled numbers indicate that the transmission must be removed from the vehicle.

Overrun clutch
Low one-way clutch

Revolution sensor and vehicle speed sensor
Engine speed signal

Failure to change from “D3” to “2” when changing
lever into “2” position.

)

PNP switch
Throttle (accelerator) position sensor (Adjustment)

)

OFF vehicle

Fluid level
Control linkage

Reference page (AT-

ON vehicle

1064,
1041,
1070, 1072, 1076, 1079,
1133, 1161, 1167, 1167, 1171,
1125 1066 1044
1124 1124
1184
1126
1148 1084 1074 1124
1144 1165 1177 1175 1137
1082

—

Gear change from “21” to “22” in “2” position.

1112

Engine brake does not operate in “1” position.

—

Gear change from “11” to “12” in “1” position.

—

Does not change from “12” to “11” in “1” position.

—

Large shock changing from “12” to “11” in “1” position.

2
V

14 V V V V
11
V

12
V

13 V
10
V

2 V
3 V
5
V

6
V

7 V
4
V

2 V
3 V
4 V
5 V
7
V
9
. . . .
V
7
. . . .
V

8
V

9 V
6
V

—

Transmission overheats.

—

ATF shoots out during operation.
White smoke emitted from exhaust pipe during
operation.

—

Offensive smell at fluid charging pipe.

—

Torque converter is not locked up.

—

Torque converter clutch piston slip

Lock-up point is extremely high or low.

—

A/T does not shift to “D4” when driving with overdrive control switch “ON”.

10
V

9
V

—

Engine is stopped at “R”, “D”, “2” and “1” positions.

1109

AT-1059

TROUBLE DIAGNOSIS — General Description
TCM Terminals and Reference Value
PREPARATION
+ Measure voltage between each terminal and terminal V
25 or
48
by
following
“TCM
INSPECTION
TABLE”.
V

SAT216J

TCM HARNESS CONNECTOR TERMINAL LAYOUT

SAT217J

TCM INSPECTION TABLE
(Data are reference values.)
Terminal
Wire color
No.

G/Y

BR/Y

Item

Judgement
standard (Approx.)

Condition
When releasing accelerator
pedal after warming up engine.
When depressing accelerator
pedal fully after warming up
engine.
When releasing accelerator
pedal after warming up engine.
When depressing accelerator
pedal fully after warming up
engine.

Line pressure
solenoid valve

Line pressure
solenoid valve
(with dropping
resistor)

When A/T performs lock-up.
3

G/OR

Torque converter
clutch solenoid
valve

—

5*
6*
7*
8
9*

PU/W
P/B
P
—
L/OR

DT1
DT2
DT3
—
DT4

G/OR

1.5 — 3.0V
0V
5 — 14V
0V

8 — 15V

When A/T does not perform lock0V
up.
—

—

Refer to EC section.
—
Refer to EC section.
When turning ignition switch to
“ON”.
When turning ignition switch to
“OFF”.

Power source

*: These terminals are connected to the ECM.

AT-1060

—

Battery voltage
0V

TROUBLE DIAGNOSIS — General Description
TCM Terminals and Reference Value (Cont’d)
Terminal
No.

Wire color

L/W

Item

L/R

R/W

SPORT indicator
lamp

14*1
15

P/B
—

R/L

W/G

—

G/OR

When shift solenoid valve A
operates.
(When driving in “D1” or “D4”.)

Shift solenoid
valve A

Shift solenoid
valve B

Battery voltage

When shift solenoid valve A does
not operate.
0V
(When driving in “D2” or “D3”.)
When shift solenoid valve B
operates.
(When driving in “D1” or “D2”.)

Battery voltage

When shift solenoid valve B does
not operate.
0V
(When driving in “D3” or “D4”.)
When setting A/T mode switch in
0V
“SPORT” position.
When setting A/T mode switch in
Battery voltage
other positions.
Refer to EC section.
—
—

N position signal
—
Closed throttle
position switch
(in throttle (accelerator) position
switch)
Wide open throttle
position switch
(in throttle (accelerator) position
switch)
—

Judgement
standard (Approx.)

Condition

—

When releasing accelerator
pedal after warming up engine.

Battery voltage

When depressing accelerator
pedal after warming up engine.

When depressing accelerator
pedal more than half-way after
warming up engine.
When releasing accelerator
pedal after warming up engine.
—

Battery voltage
0V

Same as No. 10

Power source

*1: These terminals are connected to the ECM.

AT-1061

—

TROUBLE DIAGNOSIS — General Description
TCM Terminals and Reference Value (Cont’d)
Terminal
No.

Wire color

L/B

Item

Overrun clutch
solenoid valve

—

—
—
B

PNP “1” position
switch

G/W

PNP “2” position
switch

R/Y

—
—

—

Ground

Power source
(Back-up)

30*1

Y/G

(RX)

31*1

Y/R

G/R

—

(TX)
Accelerator position sensor
(Power source)
—

Battery voltage

When overrun clutch solenoid
valve does not operate.

When setting overdrive control
switch in “ON” position
When setting overdrive control
switch in “OFF” position
—
—

—
Battery voltage
0V
—
—

—
—
When setting selector lever to “1”
Battery voltage
position.
When setting selector lever to
0V
other positions.
When setting selector lever to “2”
Battery voltage
position.
When setting selector lever to
other positions.
When turning ignition switch to
“OFF”.
When turning ignition switch to
“ON”.

When vehicle cruises at 30 km/h
(19 MPH).

Revolution sensor
(Measure in AC
range)

When overrun clutch solenoid
valve operates.

—

Overdrive control
switch

23
24
25

Judgement
standard (Approx.)

Condition

When vehicle parks.

0V
Battery voltage
Battery voltage
1V or more
Voltage rises gradually in response to
vehicle speed.
0V

—
—

*1: These terminals are connected to the data link connector.

AT-1062

—
—

Turn ignition switch to “ON”.

4.5 — 5.5V

Turn ignition switch to “OFF”.

TROUBLE DIAGNOSIS — General Description
TCM Terminals and Reference Value (Cont’d)
Terminal
Wire color
No.

Item

Judgement
standard (Approx.)

Condition
When setting selector lever to
“D” position.
When setting selector lever to
other positions.

PNP “D” position
switch

When setting selector
“R” position.
When setting selector
other positions.
When setting selector
“N” or “P” position.
When setting selector
other positions.
—
—

PNP “R” position
switch

PNP “N” or “P”
position switch

lever to
lever to
lever to
lever to

Battery voltage
0V
Battery voltage
0V
Battery voltage
0V

37
38

—
—

Y/B

Engine speed signal

Refer to EC section.

L/OR

Vehicle speed
sensor

When moving vehicle at 2 to 3
km/h (1 to 2 MPH) for 1 m (3 ft)
or more.

Voltage varies
between less than 0V
and more than 4.5V.

B/W

Accelerator position sensor

When depressing accelerator
pedal slowly after warming up
engine.
(Voltage rises gradually in
response to throttle position.)

Fully-closed throttle:
0.5 — 0.7V
Fully-open throttle:
4V

Accelerator position sensor
(Ground)

W/G

A/T mode switch
(“SPORT”)

Y/R

A/T mode switch
(“
”)

45
46

—
—

A/T fluid temperature sensor

—

—
—

When setting A/T mode switch in
Battery voltage
“SPORT” position.
When setting A/T mode switch in
0V
other positions.
When setting A/T mode switch in
Battery voltage
” position.
“
When setting A/T mode switch in
0V
other positions.
—
—
When ATF temperature is 20°C
(68°F).
When ATF temperature is 80°C
(176°F).
—

Ground

AT-1063

—
—
1.5V
0.5V
0V

TROUBLE DIAGNOSIS FOR VHCL SPEED SENzA/T
Vehicle Speed SensorzA/T (Revolution
sensor)
DESCRIPTION
The revolution sensor detects the revolution of the out put shaft
parking pawl lock gear and emits a pulse signal. The pulse signal is sent to the TCM which converts it into vehicle speed.

SAT218JA

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: VHCL SPEED SENzA/T
:

TCM does not receive the proper voltage signal from the sensor.

1st judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The sensor circuit is open or
shorted.)
+ Revolution sensor

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

SAT806H

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in “D” position, vehicle speed higher
than 30 km/h (19 MPH), throttle opening greater than
1/8 of the full throttle position and driving for more than
5 seconds.
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in “D” position, vehicle speed higher
than 30 km/h (19 MPH), throttle opening greater than
1/8 of the full throttle position and driving for more than
5 seconds.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

AT-1064

TROUBLE DIAGNOSIS FOR VHCL SPEED SENzA/T
Vehicle Speed SensorzA/T (Revolution
sensor) (Cont’d)
DIAGNOSTIC PROCEDURE
NG

CHECK REVOLUTION SENSOR.
Refer to “COMPONENT INSPECTION”
below.

Repair or replace revolution sensor.

OK
.

SAT738J

SAT235J

NG
CHECK INPUT SIGNAL.
Check the following items:
c
+ Harness for short or
1. Start engine.
open between TCM and
2. Select “TCM INPUT SIGNALS”
revolution sensor (Main
in Data Monitor.
harness)
3. Read out the value of “VHCL/S
+ Harness for short or
SEzA/T” while driving.
open between revolution
Check the value changes
sensor and ECM (Main
according to driving speed.
harness)
—————————————————————— OR ——————————————————————+
Ground circuit for ECM
1. Start engine.
Refer
to EC section
2. Check voltage between TCM
(“TROUBLE DIAGNOterminal V
29 and ground while
SIS FOR POWER SUPdriving.
PLY”).
(Measure in AC range.)
Voltage:
At 0 km/h (0 MPH):
0V
At 30 km/h (19 MPH):
1V or more
(Voltage rises gradually in
response to vehicle speed.)
OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1064.
OK
.

INSPECTION END

NG
c

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

COMPONENT INSPECTION
Revolution sensor
+ For removal, refer to AT-1124.
1 ,V
2 and V
3 .
+ Check resistance between terminals V
Terminal No.
1
V
2
V
1
V
SAT236J

AT-1065

Resistance
2
V
3
V
3
V

500 — 650Ω
No continuity
No continuity

TROUBLE DIAGNOSIS FOR VHCL SPEED SENzMTR
Vehicle Speed SensorzMTR
DESCRIPTION
The vehicle speed sensorzMTR is built into the speedometer
assembly. The sensor functions as an auxiliary device to the
revolution sensor when it is malfunctioning. The TCM will then
use a signal sent from the vehicle speed sensorzMTR.

SAT237J

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: VHCL SPEED SENzMTR
:

TCM does not receive the proper voltage signal from the sensor.

2nd judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The sensor circuit is open or
shorted.)
+ Vehicle speed sensor

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in “D” position and vehicle speed higher
than 20 km/h (12 MPH).
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in “D” position and vehicle speed higher
than 20 km/h (12 MPH).
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

SAT807H

AT-1066

TROUBLE DIAGNOSIS FOR VHCL SPEED SENzMTR
Vehicle Speed SensorzMTR (Cont’d)
DIAGNOSTIC PROCEDURE

SAT738J

NG
CHECK INPUT SIGNAL.
Check the following items:
c
+ Vehicle speed sensor
1. Start engine.
and ground circuit for
2. Select “TCM INPUT SIGNALS”
vehicle speed sensor
in Data Monitor.
Refer to EL section
3. Read out the value of “VHCL/S
(“METERS AND
SEzMTR” while driving.
GAUGES”).
Check the value changes
+ Harness for short or
according to driving speed.
open between TCM and
—————————————————————— OR ——————————————————————vehicle speed sensor
1. Start engine.
(Main harness)
2. Check voltage between TCM
terminal V
40 and ground while
driving at 2 to 3 km/h (1 to 2
MPH) for 1 m (3 ft) or more.
Voltage:
Voltage varies between
less than 1V and more than
4.5V.
OK

SAT238J

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1066.
OK
.

INSPECTION END

AT-1067

NG
c

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

TROUBLE DIAGNOSIS FOR THROTTLE POSI SEN
Accelerator Position Sensor
DESCRIPTION
The accelerator position sensor detects the throttle valve position
and sends a signal to the TCM.

SAT222JA

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: THROTTLE POSI SEN

TCM receives an excessively low or
high voltage from the sensor.

: 3rd judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The sensor circuit is open or
shorted.)
+ Accelerator position sensor

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
Monitor item

Condition

Specification

Fully-closed throttle

Approximately 0.5V

Fully-open throttle

Approximately 4V

Accelerator position sensor

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

SAT808H

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in “D” position, vehicle speed higher
than 10 km/h (6 MPH), throttle opening greater than
1/2 of the full throttle position and driving for more than
3 seconds.
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in “D” position, vehicle speed higher
than 10 km/h (6 MPH), throttle opening greater than
1/2 of the full throttle position and driving for more than
3 seconds.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

AT-1068

TROUBLE DIAGNOSIS FOR THROTTLE POSI SEN
Accelerator Position Sensor (Cont’d)
DIAGNOSTIC PROCEDURE
Perform diagnostic test mode II (selfdiagnostic results) for engine control.
Refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC
SYSTEM DESCRIPTION”].

NG
c

.
SAT738J

SAT239J

CHECK INPUT SIGNAL.
1. Turn ignition switch to “ON”
position.
(Do not start engine.)
2. Select “TCM INPUT SIGNALS”
in Data Monitor.
3. Read out the value of “THRTL
POS SEN”.
Voltage:
Fully-closed throttle:
Approximately 0.5V
Fully-open throttle:
Approximately 4V
—————————————————————— OR ——————————————————————1. Turn ignition switch to “ON”
position. (Do not start engine.)
2. Check voltage between TCM
terminals V
41 and V
42 while
accelerator pedal is depressed
slowly.
Voltage:
Fully-closed throttle valve:
Approximately 0.5 — 0.7V
Fully-open throttle valve:
Approximately 4V
(Voltage rises gradually in
response to throttle position)

NG
c

Check accelerator position
sensor circuit for engine
control. Refer to EC section [“TROUBLE DIAGNOSIS FOR “THRTL
(ACCEL) POSI SEN”
(DTC 43)].

Check harness for short or
open between ECM and
TCM regarding accelerator
position sensor circuit.
(Main harness)

OK
.

CHECK ACCELERATOR POSITION
SWITCH.
Refer to “CHECK ACCELERATOR POSITION SWITCH”, AT-1091.

NG
c

Repair or replace damaged parts.

OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1068.
OK
.

INSPECTION END

AT-1069

NG
c

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V A
Shift Solenoid Valve A
DESCRIPTION
Shift solenoid valves A and B are turned “ON” or “OFF” by the
TCM in response to signals sent from the inhibitor switch, vehicle
speed and throttle position sensors. Gears will then be shifted to
the optimum position.

SAT341H

Gear position

Shift solenoid valve A

OFF

Shift solenoid valve B

OFF

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: SHIFT SOLENOID/V A

TCM detects an improper voltage drop
when it tires to operate the solenoid
valve.

: 4th judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The solenoid circuit is open or
shorted.)
+ Shift solenoid valve A

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle in D1 → D2 position.
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle in D1 → D2 position.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

SAT809H

AT-1070

TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V A
Shift Solenoid Valve A (Cont’d)
DIAGNOSTIC PROCEDURE
CHECK GROUND CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect terminal cord assembly
connector in engine compartment.
3
3. Check resistance between terminal V
and ground.
Resistance: 20 — 40Ω

NG
c

SAT240J

CHECK POWER SOURCE CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM harness connector.
3
3. Check resistance between terminal V
and TCM harness connector terminal
11 .
V
Resistance:
Approximately 0Ω
If OK, check harness for short to
ground and short to power.
4. Reinstall any part removed.

NG
c

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Shift solenoid valve A
Refer to “COMPONENT
INSPECTION” below.
+ Harness of terminal cord
assembly for short or
open

Repair open circuit or
short to ground or short to
power in harness or connector.

OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1070.

NG
c

OK
.

INSPECTION END

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

SAT241J

COMPONENT INSPECTION
Shift solenoid valve A
+ For removal, refer to AT-1124.
Resistance check
3 and ground.
+ Check resistance between terminal V
Solenoid valve
Shift solenoid
valve A

Terminal No.
3
V

Ground

Resistance
(Approx.)
20 — 40Ω

SAT537IA

Operation check
+ Check solenoid valve by listening for its operating sound
3 and ground.
while applying battery voltage to the terminal V

SAT536IA

AT-1071

TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V B
Shift Solenoid Valve B
DESCRIPTION
Shift solenoid valves A and B are turned “ON” or “OFF” by the
TCM in response to signals sent from the inhibitor switch, vehicle
speed and throttle position sensors. Gears will then be shifted to
the optimum position.

SAT341H

Gear position

Shift solenoid valve A

OFF

Shift solenoid valve B

OFF

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: SHIFT SOLENOID/V B

TCM detects an improper voltage drop
when it tires to operate the solenoid
valve.

: 5th judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The solenoid circuit is open or
shorted.)
+ Shift solenoid valve B

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle in D1 → D2 → D3 position.
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle in D1 → D2 → D3 position.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

SAT812H

AT-1072

TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V B
Shift Solenoid Valve B (Cont’d)
DIAGNOSTIC PROCEDURE
CHECK GROUND CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect terminal cord assembly
connector in engine compartment.
2
3. Check resistance between terminal V
and ground.
Resistance: 20 — 40Ω

NG
c

SAT242J

CHECK POWER SOURCE CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM harness connector.
2
3. Check resistance between terminal V
and TCM harness connector terminal
12 .
V
Resistance:
Approximately 0Ω
If OK, check harness for short to
ground and short to power.
4. Reinstall any part removed.

NG
c

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Shift solenoid valve B
Refer to “COMPONENT
INSPECTION” below.
+ Harness of terminal cord
assembly for short or
open

Repair open circuit or
short to ground or short to
power in harness or connector.

OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1072.

NG
c

OK
.

INSPECTION END

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

SAT243J

COMPONENT INSPECTION
Shift solenoid valve B
+ For removal, refer to AT-1124.
Resistance check
2 and ground.
+ Check resistance between terminal V
Solenoid valve
Shift solenoid
valve B

Terminal No.
2
V

Ground

Resistance
(Approx.)
20 — 40Ω

SAT535IA

Operation check
+ Check solenoid valve by listening for its operating sound
2 and ground.
while applying battery voltage to the terminal V

SAT534IA

AT-1073

TROUBLE DIAGNOSIS FOR OVERRUN CLUTCH S/V
Overrun Clutch Solenoid Valve
DESCRIPTION
The overrun clutch solenoid valve is activated by the TCM in
response to signals sent from the inhibitor switch, overdrive control switch, vehicle speed and throttle position sensors. The overrun clutch operation will then be controlled.

SAT341H

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: OVERRUN CLUTCH S/V

TCM detects an improper voltage drop
when it tires to operate the solenoid
valve.

: 6th judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The solenoid circuit is open or
shorted.)
+ Overrun clutch solenoid valve

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in “D” position, overdrive control switch
in “OFF” position and vehicle speed higher than 10
km/h (6 MPH).
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in “D” position, overdrive control switch
in “OFF” position and vehicle speed higher than 10
km/h (6 MPH).
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

SAT815H

AT-1074

TROUBLE DIAGNOSIS FOR OVERRUN CLUTCH S/V
Overrun Clutch Solenoid Valve (Cont’d)
DIAGNOSTIC PROCEDURE
CHECK GROUND CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect terminal cord assembly
connector in engine compartment.
4
3. Check resistance between terminal V
and ground.
Resistance: 20 — 40Ω

NG
c

OK
SAT244J

CHECK POWER SOURCE CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM harness connector.
4
3. Check resistance between terminal V
and TCM harness connector terminal
20 .
V
Resistance:
Approximately 0Ω
If OK, check harness for short to
ground and short to power.
4. Reinstall any part removed.

NG
c

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Overrun clutch solenoid
valve
Refer to “COMPONENT
INSPECTION” below.
+ Harness of terminal cord
assembly for short or
open

Repair open circuit or
short to ground or short to
power in harness or connector.

OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1074.

NG
c

OK
.

INSPECTION END

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

SAT245J

COMPONENT INSPECTION
Overrun clutch solenoid valve
+ For removal, refer to AT-1124.
Resistance check
4 and ground.
+ Check resistance between terminal V
Solenoid valve
Overrun clutch
solenoid valve

Terminal No.
4
V

Ground

Resistance
(Approx.)
20 — 40Ω

SAT392JC

Operation check
+ Check solenoid valve by listening for its operating sound
4 and ground.
while applying battery voltage to the terminal V

SAT567IB

AT-1075

TROUBLE DIAGNOSIS FOR T/C CLUTCH SOL/V
Torque Converter Clutch Solenoid Valve
DESCRIPTION
The torque converter clutch solenoid valve is activated, with the
gear in D4, by the TCM in response to signals sent from the
vehicle speed and throttle (accelerator) position sensors. Torque
converter clutch piston operation will then be controlled.
Lock-up operation, however, is prohibited when A/T fluid temperature is too low.
SAT342HA

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: T/C CLUTCH SOL/V

TCM detects an improper voltage drop
when it tires to operate the solenoid
valve.

: 7th judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The solenoid circuit is open or
shorted.)
+ T/C clutch solenoid valve

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
Monitor item

Torque converter clutch solenoid valve
duty

Condition

Specification

Lock-up “OFF”
↓
Lock-up “ON”

Approximately
4%
↓
Approximately
94%

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle in D1 → D2 → D3 → D4 → D4 lock-up
position.
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle in D1 → D2 → D3 → D4 → D4 lock-up
position.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

SAT818H

AT-1076

TROUBLE DIAGNOSIS FOR T/C CLUTCH SOL/V
Torque Converter Clutch Solenoid Valve
(Cont’d)
DIAGNOSTIC PROCEDURE

SAT246J

CHECK GROUND CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect terminal cord assembly
connector in engine compartment.
7
3. Check resistance between terminal V
and ground.
Resistance: 10 — 20Ω

NG
c

CHECK POWER SOURCE CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM harness connector.
7
3. Check resistance between terminal V
and TCM harness connector terminal
3 .
V
Resistance:
Approximately 0Ω
If OK, check harness for short to
ground and short to power.
4. Reinstall any part removed.

NG
c

1. Remove oil pan. Refer
to AT-1124.
2. Check the following
items:
+ Torque converter clutch
solenoid valve
Refer to “COMPONENT
INSPECTION” on next
page.
+ Harness of terminal cord
assembly for short or
open

Repair open circuit or
short to ground or short to
power in harness or connector.

OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1076.
SAT247J

OK
.

INSPECTION END

AT-1077

NG
c

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

TROUBLE DIAGNOSIS FOR T/C CLUTCH SOL/V
Torque Converter Clutch Solenoid Valve
(Cont’d)
COMPONENT INSPECTION
Torque converter clutch solenoid valve
+ For removal, refer to AT-1124.
Resistance check
7 and ground.
+ Check resistance between terminal V
Solenoid valve
SAT543I

Torque converter
clutch solenoid
valve

Terminal No.

7
V

Ground

Resistance
(Approx.)
10 — 20Ω

Operation check
+ Check solenoid valve by listening for its operating sound
7 and ground.
while applying battery voltage to the terminal V

SAT544I

AT-1078

TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP SEN
A/T Fluid Temperature Sensor and TCM
Power Source
DESCRIPTION
The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM.

SAT342HA

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: BATT/FLUID TEMP SEN

TCM receives an excessively low or
high voltage from the sensor.

: 8th judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The sensor circuit is open or
shorted.)
+ A/T fluid temperature sensor

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
Monitor item

A/T fluid temperature sensor

Condition

Specification

Cold [20°C (68°F)]
↓
Hot [80°C (176°F)]

Approximately
1.5V
↓
Approximately
0.5V

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

SAT821H

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in “D” position, vehicle speed higher
than 10 km/h (6 MPH), throttle opening greater than
1/8 of the full open position, engine speed higher than
450 rpm and driving for more than 10 minutes.
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in “D” position, vehicle speed higher
than 10 km/h (6 MPH), throttle opening greater than
1/8 of the full open position, engine speed higher than
450 rpm and driving for more than 10 minutes.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

AT-1079

TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP SEN
A/T Fluid Temperature Sensor and TCM
Power Source (Cont’d)
DIAGNOSTIC PROCEDURE
CHECK TCM POWER SOURCE.
1. Turn ignition switch to “ON” position.
(Do not start engine.)
2. Check voltage between TCM terminals
10 , V
19 and ground.
V
Battery voltage should exist.
SAT248J

SAT249J

CHECK A/T FLUID TEMPERATURE
SENSOR WITH TERMINAL CORD
ASSEMBLY.
1. Turn ignition switch to “OFF” position.
2. Disconnect terminal cord assembly
connector in engine compartment.
3. Check resistance between terminals
8 and V
9 when A/T is cold.
V
Resistance:
Cold [20°C (68°F)]
Approximately 2.5 kΩ
4. Reinstall any part removed.
OK
.

A
V

(Go to next page.)

AT-1080

NG
c

Check the following items:
+ Harness for short or
open between ignition
switch and TCM (Main
harness)
+ Ignition switch and fuse
Refer to EL section
(“POWER SUPPLY
ROUTING”).

1. Remove oil pan.
2. Check the following
items:
+ A/T fluid temperature
sensor
Refer to “COMPONENT
INSPECTION” on next
page.
+ Harness of terminal cord
assembly for short or
open

TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP SEN
A/T Fluid Temperature Sensor and TCM
Power Source (Cont’d)
A
V

SAT738J

SAT250J

NG
Check the following item:
CHECK INPUT SIGNAL OF A/T FLUID
c
+ Harness for short or
TEMPERATURE SENSOR.
open between TCM and
1. Start engine.
terminal cord assembly
2. Select “TCM INPUT SIGNALS”
(Main harness)
in Data Monitor.
3. Read out the value of “FLUID
TEMP SE”.
Voltage:
Cold [20°C (68°F)] →
Hot [80°C (176°F)]:
Approximately
1.5V → 0.5V
—————————————————————— OR ——————————————————————1. Start engine.
2. Check voltage between TCM
terminal V
47 and ground while
warming up A/T.
Voltage:
Cold [20°C (68°F)] →
Hot [80°C (176°F)]:
Approximately
1.5V → 0.5V
OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1079.
OK
.

INSPECTION END

NG
c

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

COMPONENT INSPECTION
A/T fluid temperature sensor
+ For removal, refer to AT-1124.
8 and V
9 while chang+ Check resistance between terminals V
ing temperature as shown at left.
Temperature °C (°F)

Resistance

20 (68)

Approximately 2.5 kΩ

80 (176)

Approximately 0.3 kΩ

SAT252J

AT-1081

TROUBLE DIAGNOSIS FOR ENGINE SPEED SIG
Engine Speed Signal
DESCRIPTION
The engine speed signal is sent from the ECM to the TCM.

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: ENGINE SPEED SIG

TCM does not receive the proper voltage signal from ECM.

: 9th judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The sensor circuit is open or
shorted.)

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

SAT823H

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in “D” position, vehicle speed higher
than 10 km/h (6 MPH), throttle opening greater than
1/8 of the full throttle position and driving for more than
10 seconds.
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in “D” position, vehicle speed higher
than 10 km/h (6 MPH), throttle opening greater than
1/8 of the full throttle position and driving for more than
10 seconds.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

AT-1082

TROUBLE DIAGNOSIS FOR ENGINE SPEED SIG
Engine Speed Signal (Cont’d)
DIAGNOSTIC PROCEDURE
Perform diagnostic test mode II (selfdiagnostic results) for engine control.
Check ignition signal circuit condition.

NG
c

Check ignition signal circuit for engine control.
Refer to EC section
[TROUBLE DIAGNOSIS
FOR “IGN SIGNAL-PRIMARY” (DTC 21)].

SAT740J

SAT253J

NG
CHECK INPUT SIGNAL.
Check the following items:
c
1. Start engine.
+ Harness for short or
2. Select “TCM INPUT SIGNALS”
open between TCM and
in Data Monitor.
ECM
3. Read out the value of “ENGINE
+ Resistor
SPEED”.
+ Ignition coil
Check engine speed changes
Refer to EC section
according to throttle position.
[TROUBLE DIAGNOSIS
—————————————————————— OR ——————————————————————FOR “IGN SIGNAL-PRIMARY” (DTC 21)].
1. Start engine.
2. Check voltage between TCM
terminal V
39 and ground.
Voltage:
Refer to EC section.
OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1082.
OK
.

INSPECTION END

AT-1083

NG
c

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

TROUBLE DIAGNOSIS FOR LINE PRESSURE S/V
Line Pressure Solenoid Valve
DESCRIPTION
The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in response to a
signal sent from the TCM.

SAT341H

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …

: LINE PRESSURE S/V

TCM detects an improper voltage drop
when it tries to operate the solenoid
valve.

: 10th judgement flicker

Check items
(Possible cause)
+ Harness or connectors
(The solenoid circuit is open or
shorted.)
+ Line pressure solenoid valve

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
Monitor item

Line pressure solenoid valve duty

Condition

Specification

Low line-pressure
(Small throttle opening)
↓
High line-pressure
(Large throttle opening)

Approximately
0%
↓
Approximately
95%

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE

SAT014K

After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select “SELF-DIAG RESULTS” mode for A/T with
CONSULT-II.
3) With brake pedal depressed, shift the lever from “P” →
“N” → “D” → “N” → “P” positions.
————————————————————————————————————————- OR ————————————————————————————————————————1) Start engine.
2) With brake pedal depressed, shift the lever from “P” →
“N” → “D” → “N” → “P” positions.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-1029.

SAT824H

AT-1084

TROUBLE DIAGNOSIS FOR LINE PRESSURE S/V
Line Pressure Solenoid Valve (Cont’d)
DIAGNOSTIC PROCEDURE
CHECK GROUND CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect terminal cord assembly
connector in engine compartment.
6
3. Check resistance between terminal V
and ground.
Resistance: 2.5 — 5Ω

NG
c

SAT254J

CHECK POWER SOURCE CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM harness connector.
6
3. Check resistance between terminal V
and TCM harness connector terminal
2 .
V
Resistance: 11.2 — 12.8Ω

NG
c

SAT255J

CHECK POWER SOURCE CIRCUIT.
1. Turn ignition switch to “OFF” position.
6
2. Check resistance between terminal V
and TCM harness connector terminal
1 .
V
Resistance:
Approximately 0Ω
If OK, check harness for short to
ground and short to power.
3. Reinstall any part removed.

NG
c

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Line pressure solenoid valve
Refer to “COMPONENT INSPECTION”
on next page.
+ Harness of terminal
cord assembly for
short or open

Check the following items:
+ Dropping resistor
Refer to “COMPONENT
INSPECTION” on next
page.
+ Harness for short or
open between TCM ter2 and terminal
minal V
cord assembly (Main
harness)

Repair open circuit or
short to ground or short to
power in harness or connector.

OK
.

Perform “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”, AT-1084.
OK
.

INSPECTION END

AT-1085

NG
c

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

TROUBLE DIAGNOSIS FOR LINE PRESSURE S/V
Line Pressure Solenoid Valve (Cont’d)
COMPONENT INSPECTION
Line pressure solenoid valve
+ For removal, refer to AT-1124.
Resistance check
6 and ground.
+ Check resistance between terminal V
Solenoid valve
Line pressure
solenoid valve

Terminal No.
6
V

Ground

Resistance
(Approx.)
2.5 — 5Ω

SAT548IA

Operation check
+ Check solenoid valve by listening for its operating sound
6 and ground.
while applying battery voltage to the terminal V

SAT549IA

Dropping resistor
1 and V
2 .
+ Check resistance between terminals V
Resistance: 11.2 — 12.8Ω

SAT550IC

AT-1086

TROUBLE DIAGNOSIS FOR CONTROL UNIT (RAM), CONTROL UNIT (ROM)
Description
The TCM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the A/T.

SAT574J

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Check item
(Possible cause)

Malfunction is detected when …

: CONTROL UNIT (RAM)

TCM memory (RAM) or (ROM) is malfunctioning.

: CONTROL UNIT (ROM)

TCM

SELF-DIAGNOSIS CODE CONFIRMATION
PROCEDURE
NOTE:
If “SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE”
has been previously conducted, always turn ignition switch
“OFF” and wait at least 5 seconds before conducting the
next test.

WITH CONSULT-II
SAT014K

1) Turn ignition switch “ON” and select “DATA MONITOR”
mode for A/T with CONSULT-II.
2) Start engine.
3) Run engine for at least 2 seconds at idle speed.

SAT971J

AT-1087

TROUBLE DIAGNOSIS FOR CONTROL UNIT (RAM), CONTROL UNIT (ROM)
Diagnostic Procedure
1

CHECK DTC
WITH CONSULT-II

1. Turn ignition switch “ON” and select “SELF DIAG RESULTS” mode for A/T with CONSULT-II.
2. Touch “ERASE”.
Perform Self-diagnosis Code confirmation procedure.
See previous page.
Is the “CONTROL UNIT (RAM) or CONTROL UNIT (ROM)” displayed again?
Yes

c Replace TCM.

c INSPECTION END

AT-1088

TROUBLE DIAGNOSIS FOR CONTROL UNIT (EFP ROM)
Description
The TCM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the A/T.

SAT574J

ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code

Malfunction is detected when …
TCM memory (EEP ROM) is malfunctioning.

: CONT UNIT (EEP ROM)

Check item (Possible cause)
TCM

WITH CONSULT-II
SAT014K

1) Turn ignition switch “ON” and select “DATA MONITOR”
mode for A/T with CONSULT-II.
2) Start engine.
3) Run engine for at least 2 seconds at idle speed.

SAT971J

AT-1089

TROUBLE DIAGNOSIS FOR CONTROL UNIT (EFP ROM)
Diagnostic Procedure
1

CHECK DTC
WITH CONSULT-II

1. Turn ignition switch “ON” and select “SELF DIAG RESULTS” mode for A/T with CONSULT-II.
2. Move selector lever to “R” position.
3. Depress accelerator pedal (Full throttle position).
4. Touch “ERASE”.
5. Turn ignition switch “OFF” position for 10 seconds.
Perform Self-diagnosis Code confirmation procedure.
See previous page.
Is the “CONT UNIT (EEP ROM)” displayed again?
Yes

c Replace TCM.

c INSPECTION END

AT-1090

TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
PNP, Overdrive Control, A/T Mode or
Accelerator Position Switches
DESCRIPTION

SAT218JA

+ PNP switch
Detects the selector lever position and sends a signal to the
TCM.
+ Overdrive control switch, A/T mode switch
Detects the overdrive control switch position (ON or OFF)
and sends a signal to the TCM.
+ Accelerator position switch
Consists of a wide open throttle position switch and a closed
Accelerator position switch.
The wide open throttle position switch sends a signal to the
TCM when the throttle valve is open at least 1/2 of the full
throttle position. The closed throttle position switch sends a
signal to the TCM when the throttle valve is fully closed.

SAT220JA

SAT222JA

AT-1091

TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
PNP, Overdrive Control, A/T Mode or
Accelerator Position Switches (Cont’d)
DIAGNOSTIC PROCEDURE

SAT738J

SAT227J

NG
Check the following items:
CHECK PNP SWITCH CIRCUIT.
c
+ PNP switch
1. Turn ignition switch to “ON”
Refer to “COMPONENT
position.
INSPECTION”,
(Do not start engine.)
AT-1095.
2. Select “TCM INPUT SIGNALS”
+ Harness for short or
in Data Monitor.
open between ignition
3. Read out “R, N, D, 2 and 1
switch and PNP switch
position switches” moving
(Main harness)
selector lever to each position.
+ Harness for short or
Check the signal of the selector
open between PNP
lever position is indicated propswitch and TCM (Main
erly.
harness)
—————————————————————— OR ——————————————————————+ Diode
1. Turn ignition switch to “ON”
position. (Do not start engine.)
2. Check voltage between TCM
terminals V
26 , V
27 , V
34 , V
35 , V
36
and ground while moving selector lever through each position.
Voltage:
B: Battery voltage
0: 0V
Terminal No.
Lever position
36
35
34
27
26
V
V
V
V
V

P, N

OK
.

A
V

(Go to next page.)

AT-1092

TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
PNP, Overdrive Control, A/T Mode or
Accelerator Position Switches (Cont’d)
A
V

SAT740J

SAT224J

CHECK OVERDRIVE CONTROL
SWITCH CIRCUIT.
— Except for the Middle East —
1. Turn ignition switch to “ON”
position.
(Do not start engine.)
2. Select “TCM INPUT SIGNALS”
in Data Monitor.
3. Read out “OVERDRIVE
SWITCH”.
Check the signal of the overdrive control switch is indicated
properly.
(Overdrive control switch “ON”
displayed on CONSULT-II
means overdrive “OFF”.)
—————————————————————— OR ——————————————————————1. Turn ignition switch to “ON”
position.
(Do not start engine.)
2. Check voltage between TCM
terminal V
22 and ground when
overdrive control switch is “ON”
and “OFF”.
Switch position

Voltage

Battery voltage

OFF

1V or less

V
(Go to next page.)

AT-1093

NG
c

Check the following items.
+ Overdrive control switch
Refer to “COMPONENT
INSPECTION”,
AT-1095.
+ Harness for short or
open between TCM and
overdrive control switch
(Main harness)
+ Harness for short or
open of ground circuit
for overdrive control
switch (Main harness)

TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
PNP, Overdrive Control, A/T Mode or
Accelerator Position Switches (Cont’d)
B
V

CHECK ACCELERATOR POSITION
SWITCH CIRCUIT.
1. Turn ignition switch to “ON”
position.
(Do not start engine.)
2. Select “TCM INPUT SIGNALS”
in Data Monitor.
3. Read out “CLOSED THL/SW”
and “W/O THRL/P-SW”
depressing and releasing accelerator pedal.
Check the signal of accelerator
position switch is indicated
properly.

Check the following items:
+ Accelerator position
switch
Refer to “COMPONENT
INSPECTION”,
AT-1096.
+ Harness for short or
open between ignition
switch and accelerator
position switch (Main
harness)
+ Harness for short or
open between accelerator position switch and
TCM (Main harness)

Data monitor

Accelerator
pedal condition

CLOSED
THL/SW

W/O THRL/
P-SW

Released

OFF

Fully
depressed

OFF

SAT739J

—————————————————————— OR ——————————————————————1. Turn ignition switch to “ON”
position.
(Do not start engine.)
2. Check voltage between TCM
terminals V
16 , V
17 and ground
while depressing, and releasing
accelerator pedal slowly. (after
warming up engine)
Accelerator
pedal condition

Voltage
Terminal
No. V
16

Terminal No.
17
V

Released

Battery voltage

1V or less

Fully
depressed

1V or less

Battery
voltage

OK
.
SAT226J

Perform “DIAGNOSTIC PROCEDURE”,
AT-1092.
OK
.

INSPECTION END

AT-1094

NG
c

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
PNP, Overdrive Control, A/T Mode or
Accelerator Position Switches (Cont’d)
COMPONENT INSPECTION
Overdrive control switch
1 and V
2 .
+ Check continuity between terminals V
Switch position

Continuity

OFF

Yes

SAT228J

A/T mode switch
1 , (V
3 ) and V
2 .
+ Check continuity between terminals V
Switch position

Terminal No.
ON

SPORT
OFF
ON
OFF

2
V

3
—V

1
V

2
—V

Continuity
Yes
No
Yes
No

SAT208K

PNP switch
1 and V
2 and between
1. Check continuity between terminals V
3 and V
4 , V
5 , V
6 , V
7 , V
8 , V
9 while moving
terminals V
manual shaft through each position.
Lever position
P
R
SAT517GB

N
D
2
1

Terminal No.
1 — 2

V
3
V
1
V
3
V
3
V
3
V

V
8
—V
2
—V
6
—V
5
—V
4
—V

3
V

7
—V

3
V

9
—V

2. If NG, check again with manual control linkage disconnected
from manual shaft of A/T assembly. Refer to step 1.
3. If OK on step 2, adjust manual control linkage. Refer to
AT-1126.

SAT231JA

4. If NG on step 2, remove PNP switch from A/T and check
continuity of PNP switch terminals. Refer to step 1.
5. If OK on step 4, adjust PNP switch. Refer to AT-1125.
6. If NG on step 4, replace PNP switch.

SAT232JA

AT-1095

TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
PNP, Overdrive Control, A/T Mode or
Accelerator Position Switches (Cont’d)
Accelerator position switch
Accelerator position switch (Off accel)
5 and V
6 .
+ Check continuity between terminals V

SAT209K

Accelerator pedal condition

Continuity

Released

Yes

Depressed

+ To adjust closed throttle (accelerator) position switch, refer to
EC section (“Basic Inspection”, “TROUBLE DIAGNOSIS —
Basic Inspection”).

Accelerator position switch (Full accel)
4 and V
5 .
+ Check continuity between terminals V
Accelerator pedal condition

Continuity

Released

Depressed

Yes

SAT210K

A/T fluid temperature switch
1. Make sure the A/T fluid warning lamp lights when the key is
inserted and turned to “ON”.
2. Make sure the A/T fluid warning lamp goes off when turning
the ignition switch to “ON”.
3. For removal, refer to AT-1124.
4. Check resistance between terminal V
10 and ground while
changing temperature as shown at left.

SAT251J

Temperature °C (°F)

Resistance

140 (284) or more

Yes

140 (284) or less

AT-1096

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
1. SPORT Indicator Lamp Does Not Come On
SYMPTOM:
SPORT indicator lamp does not come on for about 2 seconds when turning ignition switch to “ON”.

SAT211JA

CHECK TCM POWER SOURCE.
1. Turn ignition switch to “ON” position.
(Do not start engine.)
2. Check voltage between TCM terminals
10 , V
19 and ground.
V
Battery voltage should exist.

NG
c

SAT256J

CHECK TCM GROUND CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM harness connector.
3. Check resistance between TCM terminals V
25 , V
48 and ground.
Resistance:
Approximately 0Ω
If OK, check harness for short to
ground and short to power.

NG
c

Check the following items:
+ Harness for short or
open between ignition
switch and TCM (Main
harness)
+ Ignition switch and fuse
Refer to EL section
(“POWER SUPPLY
ROUTING”).

Repair open circuit or
short to ground or short to
power in harness or connector.

OK
.

SAT257J

CHECK LAMP CIRCUIT.
1. Turn ignition switch to “ON” position.
2. Set A/T mode switch to “SPORT” position.
3. Check voltage between TCM terminal
13 and ground.
V
Voltage: Battery voltage
4. Reinstall any part removed.

NG
c

Check again.

OK
SAT258J

INSPECTION END

AT-1097

Check the following items:
+ Fuse (7.5A)
+ SPORT indicator lamp
Refer to EL section
(“WARNING LAMPS”).
+ Harness for short or
open between ignition
switch and SPORT indicator lamp (Main harness)
Refer to EL section
(“POWER SUPPLY
ROUTING”).
+ Harness for short or
open between SPORT
indicator lamp and TCM
1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
2. SPORT Indicator Lamp Does Not Come On
SYMPTOM:
SPORT indicator lamp does not come on when turning A/T
mode switch to the appropriate position.
Is 1. SPORT Indicator Lamp Does Not
Come On OK?

No
c

Yes
.
SAT211JA

Check the following items:
+ A/T mode switch
Refer to AT-1095.
+ Harness continuity between ignition
switch and A/T mode switch
+ Harness continuity between A/T mode
switch and TCM

NG
c

Go to 1. SPORT Indicator
Lamp Does Not Come On,
AT-1097.

Repair or replace damaged parts.

3. O/D OFF Indicator Lamp Does Not Come
On
SYMPTOM:
O/D OFF indicator lamp does not come on when setting
overdrive control switch to “OFF” position.

SAT210J

Check the following items:
+ Overdrive control switch
Refer to AT-1095.
+ O/D OFF indicator lamp
+ Harness continuity between ignition
switch and O/D OFF indicator lamp

AT-1098

NG
c

Repair or replace damaged parts.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
4. SPORT Indicator Lamp Does Not Come On
SYMPTOM:
SPORT indicator lamp does not come on for about 3 seconds when depressing and releasing accelerator pedal fully.
Does self-diagnosis show damage to
accelerator position sensor circuit?

No
c

Check accelerator position
sensor. Refer to AT-1068.

Repair or replace accelerator position sensor.

Yes
SAT211JA
.

Check accelerator position sensor. —
Refer to EC section [TROUBLE DIAGNOSIS FOR “THROTTLE (ACCEL) POSI
SEN” (DTC 43)].
OK
.

SAT831HA

1. Perform TCM input/output signal
inspection.
2. If NG, recheck TCM pin terminals for
damage or loose connection with harness connector.

SAT222JA

AT-1099

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
5. Engine Cannot Be Started In “P” and “N”
Position
SYMPTOM:
+ Engine cannot be started with selector lever in “P” or
“N” position.
+ Engine can be started with selector lever in “D”, “2”, “1”
or “R” position.

SAT146BA

Yes
Does “TCM INPUT SIGNALS” in
Check PNP switch. Refer
c
Data Monitor show damage to
to AT-1091.
PNP switch circuit?
—————————————————————— OR ——————————————————————Does self-diagnosis show damage
to PNP switch circuit?
No
.

Check for short or open of PNP switch
2-pin connector. Refer to AT-1095.

NG
c

Repair or replace PNP
switch.

Repair or replace damaged parts.

SAT259JA
.

Check starting system. Refer to EL section (“System Description”, “STARTING
SYSTEM”).

OK
.

INSPECTION END

6. In “P” Position, Vehicle Moves Forward Or
Backward When Pushed
SYMPTOM:
Vehicle moves when it is pushed forward or backward with
selector lever in “P” position.
Check parking pawl components. Refer to
AT-1184.
OK
SAT133B

INSPECTION END

AT-1100

NG
c

Repair or replace damaged parts.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
7. In “N” Position, Vehicle Moves
SYMPTOM:
Vehicle moves forward or backward when selecting “N”
position.
Yes
Does “TCM INPUT SIGNALS” in
Check PNP switch.
c
Data Monitor show damage to
Refer to AT-1091.
PNP switch circuit?
—————————————————————— OR ——————————————————————SAT146BA

Does self-diagnosis show damage
to PNP switch circuit?
No
.

Check control linkage. Refer to AT-1126.

NG
c

OK
.

Check A/T fluid level again.
SAT262J

NG
c

Adjust control linkage.
Refer to AT-1126.

Refill ATF.

OK
.

1. Remove oil pan.
2. Check A/T fluid condition.

NG
c

SAT638A

Check again.

OK
.

INSPECTION END

SAT171B

AT-1101

1. Disassemble A/T.
2. Check the following
items:
+ Forward clutch assembly
+ Overrun clutch assembly
+ Reverse clutch assembly

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
8. Large Shock. “N” → “R” Position
SYMPTOM:
There is large shock when changing from “N” to “R” position.
Does self-diagnosis show damage to line
pressure solenoid valve or accelerator
position sensor, A/T fluid temperature
sensor circuit?

Yes
c

Check damaged circuit.
Refer to AT-1068, 1079 or
1084.

SAT831HA

No
.

Check accelerator position sensor. Refer
to EC section [TROUBLE DIAGNOSIS
FOR “THROTTLE (ACCEL) POSI SEN”
(DTC 43)].

NG
c

Repair or replace throttle
position sensor.

OK
.
SAT222JA

Check line pressure at idle with selector
lever in “D” position. Refer to “Line Pressure Test”, AT-1044.

NG
c

SAT494G
.

Check again.

OK
.

INSPECTION END

AT-1102

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
9. Vehicle Does Not Creep Backward In “R”
Position
SYMPTOM:
Vehicle does not creep backward when selecting “R” position.
NG

Check A/T fluid level again.

Refill ATF.

A
V

SAT638A

NG in both “1”
and “R” positions
.

Check stall revolution with selector lever
in “1” and “R” positions.
OK

OK in “1” position
NG in “R” position
.

1. Remove control valve assembly. Refer to AT-1124.
2. Check the following items:
+ Valves to control line pressure
(Pressure regulator valve, pressure modifier valve, pilot valve
and pilot filter)
+ Line pressure solenoid valve
3. Disassemble A/T.
4. Check the following items:
+ Oil pump assembly
+ Torque converter
+ Reverse clutch assembly
+ High clutch assembly

SAT493G

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Valves to control line
pressure (Pressure
regulator valve, pressure
modifier valve, pilot
valve and pilot filter)
+ Line pressure solenoid
valve
3. Disassemble A/T.
4. Check the following
items:
+ Oil pump assembly
+ Torque converter
+ Reverse clutch assembly
+ High clutch assembly
+ Low & reverse brake
assembly
+ Low one-way clutch

SAT494G

Check line pressure at idle with selector
lever in “R” position. Refer to “Line Pressure Test”, AT-1044.
OK

1. Remove oil pan.
2. Check A/T fluid condition.
SAT171B

A
V
.

Check again.

NG
c

OK
.

INSPECTION END

AT-1103

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Valves to control line
pressure (Pressure
regulator valve, pressure
modifier valve, pilot
valve and pilot filter)
+ Line pressure solenoid
valve
3. Disassemble A/T.
4. Check the following
item:
+ Oil pump assembly

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
10. Vehicle Does Not Creep Forward In “D”,
“2” Or “1” Position
SYMPTOM:
Vehicle does not creep forward when selecting “D”, “2” or
“1” position.
Check A/T fluid level again.

NG
c

Refill ATF.

OK
SAT638A

A
V

Check stall revolution with selector lever in
“D” position. Refer to “STALL TEST”,
AT-1041.

OK
.

SAT493G

Check line pressure at idle with selector
lever in “D” position. Refer to “Line Pressure
Test”, AT-1044.
OK

NG
.

1. Remove control valve assembly.
Refer to AT-1124.
2. Check the following items:
+ Valves to control line pressure
(Pressure regulator valve, pressure
modifier valve, pilot valve and pilot
filter)
+ Line pressure solenoid valve
3. Disassemble A/T.
4. Check the following item:
+ Oil pump assembly

SAT494G

1. Remove control
c
valve assembly.
Refer to AT-1124.
2. Check the following
items:
+ Valves to control line
pressure (Pressure
regulator valve, pressure modifier valve,
pilot valve and pilot
filter)
+ Line pressure solenoid valve
3. Disassemble A/T.
4. Check the following
items:
+ Oil pump assembly
+ Forward clutch
assembly
+ Forward one-way
clutch
+ Low one-way clutch
+ Low & reverse brake
assembly
+ Torque converter

c A

1. Remove oil pan.
2. Check A/T fluid condition.
OK
.

Check again.

SAT171B

INSPECTION END

AT-1104

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM
pin terminals for
damage or loose
connection with harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
11. Vehicle Cannot Be Started From D1
SYMPTOM:
Vehicle cannot be started from D1 on Cruise test — Part 1.
Is 9. Vehicle Does Not Creep Backward
In “R” Position OK?

No
c

Go to 9. Vehicle Does Not
Creep Backward In “R”
Position, AT-1103.

Yes
.
SAT832H

Does self-diagnosis show damage to
vehicle speed sensorzA/T (revolution
sensor), shift solenoid valve A, B or
vehicle speed sensorzMTR after cruise
test?

Yes
c

Check damaged circuit.
Refer to AT-1064, 1066,
1070 or 1072.

No
.

Check accelerator position sensor. Refer
to EC section [TROUBLE DIAGNOSIS
FOR “THROTTLE (ACCEL) POSI SEN”
(DTC 43)].

NG
c

Repair or replace throttle
position sensor.

OK
.

SAT222JA

Check line pressure at stall point with
selector lever in “D” position. Refer to
“Line Pressure Test”, AT-1044.
OK
.

1. Remove oil pan.
2. Check A/T fluid condition.
OK
.

SAT494G

1. Remove control valve assembly. Refer
to AT-1124.
2. Check the following items:
+ Shift valve A
+ Shift valve B
+ Shift solenoid valve A
+ Shift solenoid valve B
+ Pilot valve
+ Pilot filter
OK

NG
c

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
NG
c + Shift valve A
+ Shift valve B
+ Shift solenoid valve A
+ Shift solenoid valve B
+ Pilot valve
+ Pilot filter
3. Disassemble A/T.
4. Check the following
items:
+ Forward clutch assembly
+ Forward one-way clutch
+ Low one-way clutch
+ High clutch assembly
+ Torque converter
+ Oil pump assembly
OK

b
.

Check again.

SAT171B
.

INSPECTION END

AT-1105

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
12. A/T Does Not Shift: D1 → D2 Or Does Not
Kickdown: D4 → D2
SYMPTOM:
A/T does not shift from D1 to D2 at the specified speed.
A/T does not shift from D4 to D2 when depressing accelerator pedal fully at the specified speed.
Are 10. Vehicle Does Not Creep Forward
In “D”, “2” Or “1” Position and 11. Vehicle
Cannot Be Started From D1 OK?

No
c

SAT146BA

Yes
.

Does “TCM INPUT SIGNALS” in
Data Monitor show damage to
PNP switch circuit?
—————————————————————— OR ——————————————————————

Yes
c

Go to 10. Vehicle Does
Not Creep Forward In “D”,
“2” Or “1” Position and 11.
Vehicle Cannot Be Started
From D1, AT-1104, 1105.
Check PNP switch. Refer
to AT-1091.

Does self-diagnosis show damage
to PNP switch circuit?
No
.
SAT222JA

Check vehicle speed sensorzA/T (revolution sensor) and vehicle speed
sensorzMTR. Refer to AT-1064, 1066.

NG
c

Check accelerator position sensor. Refer
to EC section [TROUBLE DIAGNOSIS
FOR “THROTTLE (ACCEL) POSI SEN”
(DTC 43)].

NG
c

Repair or replace vehicle
speed sensorzA/T (revolution sensor) and vehicle
speed sensorzMTR. Refer
to AT-1064, 1066.

Repair or replace throttle
position sensor.

OK
SAT171B

1. Remove oil pan.
2. Check A/T fluid condition.
OK
.

1. Remove control valve. Refer to
AT-1124.
2. Check the following items:
+ Shift valve A
+ Shift solenoid valve A
+ Pilot valve
+ Pilot filter
OK

1. Remove control valve.
Refer to AT-1124.
2. Check the following
items:
+ Shift valve A
+ Shift solenoid valve A
+ Pilot valve
+ Pilot filter
3. Disassemble A/T.
4. Check the following
items:
+ Servo piston assembly
+ Brake band
OK + Oil pump assembly
c

Check again.

OK
.

INSPECTION END

AT-1106

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
13. A/T Does Not Shift: D2 → D3
SYMPTOM:
A/T does not shift from D2 to D3 at the specified speed.
Are 10. Vehicle Does Not Creep Forward
In “D”, “2” Or “1” Position and 11. Vehicle
Cannot Be Started From D1 OK?

No
c

Yes

Go to 10. Vehicle Does
Not Creep Forward In “D”,
“2” Or “1” Position and 11.
Vehicle Cannot Be Started
From D1, AT-1104, 1105.

SAT146BA

SAT222JA

Check accelerator position sensor. Refer
to EC section [TROUBLE DIAGNOSIS
FOR “THROTTLE (ACCEL) POSI SEN”
(DTC 43)].

NG
c

Repair or replace throttle
position sensor.

OK
.

1. Remove oil pan.
2. Check A/T fluid condition.
OK
.

SAT171B

1. Remove control valve assembly. Refer
to AT-1124.
2. Check the following items:
+ Shift valve B
+ Shift solenoid valve B
+ Pilot valve
+ Pilot filter
OK
b

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Shift valve B
+ Shift solenoid valve B
+ Pilot valve
+ Pilot filter
3. Disassemble A/T.
4. Check the following
items:
+ Servo piston assembly
OK + High clutch assembly
+ Oil pump assembly
c

Check again.

OK
.

INSPECTION END

AT-1107

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
14. A/T Does Not Shift: D3 → D4
SYMPTOM:
+ A/T does not shift from D3 to D4 at the specified speed.
+ A/T must be warm before D3 to D4 shift will occur.
Are 10. Vehicle Does Not Creep Forward
In “D”, “2” Or “1” Position and 11. Vehicle
Cannot Be Started From D1 OK?

No
c

Yes

Go to 10. Vehicle Does
Not Creep Forward In “D”,
“2” Or “1” Position and 11.
Vehicle Cannot Be Started
From D1, AT-1104, 1105.

SAT833HA
.

Does self-diagnosis, after cruise
test, show damage to any of the
following circuits?
+ PNP switch
+ Overdrive control switch
+ A/T fluid temperature sensor
+ Vehicle speed sensorzA/T
(Revolution sensor)
+ Shift solenoid valve A or B
+ Vehicle speed sensorzMTR

Yes
c

Check damaged circuit.
Refer to AT-1064, 1066,
1070, 1072 or 1091.

No
SAT222JA

Check accelerator position sensor. Refer
to EC section [TROUBLE DIAGNOSIS
FOR “THROTTLE (ACCEL) POSI SEN”
(DTC 43)].

NG
c

Repair or replace throttle
position sensor.

OK
.

1. Remove oil pan.
2. Check A/T fluid condition.
OK
.
SAT171B

1. Remove control valve assembly. Refer
to AT-1124.
2. Check the following items:
+ Shift valve B
+ Overrun clutch control valve
+ Shift solenoid valve B
+ Pilot valve
+ Pilot filter
OK
b

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Shift valve B
+ Overrun clutch control
valve
+ Shift solenoid valve B
+ Pilot valve
+ Pilot filter
3. Disassemble A/T.
4. Check the following
items:
+ Servo piston assembly
OK + Brake band
+ Torque converter
+ Oil pump assembly
c

Check again.

OK
.

INSPECTION END

AT-1108

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
15. A/T Does Not Perform Lock-up
SYMPTOM:
A/T does not perform lock-up at the specified speed.
Does self-diagnosis show damage to
torque converter clutch solenoid valve
after cruise test?

Yes
c

Check torque converter
clutch solenoid valve.
Refer to AT-1076.

No
SAT844H
.

Check accelerator position sensor. Refer
to EC section [TROUBLE DIAGNOSIS
FOR “THROTTLE (ACCEL) POSI SEN”
(DTC 43)].

NG
c

Repair or replace throttle
position sensor.

Repair or replace damaged parts.

OK
.

SAT222JA

1. Remove control valve. Refer to
AT-1124.
2. Check following items:
+ Torque converter clutch control valve
+ Torque converter relief valve
+ Torque converter clutch solenoid valve
+ Pilot valve
+ Pilot filter

OK
.

Check again.

OK
.

INSPECTION END

AT-1109

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
16. A/T Does Not Hold Lock-up Condition
SYMPTOM:
A/T does not hold lock-up condition for more than 30 seconds.
Does self-diagnosis show damage to
engine speed signal circuit after cruise
test?

Yes
c

Check engine speed signal. Refer to AT-1082.

No
.

SAT835H

1. Remove oil pan.
2. Check A/T fluid condition.
OK

1. Remove control valve assembly. Refer
to AT-1124.
2. Check the following items:
+ Torque converter clutch control valve
+ Pilot valve
+ Pilot filter
OK

NG
c

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Torque converter clutch
control valve
+ Pilot valve
+ Pilot filter
3. Disassemble A/T.
4. Check torque converter
and oil pump assembly.
OK

b
SAT171B

Check again.

OK
.

INSPECTION END

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

17. Lock-up Is Not Released
SYMPTOM:
Lock-up is not released when accelerator pedal is released.
Does “TCM INPUT SIGNALS” in
Data Monitor show damage to
closed throttle position switch circuit?
—————————————————————— OR ——————————————————————

SAT146BA

Yes
c

Check closed throttle position switch. Refer to
AT-1091.

Does self-diagnosis show damage
to closed throttle position switch
circuit?
No
.

Check again.

OK
.

INSPECTION END

AT-1110

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
18. Engine Speed Does Not Return To Idle
(Light Braking D4 → D3)
SYMPTOM:
+ Engine speed does not smoothly return to idle when A/T
shifts from D4 to D3.
+ Vehicle does not decelerate by engine brake when turning overdrive control switch OFF.
+ Vehicle does not decelerate by engine brake when shifting A/T from “D” to “2” position.
SAT836H

Does self-diagnosis show damage to
overrun clutch solenoid valve circuit after
cruise test?

Yes
c

Check overrun clutch solenoid valve. Refer to
AT-1074.

No
.

Check accelerator position sensor. Refer
to EC section [TROUBLE DIAGNOSIS
FOR “THROTTLE (ACCEL) POSI SEN”
(DTC 43)].

NG
c

Repair or replace throttle
position sensor.

OK
SAT222JA
.

1. Remove oil pan.
2. Check A/T fluid condition.
OK
.

1. Remove control valve assembly. Refer
to AT-1124.
2. Check the following items:
+ Overrun clutch control valve
+ Overrun clutch reducing valve
+ Overrun clutch solenoid valve
OK

SAT171B

1. Remove control valve
assembly. Refer to
AT-1124.
2. Check the following
items:
+ Overrun clutch control
valve
+ Overrun clutch reducing
valve
+ Overrun clutch solenoid
valve
3. Disassemble A/T.
4. Check the following
items:
OK
+ Overrun clutch assembly
+ Oil pump assembly
c

Check again.

OK
.

INSPECTION END

AT-1111

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
19. Vehicle Does Not Start From D1
SYMPTOM:
Vehicle does not start from D1 on Cruise test — Part 2.
Does self-diagnosis show damage to
vehicle speed sensorzA/T (revolution
sensor), shift solenoid valve A, B or
vehicle speed sensorzMTR after cruise
test?

Yes
c

Check damaged circuit.
Refer to AT-1064, 1066,
1070 or 1072.

SAT832H

No
.

Check again.

OK
.

Go to 8. Vehicle Cannot Be Started From
D1, AT-1102.

AT-1112

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
20. A/T Does Not Shift: D2 → D1 When
Depressing Accelerator Pedal
SYMPTOM:
A/T does not shift from D2 to D1 when depressing accelerator pedal fully at the specified speed.
Are 9. Vehicle Does Not Creep Backward
In “R” Position and 10. Vehicle Does Not
Creep Forward In “D”, “2” Or “1” Position
OK?
SAT146BA

No
c

Yes

Go to 9. Vehicle Does Not
Creep Backward In “R”
Position and 10. Vehicle
Does Not Creep Forward In
“D”, “2” Or “1” Position,
AT-1103, 1104.

Check PNP switch.
Does “TCM INPUT SIGNAL” show Yes
c
Refer to AT-1091.
damage to PNP switch circuit?
—————————————————————— OR ——————————————————————Does self-diagnosis show damage
to PNP switch circuit?
No
.

SAT222JA

Check vehicle speed sensorzA/T (revolution sensor) and vehicle speed
sensorzMTR. Refer to AT-1064, 1066.

NG
c

OK
.

Check accelerator position sensor. Refer
to EC section [TROUBLE DIAGNOSIS
FOR “THROTTLE (ACCEL) POSI SEN”
(DTC 43)].

NG
c

Repair or replace vehicle
speed sensorzA/T (revolution sensor) and vehicle
speed sensorzMTR.

Repair or replace throttle
position sensor.

OK
.

1. Remove oil pan.
2. Check A/T fluid condition.

NG
c

SAT171B
.

1. Remove control valve. Refer to
AT-1124.
2. Check the following items:
+ Shift valve A
+ Shift solenoid valve A
+ Pilot valve
+ Pilot filter
OK

b
.

Check again.

OK
.

INSPECTION END

AT-1113

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
21. A/T Does Not Shift: D4 → D3, When
Overdrive Control Switch “ON” → “OFF”
SYMPTOM:
A/T does not shift from D4 to D3 when changing overdrive
control switch to “OFF” position.
Yes
Does “TCM INPUT SIGNALS” in
Check overdrive control
c
Data Monitor show damage to
switch circuit. Refer to
overdrive control switch circuit?
AT-1091.
—————————————————————— OR ——————————————————————SAT146BA

Does self-diagnosis show damage
to overdrive control switch circuit?
No
.

Go to 10. A/T Does Not Shift: D2 → D3,
AT-1104.

22. A/T Does Not Shift: D3 → 22, When
Selector Lever “D” → “2” Position
SYMPTOM:
A/T does not shift from D3 to 22 when changing selector
lever from “D” to “2” position.
Yes
Does “TCM INPUT SIGNALS” in
Check PNP switch circuit.
c
Data Monitor show damage to
Refer to AT-1091.
PNP switch circuit?
—————————————————————— OR ——————————————————————SAT146BA

Does self-diagnosis show damage
to PNP switch circuit?
No
.

Go to 12. A/T Does Not Shift: D1 → D2
Or Does Not Kickdown: D4 → D2,
AT-1106.

AT-1114

DIAGNOSTIC PROCEDURES FOR SYMPTOMS
23. A/T Does Not Shift: 22 → 11, When
Selector Lever “2” → “1” Position
SYMPTOM:
A/T does not shift from 22 to 11 when changing selector
lever from “2” to “1” position.
Does “TCM INPUT SIGNALS” in
Data Monitor show damage to
PNP switch circuit?
—————————————————————— OR ——————————————————————

Yes
c

Check PNP switch circuit.
Refer to AT-1091.

SAT146BA

Does self-diagnosis show damage
to PNP switch circuit?
No
NG

Check again.
OK
.

INSPECTION END

1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.

SAT778B

24. Vehicle Does Not Decelerate By Engine
Brake
SYMPTOM:
Vehicle does not decelerate by engine brake when shifting
from 22 (12) to 11.
Is 9. Vehicle Does Not Creep Backward
In “R” Position OK?
Yes
.

Go to 18. Engine Speed Does Not Return
To Idle (Light Braking D4 → D3),
AT-1111.

AT-1115

No
c

Go to 9. Vehicle Does Not
Creep Backward In “R”
Position, AT-1103.

TROUBLE DIAGNOSES — A/T Shift Lock System
Description
+ The mechanical key interlock mechanism also operates as a
shift lock:
With the key switch turned to “ON”, the selector lever cannot
be shifted from “P” (parking) to any other position unless the
brake pedal is depressed.
With the key removed, the selector lever cannot be shifted
from “P” to any other position.
The key cannot be removed unless the selector lever is
placed in “P”.
+ The shift lock and key interlock mechanisms are controlled
by the ON-OFF operation of the shift lock solenoid and by the
operation of the rotator and slider located inside the key
cylinder, respectively.

SAT914J

AT-1116

TROUBLE DIAGNOSES — A/T Shift Lock System
Wiring Diagram — SHIFT —

TAT025M

AT-1117

TROUBLE DIAGNOSES — A/T Shift Lock System
Diagnostic Procedure
SYMPTOM 1:
+ Selector lever cannot be moved from “P” position with
key in “ON” position and brake pedal applied.
+ Selector lever can be moved from “P” position with key
in “ON” position and brake pedal released.
+ Selector lever can be moved from “P” position when key
is removed from key cylinder.
SYMPTOM 2:
Ignition key cannot be removed when selector lever is set to
“P” position. It can be removed when selector lever is set to
any position except “P”.
Check key interlock cable for damage.

NG
c

OK
.

Check selector lever position for damage.

NG
c

CHECK POWER SOURCE.
1. Turn ignition switch to “OFF” position.
(Do not start engine.)
2. Check voltage between stop lamp
1 and
switch harness terminal V
ground.
Voltage: Battery voltage

NG
c

Repair key interlock cable.
Refer to “Key Interlock
Cable”, AT-1121.

Check selector lever.
Refer to “ON-VEHICLE
SERVICE — PNP Switch
and Manual Control Linkage Adjustment”.

Check the following items:
1. Harness for short or
open between battery
and stop lamp switch
1
harness terminal V
2. 10A fuse

OK
SAT915J
.

CHECK INPUT SIGNAL
(STOP LAMP SWITCH).
Turn ignition switch to “OFF” position.
(Do not start engine.)
+ Check voltage between shift lock relay
2 and ground.
harness terminal V
Brake pedal

Voltage

Released

Depressed

Battery voltage

SAT916J

OK
.

A
V

AT-1118

NG
c

Check the following items:
1. Harness for short or
open between shift lock
relay harness connector
2 and stop lamp
V
switch harness connec2
tor V
2. Stop lamp switch
(Refer to “Component
Check”, AT-1123.)

TROUBLE DIAGNOSES — A/T Shift Lock System
Diagnostic Procedure (Cont’d)
A
V

SAT926J

CHECK POWER SOURCE.
1. Turn ignition switch to “ON” position.
(Do not start engine.)
2. Check voltage between shift lock relay
4 and ground.
harness terminal V
Voltage: Battery voltage

NG
c

CHECK INPUT SIGNAL-1
(SHIFT LOCK RELAY).
Turn ignition switch to “ON” position.
(Do not start engine.)
+ Check voltage between A/T device har5 and ground.
ness terminal V
SAT927J

Brake pedal

Voltage

Released

Battery voltage

Depressed

NG
c

Check the following items:
1. Harness for short or
open between battery
and shift lock relay har4
ness terminal V
2. 7.5A fuse
3. Ignition switch (Refer to
EL section.)

Check the following items:
1. Harness for short or
open between A/T
device harness connec5 and shift lock
tor V
relay harness connector
3
V

2. Shift lock relay
Refer to EL section,
“STANDARDIZED
RELAY”.

OK
.

CHECK INPUT SIGNAL-2
(SHIFT LOCK RELAY).
Turn ignition switch to “OFF” position.
+ Check voltage between A/T device har7 and ground.
ness terminal V
SAT928J

Brake pedal

Voltage

Released

Depressed

Battery voltage

NG
c

1
V

2. Shift lock relay
Refer to EL section,
“STANDARDIZED
RELAY”.
3. Diode-1

SAT929J

CHECK INPUT SIGNAL
(DIODE-2).
Turn ignition switch to “OFF” position.
(Do not start engine.)
+ Check continuity between A/T device
6 and V
7 .
harness terminals V
OK
.

B
V

AT-1119

Check the following items:
1. Harness for short or
open between A/T
device harness connec7 and shift lock
tor V
relay harness connector

NG
c

Check the following item:
1. Diode-2

TROUBLE DIAGNOSES — A/T Shift Lock System
Diagnostic Procedure (Cont’d)
B
V

CHECK GROUND CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect A/T device harness connector.
3. Check continuity between A/T device
8 and ground.
harness terminal V

NG
c

Repair harness or connector.

Replace park position
switch.

Replace shift lock solenoid.

SAT917J

OK
.

CHECK PARK POSITION SWITCH.
(Refer to “Component Check”, AT-1122.)

OK
.

CHECK SHIFT LOCK SOLENOID.
(Refer to “Component Check”, AT-1122.)

OK
.

Reconnect shift lock harness connector.

Turn ignition switch from “OFF” to “ON”
position. (Do not start engine.)

Recheck shift lock operation.
OK
.

INSPECTION END

AT-1120

NG
c

1. Perform A/T device
input/output signal
inspection test.
2. If NG, recheck harness
connector connection.

TROUBLE DIAGNOSES — A/T Shift Lock System
Key Interlock Cable

SAT918J

CAUTION:
+ Install key interlock cable in such a way that it will not
be damaged by sharp bends, twists or interference with
adjacent parts.
+ After installing key interlock cable to control device,
make sure that casing cap and bracket are firmly
secured in their positions. If casing cap can be removed
with an external load of less than 39.2 N (4.0 kg, 8.8 lb),
replace key interlock cable with new one.

REMOVAL
Unlock slider from adjuster holder and remove rod from cable.

SAT919J

AT-1121

TROUBLE DIAGNOSES — A/T Shift Lock System
Key Interlock Cable (Cont’d)
INSTALLATION
1. Set key interlock cable to steering lock assembly and install
lock plate.
2. Clamp cable to steering column and fix to control cable with
band.
3. Set selector lever to P position.

SAT920J

4. Insert interlock rod into adjuster holder.

SAT921J

5. Install casing cap to bracket.
6. Move slider in order to fix adjuster holder to interlock rod.

SAT922J

Component Check
SHIFT LOCK SOLENOID
+ Check operation by applying battery voltage between A/T
5 and V
6 .
device harness connector terminals V

SAT923J

PARK POSITION SWITCH
+ Check continuity between A/T device harness connector ter7 and V
8 .
minals V
Condition

Continuity

When selector lever is set in “P” position and selector lever button is released

Yes

Except above

SAT924J

AT-1122

TROUBLE DIAGNOSES — A/T Shift Lock System
Component Check (Cont’d)
STOP LAMP SWITCH
+ Check continuity between stop lamp switch harness connec1 and V
2 .
tor terminals V
Condition

SAT925J

Continuity

When brake pedal is released

When brake pedal is depressed

Yes

Check stop lamp switch after adjusting brake pedal — refer
to BR section.

AT-1123

ON-VEHICLE SERVICE
Control Valve Assembly and Accumulators
REMOVAL
1. Drain ATF.
2. Remove oil pan and gasket.

SAT260J

3. Remove A/T fluid temperature sensor if necessary.
4. Remove oil strainer.

SAT073BA

5. Remove control valve assembly by removing fixing bolts and
disconnecting harness connector.
Bolt length and location
Bolt symbol
A

V
B
V

! mm (in)
33 (1.30)
45 (1.77)

6. Remove solenoids and valves from valve body if necessary.
7. Remove terminal cord assembly if necessary.

SAT353B

A , V
B , V
C and V
D by applying com8. Remove accumulator V
pressed air if necessary.
+ Hold each piston with rag.
9. Reinstall any part removed.
+ Always use new sealing parts.

SAT074BA

AT-1124

ON-VEHICLE SERVICE
Revolution Sensor Replacement
1. Remove revolution sensor from A/T.
2. Reinstall any part removed.
+ Always use new sealing parts.

SAT261J

Rear Oil Seal Replacement
1. Remove transfer case from vehicle. Refer to TF section
(“Removal”, “REMOVAL AND INSTALLATION”).
2. Remove rear oil seal.
3. Install rear oil seal.
+ Apply ATF before installing.
4. Reinstall any part removed.

SAT035EB

Parking Pawl Components Inspection
1. Remove front and rear propeller shafts. Refer to PD section
(“Removal”, “PROPELLER SHAFT”).
2. Remove transfer case from vehicle. Refer to TF section
(“Removal”, “REMOVAL AND INSTALLATION”).
3. Remove select rod.

SAT262J

4. Support A/T assembly with a jack.
5. Remove rear engine mounting member from body. Refer to
EM section (“ENGINE REMOVAL”).
6. Remove adapter case from transmission case.
7. Replace parking pawl components if necessary.
8. Reinstall any part removed.
+ Always use new sealing parts.

SAT228B

PNP Switch Adjustment
1. Remove manual control linkage from manual shaft of A/T
assembly.
2. Set manual shaft of A/T assembly in “N” position.
3. Loosen PNP switch fixing bolts.
4. Insert pin into adjustment holes in both PNP switch and
manual shaft of A/T assembly as near vertical as possible.
5. Reinstall any part removed.
6. Check continuity of PNP switch. Refer to AT-1095.
SAT081B

AT-1125

ON-VEHICLE SERVICE
Manual Control Linkage Adjustment
Move selector lever from “P” position to “1” position. You should
be able to feel the detents in each position.
If the detents cannot be felt or the pointer indicating the position
is improperly aligned, the linkage needs adjustment.
1. Place selector lever in “P” position.

SAT768B

2.
3.
4.
5.

Loosen lock nuts.
Place manual shaft in “P” position.
Tighten lock nuts to the specified torque.
Move selector lever from “P” position to “1” position. Make
sure that selector lever can move smoothly.

SAT262J

AT-1126

REMOVAL AND INSTALLATION

SAT263J

Removal
1.
2.
3.
4.
5.
6.
7.

Remove battery negative terminal.
Remove air breather hose.
Remove heat insulator and exhaust front tube.
Remove fluid charging pipe from A/T assembly.
Remove oil cooler pipe from A/T assembly.
Plug up openings such as the fluid charging pipe hole, etc.
Remove front and rear propeller shafts. Refer to PD section
(“Removal”, “PROPELLER SHAFT”).
8. Remove center brake control cable from center brake. Refer
to BR section (“PARKING BRAKE CONTROL”).
9. Remove transfer control linkage and transfer harness connectors from transfer. Refer to TF section (“Removal”,
“REMOVAL AND INSTALLATION”).
10. Remove A/T control linkage from A/T assembly.
11. Disconnect A/T solenoid, PNP switch and revolution sensor
harness connectors.
12. Remove starter motor. Refer to EL section (“STARTING
SYSTEM”).

SAT166K

13. Remove bolts securing torque converter to drive plate.
+ Remove the bolts by turning crankshaft.

SAT167K

AT-1127

REMOVAL AND INSTALLATION
Removal (Cont’d)
14. Support A/T and transfer assembly with a jack.
15. Remove engine rear mounting member from body and A/T
assembly. Refer to EM section (“ENGINE REMOVAL”).
16. Remove bolts securing A/T assembly to engine.
+ Secure torque converter to prevent it from dropping.
+ Secure A/T assembly with transfer to a jack.
17. Lower A/T assembly with transfer.

SAT801C

Installation
+ Drive plate runout
CAUTION:
Do not allow any magnetic materials to contact the ring gear
teeth.
Maximum allowable runout:
Refer to EM section (“Inspection”, CYLINDER
BLOCK”).
If this runout is out of specification, replace drive plate with
ring gear.
SAT977H

+ When connecting torque converter to transmission, measure
distance “A” to be certain that they are correctly assembled.
Distance “A”:
Refer to SDS, AT-1210.
+ Install converter to drive plate.
+ After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that transmission rotates freely without binding.
+ Tighten bolts securing transmission.
SAT017B

Bolt No.
1
V
2
V
3
V

Tightening torque
Nzm (kg-m, ft-lb)

Bolt length “!”
mm (in)

83 — 113 (8.4 — 11.6, 61 — 83)

65 (2.56)

29 — 39 (2.9 — 4.0, 21 — 28)

63 (2.48)

29 — 39 (3.0 — 4.0, 22 — 29)

43 (1.69)

+ Reinstall any part removed.
SAT266JB

+ Check fluid level in transmission.
+ Move selector lever through all positions to be sure that
transmission operates correctly.
With parking brake applied, rotate engine at idling. Move
selector lever through “N” to “D”, to “2”, to “1” and to “R”
positions. A slight shock should be felt by hand gripping
selector each time transmission is shifted.
+ Perform road test. Refer to “ROAD TEST”, AT-1046.

SAT638A

AT-1128

MAJOR OVERHAUL

SAT267J

AT-1129

MAJOR OVERHAUL

SAT268J

AT-1130

MAJOR OVERHAUL
Oil Channel

SAT185B

AT-1131

MAJOR OVERHAUL
Locations of Needle Bearings, Thrust
Washers and Snap Rings

SAT269J

AT-1132

DISASSEMBLY
1. Drain ATF through drain plug.
2. Remove torque converter by holding it firmly and turning
while pulling straight out.

SAT018B

3. Check torque converter one-way clutch.
a. Insert Tool into spline of one-way clutch inner race.
b. Hook bearing support unitized with one-way clutch outer race
with suitable wire.
c. Check that one-way clutch inner race rotates only clockwise
with Tool while holding bearing support with wire.

SAT303B

4. Remove PNP switch from transmission case.

SAT021BC

5. Remove oil pan.
+ Always place oil pan straight down so that foreign particles inside will not move.

SAT754I

AT-1133

DISASSEMBLY
6. Place transmission into Tool with the control valve facing up.

SAT522GA

7. Check foreign materials in oil pan to help determine cause of
malfunction. If the fluid is very dark, smells burned, or contains foreign particles, the frictional material (clutches, band)
may need replacement. A tacky film that will not wipe clean
indicates varnish build up. Varnish can cause valves, servo,
and clutches to stick and may inhibit pump pressure.
+ If frictional material is detected, replace radiator after
repair of A/T. Refer to LC section (“Radiator”, “ENGINE
COOLING SYSTEM”).
SAT171B

8. Remove torque converter clutch solenoid valve and A/T fluid
temperature sensor connectors.
+ Be careful not to damage connector.

SAT024BA

9. Remove oil strainer.
a. Remove oil strainer from control valve assembly.
Then remove O-ring from oil strainer.

SAT008B

b. Check oil strainer screen for damage.

SAT025B

AT-1134

DISASSEMBLY
10. Remove control valve assembly.
a. Straighten terminal clips to free terminal cords then remove
terminal clips.

SAT009B

A and V
B , and remove control valve assemb. Remove bolts V
bly from transmission.
Bolt symbol

Length mm (in)

33 (1.30)

V
B
V

45 (1.77)

SAT353B

c. Remove solenoid connector.
+ Be careful not to damage connector.

SAT026B

d. Remove manual valve from control valve assembly.

SAT127B

AT-1135

DISASSEMBLY
11. Remove terminal cord assembly from transmission case
while pushing on stopper.
+ Be careful not to damage cord.
+ Do not remove terminal cord assembly unless it is damaged.

SAT128B

12. Remove converter housing from transmission case.
+ Be careful not to scratch converter housing.

SAT307B

13. Remove O-ring from input shaft.

SAT995A

14. Remove oil pump assembly.
a. Attach Tool to oil pump assembly and extract it evenly from
transmission case.

SAT027BA

b. Remove O-ring from oil pump assembly.
c. Remove traces of sealant from oil pump housing.
+ Be careful not to scratch pump housing.

SAT028B

AT-1136

DISASSEMBLY
d. Remove needle bearing and thrust washer from oil pump
assembly.

SAT108B

15. Remove input shaft and oil pump gasket.

SAT988A

16. Remove brake band and band strut.
a. Loosen lock nut and remove band servo anchor end pin from
transmission case.

SAT029B

b. Remove brake band and band strut from transmission case.

SAT986A

c. Hold brake band in a circular shape with clip.

SAT655

AT-1137

DISASSEMBLY
17. Remove front side clutch and gear components.
a. Remove clutch pack (reverse clutch, high clutch and front
sun gear) from transmission case.

SAT030B

b. Remove front bearing race from clutch pack.
c. Remove rear bearing race from clutch pack.

SAT113B

d. Remove front planetary carrier from transmission case.

SAT031B

e. Remove front needle bearing from front planetary carrier.
f. Remove rear bearing from front planetary carrier.

SAT968A

g. Remove rear sun gear from transmission case.

SAT974A

AT-1138

DISASSEMBLY
18. Remove adapter case.
a. Remove adapter case from transmission case.
b. Remove adapter case gasket from transmission case.

SAT755I

c. Remove oil seal from adapter case.
+ Do not remove oil seal unless it is to be replaced.

SAT756I

d. Remove revolution sensor from adapter case.
e. Remove O-ring from revolution sensor.

SAT305B

19. Remove output shaft and parking gear.
a. Remove rear snap ring from output shaft.

SAT960A

b. Slowly push output shaft all the way forward.
+ Do not use excessive force.
c. Remove snap ring from output shaft.

SAT957A

AT-1139

DISASSEMBLY
d. Remove output shaft and parking gear as a unit from transmission case.
e. Remove parking gear from output shaft.

SAT109B

Remove needle bearing from transmission case.

SAT033B

20. Remove rear side clutch and gear components.
a. Remove front internal gear.

SAT954A

b. Remove bearing race from front internal gear.

SAT110B

c. Remove needle bearing from rear internal gear.

SAT111B

AT-1140

DISASSEMBLY
d. Remove rear internal gear, forward clutch hub and overrun
clutch hub as a set from transmission case.

SAT951A

e. Remove needle bearing from overrun clutch hub.
f. Remove overrun clutch hub from rear internal gear and forward clutch hub.

SAT148G

g. Remove thrust washer from overrun clutch hub.

SAT036B

h. Remove forward clutch assembly from transmission case.

SAT037B

21. Remove band servo and accumulator components.
a. Remove band servo retainer from transmission case.

SAT038B

AT-1141

DISASSEMBLY
b. Apply compressed air to oil hole until band servo piston
comes out of transmission case.
+ Hold piston with a rag and gradually direct air to oil hole.
c. Remove return springs.

SAT039B

B ,V
C and V
D .
d. Remove springs from accumulator pistons V
e.Apply compressed air to each oil hole until piston comes out.
+ Hold piston with a rag and gradually direct air to oil hole.
Identification of accumulator pistons
Identification of oil holes

A
V
a
V

B
V
b
V

C
V
c
V

D
V
d
V

SAT040BA

Remove O-ring from each piston.

SAT523GA

22. Remove manual shaft components, if necessary.
a. Hold width across flats of manual shaft (outside the transmission case) and remove lock nut from shaft.

SAT041B

b. Remove retaining pin from transmission case.

SAT042B

AT-1142

DISASSEMBLY
c. While pushing detent spring down, remove manual plate and
parking rod from transmission case.

SAT935A

d. Remove manual shaft from transmission case.

SAT043B

e. Remove spacer and detent spring from transmission case.

SAT934A

Remove oil seal from transmission case.

SAT044B

AT-1143

REPAIR FOR COMPONENT PARTS
Oil Pump

SAT648AB

DISASSEMBLY
1. Loosen bolts in numerical order and remove oil pump cover.

SAT649A

2. Remove rotor, vane rings and vanes.
+ Inscribe a mark on back of rotor for identification of
fore-aft direction when reassembling rotor. Then remove
rotor.

SAT650A

3. While pushing on cam ring remove pivot pin.
+ Be careful not to scratch oil pump housing.

SAT651A

AT-1144

REPAIR FOR COMPONENT PARTS
Oil Pump (Cont’d)
4. While holding cam ring and spring lift out cam ring spring.
+ Be careful not to damage oil pump housing.
+ Hold cam ring spring to prevent it from jumping.

SAT652A

5. Remove cam ring and cam ring spring from oil pump housing.

SAT653A

6. Remove pivot pin from control piston and remove control
piston assembly.

SAT654A

7. Remove oil seal from oil pump housing.
+ Be careful not to scratch oil pump housing.

SAT655A

INSPECTION
Oil pump cover, rotor, vanes, control piston, side
seals, cam ring and friction ring
+ Check for wear or damage.

SAT656A

AT-1145

REPAIR FOR COMPONENT PARTS
Oil Pump (Cont’d)
Side clearances

SAT657A

+ Measure side clearances between end of oil pump housing
and cam ring, rotor, vanes and control piston. Measure in at
least four places along their circumferences. Maximum measured values should be within specified positions.
+ Before measurement, check that friction rings, O-ring,
control piston side seals and cam ring spring are
removed.
Standard clearance (Cam ring, rotor, vanes and
control piston):
Refer to SDS, AT-1210.
+ If not within standard clearance, replace oil pump assembly
except oil pump cover assembly.

Seal ring clearance
+ Measure clearance between seal ring and ring groove.
Standard clearance:
0.10 — 0.25 mm (0.0039 — 0.0098 in)
Wear limit:
0.25 mm (0.0098 in)
+ If not within wear limit, replace oil pump cover assembly.
SAT658A

ASSEMBLY
1. Drive oil seal into oil pump housing.
+ Apply ATF to outer periphery and lip surface.

SAT081EA

2. Install cam ring in oil pump housing by the following steps.
a. Install side seal on control piston.
+ Pay attention to its direction — Black surface goes
toward control piston.
+ Apply petroleum jelly to side seal.
b. Install control piston on oil pump.

SAT654A

c. Install O-ring and friction ring on cam ring.
+ Apply petroleum jelly to O-ring.

SAT660A

AT-1146

REPAIR FOR COMPONENT PARTS
Oil Pump (Cont’d)
d. Assemble cam ring, cam ring spring and spring seat. Install
spring by pushing it against pump housing.

SAT661A

e. While pushing on cam ring install pivot pin.

SAT651A

3. Install rotor, vanes and vane rings.
+ Pay attention to direction of rotor.

SAT662A

4. Install oil pump housing and oil pump cover.
a. Wrap masking tape around splines of oil pump cover assembly to protect seal. Position oil pump cover assembly in oil
pump housing assembly, then remove masking tape.
b. Tighten bolts in a criss-cross pattern.

SAT649A

5. Install new seal rings carefully after packing ring grooves with
petroleum jelly. Press rings down into jelly to a close fit.
+ Seal rings come in two different diameters. Check fit
carefully in each groove.
Small dia. seal ring:
No mark
Large dia. seal ring:
Yellow mark in area shown by arrow
+ Do not spread gap of seal ring excessively while installing. It may deform ring.
SAT663A

AT-1147

REPAIR FOR COMPONENT PARTS
Control Valve Assembly

SAT141J

AT-1148

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont’d)
DISASSEMBLY
1. Remove solenoids.
a. Remove torque converter clutch solenoid valve and side
plate from lower body.
b. Remove O-ring from solenoid.

SAT194B

c. Remove line pressure solenoid valve from upper body.
d. Remove O-ring from solenoid.

SAT667A

e. Remove 3-unit solenoid assembly from upper body.
f. Remove O-rings from solenoids.

SAT043G

2. Disassemble upper and lower bodies.
a. Place upper body facedown, and remove bolts, reamer bolts
and support plates.
b. Remove lower body, separator plate and separate gasket as
a unit from upper body.
+ Be careful not to drop pilot filter, orifice check valve,
spring and steel balls.

SAT195B

c. Place lower body facedown, and remove separate gasket
and separator plate.
d. Remove pilot filter, orifice check valve and orifice check
spring.

SAT670A

AT-1149

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont’d)
e. Check to see that steel balls are properly positioned in upper
body. Then remove them from upper body.

SAT671A

INSPECTION
Lower and upper bodies
+ Check to see that there are pins and retainer plates in lower
body.

SAT672A

+ Check to see that there are pins and retainer plates in upper
body.
+ Be careful not to lose these parts.

SAT673A

+ Check to make sure that oil circuits are clean and free from
damage.
+ Check tube brackets and tube connectors for damage.

SAT674A

Separator plates
+ Make sure that separator plate is free of damage and not
deformed and oil holes are clean.

SAT675A

AT-1150

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont’d)
Pilot filter
+ Check to make sure that filter is not clogged or damaged.

SAT676A

Torque converter clutch solenoid valve
+ Check that filter is not clogged or damaged.
+ Measure resistance. Refer to “COMPONENT INSPECTION”,
AT-1078.

Line pressure solenoid valve
+ Check that filter is not clogged or damaged.
+ Measure resistance. Refer to “COMPONENT INSPECTION”,
AT-1086.
SAT149G

3-unit solenoid assembly (Shift solenoid valves A
and B and overrun clutch solenoid valve)
+ Measure resistance of each solenoid. Refer to “COMPONENT INSPECTION”, AT-1071, 1073, 1075.

SAT095B

A/T fluid temperature sensor and A/T fluid
temperature switch
+

Measure
resistance.
INSPECTION”, AT-1081.

Refer

“COMPONENT

SAT096BA

ASSEMBLY
1. Install upper and lower bodies.
a. Place oil circuit of upper body face up. Install steel balls in
their proper positions.

SAT671A

AT-1151

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont’d)
b. Install reamer bolts from bottom of upper body and install
separate gaskets.

SAT681A

c. Place oil circuit of lower body face up. Install orifice check
spring, orifice check valve and pilot filter.

SAT682A

d. Install lower separate gaskets and separator plates on lower
body.
e. Install and temporarily tighten support plates, fluid temperature sensor and tube brackets.

SAT197B

Temporarily assemble lower and upper bodies, using reamer
bolt as a guide.
+ Be careful not to dislocate or drop steel balls, orifice
check spring, orifice check valve and pilot filter.

SAT198B

AT-1152

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont’d)
g. Install and temporarily tighten bolts and tube brackets in their
proper locations.
Bolt length and location:
Bolt symbol
Bolt length

mm (in)

a
V

b
V

c
V

d
V

70
(2.76)

50
(1.97)

33
(1.30)

27
(1.06)

SAT199BA

2. Install solenoids.
a. Attach O-ring and install torque converter clutch solenoid
valve and side plates onto lower body.

SAT200B

b. Attach O-rings and install 3-unit solenoids assembly onto
upper body.
c. Attach O-ring and install line pressure solenoid valve onto
upper body.
3. Tighten all bolts.

SAT150G

AT-1153

REPAIR FOR COMPONENT PARTS
Control Valve Upper Body

Apply ATF to all components before their installation.
Numbers preceding valve springs correspond with those shown in SDS on page AT-1208.

AT-1154

SAT270J

REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont’d)
DISASSEMBLY
1. Remove valves at parallel pins.
+ Do not use a magnetic hand.

SAT834A

a. Use a wire paper clip to push out parallel pins.

SAT822A

b. Remove parallel pins while pressing their corresponding
plugs and sleeves.
+ Remove plug slowly to prevent internal parts from jumping out.

SAT823A

c. Place mating surface of valve facedown, and remove internal parts.
+ If a valve is hard to remove, place valve body facedown
and lightly tap it with a soft hammer.
+ Be careful not to drop or damage valves and sleeves.

SAT824A

2. Remove valves at retainer plates.
a. Pry out retainer plate with wire paper clip.

SAT825A

AT-1155

REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont’d)
b. Remove retainer plates while holding spring.

SAT826A

c. Place mating surface of valve facedown, and remove internal parts.
+ If a valve is hard to remove, lightly tap valve body with
a soft hammer.
+ Be careful not to drop or damage valves, sleeves, etc.

SAT827A

+ 4-2 sequence valve and relay valve are located far back in
upper body. If they are hard to remove, carefully push them
out using stiff wire.
+ Be careful not to scratch sliding surface of valve with
wire.

SAT828A

INSPECTION
Valve springs
+ Measure free length and outer diameter of each valve spring.
Also check for damage or deformation.
Inspection standard:
Refer to SDS, AT-1208.
+ Replace valve springs if deformed or fatigued.

Control valves
+ Check sliding surfaces of valves, sleeves and plugs.
SAT829A

ASSEMBLY
1. Lubricate the control valve body and all valves with ATF.
Install control valves by sliding them carefully into their bores.
+ Be careful not to scratch or damage valve body.

SAT830A

AT-1156

REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont’d)
+ Wrap a small screwdriver with vinyl tape and use it to insert
the valves into proper position.

SAT831A

Pressure regulator valve
+ If pressure regulator plug is not centered properly, sleeve
cannot be inserted into bore in upper body.
If this happens, use vinyl tape wrapped screwdriver to center sleeve until it can be inserted.
+ Turn sleeve slightly while installing.

SAT832A

Accumulator control plug
+ Align protrusion of accumulator control sleeve with notch in
plug.
+ Align parallel pin groove in plug with parallel pin, and install
accumulator control valve.

SAT833A

2. Install parallel pins and retainer plates.

SAT834A

+ While pushing plug, install parallel pin.

SAT823A

AT-1157

REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont’d)
4-2 sequence valve and relay valve
+ Push 4-2 sequence valve and relay valve with wire wrapped
in vinyl tape to prevent scratching valve body. Install parallel
pins.

SAT835A

+ Insert retainer plate while pushing spring.

SAT836A

AT-1158

REPAIR FOR COMPONENT PARTS
Control Valve Lower Body

Apply ATF to all components before their installation.
Numbers preceding valve springs correspond with those shown in SDS on page AT-1208.

AT-1159

SAT271J

REPAIR FOR COMPONENT PARTS
Control Valve Lower Body (Cont’d)
DISASSEMBLY
1. Remove valves at parallel pins.
2. Remove valves at retainer plates.
For removal procedures, refer to “DISASSEMBLY” of Control
Valve Upper Body, AT-1155.

SAT838A

INSPECTION
Valve springs
+ Check each valve spring for damage or deformation. Also
measure free length and outer diameter.
Inspection standard:
Refer to SDS, AT-1208.
+ Replace valve springs if deformed or fatigued.

Control valves
SAT829A

+ Check sliding surfaces of control valves, sleeves and plugs
for damage.

ASSEMBLY
+ Install control valves.
For installation procedures, refer to “ASSEMBLY” of Control
Valve Upper Body, AT-1156.

SAT838A

AT-1160

REPAIR FOR COMPONENT PARTS
Reverse Clutch

SAT211K

DISASSEMBLY
1. Check operation of reverse clutch.
a. Install seal ring onto oil pump cover and install reverse
clutch. Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring,
+ D-ring might be damaged.
+ Oil seal might be damaged.
+ Fluid might be leaking past piston check ball.
SAT841A

2. Remove drive plates, driven plates, retaining plate, dish plate
and snap ring.

SAT842A

AT-1161

REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont’d)
3. Remove snap ring from clutch drum while compressing
clutch springs.
+ Do not expand snap ring excessively.
4. Remove spring retainer and return spring.

SAT487GA

5. Install seal ring onto oil pump cover and install reverse clutch
drum. While holding piston, gradually apply compressed air
to oil hole until piston is removed.
+ Do not apply compressed air abruptly.
6. Remove D-ring and oil seal from piston.

SAT844A

INSPECTION
Reverse clutch snap ring and spring retainer
+ Check for deformation, fatigue or damage.

Reverse clutch return springs
+ Check for deformation or damage. Also measure free length
and outside diameter.
Inspection standard:
Refer to SDS, AT-1208.

SAT829A

Reverse clutch drive plates
+ Check facing for burns, cracks or damage.
+ Measure thickness of facing.
Thickness of drive plate:
Standard value 1.90 — 2.05 mm (0.0748 — 0.0807 in)
Wear limit 1.8 mm (0.071 in)
+ If not within wear limit, replace.

Reverse clutch dish plate
+ Check for deformation or damage.
SAT845A

AT-1162

REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont’d)
Reverse clutch piston
+ Shake piston to assure that balls are not seized.
+ Apply compressed air to check ball oil hole opposite the
return spring. Make sure there is no air leakage.
+ Also apply compressed air to oil hole on return spring side
to assure that air leaks past ball.

SAT846A

ASSEMBLY
1. Install D-ring and oil seal on piston.
+ Apply ATF to both parts.

SAT847A

2. Install piston assembly by turning it slowly and evenly.
+ Apply ATF to inner surface of drum.

SAT848A

3. Install return springs and spring retainer.

SAT849A

4. Install snap ring while compressing clutch springs.

SAT487GA

AT-1163

REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont’d)
+ Do not align snap ring gap with spring retainer stopper.

SAT850A

5. Install drive plates, driven plates, retaining plate and dish
plate.
6. Install snap ring.

SAT842A

7. Measure clearance between retaining plate and snap ring. If
not within allowable limit, select proper retaining plate.
Specified clearance:
Standard
0.5 — 0.8 mm (0.020 — 0.031 in)
Allowable limit
1.4 mm (0.055 in)
Retaining plate:
Refer to SDS, AT-1209.
SAT852A

8. Check operation of reverse clutch.
Refer to “DISASSEMBLY” AT-1161.

SAT841A

AT-1164

REPAIR FOR COMPONENT PARTS
High Clutch

SAT212K

DISASSEMBLY AND ASSEMBLY
Service procedures for high clutch are essentially the same as
those for reverse clutch, with the following exception:

SAT853A

+ Check of high clutch operation

SAT854A

AT-1165

REPAIR FOR COMPONENT PARTS
High Clutch (Cont’d)
+ Removal and installation of return spring

SAT488GA

+ Inspection of high clutch return springs
Inspection standard:
Refer to SDS, AT-1208.

SAT829A

+ Inspection of high clutch drive plate
Thickness of drive plate:
Standard
1.52 — 1.67 mm (0.0598 — 0.0657 in)
Wear limit
1.4 mm (0.055 in)

SAT845A

+ Measurement of clearance between retaining plate and snap
ring
Specified clearance:
Standard
1.8 — 2.2 mm (0.071 — 0.087 in)
Allowable limit
3.6 mm (0.142 in)
Retaining plate:
Refer to SDS, AT-1209.
SAT858A

AT-1166

REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches

SAT213K

AT-1167

REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont’d)
DISASSEMBLY AND ASSEMBLY
Forward and overrun clutches are serviced essentially the same
way as reverse clutch is serviced. However, note the following
exceptions.
+ Check of forward clutch operation

SAT860A

+ Check of overrun clutch operation

SAT861A

+ Removal of forward clutch drum
Remove forward clutch drum from transmission case by
holding snap ring.

SAT865A

+ Removal of forward clutch and overrun clutch pistons
1. While holding overrun clutch piston, gradually apply compressed air to oil hole.

SAT862A

2. Remove overrun clutch from forward clutch.

SAT863A

AT-1168

REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont’d)
+ Removal and installation of return springs

SAT492GA

+ Inspection of forward clutch and overrun clutch return springs
Inspection standard:
Refer to SDS, AT-1208.

SAT829A

+ Inspection of forward clutch drive plates
Thickness of drive plate:
Standard
1.90 — 2.05 mm (0.0748 — 0.0807 in)
Wear limit
1.8 mm (0.071 in)

SAT845A

+ Inspection of overrun clutch drive plates
Thickness of drive plate:
Standard
1.52 — 1.67 mm (0.0598 — 0.0657 in)
Wear limit
1.4 mm (0.055 in)

SAT845A

+ Installation of forward clutch piston and overrun clutch piston
1. Install forward clutch piston by turning it slowly and evenly.
+ Apply ATF to inner surface of clutch drum.

SAT866A

AT-1169

REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont’d)
+ Align notch in forward clutch piston with groove in forward clutch drum.

SAT867A

2. Install overrun clutch by turning it slowly and evenly.
+ Apply ATF to inner surface of forward clutch piston.

SAT868A

+ Measurement of clearance between retaining plate and snap
ring of overrun clutch
Specified clearance:
Standard
1.0 — 1.4 mm (0.039 — 0.055 in)
Allowable limit
2.4 mm (0.094 in)
Retaining plate:
Refer to SDS, AT-1209.
SAT869A

+ Measurement of clearance between retaining plate and snap
ring of forward clutch
Specified clearance:
Standard
0.35 — 0.75 mm (0.0138 — 0.0295 in)
Allowable limit
2.55 mm (0.1004 in)
Retaining plate:
Refer to SDS, AT-1209.
SAT870A

AT-1170

REPAIR FOR COMPONENT PARTS
Low & Reverse Brake

SAT214K

DISASSEMBLY
1. Check operation of low and reverse brake.
a. Install seal ring onto oil pump cover and install reverse
clutch. Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring,
+ D-ring might be damaged.
+ Oil seal might be damaged.
+ Fluid might be leaking past piston check ball.
SAT872A

2. Remove snap ring, low and reverse brake drive plates, driven
plates and dish plate.

SAT873A

AT-1171

REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont’d)
3. Remove low one-way clutch inner race, spring retainer and
return spring from transmission case.
4. Remove seal rings from low one-way clutch inner race.
5. Remove needle bearing from low one-way clutch inner race.

SAT382I

6. Remove low and reverse brake piston using compressed air.
7. Remove oil seal and D-ring from piston.

SAT876A

INSPECTION
Low and reverse brake snap ring and spring retainer
+ Check for deformation, or damage.

Low and reverse brake return springs
+ Check for deformation or damage. Also measure free length
and outside diameter.
Inspection standard:
Refer to SDS, AT-1208.

SAT829A

Low and reverse brake drive plates
+ Check facing for burns, cracks or damage.
+ Measure thickness of facing.
Thickness of drive plate:
Standard value
1.52 — 1.67 mm (0.0598 — 0.0657 in)
Wear limit
1.4 mm (0.055 in)
+ If not within wear limit, replace.
SAT845A

AT-1172

REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont’d)
Low one-way clutch inner race
+ Check frictional surface of inner race for wear or damage.

SAT877A

+ Install a new seal rings onto low one-way clutch inner race.
+ Be careful not to expand seal ring gap excessively.
+ Measure seal ring-to-groove clearance.
Inspection standard:
Standard value 0.10 — 0.25 mm (0.0039 — 0.0098 in)
Allowable limit 0.25 mm (0.0098 in)
+ If not within allowable limit, replace low one-way clutch inner
race.

SAT878A

ASSEMBLY
1. Install needle bearing onto one-way clutch inner race.
+ Pay attention to its direction — Black surface goes to
rear side.
+ Apply petroleum jelly to needle bearing.

SAT112B

2. Install oil seal and D-ring onto piston.
+ Apply ATF to oil seal and D-ring.

SAT879A

3. Install piston by rotating it slowly and evenly.
+ Apply ATF to inner surface of transmission case.

SAT880A

AT-1173

REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont’d)
4. Install return springs, spring retainer and low one-way clutch
inner race onto transmission case.
5. Install dish plate, low and reverse brake drive plates, driven
plates and retaining plate.
6. Install snap ring on transmission case.

SAT881A

7. Check operation of low and reverse brake clutch piston.
Refer to “DISASSEMBLY”, AT-1171.

SAT872A

8. Measure clearance between retaining plate and snap ring.
If not within allowable limit, select proper retaining plate.
Specified clearance:
Standard
0.5 — 0.8 mm (0.020 — 0.031 in)
Allowable limit
2.4 mm (0.094 in)
Retaining plate:
Refer to SDS, AT-1210.
SAT885A

9. Install low one-way clutch inner race seal ring.
+ Apply petroleum jelly to seal ring.
+ Make sure seal rings are pressed firmly into place and
held by petroleum jelly.

SAT884A

AT-1174

REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly

SAT211GA

DISASSEMBLY
1. Remove snap ring from forward clutch drum.
2. Remove side plate from forward clutch drum.

SAT212G

3. Remove low one-way clutch from forward clutch drum.
4. Remove snap ring from forward clutch drum.

SAT213G

5. Remove needle bearing from forward clutch drum.

SAT891A

AT-1175

REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly (Cont’d)
INSPECTION
Forward clutch drum
+ Check spline portion for wear or damage.
+ Check frictional surfaces of low one-way clutch and needle
bearing for wear or damage.

SAT892A

Needle bearing and low one-way clutch
+ Check frictional surface for wear or damage.

SAT893A

ASSEMBLY
1. Install needle bearing in forward clutch drum.
2. Install snap ring onto forward clutch drum.

SAT214G

3. Install low one-way clutch onto forward clutch drum by pushing the roller in evenly.

SAT894A

+ Install low one-way clutch with flange facing rearward.

SAT895A

AT-1176

REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly (Cont’d)
4. Install side plate onto forward clutch drum.
5. Install snap ring onto forward clutch drum.

SAT887A

Rear Internal Gear and Forward Clutch Hub

SAT896AA

DISASSEMBLY
1. Remove rear internal gear by pushing forward clutch hub
forward.

SAT897A

2. Remove thrust washer from rear internal gear.

SAT898A

AT-1177

REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub
(Cont’d)
3. Remove snap ring from forward clutch hub.

SAT899A

4. Remove end bearing.

SAT900A

5. Remove forward one-way clutch and end bearing as a unit
from forward clutch hub.

SAT955A

6. Remove snap ring from forward clutch hub.

SAT901A

INSPECTION
Rear internal gear and forward clutch hub
+ Check gear for excessive wear, chips or cracks.
+ Check frictional surfaces of forward one-way clutch and
thrust washer for wear or damage.
+ Check spline for wear or damage.

SAT902A

AT-1178

REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub
(Cont’d)
Snap ring and end bearing
+ Check for deformation or damage.

SAT903A

ASSEMBLY
1. Install snap ring onto forward clutch hub.
2. Install end bearing.

SAT901A

3. Install forward one-way clutch onto clutch hub.
+ Install forward one-way clutch with flange facing rearward.
4. Install end bearing.
5. Install snap ring onto forward clutch hub.

SAT904A

6. Install thrust washer onto rear internal gear.
+ Apply petroleum jelly to thrust washer.
+ Securely insert pawls of thrust washer into holes in rear
internal gear.

SAT906A

7. Position forward clutch hub in rear internal gear.

SAT907A

AT-1179

REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub
(Cont’d)
8. After installing, check to assure that forward clutch hub
rotates clockwise.

SAT905A

Band Servo Piston Assembly

SAT908AD

DISASSEMBLY
1. Block one oil hole in OD servo piston retainer and the center hole in OD band servo piston.
2. Apply compressed air to the other oil hole in piston retainer
to remove OD band servo piston from retainer.
3. Remove D-ring from OD band servo piston.

SAT909A

4. Remove band servo piston assembly from servo piston
retainer by pushing it forward.

SAT910A

AT-1180

REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont’d)
5. Place piston stem end on a wooden block. While pushing
servo piston spring retainer down, remove E-ring.

SAT911A

6. Remove servo piston spring retainer, return spring C and
piston stem from band servo piston.

SAT912A

7. Remove E-ring from band servo piston.

SAT913A

8. Remove servo cushion spring retainer from band servo piston.
9. Remove D-rings from band servo piston.
10. Remove O-rings from servo piston retainer.

SAT914A

INSPECTION
Pistons, retainers and piston stem
+ Check frictional surfaces for abnormal wear or damage.

SAT915A

AT-1181

REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont’d)
Return springs
+ Check for deformation or damage. Measure free length and
outer diameter.
Inspection standard:
Refer to SDS, AT-1208.

SAT916AB

ASSEMBLY
1. Install O-rings onto servo piston retainer.
+ Apply ATF to O-rings.
+ Pay attention to position of each O-ring.

SAT917A

2. Install servo cushion spring retainer onto band servo piston.

SAT918A

3. Install E-ring onto servo cushion spring retainer.

SAT919A

4. Install D-rings onto band servo piston.
+ Apply ATF to D-rings.

SAT920A

AT-1182

REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont’d)
5. Install servo piston spring retainer, return spring C and piston stem onto band servo piston.

SAT912A

6. Place piston stem end on a wooden block. While pushing
servo piston spring retainer down, install E-ring.

SAT921A

7. Install band servo piston assembly onto servo piston retainer
by pushing it inward.

SAT922A

8. Install D-ring on OD band servo piston.
+ Apply ATF to D-ring.

SAT923A

9. Install OD band servo piston onto servo piston retainer by
pushing it inward.

SAT924A

AT-1183

REPAIR FOR COMPONENT PARTS
Parking Pawl Components

SAT276J

DISASSEMBLY
1. Slide return spring to the front of adapter case flange.

SAT505B

2. Remove return spring, pawl spacer and parking pawl from
adapter case.
3. Remove parking pawl shaft from adapter case.

SAT202E

4. Remove parking actuator support from adapter case.
5. Remove rear oil seal.

SAT203E

AT-1184

REPAIR FOR COMPONENT PARTS
Parking Pawl Components (Cont’d)
INSPECTION
Parking pawl and parking actuator support
+ Check contact surface of parking rod for wear.

SAT511B

ASSEMBLY
1. Install rear oil seal.

SAT513B

2. Install parking actuator support onto adapter case.
3. Install parking pawl shaft into adapter case.

SAT204E

4. Install return spring, pawl spacer and parking pawl onto parking pawl shaft.

SAT202E

5. Bend return spring upward and install it onto adapter case.

SAT505B

AT-1185

ASSEMBLY
Assembly (1)
1.
a.
+
+
b.

Install manual shaft components.
Install oil seal onto manual shaft.
Apply ATF to oil seal.
Wrap threads of manual shaft with masking tape.
Insert manual shaft and oil seal as a unit into transmission
case.
c. Remove masking tape.
SAT931A

d. Push oil seal evenly and install it onto transmission case.

SAT932A

e. Align groove in shaft with drive pin hole, then drive pin into
position as shown in figure at left.

SAT933A

f. Install detent spring and spacer.
g. While pushing detent spring down, install manual plate onto
manual shaft.

SAT901E

h. Install lock nuts onto manual shaft.

SAT936A

AT-1186

ASSEMBLY
Assembly (1) (Cont’d)
2. Install accumulator piston.
a. Install O-rings onto accumulator piston.
+ Apply ATF to O-rings.
Accumulator piston O-rings
Unit: mm (in)
Accumulator

D
V

Small diameter end

29 (1.14)

32 (1.26)

45 (1.77)

29 (1.14)

Large diameter end

45 (1.77)

50 (1.97)

45 (1.77)

SAT523GA

b. Install return spring for accumulator A onto transmission
case.
Free length of return spring:
Refer to SDS, AT-1208.

SAT938A

A ,V
B ,V
C and V
D .
c. Install accumulator pistons V
+ Apply ATF to transmission case.

SAT939AA

3. Install band servo piston.
a. Install return springs onto servo piston.

SAT298J

b. Install band servo piston onto transmission case.
+ Apply ATF to O-ring of band servo piston and transmission case.
c. Install gasket for band servo onto transmission case.

SAT942A

AT-1187

ASSEMBLY
Assembly (1) (Cont’d)
d. Install band servo retainer onto transmission case.

SAT940A

4. Install rear side clutch and gear components.
a. Place transmission case in vertical position.

SAT943AA

b. Slightly lift forward clutch drum assembly. Then slowly rotate
it clockwise until its hub passes fully over clutch inner race
inside transmission case.

SAT944A

c. Check to be sure that rotation direction of forward clutch
assembly is correct.

SAT945A

d. Install thrust washer onto front of overrun clutch hub.
+ Apply petroleum jelly to the thrust washer.
+ Insert pawls of thrust washer securely into holes in overrun clutch hub.

SAT946A

AT-1188

ASSEMBLY
Assembly (1) (Cont’d)
e. Install overrun clutch hub onto rear internal gear assembly.

SAT947A

f. Install needle bearing onto rear of overrun clutch hub.
+ Apply petroleum jelly to needle bearing.

SAT948A

g. Check that overrun clutch hub rotates as shown while holding forward clutch hub.
h. Place transmission case into horizontal position.

SAT949A

Install rear internal gear, forward clutch hub and overrun
clutch hub as a unit onto transmission case.

SAT951A

j. Install needle bearing onto rear internal gear.
+ Apply petroleum jelly to needle bearing.

SAT952A

AT-1189

ASSEMBLY
Assembly (1) (Cont’d)
k. Install bearing race onto rear of front internal gear.
+ Apply petroleum jelly to bearing race.
+ Securely engage pawls of bearing race with holes in
front internal gear.

SAT953A

Install front internal gear on transmission case.

SAT954A

Adjustment
When any parts listed in the following table are replaced, total
end play or reverse clutch end play must be adjusted.
Total end play

Reverse clutch end
play

Transmission case

Low one-way clutch inner race

Overrun clutch hub

Rear internal gear

Rear planetary carrier

Rear sun gear

Front planetary carrier

Front sun gear

High clutch hub

High clutch drum

Oil pump cover

Reverse clutch drum

—

Part name

1. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
+ Pay attention to its direction.

SAT974A

AT-1190

ASSEMBLY
Adjustment (Cont’d)
b.
+
c.
+
+

Install needle bearing on front of front planetary carrier.
Apply petroleum jelly to needle bearing.
Install needle bearing on rear of front planetary carrier.
Apply petroleum jelly to bearing.
Pay attention to its direction — Black side goes to front.

SAT967A

d. While rotating forward clutch drum clockwise, install front
planetary carrier on forward clutch drum.

SAT969A

+ Check that portion A of front planetary carrier protrudes
approximately 2 mm (0.08 in) beyond portion B of forward clutch assembly.

SAT970A

e. Install bearing races on rear of clutch pack.
+ Apply petroleum jelly to bearing races.
+ Securely engage pawls of bearing race with hole in
clutch pack.

SAT204B

Place transmission case in vertical position.

SAT972A

AT-1191

ASSEMBLY
Adjustment (Cont’d)
g. Install clutch pack into transmission case.

SAT973A

2. Adjust total end play.
a. Install new oil pump gasket on transmission case.

SAT206B

b. Install pump cover bearing race on clutch pack.

SAT207B

c. Measure distance “B” between front end of transmission
case and oil pump cover bearing race.

SAT208B

d. Measure distance “C” between front end of transmission
case and oil pump gasket.

SAT209B

AT-1192

ASSEMBLY
Adjustment (Cont’d)
e. Determine dimension “A” by using the following equation.
A=B−C

SAT210B

f. Install needle bearing on oil pump assembly.
g. Measure distance “D” between needle bearing and machined
surface of oil pump cover assembly.

SAT211B

h. Determine total end play “T1” by using the following equation.
T1 = A − D − 0.1
Total end play “T1”:
0.25 — 0.55 mm (0.0098 — 0.0217 in)
+ If end play is out of specification, decrease or increase thickness of oil pump cover bearing race as necessary.
Available oil pump cover bearing race:
Refer to SDS, AT-1210.

SAT975A

3. Adjust reverse clutch drum end play.
a. Install oil pump thrust washer on clutch pack.

SAT212B

AT-1193

ASSEMBLY
Adjustment (Cont’d)
b. Measure distance “F” between front end of transmission case
and oil pump thrust washer.
c. Measure distance “G” between front end of transmission
case and gasket.

SAT213B

d. Determine dimension “E” by using the following equation.
E=F−G

SAT214B

e. Measure distance “H”.

SAT215B

Determine reverse clutch drum end play “T2” by using the
following equation.
T2 = E − H − 0.1
Reverse clutch drum end play “T2”:
0.55 — 0.90 mm (0.0217 — 0.0354 in)
+ If end play is out of specification, decrease or increase thickness of oil pump thrust washer as necessary.
Available oil pump thrust washer:
Refer to SDS, AT-1210.
4. Remove any part installed to adjust end plays.

SAT980A

AT-1194

ASSEMBLY
Assembly (2)
1. Install output shaft and parking gear.
a. Insert output shaft from rear of transmission case while
slightly lifting front internal gear.
+ Do not force output shaft against front of transmission
case.

SAT216B

b. Carefully push output shaft against front of transmission
case. Install snap ring on front of output shaft.
+ Check to be sure output shaft cannot be removed in rear
direction.

SAT957A

c. Install needle bearing on transmission case.
+ Pay attention to its direction — Black side goes to rear.
+ Apply petroleum jelly to needle bearing.

SAT217B

d. Install parking gear on transmission case.

SAT218B

e. Install snap ring on rear of output shaft.
+ Check to be sure output shaft cannot be removed in forward direction.

SAT960A

AT-1195

ASSEMBLY
Assembly (2) (Cont’d)
2. Install adapter case.
a. Install oil seal on adapter case.
+ Apply ATF to oil seal.

SAT513B

b. Install O-ring on revolution sensor.
+ Apply ATF to O-ring.
c. Install revolution sensor on adapter case.

SAT602B

d. Install adapter case gasket on transmission case.

SAT963A

e. Install parking rod on transmission case.

SAT964A

Install adapter case on transmission case.

SAT580B

AT-1196

ASSEMBLY
Assembly (2) (Cont’d)
3. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
+ Pay attention to its direction.

SAT974A

b. Make sure needle bearing is on front of front planetary carrier.
+ Apply petroleum jelly to needle bearing.
c. Make sure needle bearing is on rear of front planetary carrier.
+ Apply petroleum jelly to bearing.
+ Pay attention to its direction — Black side goes to front.

SAT967A

d. While rotating forward clutch drum clockwise, install front
planetary carrier on forward clutch drum.

SAT969A

+ Check that portion A of front planetary carrier protrudes
approximately 2 mm (0.08 in) beyond portion B of forward clutch assembly.

SAT970A

e. Make sure bearing races are on front and rear of clutch pack.
+ Apply petroleum jelly to bearing races.
+ Securely engage pawls of bearing races with holes in
clutch pack.

SAT971A

AT-1197

ASSEMBLY
Assembly (2) (Cont’d)
f.

Install clutch pack into transmission case.

SAT220B

4. Install brake band and band strut.
a. Install band strut on brake band.
+ Apply petroleum jelly to band strut.

SAT985A

b. Place brake band on periphery of reverse clutch drum, and
insert band strut into end of band servo piston stem.

SAT986A

c. Install anchor end pin on transmission case. Then, tighten
anchor end pin just enough so that reverse clutch drum
(clutch pack) will not tilt forward.

SAT987A

5. Install input shaft on transmission case.
+ Pay attention to its direction — O-ring groove side is
front.
6. Install gasket on transmission case.

SAT988A

AT-1198

ASSEMBLY
Assembly (2) (Cont’d)
7.
a.
+
b.
+

Install oil pump assembly.
Install needle bearing on oil pump assembly.
Apply petroleum jelly to the needle bearing.
Install selected thrust washer on oil pump assembly.
Apply petroleum jelly to thrust washer.

SAT989A

c. Carefully install seal rings into grooves and press them into
the petroleum jelly so that they are a tight fit.

SAT990A

d. Install O-ring on oil pump assembly.
+ Apply petroleum jelly to O-ring.

SAT991A

e. Apply petroleum jelly to mating surface of transmission case
and oil pump assembly.

SAT992A

f. Install oil pump assembly.
+ Install two converter housing securing bolts in bolt
holes in oil pump assembly as guides.

SAT993A

AT-1199

ASSEMBLY
Assembly (2) (Cont’d)
+ Insert oil pump assembly to the specified position in
transmission, as shown at left.

SAT994A

8. Install O-ring on input shaft.
+ Apply ATF to O-rings.

SAT114B

9. Install converter housing.
a. Apply recommended sealant (Nissan genuine part: KP61000250 or equivalent) to outer periphery of bolt holes in converter housing.
+ Do not apply too much sealant.

SAT279J

b. Apply recommended sealant (Nissan genuine part: KP61000250 or equivalent) to seating surfaces of bolts that secure
front of converter housing.
c. Install converter housing on transmission case.

SAT280J

10. Adjust brake band.
a. Tighten anchor end pin to specified torque.
Anchor end pin:
: 3.9 — 5.9 Nzm
(0.4 — 0.6 kg-m, 35 — 52 in-lb)
b. Back off anchor end pin two and a half turns.

SAT001B

AT-1200

ASSEMBLY
Assembly (2) (Cont’d)
c. While holding anchor end pin, tighten lock nut.

SAT002B

11. Install terminal cord assembly.
a. Install O-ring on terminal cord assembly.
+ Apply petroleum jelly to O-ring.
b. Compress terminal cord assembly stopper and install terminal cord assembly on transmission case.

SAT115B

12. Install control valve assembly.
B ,V
C and V
D .
a. Install accumulator piston return springs V
Free length of return springs:
Refer to SDS, AT-1208.

SAT004BA

b. Install manual valve on control valve.
+ Apply ATF to manual valve.

SAT005B

c. Place control valve assembly on transmission case. Connect
solenoid connector for upper body.
d. Install connector clip.

SAT006B

AT-1201

ASSEMBLY
Assembly (2) (Cont’d)
e. Install control valve assembly on transmission case.
A and V
B .
f. Install connector tube brackets and tighten bolts V
+ Check that terminal assembly does not catch.
Bolt symbol
A

V
B
V

! mm (in)
33 (1.30)
45 (1.77)

SAT353B

g. Install O-ring on oil strainer.
+ Apply petroleum jelly to O-ring.
h. Install oil strainer on control valve.

SAT221B

Securely fasten terminal harness with clips.

Install torque converter clutch solenoid valve and A/T fluid
temperature sensor connectors.

SAT009B

SAT010B

AT-1202

ASSEMBLY
Assembly (2) (Cont’d)
13. Install oil pan.
a. Attach a magnet to oil pan.

SAT011B

b. Install new oil pan gasket on transmission case.
c. Install oil pan and bracket on transmission case.
+ Always replace oil pan bolts as they are self-sealing
bolts.
+ Before installing bolts, remove traces of sealant and oil
from mating surface and thread holes.
+ Tighten four bolts in a criss-cross pattern to prevent
dislocation of gasket.
d. Tighten drain plug.
SAT601B

14. Install PNP switch.
a. Check that manual shaft is in “1” position.
b. Temporarily install PNP switch on manual shaft.
c. Move manual shaft to “N”.

SAT299I

d. Tighten bolts while inserting 4.0 mm (0.157 in) dia. pin vertically into locating holes in PNP switch and manual shaft.

SAT014B

15. Install torque converter.
a. Pour ATF into torque converter.
+ Approximately 2 liters (1-3/4 Imp qt) of fluid are required
for a new torque converter.
+ When reusing old torque converter, add the same
amount of fluid as was drained.

SAT428DA

AT-1203

ASSEMBLY
Assembly (2) (Cont’d)
b. Install torque converter while aligning notches and oil pump.

SAT016B

c. Measure distance A to check that torque converter is in
proper position.
Distance “A”:
Refer to SDS, AT-1210.

SAT017B

AT-1204

A/T FLUID COOLER SYSTEM
A/T Fluid Cooler

SAT959J

REMOVAL AND INSTALLATION
1. Remove front radiator grill. Refer to BT section (“BODY
END”).
2. Disconnect fluid hoses from A/T fluid cooler unit.
3. Remove A/T fluid cooler unit.
4. Remove A/T fluid cooler upper and lower brackets.
5. Remove clips securing fluid hose (A/T fluid cooler unit to
radiator) and loosen hose clamps, then remove the fluid
hose.
6. Loosen clamps securing fluid hose (A/T assembly to A/T fluid
cooler unit), then remove the fluid hose.
7. Remove bolts securing A/T fluid cooler tube bracket.
8. Remove fluid hose with bracket.
+ Reverse the removal procedure to install the A/T fluid cooler
unit. Refer to the component drawing and specified tightening torque.
+ Check A/T fluid level and refill if necessary. Refer to MA
section (“CHASSIS AND BODY MAINTENANCE”).

AT-1205

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Engine

ZD30DDTi

Automatic transmission
model

RE4R03A

Transmission model
code number

57X17

Stall torque ratio

2.0 : 1

Transmission gear ratio
1st

2.784

2nd

1.544

Top

1.000

0.694

Reverse

2.275

Recommended fluid

Genuine Nissan ATF or equivalent*

Fluid capacity
! (Imp qt)

11.8 (10-3/8)

*: Refer to MA section (“Fluids and Lubricants”, “RECOMMENDED
FLUIDS AND LUBRICANTS”).

Specifications and Adjustment
SHIFT SCHEDULE
Vehicle speed when shifting gears
Throttle position

Vehicle speed km/h (MPH)
Shift pattern

D 1 → D2

D2 → D 3

D3 → D 4

D4 → D 3

D3 → D 2

D2 → D 1

12 → 1 1

Standard

36 — 46
(22 — 29)

72 — 80
(45 — 50)

117 — 127
(73 — 79)

113 — 123
(70 — 76)

65 — 73
(40 — 45)

33 — 37
(21 — 23)

36 — 46
(22 — 29)

Power

36 — 46
(22 — 29)

72 — 80
(45 — 50)

117 — 127
(73 — 79)

113 — 123
(70 — 76)

65 — 73
(40 — 45)

33 — 37
(21 — 23)

36 — 46
(22 — 29)

Standard

36 — 46
(22 — 29)

72 — 80
(45 — 50)

117 — 127
(73 — 79)

113 — 123
(70 — 76)

65 — 73
(40 — 45)

33 — 37
(21 — 23)

36 — 46
(22 — 29)

Power

36 — 46
(22 — 29)

72 — 80
(45 — 50)

117 — 127
(73 — 79)

113 — 123
(70 — 76)

65 — 73
(40 — 45)

33 — 37
(21 — 23)

36 — 46
(22 — 29)

Full throttle

Half throttle

AT-1206

SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont’d)
Vehicle speed when performing and
releasing lock-up

STALL REVOLUTION
Stall revolution

rpm

2,480 — 2,680

D4
Throttle
position

Shift pattern

Vehicle speed km/h (MPH)
Lock-up
“ON”

Lock-up
“OFF”

Standard

118 — 126
(73 — 78)

114 — 122
(71 — 76)

Power

118 — 126
(73 — 78)

114 — 122
(71 — 76)

Standard

118 — 126
(73 — 78)

114 — 122
(71 — 76)

Power

118 — 126
(73 — 78)

114 — 122
(71 — 76)

LINE PRESSURE
Engine speed
rpm

Full throttle

Idle

Stall

Half throttle

AT-1207

Line pressure kPa (bar, kg/cm2, psi)
D, 2 and 1 positions

R position

450 — 490
670 — 700
(4.50 — 4.90, 4.59 — 5.00, (6.70 — 7.00, 6.83 — 7.14,
65.3 — 71.1)
97.1 — 101.5)
1,020 — 1,098
(10.20 — 10.98,
10.4 — 11.2, 148 — 159)

1,422 — 1,500
(14.22 — 15.00,
14.5 — 15.3, 206 — 218)

SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont’d)
RETURN SPRINGS
Unit: mm (in)
Item
Parts

Upper
body

Control
valve

Lower
body

Part No.*

Free length

Outer diameter

1
V

Torque converter relief
valve spring

31742-41X23

38.0 (1.496)

9.0 (0.354)

2
V

Pressure regulator valve
spring

31742-41X24

44.02 (1.7331)

14.0 (0.551)

3
V

Pressure modifier valve
spring

31742-41X19

31.95 (1.2579)

6.8 (0.268)

4
V

Shuttle shift valve D
spring

31762-41X01

25.0 (0.984)

7.0 (0.276)

4-2 sequence valve sprig

31756-41X00

29.1 (1.146)

6.95 (0.2736)

Shift valve B spring

31762-41X01

25.0 (0.984)

7.0 (0.276)

4-2 relay valve spring

31756-41X00

29.1 (1.146)

6.95 (0.2736)

Shift valve A spring

31762-41X01

25.0 (0.984)

7.0 (0.276)

9
V

Overrun clutch control
valve spring

31762-41X03

23.6 (0.929)

7.0 (0.276)

10
V

Overrun clutch reducing
valve spring

31742-41X20

32.5 (1.280)

7.0 (0.276)

11
V

Shuttle shift valve S
spring

31762-41X01

25.0 (0.984)

7.0 (0.276)

12
V

Pilot valve spring

31742-41X13

25.7 (1.012)

9.0 (0.354)

13
V

Torque converter clutch
control valve spring

31742-41X22

18.5 (0.728)

13.0 (0.512)

1
V

Modifier accumulator piston spring

31742-27X70

31.4 (1.236)

9.8 (0.386)

1st reducing valve spring

31756-41X05

25.4 (1.000)

6.75 (0.266)

3-2 timing valve spring

31742-41X06

23.0 (0.906)

6.7 (0.264)

Servo charger valve
spring

31742-41X06

23.0 (0.906)

6.7 (0.264)

5
V
6
V
7
V
8
V

2
V
3
V
4
V

Reverse clutch

12 pcs

31521-51X02
(Assembly)

40.0 (1.575)

14.8 (0.583)

High clutch

10 pcs

31521-51X03
(Assembly)

24.2 (0.953)

11.6 (0.457)

Forward clutch
(Overrun clutch)

20 pcs

32521-51X01
(Assembly)

36.8 (1.449)

10.7 (0.421)

Inner spring

16 pcs

31505-51X06

20.43 (0.8043)

10.3 (0.406)

Outer spring

16 pcs

31505-51X05

20.35 (0.8012)

13.0 (0.512)

B
Spring V

31605-41X18

47.6 (1.874)

26.3 (1.035)

C
Spring V

31605-41X01

29.7 (1.169)

27.6 (1.087)

Accumulator A

31605-41X02

43.0 (1.693)

20.0 (0.787)

B
Accumulator V

31605-41X10

66.0 (2.598)

20.0 (0.787)

C
Accumulator V

31605-41X09

45.0 (1.772)

29.3 (1.154)

D
Accumulator V

31605-41X06

58.4 (2.299)

17.3 (0.681)

Low & reverse brake

Band servo

Accumulator

*: Always check with the Parts Department for the latest parts information.

AT-1208

SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont’d)
ACCUMULATOR O-RING

Forward clutch

Diameter mm (in)
Accumulator

A
V

B
V

C
V

D
V

Small diameter end

29 (1.14)

32 (1.26)

45 (1.77)

29 (1.14)

Large diameter end

45 (1.77)

50 (1.97)

45 (1.77)

Number of drive plates

Number of driven plates

Standard

1.90 — 2.05 (0.0748 — 0.0807)

Wear limit

1.8 (0.071)
mm (in)

Standard

0.35 — 0.75 (0.0138 — 0.0295)

Allowable limit

Thickness of drive plate
mm (in)

2.55 (0.1004)

Thickness of retaining plate
1.90 — 2.05 (0.0748 — 0.0807)

Wear limit
Clearance

Number of driven plates

Clearance
57X17

Standard

Thickness of drive plate
mm (in)

CLUTCHES AND BRAKES
Reverse clutch

57X17

Number of drive plates

1.8 (0.071)
mm (in)

Standard

1.4 (0.055)

Thickness of retaining plate

Thickness
mm (in)

Part number*

4.4
4.6
4.8
5.0
5.2

31537-51X61
31537-51X00
31537-51X01
31537-51X02
31537-51X03

High clutch

(0.173)
(0.181)
(0.189)
(0.197)
(0.205)

Number of driven plates

Number of drive plates

Number of driven plates

Standard

1.52 — 1.67 (0.0598 — 0.0657)

Wear limit
Clearance

1.4 (0.055)
mm (in)

Standard

1.52 — 1.67 (0.0598 — 0.0657)

Wear limit

1.4 (0.055)

Thickness of retaining plate

mm (in)
1.8 — 2.2 (0.071 — 0.087)

Allowable limit

Thickness of retaining plate

2.4 (0.094)
Thickness
mm (in)

Part number*

3.8
4.0
4.2
4.4
4.6
4.8

31537-51X11
31537-51X12
31537-51X13
31537-51X14
31537-51X15
31537-51X64

(0.150)
(0.157)
(0.165)
(0.173)
(0.181)
(0.189)

*: Always check with the Parts Department for the latest parts information.

3.6 (0.142)
Thickness
mm (in)

Part number*

4.4
4.6
4.8
5.0
5.2
5.4

31537-51X61
31537-51X00
31537-51X01
31537-51X02
31537-51X03
31537-51X04

(0.173)
(0.181)
(0.189)
(0.197)
(0.205)
(0.213)

1.0 — 1.4 (0.039 — 0.055)

Allowable limit

Standard

31537-51X06
31537-51X07
31537-51X08
31537-51X09
31537-51X10
31537-51X69

(0.181)
(0.189)
(0.197)
(0.205)
(0.213)
(0.220)

57X17

Thickness of drive plate
mm (in)

Clearance

4.6
4.8
5.0
5.2
5.4
5.6

Thickness of drive plate
mm (in)

57X17

Number of drive plates

Part number*

Overrun clutch

0.5 — 0.8 (0.020 — 0.031)

Allowable limit

Thickness
mm (in)

*: Always check with the Parts Department for the latest parts information.

AT-1209

SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont’d)
Low & reverse brake

TOTAL END PLAY

57X17

Number of drive plates

Number of driven plates

Thickness of drive plate
mm (in)
Standard

1.52 — 1.67 (0.0598 — 0.0657)

Wear limit
Clearance

Thickness of oil pump
cover bearing race

1.4 (0.055)
mm (in)

Standard

0.5 — 0.8 (0.020 — 0.031)

Allowable limit

2.4 (0.094)

Thickness of retaining plate

Thickness
mm (in)

Part number*

3.6 (0.142)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220)
5.8 (0.228)
6.0 (0.236)*
6.2 (0.244)*

31667-51X12
31667-51X11
31667-51X10
31667-51X00
31667-51X01
31667-51X02
31667-51X03
31667-51X04
31667-51X05
31667-51X06
31667-51X07
31667-51X08
31667-51X09

Brake band
Anchor end pin tightening
torque
Nzm (kg-m, in-lb)

3.9 — 5.9
(0.4 — 0.6, 35 — 52)

Number of returning revolutions
for anchor end pin

2.5

Thickness of oil pump thrust
washer

Allowable limit

0.55 — 0.90 mm
(0.0217 — 0.0354 in)
Thickness
mm (in)

Part number*

0.9
1.1
1.3
1.5
1.7
1.9

31528-21X01
31528-21X02
31528-21X03
31528-21X04
31528-21X05
31528-21X06

(0.035)
(0.043)
(0.051)
(0.059)
(0.067)
(0.075)

REMOVAL AND INSTALLATION MODEL
Manual control linkage
Number of returning
revolutions for lock
nut

Lock nut tightening
torque

25.5 — 32.4 Nzm
(2.6 — 3.3 kg-m, 19 — 24 ft-lb)

Distance between end of
converter housing and
torque converter

0.01 — 0.024
(0.0004 — 0.0009)

Rotor, vanes and control
piston — oil pump housing

Standard

31435-41X01
31435-41X02
31435-41X03
31435-41X04
31435-41X05
31435-41X06
31435-41X07

(0.031)
(0.039)
(0.047)
(0.055)
(0.063)
(0.071)
(0.079)

*: Always check with the Parts Department for the latest parts information.

Cam ring — oil pump housing

Seal ring clearance

0.8
1.0
1.2
1.4
1.6
1.8
2.0

Reverse clutch drum end play “T2”

mm (in)

0.03 — 0.044
(0.0012 — 0.0017)

Standard

Part number*

REVERSE CLUTCH DRUM END PLAY

OIL PUMP AND LOW ONE-WAY CLUTCH

Standard

Thickness
mm (in)

*: Always check with the Parts Department for the latest parts information.

Oil pump clearance

0.25 — 0.55 mm
(0.0098 — 0.0217 in)

Total end play “T1”

mm (in)
0.10 — 0.25 (0.0039 — 0.0098)
0.25 (0.0098)

AT-1210

57X17

18.1 mm (0.713 in)
or more

BRAKE SYSTEM
SECTION

MODIFICATION NOTICE:
+ CONSULT-II is available for all models.
+ Service Data and Specifications (SDS) have been changed.
+ Wiring Diagrams have been changed.

CONTENTS
TROUBLE DIAGNOSES ………………………………. 1002
Schematic ……………………………………………….. 1002
Wiring Diagram — ABS — ………………………… 1003

Self-diagnosis…………………………………………… 1008
SERVICE DATA AND SPECIFICATIONS (SDS)1010
General Specifications ………………………………. 1010

TROUBLE DIAGNOSES
Schematic

TBR014M

BR-1002

TROUBLE DIAGNOSES
Wiring Diagram — ABS —

TBR015M

BR-1003

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR016M

BR-1004

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR017M

BR-1005

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR018M

BR-1006

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR019M

BR-1007

TROUBLE DIAGNOSES
Self-diagnosis
FUNCTION
+ When a problem occurs in the ABS, the warning lamp on the
instrument panel comes on. To start the self-diagnostic
results mode, ground the self-diagnostic (check) terminal
located on “Data Link Connector”. The location of the malfunction is indicated by the warning lamp flashing.
+ While DIFF-LOCK is on, anti-lock warning light flashes.

SELF-DIAGNOSIS PROCEDURE
Turn off DIFF-LOCK switch.
Drive vehicle over 30 km/h (19 MPH) for
at least one minute.
.

Turn ignition switch “OFF”.
.
SBR679E

Ground terminal “9” of “Data link connector” with a suitable harness.
.

Turn ignition switch “ON” while grounding terminal “9”.
Do not depress brake pedal.
.

After 3.0 seconds, the warning lamp
starts flashing to indicate the malfunction
code No. (See NOTE.)
SBR186E

Verify the location of the malfunction
with the malfunction code chart. Refer to
the original Service Manual. Then make
the necessary repairs following the diagnostic procedures.
.

After the malfunctions are repaired,
erase the malfunction codes stored in
the control unit. Refer to the original Service Manual.
SBR679E

Rerun the self-diagnostic results mode to
verify that the malfunction codes have
been erased.

Disconnect the check terminal from the
ground. The self-diagnostic results mode
is now complete.
.

A
V

BR-1008

NOTE: The indication terminates
after five minutes.
However, when the ignition
switch is turned from
“OFF” to “ON”, the indication starts flashing again.

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
A
V
.

Check warning lamp for deactivation
after driving vehicle over 30 km/h (19
MPH) for at least one minute.
.

After making certain that warning lamp
does not come on, test the ABS in a
safe area to verify that it functions properly.

BR-1009

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Europe
Body
Hardtop

Wagon

Front brake
Type

CL36VE disc brake

Cylinder bore diameter

mm (in)

Pad dimension
Length x width x thickness

mm (in)

48.1 (1.894) x 2
147 x 56.5 x 12 (5.79 x 2.224 x 0.47)

Rotor outer diameter x thickness
mm (in)

306 x 32 (12.05 x 1.26)

Rear brake
Type

CL18VF disc brake

Cylinder bore diameter

mm (in)

48.1 (1.894)

Lining or pad dimension
Length x width x thickness

mm (in)

111 x 41.8 x 10
(4.37 x 1.646 x 0.39)

Drum inner diameter

mm (in)

—

Rotor outer diameter x thickness
mm (in)

316 x 18 (12.44 x 0.71)

Brake booster
Model

235T

Diaphragm diameter

Primary: 252 (9.92)
Secondary: 230 (9.06)

mm (in)
Master cylinder bore diameter

25.4 (1.00)

mm (in)
Control valve
Type
Split point x reducing ratio
kPa (bar, kg/cm2, psi)

LSV
(Variable) x 0.3

Recommended brake fluid

(Variable) x 0.1
DOT 3 or DOT 4

BR-1010

BODY & TRIM
SECTION

MODIFICATION NOTICE:
+ The door trim has been changed.
+ The front seat with side air bag has been added.
+ An auto reverse function has been added to the driver’s door window.

CONTENTS
PRECAUTIONS …………………………………………… 1002
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 1002
DOOR…………………………………………………………. 1003
Front Door Limit Switch Reset (Driver side
only) ……………………………………………………….. 1003

INTERIOR TRIM ………………………………………….. 1004
Door Trim ………………………………………………… 1004
SEAT ………………………………………………………….. 1006
Front Seat ……………………………………………….. 1006
MIRROR ……………………………………………………… 1007
Door Mirror………………………………………………. 1007

PRECAUTIONS
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by intentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.

BT-1002

DOOR
Front Door Limit Switch Reset (Driver side
only)
RESET CONDITIONS
After each of the following operations are performed, reset the
limit switch (with built-in motor).
+ Regulator removal and installation
+ Removal of motor from regulator
+ Operation of regulator as a single unit
+ Door glass removal and installation
+ Glass run removal and installation

RESET PROCEDURES

SBT846

After installing parts, proceed as follows:
1. Close the door window completely.
2. Press the reset switch and open the door window completely.
3. Release the reset switch. After making sure the reset switch
has returned to the original position, close the door window
completely.
4. The limit switch is now reset.
CAUTION:
Be sure to manually open or close the door window. (Do not
use the automatic open-close procedures.)

BT-1003

INTERIOR TRIM
Door Trim
REMOVAL — Door trim
1
V
2
V
3
V
4
V
5
V
6
V
7
V

Remove inner cover from front corner of door. Refer to “Door Mirror” for details, BT-1007.
Remove inside handle escutcheon.
Remove door armrest.
Remove cover and screw securing power window switches, then disconnect the connector.
Remove screw securing door trim.
Remove clips securing door trim.
Lift out door trim.

SBT847

BT-1004

INTERIOR TRIM
Door Trim (Cont’d)

SBT566

BT-1005

SEAT
Front Seat
+When removing or installing the seat trim, carefully handle it to keep dirt out and avoid damage.

POWER SEAT

SBT848

BT-1006

MIRROR
Door Mirror
CAUTION:
Be careful not to scratch door rearview mirror body.
★ For Wiring Diagram, refer to “POWER DOOR MIRROR” in EL section.

REMOVAL — Door mirror
1
V
2
V
3
V
4
V
5
V

Remove clip securing inner cover, then remove inner cover.
Remove door trim. Refer to “Door Trim” for details, BT-1004.
Roll back sealing screen and remove door mirror harness connector.
Remove door mirror harness clip.
Remove bolts securing door mirror, then remove door mirror assembly.

SBT849

BT-1007

CLUTCH
SECTION

MODIFICATION NOTICE:
+ The ZD30DDTi engine model has been added.

CONTENTS
CLUTCH SYSTEM……………………………………….. 1002
HYDRAULIC CLUTCH CONTROL ………………… 1003
Clutch Operating Cylinder………………………….. 1003
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1004

General Specifications ………………………………. 1004
Inspection and Adjustment ………………………… 1004

CLUTCH SYSTEM

SMA for VIN > JN1KESY61U0141418 and
>JN1TESY61U0144435

SCL824

CL-1002

HYDRAULIC CLUTCH CONTROL
Clutch Operating Cylinder

SCL771-C

SMA for VIN > JN1KESY61U0141418 and
>JN1TESY61U0144435

CL-1003

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
CLUTCH DISC

CLUTCH COVER

Model

275

Body

Engine

ZD30DDTi

Model

275

Engine

ZD30DDTi

Facing size
(Outer dia. x inner dia. x thickness)
mm (in)

275 x 180 x 3.5
(10.83 x 7.09 x 0.138)

Thickness of disc assembly with load
mm (in)/N (kg, lb)

7.7 — 8.3 (0.303 — 0.327)/
7,846 (800, 1,764)

Full load

Hardtop

N (kg, lb)

6,473 — 7,257
(660 — 740,
1,455 — 1,632)

Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)

ZD30DDTi
Pedal height “H*”

Pedal free play “A” (at pedal pad)

195 — 205
(7.68 — 8.07)
1.0 — 3.0 (0.039 — 0.118)

*: Measured from surface of melt sheet to pedal pad

CL-1004

Except Hardtop

7,355 — 8,336
(750 — 850,
1,654 — 1,874)

ENGINE CONTROL SYSTEM
SECTION

MODIFICATION NOTICE:
+ The RD28ETi engine has been replaced by the ZD30DDTi engine.

CONTENTS
ZD30DDTi
PRECAUTIONS AND PREPARATION …………… 1005
Special Service Tool …………………………………. 1005
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 1005
TROUBLE DIAGNOSIS — INDEX…………………. 1006
Alphabetical & Numerical Index for DTC……… 1006
PRECAUTIONS …………………………………………… 1008
Precautions ……………………………………………… 1008
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM……………………………………………………… 1011
ECCS-D Component Parts Location …………… 1011
Circuit Diagram ………………………………………… 1015
System Diagram ………………………………………. 1016
Vacuum Hose Drawing ……………………………… 1017
System Chart …………………………………………… 1018
ENGINE AND EMISSION BASIC CONTROL
SYSTEM……………………………………………………… 1019
Fuel Injection Control System…………………….. 1019
Fuel Injection Timing Control System………….. 1021
Air Conditioning Cut Control ………………………. 1021
Fuel Cut Control (at no load & high engine
speed) …………………………………………………….. 1021
Crankcase Ventilation System……………………. 1022
BASIC SERVICE PROCEDURE ……………………. 1023
Injection Tube and Injection Nozzle ……………. 1023
Electronic Control Fuel Injection Pump ……….. 1026
Air Bleeding……………………………………………… 1031
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION …………………………………………….. 1032
DTC and MI Detection Logic ……………………… 1032
Diagnostic Trouble Code (DTC) …………………. 1032
Malfunction Indicator (MI) ………………………….. 1033

CONSULT-II…………………………………………….. 1038
TROUBLE DIAGNOSIS — INTRODUCTION ….. 1045
Introduction ……………………………………………… 1045
Work Flow ……………………………………………….. 1047
TROUBLE DIAGNOSIS — BASIC
INSPECTION……………………………………………….. 1049
Basic Inspection……………………………………….. 1049
TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION …………………………………………….. 1055
Symptom Matrix Chart ………………………………. 1055
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1065
Major Sensor Reference Graph in Data
Monitor Mode …………………………………………… 1067
ECM Terminals and Reference Value…………. 1068
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT……………………………………………………. 1076
Description ………………………………………………. 1076
Diagnostic Procedure………………………………… 1076
TROUBLE DIAGNOSIS FOR POWER
SUPPLY ……………………………………………………… 1077
Main Power Supply and Ground Circuit ………. 1077
DTC 0102 MASS AIR FLOW SEN…………………. 1086
Component Description …………………………….. 1086
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1086
ECM Terminals and Reference Value…………. 1086
On Board Diagnosis Logic…………………………. 1086
DTC Confirmation Procedure …………………….. 1087
Wiring Diagram ………………………………………… 1088
Diagnostic Procedure………………………………… 1089
DTC 0103 COOLANT TEMP SEN …………………. 1092
Description ………………………………………………. 1092

On Board Diagnosis Logic…………………………. 1092
DTC Confirmation Procedure …………………….. 1092
Wiring Diagram ………………………………………… 1093
Diagnostic Procedure………………………………… 1094
DTC 0104 VEHICLE SPEED SEN …………………. 1096
Description ………………………………………………. 1096
ECM Terminals and Reference Value…………. 1096
On Board Diagnosis Logic…………………………. 1096
Overall Function Check …………………………….. 1097
Wiring Diagram ………………………………………… 1098
Diagnostic Procedure………………………………… 1099
DTC 0203 ACCEL POS SW (F/C) …………………. 1100
Description ………………………………………………. 1100
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1100
ECM Terminals and Reference Value…………. 1100
On Board Diagnosis Logic…………………………. 1100
DTC Confirmation Procedure …………………….. 1101
Wiring Diagram ………………………………………… 1102
Diagnostic Procedure………………………………… 1103
DTC 0208 OVER HEAT………………………………… 1105
Description ………………………………………………. 1105
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1105
ECM Terminals and Reference Value…………. 1106
On Board Diagnosis Logic…………………………. 1106
Overall Function Check …………………………….. 1107
Wiring Diagram ………………………………………… 1108
Diagnostic Procedure………………………………… 1109
Main 12 Causes of Overheating…………………. 1116
DTC 0301 ECM 2, DTC 0901 ECM 12 …………… 1117
Description ………………………………………………. 1117
On Board Diagnosis Logic…………………………. 1117
DTC Confirmation Procedure …………………….. 1117
Diagnostic Procedure………………………………… 1118
DTC 0402 P9zFUEL TEMP SEN ……………………. 1119
Description ………………………………………………. 1119
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1120
ECM Terminals and Reference Value…………. 1120
On Board Diagnosis Logic…………………………. 1120
DTC Confirmation Procedure …………………….. 1121
Wiring Diagram ………………………………………… 1122
Diagnostic Procedure………………………………… 1123
DTC 0403 ACCEL POS SENSOR …………………. 1125
Description ………………………………………………. 1125
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1125
ECM Terminals and Reference Value…………. 1126
On Board Diagnosis Logic…………………………. 1126
DTC Confirmation Procedure …………………….. 1127
Wiring Diagram ………………………………………… 1128
Diagnostic Procedure………………………………… 1130
DTC 0406 INT AIR VOL ……………………………….. 1138

On Board Diagnosis Logic…………………………. 1138
DTC Confirmation Procedure …………………….. 1138
Diagnostic Procedure………………………………… 1139
DTC 0407 CRANK POS SEN (TDC) ……………… 1140
Description ………………………………………………. 1140
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1140
ECM Terminals and Reference Value…………. 1140
On Board Diagnosis Logic…………………………. 1141
DTC Confirmation Procedure …………………….. 1141
Wiring Diagram ………………………………………… 1142
Diagnostic Procedure………………………………… 1143
DTC 0502 BATTERY VOLTAGE …………………… 1146
On Board Diagnosis Logic…………………………. 1146
DTC Confirmation Procedure …………………….. 1146
Diagnostic Procedure………………………………… 1146
DTC 0504 A/T COMM LINE ………………………….. 1148
System Description …………………………………… 1148
ECM Terminals and Reference Value…………. 1148
On Board Diagnosis Logic…………………………. 1148
DTC Confirmation Procedure …………………….. 1149
Overall Function Check …………………………….. 1149
Wiring Diagram ………………………………………… 1150
Diagnostic Procedure………………………………… 1151
DTC 0701 P1zCAM POS SEN ……………………….. 1153
Description ………………………………………………. 1153
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1154
ECM Terminals and Reference Value…………. 1154
On Board Diagnosis Logic…………………………. 1154
DTC Confirmation Procedure …………………….. 1155
Wiring Diagram ………………………………………… 1156
Diagnostic Procedure………………………………… 1157
DTC 0702 P2zTDC PULSE SIG……………………… 1159
Description ………………………………………………. 1159
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1160
ECM Terminals and Reference Value…………. 1160
On Board Diagnosis Logic…………………………. 1160
DTC Confirmation Procedure …………………….. 1161
Wiring Diagram ………………………………………… 1162
Diagnostic Procedure………………………………… 1163
DTC 0703 P3zPUMP COMM LINE …………………. 1165
Description ………………………………………………. 1165
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1166
ECM Terminals and Reference Value…………. 1166
On Board Diagnosis Logic…………………………. 1166
DTC Confirmation Procedure …………………….. 1167
Wiring Diagram ………………………………………… 1168
Diagnostic Procedure………………………………… 1169
DTC 0704 P4zSPILL/V CIRC, DTC 0706
P6zSPILL VALVE …………………………………………. 1171
Description ………………………………………………. 1171

EC-1002

CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1172
ECM Terminals and Reference Value…………. 1172
On Board Diagnosis Logic…………………………. 1172
DTC Confirmation Procedure …………………….. 1173
Wiring Diagram ………………………………………… 1174
Diagnostic Procedure………………………………… 1175
DTC 0705 P5zPUMP C/MODULE…………………… 1177
Description ………………………………………………. 1177
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1178
ECM Terminals and Reference Value…………. 1178
On Board Diagnosis Logic…………………………. 1178
DTC Confirmation Procedure …………………….. 1179
Diagnostic Procedure………………………………… 1179
DTC 0707 P7zF/INJ TIMG FB………………………… 1180
Description ………………………………………………. 1180
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1181
ECM Terminals and Reference Value…………. 1181
On Board Diagnosis Logic…………………………. 1181
DTC Confirmation Procedure …………………….. 1182
Wiring Diagram ………………………………………… 1183
Diagnostic Procedure………………………………… 1184
DTC 0802 ECM 10……………………………………….. 1187
Description ………………………………………………. 1187
On Board Diagnosis Logic…………………………. 1187
DTC Confirmation Procedure …………………….. 1187
Diagnostic Procedure………………………………… 1188
DTC 0804 ECM 11……………………………………….. 1189
Description ………………………………………………. 1189
On Board Diagnosis Logic…………………………. 1189
DTC Confirmation Procedure …………………….. 1189
Diagnostic Procedure………………………………… 1190
DTC 0807 ECM 14……………………………………….. 1191
Description ………………………………………………. 1191
ECM Terminals and Reference Value…………. 1191
On Board Diagnosis Logic…………………………. 1191
DTC Confirmation Procedure …………………….. 1191
Wiring Diagram ………………………………………… 1192
Diagnostic Procedure………………………………… 1193
DTC 0902 ECM RLY ……………………………………. 1196
ECM Terminals and Reference Value…………. 1196
On Board Diagnosis Logic…………………………. 1196
DTC Confirmation Procedure …………………….. 1196
Wiring Diagram ………………………………………… 1197
Diagnostic Procedure………………………………… 1198
DTC 0903 ECM 15……………………………………….. 1200
Description ………………………………………………. 1200
On Board Diagnosis Logic…………………………. 1200
DTC Confirmation Procedure …………………….. 1200
Diagnostic Procedure………………………………… 1201
DTC 0905 TURBO PRESSURE …………………….. 1202
Component Description …………………………….. 1202

ECM Terminals and Reference Value…………. 1202
On Board Diagnosis Logic…………………………. 1202
DTC Confirmation Procedure …………………….. 1203
Wiring Diagram ………………………………………… 1204
Diagnostic Procedure………………………………… 1205
DTC 1003 EGR VOLUME CONT/V………………… 1207
Description ………………………………………………. 1207
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1208
ECM Terminals and Reference Value…………. 1208
DTC Confirmation Procedure …………………….. 1208
Wiring Diagram ………………………………………… 1209
Diagnostic Procedure………………………………… 1210
DTC 1004 FUEL CUT SYSTEM1…………………… 1215
Description ………………………………………………. 1215
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1216
ECM Terminals and Reference Value…………. 1216
On Board Diagnosis Logic…………………………. 1216
DTC Confirmation Procedure …………………….. 1217
Wiring Diagram ………………………………………… 1218
Diagnostic Procedure………………………………… 1219
GLOW CONTROL SYSTEM …………………………. 1221
Description ………………………………………………. 1221
ECM Terminals and Reference Value…………. 1222
Wiring Diagram ………………………………………… 1223
Diagnostic Procedure………………………………… 1224
START SIGNAL…………………………………………… 1230
Wiring Diagram ………………………………………… 1230
Diagnostic Procedure………………………………… 1231
PARK/NEUTRAL POSITION (PNP) SWITCH …. 1233
Description ………………………………………………. 1233
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1233
ECM Terminals and Reference Value…………. 1233
Wiring Diagram ………………………………………… 1234
Diagnostic Procedure………………………………… 1235
HEAT UP SWITCH ………………………………………. 1241
Component Description …………………………….. 1241
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1241
ECM Terminals and Reference Value…………. 1241
Wiring Diagram ………………………………………… 1242
Diagnostic Procedure………………………………… 1243
SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE………………………………………. 1246
Description ………………………………………………. 1246
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1247
ECM Terminals and Reference Value…………. 1247
Wiring Diagram ………………………………………… 1248
Diagnostic Procedure………………………………… 1249
INTAKE AIR CONTROL VALVE CONTROL
SOLENOID………………………………………………….. 1254

EC-1003

Description ………………………………………………. 1254
ECM Terminals and Reference Value…………. 1254
Wiring Diagram ………………………………………… 1255
Diagnostic Procedure………………………………… 1256
VARIABLE NOZZLE TURBOCHARGER
CONTROL…………………………………………………… 1261
Description ………………………………………………. 1261
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1261
ECM Terminals and Reference Value…………. 1262
Wiring Diagram ………………………………………… 1263
Diagnostic Procedure………………………………… 1264
EXHAUST GAS CONTROL VALVE CONTROL
SOLENOID………………………………………………….. 1269
Description ………………………………………………. 1269
CONSULT-II Reference Value in Data Monitor
Mode ………………………………………………………. 1269

ECM Terminals and Reference Value…………. 1269
Wiring Diagram ………………………………………… 1270
Diagnostic Procedure………………………………… 1271
AIR CONDITIONER CONTROL …………………….. 1275
Wiring Diagram ………………………………………… 1275
MI & DATA LINK CONNECTORS …………………. 1276
Wiring Diagram ………………………………………… 1276
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1277
General Specifications ………………………………. 1277
Injection Pump Numbers …………………………… 1277
Injection Nozzle………………………………………… 1277
Engine Coolant Temperature Sensor ………….. 1277
Crankshaft Position Sensor (TDC) ……………… 1277
Glow Plug………………………………………………… 1277
Accelerator Position Sensor ………………………. 1277
EGR Volume Control Valve ……………………….. 1277

EC-1004

PRECAUTIONS AND PREPARATION

ZD30DDTi

Special Service Tool
Tool number
Tool name

Description

KV10109300
Puller holder

a = 68 mm (2.68 in)
b = 8 mm (0.31 in) dia.

NT628

EC-1005

TROUBLE DIAGNOSIS — INDEX

ZD30DDTi

Alphabetical & Numerical Index for DTC
ALPHABETICAL INDEX FOR DTC
X: Applicable —: Not applicable
Items
(CONSULT-II screen terms)

DTC

MI illumination

Reference page

ACCEL POS SENSOR

0403

EC-1125

ACCEL POS SW (F/C)

0203

EC-1100

A/T COMM LINE

0504

—

EC-1148

COOLANT TEMP SEN

0103

EC-1092

CRANK POS SEN (TDC)

0407

EC-1140

ECM 2

0301

EC-1117

ECM 10

0802

EC-1187

ECM 11

0804

—

EC-1189

ECM 14

0807

EC-1191

ECM 15

0903

—

EC-1200

ECM RLY

0902

EC-1196

EGR VOLUME CONT/V

1003

EC-1207

FUEL CUT SYSTEM1

1004

EC-1215

INT/AIR VOLUME

0406

—

EC-1138

MASS AIR FLOW SEN

0102

EC-1086

NATS MALFUNCTION

1401 — 1408

—

EL section

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

0505

—

OVER HEAT

0208

EC-1105

P1zCAM POS SEN

0701

EC-1153

P2zTDC PULSE SIG

0702

EC-1159

P3zPUMP COMM LINE

0703

EC-1165

P4zSPILL/V CIRC

0704

EC-1171

P5zPUMP C/MODULE

0705

EC-1177

P6zSPILL VALVE

0706

EC-1171

P7zF/INJ TIMG FB

0707

EC-1180

P9zFUEL TEMP SEN

0402

EC-1119

TURBO PRESSURE

0905

EC-1202

VEHICLE SPEED SEN

0104

EC-1096

EC-1006

ZD30DDTi
TROUBLE DIAGNOSIS — INDEX
Alphabetical & Numerical Index for DTC
(Cont’d)

NUMERICAL INDEX FOR DTC
X: Applicable —: Not applicable
DTC

Items
(CONSULT-II screen terms)

MI illumination

Reference page

0102

MASS AIR FLOW SEN

EC-1086

0103

COOLANT TEMP SEN

EC-1092

0104

VEHICLE SPEED SEN

EC-1096

0203

ACCEL POS SW (F/C)

EC-1100

0208

OVER HEAT

EC-1105

0301

ECM 2

EC-1117

0402

P9zFUEL TEMP SEN

EC-1119

0403

ACCEL POS SENSOR

EC-1125

0406

INT/AIR VOLUME

—

EC-1138

0407

CRANK POS SEN (TDC)

EC-1140

0504

A/T COMM LINE

—

EC-1148

0505

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

—

0701

P1zCAM POS SEN

EC-1153

0702

P2zTDC PULSE SIG

EC-1159

0703

P3zPUMP COMM LINE

EC-1165

0704

P4zSPILL/V CIRC

EC-1171

0705

P5zPUMP C/MODULE

EC-1177

0706

P6zSPILL VALVE

EC-1171

0707

P7zF/INJ TIMG FB

EC-1180

0802

ECM 10

EC-1187

0804

ECM 11

—

EC-1189

0807

ECM 14

EC-1191

0902

ECM RLY

EC-1196

0903

ECM 15

—

EC-1200

0905

TURBO PRESSURE

EC-1202

1003

EGR VOLUME CONT/V

EC-1207

1004

FUEL CUT SYSTEM1

EC-1215

1401 — 1408

NATS MALFUNCTION

—

EL section

EC-1007

PRECAUTIONS

ZD30DDTi

Precautions

SEF706Y

+ Always use a 12 volt battery as power source.
+ Do not attempt to disconnect battery cable while engine
is running.
+ Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect
negative battery terminal. Failure to do so may damage
the ECM because battery voltage is applied to ECM even
if ignition switch is turned off.
+ Before removing parts, turn off ignition switch and then
disconnect battery ground cable.
+ Do not disassemble ECM.
+ If a battery terminal is disconnected, the memory will
return to the ECM value.
The ECM will now start to self-control at its initial value.
Engine operation can vary slightly when the terminal is
disconnected. However, this is not an indication of a
problem. Do not replace parts because of a slight variation.

SEC220B

+ When ECM is removed for inspection, make sure to
ground the ECM mainframe.

SEF665S

+ When connecting ECM harness connector, tighten
securing bolt until the gap between the orange indicators disappears.
: 3.0 — 5.0 Nzm (0.3 — 0.5 kg-m, 26 — 43 in-lb)

SEF308Q

SEF291H

+ When connecting or disconnecting pin connectors into
or from ECM, take care not to damage pin terminals
(bend or break).
Make sure that there are not any bends or breaks on
ECM pin terminal, when connecting pin connectors.
+ Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in the circuit, thus resulting in damage to ICs.
+ Keep ECM harness at least 10 cm (3.9 in) away from
adjacent harnesses, to prevent an ECM system malfunc-

EC-1008

PRECAUTIONS
Precautions (Cont’d)

ZD30DDTi

tion due to receiving external noise, degraded operation
of ICs, etc.
+ Keep ECM parts and harnesses dry.

+ Before replacing ECM, perform Terminals and Reference
Value inspection and make sure ECM functions properly.
Refer to EC-1068.

MEF040D

SAT652J

+ If MI illuminates or blinks irregularly when engine is
running, water may have accumulated in fuel filter. Drain
water from fuel filter. If this does not correct the problem,
perform specified trouble diagnostic procedures.
+ After performing each TROUBLE DIAGNOSIS, perform
“DTC Confirmation Procedure” or “Overall Function
Check”.
The DTC should not be displayed in the “ DTC Confirmation Procedure” if the repair is completed. The “Overall
Function Check” should be a good result if the repair is
completed.
+ When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit
and damage the ECM power transistor.
+ Do not use ECM ground terminals when measuring
input/output voltage. Doing so may result in damage to
the ECM’s transistor. Use a ground other than ECM
terminals, such as the ground.

SEF348N

EC-1009

PRECAUTIONS
Precautions (Cont’d)

ZD30DDTi

+ Do not disconnect pump harness connector with engine
running.
+ Do not disassemble electronic fuel injection pump.
If NG, take proper action.
+ Do not disassemble injection nozzle.
If NG, replace injection nozzle.
+ Even a slight leak in the air intake system can cause
serious problems.
+ Do not shock or jar the crankshaft position sensor
(TDC).
SEF437Y

+ Do not depress accelerator pedal when starting.
+ Immediately after starting, do not rev up engine unnecessarily.
+ Do not rev up engine just prior to shutdown.

SEF709Y

SEF708Y

+ When installing C.B. ham radio or a mobile phone, be
sure to observe the following as it may adversely affect
electronic control systems depending on its installation
location.
1) Keep the antenna as far as possible away from the ECM.
2) Keep the antenna feeder line more than 20 cm (7.9 in)
away from the harness of electronic controls.
Do not let them run parallel for a long distance.
3) Adjust the antenna and feeder line so that the standingwave ratio can be kept smaller.
4) Be sure to ground the radio to vehicle body.

EC-1010

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ZD30DDTi

ECCS-D Component Parts Location

SEF219Z

EC-1011

ENGINE AND EMISSION CONTROL OVERALL SYSTEM ZD30DDTi
ECCS-D Component Parts Location (Cont’d)

SEF220Z

EC-1012

ENGINE AND EMISSION CONTROL OVERALL SYSTEM ZD30DDTi
ECCS-D Component Parts Location (Cont’d)

SEF221Z

EC-1013

ENGINE AND EMISSION CONTROL OVERALL SYSTEM ZD30DDTi
ECCS-D Component Parts Location (Cont’d)

SEF286Z

EC-1014

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ZD30DDTi

Circuit Diagram

TEC095M

EC-1015

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ZD30DDTi

System Diagram

SEF222Z

EC-1016

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ZD30DDTi

Vacuum Hose Drawing

JEF223Z

1.
2.
3.
4.

Swirl control valve control solenoid valve to 3-way connector
Swirl control valve control solenoid valve to swirl control valve
actuator
Vacuum gallery to 3-way connector
Intake air control valve control
solenoid valve to intake air control
valve actuator

5.
6.
7.
8.
9.

Intake air control valve control
solenoid valve to 3-way connector
Variable nozzle turbocharger control solenoid valve to vacuum tank
Vacuum tank to vacuum gallery
Variable nozzle turbocharger control actuator to vacuum damper
Variable nozzle turbocharger control solenoid valve to vacuum
damper

Refer to “System Diagram”, EC-1016 for vacuum control system.

EC-1017

10. Variable nozzle turbocharger control solenoid valve to resonator
11. Vacuum pump to vacuum gallery
12. Exhaust gas control valve control
solenoid valve to 3-way connector
13. Exhaust gas control valve control
solenoid valve to exhaust gas
control valve actuator

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ZD30DDTi

System Chart
Input (Sensor)
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+

Electronic control fuel injection pump
Crankshaft position sensor (TDC)
Engine coolant temperature sensor
Accelerator position sensor
Accelerator position switch
Accelerator switch (F/C)
Park/Neutral position (PNP) switch
Ignition switch
Battery voltage
Vehicle speed sensor
Air conditioner switch
Mass air flow sensor
Stop lamp switch
Heat up switch
Charge air pressure sensor*1

ECM Function

Output (Actuator)

Fuel injection control

Electronic control fuel injection pump

Fuel injection timing control

Electronic control fuel injection pump

Fuel cut control

Electronic control fuel injection pump

Glow control system

Glow relay & glow lamp

On board diagnostic system

MIL (On the instrument panel)

EGR volume control

EGR volume control valve

Cooling fan control

Cooling fan relay

Air conditioning cut control

Air conditioner relay

Variable nozzle turbocharger control

Variable nozzle turbocharger control solenoid valve

Swirl control valve control

Swirl control valve control solenoid valve

Intake air control valve control

Intake air control valve control solenoid
valve

Exhaust gas control valve control*2

Exhaust gas control valve control solenoid
valve*2

*1: This sensor is not used to control the engine system under normal conditions.
*2: For models for cold areas

EC-1018

ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTION

ZD30DDTi

Fuel Injection Control System
DESCRIPTION
System description
Three types of fuel injection control are provided to accommodate engine operating conditions; normal
control, idle control and start control. The ECM determines the appropriate fuel injection control. Under each
control, the amount of fuel injected is compensated to improve engine performance.
Pulse signals are exchanged between ECM and electronic control fuel injection pump (control unit is builtin). The fuel injection pump control unit performs duty control on the spill valve (built into the fuel injection
pump) according to the input signals to compensate the amount of fuel injected to the preset value.

Start control
Input/output signal chart
Sensor

Input Signal to ECM

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (TDC)

Engine speed

Ignition switch

Start signal

ECM Function

Actuator

Fuel injection con- Electronic control fuel injectrol (start control) tion pump

When the ECM receives a start signal from the ignition switch,
the ECM adapts the fuel injection system for the start control.
The amount of fuel injected at engine starting is a preset program
value in the ECM. The program is determined by the engine
speed and engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches the specific value, and shifts the control to the normal
or idle control.
SEF648S

Idle control
Input/output signal chart
Sensor

Input Signal to ECM

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (TDC)

Engine speed

Park/Neutral position (PNP) switch

Gear position

Battery

Battery voltage

Accelerator position switch

Idle position

Vehicle speed sensor

Vehicle speed

Air conditioner switch

Air conditioner signal

Heat up switch

Heat up switch signal

ECM Function

Actuator

Fuel injection con- Electronic control fuel injectrol (Idle control)
tion pump

When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the
engine to keep engine speed constant. The ECM also provides the system with a fast idle control in response
to the engine coolant temperature and heat up switch signal.

EC-1019

ENGINE AND EMISSION BASIC CONTROL SYSTEM
ZD30DDTi
DESCRIPTION
Fuel Injection Control System (Cont’d)
Normal control
Input/output signal chart
Sensor

Input Signal to ECM

Crankshaft position sensor (TDC)

Engine speed

Accelerator position sensor

Accelerator position

Vehicle speed sensor

Vehicle speed

ECM Function

Actuator

Fuel injection conElectronic control fuel injectrol (Normal contion pump
trol)

The amount of fuel injected under normal driving conditions is
determined according to sensor signals. The crankshaft position
sensor (TDC) detects engine speed and the accelerator position
sensor detects accelerator position. These sensors send signals
to the ECM.
The fuel injection data, predetermined by correlation between
various engine speeds and accelerator positions, are stored in
the ECM memory, forming a map. The ECM determines the
optimal amount of fuel to be injected using the sensor signals in
comparison with the map.
SEF649S

Maximum amount control
Input/output signal chart
Sensor

Input Signal to ECM

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (TDC)

Engine speed

Accelerator position sensor

Accelerator position

ECM Function

Actuator

Fuel injection conElectronic control fuel injectrol (Maximum
tion pump
amount control)

The maximum injection amount is controlled to an optimum by the engine speed, intake air amount, engine
coolant temperature, and accelerator opening in accordance with the driving conditions.
This prevents the oversupply of the injection amount caused by decreased air density at a high altitude or
during a system failure.

Deceleration control
Input/output signal chart
Sensor

Input Signal to ECM

Accelerator switch (F/C)

Accelerator position

Crankshaft position sensor (TDC)

Engine speed

ECM Function

Actuator

Fuel injection conElectronic control fuel injectrol (Deceleration
tion pump
control)

The ECM sends a fuel cut signal to the electronic control fuel injection pump during deceleration for better
fuel efficiency. The ECM determines the time of deceleration according to signals from the accelerator switch
(F/C) and crankshaft position sensor (TDC).

EC-1020

ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTION

ZD30DDTi

Fuel Injection Timing Control System
DESCRIPTION
The target fuel injection timing in accordance with the engine speed and the fuel injection amount are
recorded as a map in the ECM beforehand. The ECM and the injection pump control unit exchange signals
and perform feedback control for optimum injection timing in accordance with the map.

Air Conditioning Cut Control
DESCRIPTION
Input/output signal chart
Sensor

Input Signal to ECM

Air conditioner switch

Air conditioner “ON” signal

Accelerator position sensor

Accelerator valve opening
angle

Vehicle speed sensor

Vehicle speed

Engine coolant temperature sensor

Engine coolant temperature

ECM Function

Actuator

Air conditioner cut
Air conditioner relay
control

System description
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues until the engine coolant temperature returns to normal.

Fuel Cut Control (at no load & high engine
speed)
DESCRIPTION
Input/output signal chart
Sensor

Input Signal to ECM

Vehicle speed sensor

Vehicle speed

Park/Neutral position (PNP) switch

Neutral position

Accelerator position switch or Accelerator
switch (F/C)

Accelerator position

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (TDC)

Engine speed

ECM Function

Fuel cut control

Actuator

Electronic control fuel injection pump

If the engine speed is above 2,700 rpm with no load (for example, in neutral and engine speed over 2,700
rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed.
Fuel cut will operate until the engine speed reaches 1,500 rpm, then fuel cut is cancelled.
NOTE:
This function is different from deceleration control listed under “Fuel Injection Control System”,
EC-1019.

EC-1021

ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTION

ZD30DDTi

Crankcase Ventilation System
DESCRIPTION
In this system, blow-by gas is sucked into the air inlet pipe after
oil separation by oil separator in the rocker cover.

JEF224Z

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

SEC692

EC-1022

BASIC SERVICE PROCEDURE

ZD30DDTi

Injection Tube and Injection Nozzle
REMOVAL AND INSTALLATION
CAUTION:
+ Do not disassemble injection nozzle assembly. If NG,
replace injection nozzle assembly.
+ Plug flare nut with a cap or rag so that no dust enters the
nozzle. Cover nozzle tip for protection of needle.

JEF237Z

Injection tube

JEF238Z

Removal
1. Mark the cylinder Nos. to the injection tubes, then disconnect
them.
+ Marking should be made at proper locations and by the
proper method, so that they are not erased by fuel, etc.
2. Remove the clamps, then disconnect the tubes one by one.
+ Avoid letting leaked fuel get on the interior walls of the
engine compartment.
Take special care to prevent fuel from getting on the engine
mount insulator.

EC-1023

ZD30DDTi
BASIC SERVICE PROCEDURE
Injection Tube and Injection Nozzle (Cont’d)
Installation
+ Install the injection tubes, referring to the markings made
during removal.
+ Install the injection tubes in the order of No. 3, No. 4, No. 1,
and No. 2.

Injection nozzle oil seal

JEF248Z

Removal
Using a tool such as a flat-bladed screwdriver, pry the flange of
the seal, then remove it.
Installation
After the injection nozzle assembly is installed, push the seal
from the cylinder head side until it contacts the flange.
+ Replace the oil seal with new one when the injection
nozzle assembly is removed. (It is not necessary to
replace the oil seal when only injection tubes are
removed.)

Spill tube
Installation
+ After the spill tube is installed, check the airtightness of
the spill tube.
+ After the bolts are tightened, the joint of the spill tube gasket
might be broken. However, this will not affect function.

Injection nozzle assembly

JEF249Z

Removal
1. Remove the nozzle support, then pull out the injection nozzle
assembly by turning it clockwise/counterclockwise.
2. Using a tool such as a flat-head screwdriver, remove the
copper washer inside the cylinder head.
CAUTION:
Do not disassemble the injection nozzle.
Installation
1. Insert the nozzle gasket to the cylinder head hole.
2. Attach the O-ring to the mounting groove of the nozzle side,
then insert it in the cylinder head.

TEST AND ADJUSTMENT
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and
make sure your eyes are properly protected with goggles.

EC-1024

ZD30DDTi
BASIC SERVICE PROCEDURE
Injection Tube and Injection Nozzle (Cont’d)

Inspection for spill tube airtightness
Before the rocker cover is installed, perform the inspection as
follows.
1. Connect the handy vacuum pump to the spill hose.
2. Check that the airtightness is maintained after the negative
pressure shown below is applied.
Standard:
−53.3 to −66.7 kPa (−533 to −667 mbar, −400 to
−500 mmHg, −15.75 to −19.69 inHg)
JEF250Z

Air bleeding of fuel piping
After the repair, bleed air in the piping by pumping the priming
pump up and down until it becomes heavy.

SEF251Z

Injection pressure test
1. Install injection nozzle assembly to injection nozzle tester
and bleed air from flare nut.

JEF348Y

EC-1025

ZD30DDTi
BASIC SERVICE PROCEDURE
Injection Tube and Injection Nozzle (Cont’d)

Spray pattern test
1. Check spray pattern by pumping tester handle one full stroke
per second.
NG spray pattern:
Does not inject straight and strong (B in the figure).
Fuel drips (C in the figure).
Does not inject evenly (D in the figure).
2. If the spray pattern is not correct, replace injection nozzle
assembly.
JEF349Y

Electronic Control Fuel Injection Pump
REMOVAL AND INSTALLATION
CAUTION:
When removing or installing the timing chain as incidental work of the fuel injection pump removal/
installation, always secure the internal mechanism of the idler gear with bolts before removing or
installing the fuel injection pump sprocket. Do not refer to the procedure for “TIMING CHAIN” in EM
section based on No. 1 cylinder compression top dead center. (Unless otherwise specified.)

JEF259Z

EC-1026

ZD30DDTi
BASIC SERVICE PROCEDURE
Electronic Control Fuel Injection Pump (Cont’d)

REMOVAL
1.
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
2.

Remove the following:
Engine coolant draining
Charge air cooler
Air inlet pipe
Throttle body
Rocker cover
Oil level gauge guide
EGR guide tube
EGR volume control solenoid valve
Fuel hose
Injection tube
Radiator upper hose
Radiator shroud
Cooling fan
Drive belt
Vacuum pipe
Vacuum pump
Move the power steering pump.

3. Remove the harness connector from the fuel injection pump.
+ After pulling the connector stopper all the way back, remove
the connector.
+ When the stopper is pulled all the way back, the interlockedconnector will come off.
As for installation, when the connector is pushed all the way
forward until the stopper locks, the interlocked-connector is
inserted.
4. Remove the fuel injection pump rear bracket.
JEF260Z

5. Remove the chain cover.
+ Remove the installation bolts A, B, and C shown in the figure (left).
CAUTION:
During chain cover removal, seal the opening to prevent
foreign objects from getting into the engine.

JEF261Z

6. Fix the internal mechanism of the idler gear (scissors gear
structure).
a. Remove the plug on the front side of the gear case.
b. While turning the crankshaft pulley clockwise, check the
tightening bolt hole of the idler gear internal mechanism
through the plug hole.
+ Conduct the visual check using a mirror.
+ When checking, note that there are 2 other holes (with no
thread) beside the tightening bolt hole on the idler gear.
JEF262Z

EC-1027

ZD30DDTi
BASIC SERVICE PROCEDURE
Electronic Control Fuel Injection Pump (Cont’d)

JEF263Z

c. Install the tightening bolt [Part No.: 81-20620-28, thread
diameter: M6, under head: 20 mm (0.79 in), pitch: 1.0 mm
(0.039 in)] to the idler gear tightening bolt hole, and tighten
to the specified torque:
: 2.5 — 3.4 Nzm (0.25 — 0.35 kg-m, 22 — 30 in-lb)
CAUTION:
+ To protect the idler gear from damage, do not use the
substitute part for the tightening bolt.
+ Hereafter, do not turn the crankshaft to avoid hitting
tightening bolt head against the gear case.
+ Do not remove the idler gear tightening bolt before
installations of the timing chain and related parts are
completed.
7. Make mating marks on the cam sprocket, fuel injection pump
sprocket, and timing chain with paint.
8. Make mating marks on the fuel injection pump gear and idler
gear with paint.

JEF264Z

9. Remove the chain tensioner.
(1) Loosen the upper and lower installation bolts.
(2) While holding the chain tensioner by hand, remove the upper
installation bolt to release the spring tension.
(3) Remove the lower installation bolt first, and then the chain
tensioner.
+ Since the chain tensioner does not have a mechanism to
prevent the plunger pop-out, watch out for the fall of the
plunger and spring. (Return prevention mechanism is available.)
JEF265Z

10. Remove the timing chain slack guide.
11. Remove the cam sprocket and timing chain at the same time.
+ Make mating marks on each sprocket and timing chain.
+ Hold the hexagon head of the camshaft on the exhaust manifold side, and loosen the cam sprocket installation bolt.
CAUTION:
Do not loosen the installation bolt using a chain tension.

JEF266Z

12. Remove the fuel injection pump sprocket and gear as an
assembly.
+ Fix the fuel injection pump gear with the pulley holder (SST),
and loosen the installation bolt for removal.
+ Try not to move the pump shaft when removing.
+ Connect the sprocket and gear with a dowel pin, and tighten
them together with the installation bolt.

JEF267Z

EC-1028

ZD30DDTi
BASIC SERVICE PROCEDURE
Electronic Control Fuel Injection Pump (Cont’d)
13. Make the mating marks on the fuel injection pump flange and
front plate with paint.
14. Remove installation bolts first, and then fuel injection pump
toward the rear side of the engine.
+ When the fuel injection pump is stationary, it can still be
retained by the dowel without all bolts.
CAUTION:
Do not disassemble or adjust the fuel injection pump.

JEF268Z

INSTALLATION
+ The injection timing adjustment to correct the installation
angle deviation is not necessary. Install the pump in the
proper position according to the dowel and installation bolts.
1. Install the fuel injection pump from the rear side of the
engine.
+ Match the dowel of the spacer to the dowel hole of the pump
side for installation.
+ Replace the seal washer of the installation bolt with a new
one.
JEF269Z

2. Align the mating marks of the fuel injection pump flange and
front plate, and then adjust the approximate flange position.
+ Each hole [6 mm (0.24 in) dia.] is used as a reference point
for the fuel injection pump flange, fuel injection pump gear,
and fuel injection pump sprocket.
+ Only during removal/installation at No. 1 cylinder compression top dead center, can the hole [6 mm (0.24 in) dia.] of the
pump body be aligned.

JEF270Z

3. Install the fuel injection pump sprocket and gear as an
assembly.
+ Align the mating marks of the idler gear and fuel injection
pump gear properly.

JEF271Z

4. Tighten the installation bolt of the fuel injection pump
sprocket.
+ Fix the fuel injection pump gear with the pulley holder (SST),
and tighten the installation bolt.
CAUTION:
Before tightening the installation bolt, check again that the
mating marks of the idler gear and fuel injection pump gear
are aligned.

JEF267Z

EC-1029

ZD30DDTi
BASIC SERVICE PROCEDURE
Electronic Control Fuel Injection Pump (Cont’d)
5. Install the cam sprocket and timing chain at the same time.
+ Align the mating marks of the fuel injection pump sprocket
and cam sprocket, and install the timing chain.
+ Holding the hexagon head of the camshaft with a wrench,
tighten the cam sprocket installation bolt.
CAUTION:
Do not tighten the installation bolt using a chain tension.
6. Install the timing chain, related parts, and the chain cover.
Refer to EM section, “TIMING CHAIN”.
JEF264Z

7. Remove the tightening bolt of the idler gear internal mechanism.
8. Apply the liquid gasket to the screw of the plug, and tighten
the plug.
: 7.9 — 9.8 Nzm (0.8 — 1.0 kg-m, 70 — 86 in-lb)
+ Use Genuine Liquid Gasket or equivalent.

JEF272Z

9. Install the fuel injection pump rear bracket.
+ Tighten all the installation bolts temporarily, and then tighten
them firmly with both surfaces of the fuel injection pump and
cylinder block attached to the installation surface.

JEF273Z

10. Connect the harness connector of the fuel injection pump.
+ Insert the harness connector until the stopper is completely
locked.
+ When the connector is pushed fully to lock the stopper, the
interlocked-connector is inserted.

JEF260Z

11. Installation is in the reverse order of removal.

EC-1030

BASIC SERVICE PROCEDURE

ZD30DDTi

Air Bleeding

SEF251Z

Pump the priming pump to bleed air.
+ When air is bled completely, the pumping of the priming
pump suddenly becomes heavy. Stop operation at that
time.
+ If it is difficult to bleed air by the pumping of the priming pump (the pumping of the priming pump does not
become heavy), disconnect the fuel supply hose
between the fuel filter and the injection pump. Then, perform the operation described above, and make sure that
fuel comes out. (Use a pan, etc. so as not to spill fuel.
Do not let fuel get on engine and other parts.) After that,
connect the hose, and then bleed air again.

EC-1031

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ZD30DDTi

DTC and MI Detection Logic
When a malfunction is detected, the malfunction (DTC) is stored in the ECM memory.
The MI will light up each time the ECM detects malfunction. For diagnostic items causing the MI to light up,
refer to “TROUBLE DIAGNOSIS — INDEX”, EC-1006.

Diagnostic Trouble Code (DTC)
HOW TO READ DTC
The DTC can be read by the following methods.
Without CONSULT-II
ECM displays the DTC by a set of four digit numbers with MI illumination in the diagnostic test mode II
(Self-diagnostic results). Example: 0102, 0407, 1004, etc.
With CONSULT-II
CONSULT-II displays the DTC in “SELF-DIAG RESULTS” mode. Examples: “CRANK POS SEN (TDC)”, etc.
+ Output of the trouble code means that the indicated circuit has a malfunction. However, in the
Mode II it does not indicate whether the malfunction is still occurring or occurred in the past and
returned to normal.
CONSULT-II can identify them. Therefore, using CONSULT-II (if available) is recommended.

HOW TO ERASE DTC
How to erase DTC (

With CONSULT-II)

1.If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
5 seconds and then turn it “ON” (engine stopped) again.
2. Touch “ENGINE”.
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. (The DTC in the ECM will be erased.)

SEF371Y

The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II.

How to erase DTC (

Without CONSULT-II)

1.If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
5 seconds and then turn it “ON” (engine stopped) again.

EC-1032

ZD30DDTi
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Diagnostic Trouble Code (DTC) (Cont’d)
2. Change the diagnostic test mode from Mode II to Mode I by using the data link connector. (See
EC-1035.)
The emission related diagnostic information in the ECM can be erased by changing the diagnostic test mode.
+ If the battery is disconnected, the emission-related diagnostic information will be lost after
approx. 24 hours.
+ Erasing the emission-related diagnostic information using CONSULT-II is easier and quicker than
switching the diagnostic test mode using the data link connector.

NATS (Nissan Anti-Theft System)

SEF252Z

+ If the security indicator lights up with the ignition switch
in the “ON” position or “NATS MALFUNCTION” is displayed on “SELF-DIAG RESULTS” screen, perform selfdiagnostic results mode with CONSULT-II using NATS
program card. Refer to “NATS (Nissan Anti-Theft System)” in EL section.
+ Confirm no self-diagnostic results of NATS is displayed
before touching “ERASE” in “SELF-DIAG RESULTS”
mode with CONSULT-II.
+ When replacing ECM, initialization of NATS system and
registration of all NATS ignition key IDs must be carried
out with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle
owner. Regarding the procedures of NATS initialization
and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.

Malfunction Indicator (MI)
DESCRIPTION

SAT652J

The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON
without the engine running. This is a bulb check.
+ If the MI does not light up, refer to EL section (“WARNING
LAMPS AND CHIME”) or see EC-1276.
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.
If MI illuminates or blinks irregularly after starting engine,
water may have accumulated in fuel filter. Drain water from
fuel filter. Refer to MA section.

EC-1033

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator (MI) (Cont’d)

ZD30DDTi

On board diagnostic system function
The on board diagnostic system has the following three functions.
Diagnostic Test Mode

KEY and ENG. Status Function

Explanation of Function

Mode I

Ignition switch in ON
position

BULB CHECK

This function checks the MI bulb for damage
(blown, open circuit, etc.).
If the MI does not come on, check MI circuit.
(See EC-1276.)

Engine running

MALFUNCTION
WARNING

This is a usual driving condition. When ECM
detects a malfunction, the MI will light up to
inform the driver that a malfunction has been
detected.

Ignition switch in ON
position

SELF-DIAGNOSTIC RESULTS

This function allows DTCs to be read.

Engine stopped

Mode II

Engine stopped

EC-1034

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator (MI) (Cont’d)

ZD30DDTi

How to switch diagnostic test modes

SEF372YB

*1: EC-1276

*2: EC-1034

EC-1035

*3: EC-1276

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator (MI) (Cont’d)

ZD30DDTi

Diagnostic test mode I — Bulb check
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EL
section, “WARNING LAMPS AND CHIME” or see EC-1276.

Diagnostic test mode I — Malfunction warning
MI

Condition

When the malfunction is detected or the ECM’s CPU is malfunctioning.

OFF

No malfunction.

Diagnostic test mode II — Self-diagnostic results
In this mode, DTC is indicated by the number of blinks of the MI as shown below.

SEF298QA

SEF162PB

Long (0.6 second) blinking indicates the two LH digits of number and short (0.3 second) blinking indicates
the two RH digits of number. For example, the MI blinks 10 times for 6 seconds (0.6 sec x 10 times) and
then it blinks three times for about 1 second (0.3 sec x 3 times). This indicates the DTC “1003”.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC “0505” refers to no
malfunction. (See TROUBLE DIAGNOSIS — INDEX, EC-1006.)

How to erase diagnostic test mode II (Self-diagnostic results)
The DTC can be erased from the backup memory in the ECM when the diagnostic test mode is changed
from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to “How to Switch Diagnostic Test Modes”,
EC-1035.)
+ If the battery terminal is disconnected, the DTC will be lost from the backup memory within 24
hours.
+ Be careful not to erase the stored memory before starting trouble diagnoses.

EC-1036

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator (MI) (Cont’d)

ZD30DDTi

Relationship between MI, DTC, CONSULT-II and driving patterns

SEF659SC

*1: When a malfunction is detected,
MI will light up.
*2: When the same malfunction is
detected in two consecutive driving patterns, MI will stay lit up.
*3: MI will go off after vehicle is
driven three times without any
malfunctions.

*4: When a malfunction is detected
for the first time, the DTC will be
stored in ECM.
*5: The DTC will not be displayed any
longer after vehicle is driven 40
times without the same malfunction. (The DTC still remain in
ECM.)

EC-1037

*6: Other screens except SELF-DIAGNOSTIC RESULTS & DATA
MONITOR (AUTO TRIG) cannot
display the malfunction. DATA
MONITOR (AUTO TRIG) can display the malfunction at the
moment it is detected.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ZD30DDTi

CONSULT-II
CONSULT-II INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Connect CONSULT-II to data link connector, which is located
under the driver side dash panel.

SAT165K

3.
4.
5.
6.

Turn ignition switch ON.
Touch “START”.
Touch “ENGINE”.
Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT-II Operation
Manual.

SEF995X

SEF320Y

EC-1038

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)

ZD30DDTi

ENGINE CONTROL COMPONENT PARTS/CONTROL
SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE

ENGINE CONTROL COMPONENT PARTS

Item

SELF-DIAG
RESULTS

DATA MONITOR

Engine coolant temperature sensor

Vehicle speed sensor

Accelerator position sensor

Accelerator position switch

Accelerator switch (F/C)

Crankshaft position sensor (TDC)

Ignition switch (start signal)

Park/Neutral position (PNP) switch

Battery voltage

Air conditioner switch

ACTIVE
TEST

INPUT

Mass air flow sensor

Stop lamp switch

Heat up switch

Charge air pressure sensor

Glow relay

OUTPUT

EGR volume control valve

Cooling fan relay

Air conditioner relay

Variable nozzle turbocharger control solenoid valve

Swirl control valve control solenoid valve

Exhaust gas control valve control solenoid valve

X: Applicable

SELF-DIAGNOSTIC MODE
Regarding items detected in “SELF-DIAG RESULTS” mode,
refer to “TROUBLE DIAGNOSIS — INDEX”, EC-1006.

DATA MONITOR MODE
Monitored item
[Unit]

ECM
input
signals

Main
signals

CKPSzRPM (TDC)
[rpm]

+ The engine speed computed from the
crankshaft position sensor (TDC) signal
is displayed.

CMPSzRPMzPUMP
[rpm]

+ The engine speed computed from the
pulse signal sent from electronic control
fuel injection pump is displayed.

COOLAN TEMP/S
[°C] or [°F]
j

Description

+ The engine coolant temperature (determined by the signal voltage of the
engine coolant temperature sensor) is
displayed.

EC-1039

Remarks

+ When the engine coolant temperature
sensor is open or short-circuited, ECM
enters fail-safe mode. The engine coolant temperature determined by the ECM
is displayed.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)
Monitored item
[Unit]

ECM
input
signals

Main
signals

Description

+ The vehicle speed computed from the
vehicle speed sensor signal is displayed.

+ The fuel temperature (sent from electronic control fuel injection pump) is displayed.

+ The accelerator position sensor signal
voltage is displayed.

FULL ACCEL SW
[ON/OFF]

+ Indicates [ON/OFF] condition from the
accelerator position switch signal.

ACCEL SW (FC)
[OPEN/CLOSE]

+ Indicates [OPEN/CLOSE] condition from
the accelerator switch (FC) signal.

OFF ACCEL SW
[ON/OFF]

+ Indicates [ON/OFF] condition from the
accelerator position switch signal.

+ The control position of spill valve (sent
from electronic control fuel injection
pump) is displayed.

+ The power supply voltage of ECM is displayed.

P/N POSI SW
[ON/OFF]

+ Indicates [ON/OFF] condition from the
park/neutral position switch signal.

START SIGNAL
[ON/OFF]

+ Indicates [ON/OFF] condition from the
starter signal.

+ Indicates [ON/OFF] condition of the air
conditioner switch as determined by the
air conditioner signal.

+ Indicates [ON/OFF] condition from the
stop lamp switch signal.

IGN SW
[ON/OFF]

+ Indicates [ON/OFF] condition from ignition switch signal.

WARM UP SW
[ON/OFF]

VHCL SPEED SE
[km/h] or [mph]
FUEL TEMP SEN
[°C] or [°F]
ACCEL POS SEN [V]

SPILL/V [°CA]

BATTERY VOLT [V]

AIR COND SIG
[ON/OFF]
BRAKE SW [ON/OFF]

DECELER F/CUT
[ON/OFF]

+ The signal voltage of the mass air flow
sensor is displayed.

+ The [ON/OFF] condition from deceleration fuel cut signal (sent from electronic
control fuel injection pump) is displayed.

+ The duty ratio of fuel injection timing
control valve (sent from electronic control fuel injection pump) is displayed.

+ Indicates the control condition of the air
conditioner relay (determined by ECM
according to the input signals).

+ The glow relay control condition (determined by ECM according to the input
signal) is displayed.

INJ TIMG C/V [%]

AIR COND RLY
[ON/OFF]

Remarks

+ After starting the engine, [OFF] is displayed regardless of the starter signal.

+ Indicates [ON/OFF] condition from the
heat up switch signal.

MAS AIR/FL SE [V]
j

ZD30DDTi

GLOW RLY [ON/OFF]

EC-1040

+ When the engine is stopped, a certain
value is indicated.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)
Monitored item
[Unit]

ECM
input
signals

Main
signals

Description

+ Indicates the control condition of the
cooling fans (determined by ECM
according to the input signal).
+ ON … Operates.
OFF … Stopped.

+ Indicates the EGR volume control value
computed by the ECM according to the
input signals.
+ The opening becomes larger as the
value increases.

COOLING FAN
[ON/OFF]

EGR VOL CON/V
[step]

VNT S/V 1 [%]

+ Indicates the variable nozzle turbocharger control solenoid valve control
value computed by the ECM according
to the input signals.

BARO SEN [kPa]

+ The barometric pressure (determined by
the signal voltage from the barometric
pressure sensor built into the ECM) is
displayed.

SWRL CON S/V 1
[ON/OFF]
j

EXH/GAS REG V
[ON/OFF]

ZD30DDTi

Remarks

+ The control condition of the swirl control
valve control solenoid valve (determined
by ECM according to the input signals)
is indicated.
+ ON … Swirl control valve is closed.
+ OFF … Swirl control valve is opened.
+ The control condition of the exhaust gas
control valve control solenoid valve
(computed by ECM according to the
input signals) is indicated.
+ ON … Exhaust gas control valve is
closed.
+ OFF … Exhaust gas control valve is
opened.

+ This item is applicable for cold area
models.
On other models, “OFF” is always displayed.

NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-1041

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)

ZD30DDTi

ACTIVE TEST MODE
TEST ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

COOLING FAN

+ Ignition switch: ON
+ Operate the cooling fan at
“LOW”, “HI” speed and turn
“OFF” using CONSULT-II.

OFF ACCEL PO
SIG

+ Clears the self-learning fully closed accelerator position, detected by accelerator position sensor, from the
ECM.

GLOW RLY

+ Ignition switch: ON (Engine
stopped)
+ Turn the glow relay “ON” and
“OFF” using CONSULT-II and
listen to operating sound.

Glow relay makes the operating
sound.

INJ TIMING*

+ Engine: Return to the original
trouble condition
+ Retard the injection timing using
CONSULT-II.

If trouble symptom disappears, see + Electronic control fuel injection
CHECK ITEM.
pump

+ Ignition switch: ON
+ Turn solenoid valve “ON” and
SWIRL CONT S/V1
“OFF” with the CONSULT-II and
listen to operating sound.

EGR VOL CONT/V

+ Ignition switch: ON
+ Change EGR volume control
valve opening step using CONSULT-II.

Cooling fan moves at “LOW”, “HI”
speed and stops.

+ Harness and connector
+ Cooling fan motor
+ Cooling fan relay

+ Harness and connector
+ Glow relay

Solenoid valve makes an operating + Harness and connector
sound.
+ Solenoid valve

EGR volume control valve makes
an operating sound.

+ Harness and connector
+ EGR volume control valve

*: When using this item, DTC 0707 “P7zF/INJ TIMG FB” may be detected. If so, erase it because it is not a malfunction.

EC-1042

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)

ZD30DDTi

REAL TIME DIAGNOSIS IN DATA MONITOR MODE

SEF373Y

SEF707X

CONSULT-II has two kinds of triggers and they can be selected
by touching “SETTING” in “DATA MONITOR” mode.
1) “AUTO TRIG” (Automatic trigger):
+ The malfunction will be identified on the CONSULT-II screen
in real time.
In other words, DTC will be displayed if the malfunction is
detected by ECM.
At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording
Data … xx%” as shown at left, and the data after the malfunction detection is recorded. Then when the percentage
reached 100%, “REAL-TIME DIAG” screen is displayed. If
“STOP” is touched on the screen during “ Recording Data …
xx%”, “REAL-TIME DIAG” screen is also displayed.
The recording time after the malfunction detection and the
recording speed can be changed by “TRIGGER POINT” and
“Recording Speed”. Refer to CONSULT-II OPERATION
MANUAL.
2) “MANU TRIG” (Manual trigger):
+ DTC will not be displayed automatically on CONSULT-II
screen even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even
though a malfunction is detected.
Use these triggers as follows:
1) “AUTO TRIG”
+ While trying to detect the DTC by performing the “DTC Confirmation Procedure”, be sure to select to “DATA MONITOR
(AUTO TRIG)” mode. You can confirm the malfunction at the
moment it is detected.
+ While narrowing down the possible causes, CONSULT-II
should be set in “DATA MONITOR (AUTO TRIG)” mode,
especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or
twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a
malfunction is found the DTC will be displayed. (Refer to GI
section, “Incident Simulation Tests” in “HOW TO PERFORM
EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.)
2) “MANU TRIG”
+ If the malfunction is displayed as soon as “DATA MONITOR”
is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The
data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

EC-1043

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II (Cont’d)

ZD30DDTi

SEF720X

EC-1044

TROUBLE DIAGNOSIS — INTRODUCTION

ZD30DDTi

Introduction

SEF858S

SEF233G

The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control
system, etc. The ECM accepts input signals from sensors and
instantly drives electronic control fuel injection pump. It is essential that both input and output signals are proper and stable. At
the same time, it is important that there are no problems such as
vacuum leaks, or other problems with the engine.
It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A
road test with CONSULT-II or a circuit tester connected should
be performed. Follow the “Work Flow”, EC-1047.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The
customer can supply good information about such problems,
especially intermittent ones. Find out what symptoms are present
and under what conditions they occur. A “Diagnostic Worksheet”
like the example on next page should be used.
Start your diagnosis by looking for “conventional” problems first.
This will help troubleshoot driveability problems on an electronically controlled engine vehicle.

SEF234G

DIAGNOSTIC WORKSHEET
There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can
make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order
to organize all the information for troubleshooting.
SEF907L

EC-1045

TROUBLE DIAGNOSIS — INTRODUCTION
Introduction (Cont’d)

ZD30DDTi

Worksheet sample

MTBL0397

EC-1046

TROUBLE DIAGNOSIS — INTRODUCTION

ZD30DDTi

Work Flow

SEF374YB

Refer to MA section (“Checking
and Replacing Fuel Filter and
Draining Water”, “ENGINE MAINTENANCE”).
If time data of “SELF-DIAG
RESULTS” is other than “0”, perform “TROUBLE DIAGNOSIS
FOR INTERMITTENT INCIDENT”,
EC-1076.

If the incident cannot be verified,
perform “TROUBLE DIAGNOSIS
FOR INTERMITTENT INCIDENT”,
EC-1076.
If the on board diagnostic system
cannot be performed, check main
power supply and ground circuit.

EC-1047

Refer to “TROUBLE DIAGNOSIS
FOR POWER SUPPLY”,
EC-1077.
If malfunctioning part cannot be
detected, perform “TROUBLE
DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.

TROUBLE DIAGNOSIS — INTRODUCTION
Work Flow (Cont’d)

ZD30DDTi

DESCRIPTION FOR WORK FLOW
STEP

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using
the “DIAGNOSTIC WORKSHEET”, EC-1045.

STEP II

Before confirming the concern, check and write down (print out using CONSULT-II) the DTC, then erase the
DTC. Refer to EC-1032.
If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
“Symptom Matrix Chart” will be useful. Refer to EC-1055.) Also check related service bulletins for information.

STEP III

Try to confirm the symptom and under what conditions the incident occurs.
The “DIAGNOSTIC WORK SHEET” is useful to verify the incident. Connect CONSULT-II to the vehicle in DATA
MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
If the malfunction code is detected, skip STEP IV and perform STEP V.

STEP IV

Try to detect the DTC by driving in (or performing) the “DTC Confirmation Procedure”. Check and read the DTC
by using CONSULT-II.
During the DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG)
mode and check real time diagnosis results.
If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
In case the “DTC Confirmation Procedure” is not available, perform the “Overall Function Check” instead. The
DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative.
The “NG” result of the “Overall Function Check” is the same as the DTC detection.

STEP V

Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC XXXX.
If the normal code is indicated, proceed to the Basic Inspection, EC-1049. Then perform inspections according to
the Symptom Matrix Chart. Refer to EC-1055.

STEP VI

Identify where to begin diagnosis based on the relationship study between symptom and possible causes.
Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR
(AUTO TRIG)” mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II. Refer to EC-1068 or EC-1065.
The “Diagnostic Procedure” in EC section contains a description based on open circuit inspection. A short circuit
inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to GI section (“Circuit Inspection”, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”).
Repair or replace the malfunction parts.
If the malfunctioning part cannot be detected, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT”, EC-1076.

STEP VII

Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer’s initial complaint.
Perform the “DTC Confirmation Procedure” and confirm the normal code (DTC No. 0505) is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM.
(Refer to EC-1032.)

EC-1048

TROUBLE DIAGNOSIS — BASIC INSPECTION

ZD30DDTi

Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
+ Shift lever is in neutral position,
+ Heat up switch is OFF,
+ Headlamp switch is OFF,
+ Air conditioner switch is OFF,
+ Rear defogger switch is OFF,
+ Steering wheel is in the straight-ahead position, etc.
1

INSPECTION START

1. Check service records for any recent repairs that may indicate a related problem.
2. Check the current need for scheduled maintenance, especially for fuel filter and air cleaner filter. Refer to MA section.
3. Open engine hood and check the following:
+ Harness connectors for improper connections
+ Vacuum hoses for splits, kinks, or improper connections
+ Wiring for improper connections, pinches, or cuts

SEF142I

4. Start engine and warm it up to the normal operating temperature.
c GO TO 2.

PREPARATION FOR CHECKING IDLE SPEED

With CONSULT-II
Connect CONSULT-II to the data link connector.
Without CONSULT-II
Install diesel tacho tester to the vehicle.
c GO TO 3.

EC-1049

TROUBLE DIAGNOSIS — BASIC INSPECTION
Basic Inspection (Cont’d)
3

CHECK IDLE SPEED

With CONSULT-II
1. Select “CKPSzRPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
2. Read idle speed.

SEF817Y

Without CONSULT-II
Check idle speed.
750±25 rpm
OK or NG
OK

c INSPECTION END

c GO TO 4.

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK

c GO TO 5.

c Repair or replace.

BLEED AIR FROM FUEL SYSTEM

1. Stop engine.
2. Using priming pump, bleed air from fuel system. Refer to “Air Bleeding”, EC-1031.
c GO TO 6.

EC-1050

ZD30DDTi

TROUBLE DIAGNOSIS — BASIC INSPECTION
Basic Inspection (Cont’d)
6

ZD30DDTi

CHECK IDLE SPEED AGAIN

With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPSzRPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.

SEF817Y

Without CONSULT-II
1. Start engine and let it idle.
2. Check idle speed.
750±25 rpm
OK or NG
OK

c INSPECTION END

c GO TO 7.

DRIN WATER FROM FUEL FILTER

Drain water from fuel filter. Refer to MA section (“Checking and Replacing Fuel Filter and Draining Water”, “ENGINE MAINTENANCE”).
c GO TO 8.

EC-1051

TROUBLE DIAGNOSIS — BASIC INSPECTION
Basic Inspection (Cont’d)
8

CHECK IDLE SPEED AGAIN

With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPSzRPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.

SEF817Y

Without CONSULT-II
1. Start engine and let it idle.
2. Check idle speed.
750±25 rpm
OK or NG
OK

c INSPECTION END

c GO TO 9.

EC-1052

ZD30DDTi

TROUBLE DIAGNOSIS — BASIC INSPECTION
Basic Inspection (Cont’d)
9

CHECK AIR CLEANER FILTER

Check air cleaner filter for clogging or breaks.
OK or NG
OK

c GO TO 10.

c Replace air cleaner filter.

CHECK FUEL INJECTION NOZZLE

Check fuel injection nozzle opening pressure. Refer to “Injection pressure test”, EC-1025.
OK or NG
OK

c GO TO 11.

c Replace fuel injection nozzle assembly.

CHECK IDLE SPEED AGAIN

With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPSzRPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.

SEF817Y

Without CONSULT-II
1. Start engine and let it idle.
2. Check idle speed.
750±25 rpm
OK or NG
OK

c INSPECTION END

c GO TO 12.

CHECK COMPRESSION PRESSURE

Check compression pressure. Refer to EM section, “MEASUREMENT OF COMPRESSION PRESSURE”.
OK or NG
OK

c GO TO 13.

c Follow the instruction of “MEASUREMENT OF COMPRESSION PRESSURE”.

EC-1053

ZD30DDTi

TROUBLE DIAGNOSIS — BASIC INSPECTION
Basic Inspection (Cont’d)
13

CHECK IDLE SPEED AGAIN

With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPSzRPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.

SEF817Y

Without CONSULT-II
1. Start engine and let it idle.
2. Check idle speed.
750±25 rpm
OK or NG
OK

c INSPECTION END

c Replace electronic control fuel injection pump.

EC-1054

ZD30DDTi

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ZD30DDTi

Symptom Matrix Chart

Feature of symptom, Check point

Reference page

HI IDLE

POOR ACCELERATION

LACK OF POWER

LOW IDLE

KNOCK/DETONATION

WHEN DECELERATING

DURING DRIVING

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

Warranty symptom code

AT IDLE

NO START (without first firing)

NO START (with first firing)

SYSTEM — Basic engine control system

HARD TO START WHEN ENGINE IS HOT

HARD TO START WHEN ENGINE IS COLD

HARD/NO START/RESTART
(EXCP. HA)

SYMPTOM

—

EC-1023

Electronic control fuel injection pump
mainframe

Injection nozzle

Glow system

Engine body

EC-1221
3

EGR system

EC-1207

Air cleaner and ducts

MA section

1 — 5: The numbers refer to the order of inspection.
(continued on next page)
*1: Fuel injection system malfunction or fuel injection timing control system malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.

EC-1055

EM section

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

ZD30DDTi

Injection nozzle

—

Glow system
Engine body

Feature of symptom, Check point

Reference page

Electronic control fuel injection pump
mainframe

Fuel cut

Can be detected by CONSULT-II?

EXCESSIVE OIL CONSUMPTION

Malfunction indicator lamp illuminates.

EXCESSIVE FUEL CONSUMPTION

DEAD BATTERY (UNDER CHARGE)

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

ABNORMAL SMOKE COLOR

SLOW/NO RETURN TO IDLE

Warranty symptom code

WHITE SMOKE

IDLING VIBRATION

SYSTEM — Basic engine control system

BLACK SMOKE

ROUGH IDLE/HUNTING

SYMPTOM

EGR system

Air cleaner and ducts

EC-1221

EM section

EC-1207
3

EC-1056

EC-1023

MA section

ZD30DDTi

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

ENGINE CONTROL

Electronic control fuel injection pump
circuit

*a, *b

1
1

AE
1

LOW IDLE

HI IDLE

POOR ACCELERATION

LACK OF POWER

KNOCK/DETONATION

AC AD

AF
1

Feature of symptom, Check point

HESITATION/SURGING/FLAT SPOT

WHEN DECELERATING

ENGINE STALL
DURING DRIVING

AT IDLE

Reference page

Warranty symptom code

HARD TO START WHEN ENGINE IS HOT

NO START (without first firing)

NO START (with first firing)

Malfunction

SYSTEM — ENGINE CONTROL system

HARD TO START WHEN ENGINE IS COLD

HARD/NO START/RESTART
(EXCP. HA)

SYMPTOM

—

*c, *d
*a, *c

Mass air flow sensor circuit

EC-1086

*b
Engine coolant temperature sensor
circuit

*a, *b

Vehicle speed sensor circuit

*a, *b

1
1

1 — 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*1: Compensation according to engine coolant temperature does not function.

EC-1057

EC-1092
EC-1096

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

ZD30DDTi

*a, *b

*c, *d

—

EC-1086

EC-1092

EC-1096

Feature of symptom, Check point

Reference page

Fuel cut

DEAD BATTERY (UNDER CHARGE)

ABNORMAL SMOKE COLOR
WHITE SMOKE

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

SLOW/NO RETURN TO IDLE

BLACK SMOKE
AP

Can be detected by CONSULT-II?

Electronic control fuel injection pump
circuit

AG AH AJ AK AL AM

Malfunction indicator lamp illuminates.

ENGINE CONTROL

Warranty symptom code

IDLING VIBRATION

ROUGH IDLE/HUNTING

SYSTEM — ENGINE CONTROL system

Malfunction

SYMPTOM

*a, *c
Mass air flow sensor circuit
*b
Engine coolant temperature sensor
circuit

*a, *b

Vehicle speed sensor circuit

*a, *b

1
1

EC-1058

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

ZD30DDTi

*a, *b

LOW IDLE

HI IDLE

POOR ACCELERATION

LACK OF POWER

KNOCK/DETONATION

AC AD

Feature of symptom, Check point

HESITATION/SURGING/FLAT SPOT

WHEN DECELERATING

ENGINE STALL
DURING DRIVING

AT IDLE

Reference page

Warranty symptom code

HARD TO START WHEN ENGINE IS HOT

NO START (without first firing)

NO START (with first firing)

Malfunction

SYSTEM — ENGINE CONTROL system

HARD TO START WHEN ENGINE IS COLD

HARD/NO START/RESTART
(EXCP. HA)

SYMPTOM

Accelerator switch (FC) circuit

EC-1100
*c
*a, *c

Fuel cut system line

EC-1215

ENGINE CONTROL

*b
Accelerator position sensor circuit

*a, *b

Crankshaft position sensor (TDC)
circuit

*a, *b

Charge air pressure sensor circuit

*2
1

*a,
*b, *c

EC-1125
EC-1140

Swirl control valve control solenoid
valve circuit

*a, *b

Variable nozzle turbocharger control
solenoid valve circuit

*a, *b

EC-1202

EC-1246
*c

EC-1261

Intake air control valve control solenoid valve circuit

Exhaust gas control valve control
solenoid valve circuit

1 — 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*2: Engine runs on after turning ignition switch OFF.

EC-1059

EC-1254
1

EC-1269

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

ZD30DDTi

Feature of symptom, Check point

Reference page

Fuel cut

Can be detected by CONSULT-II?

DEAD BATTERY (UNDER CHARGE)

ABNORMAL SMOKE COLOR
WHITE SMOKE

BLACK SMOKE

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

IDLING VIBRATION

AG AH AJ AK AL AM

Malfunction indicator lamp illuminates.

Warranty symptom code

ROUGH IDLE/HUNTING

Malfunction

SYSTEM — ENGINE CONTROL system

SLOW/NO RETURN TO IDLE

SYMPTOM

*a, *b
Accelerator switch (FC) circuit

EC-1100

*c
*a, *c
Fuel cut system line

EC-1215

ENGINE CONTROL

*b
Accelerator position sensor circuit

*a, *b

Crankshaft position sensor (TDC) circuit

*a, *b

EC-1125

EC-1140

EC-1202

Charge air pressure sensor circuit

*a, *b, *c

Swirl control valve control solenoid
valve circuit

*a, *b
*c

Variable nozzle turbocharger control
solenoid valve circuit

*a, *b

1
EC-1246
1
EC-1261

Intake air control valve control solenoid valve circuit

Exhaust gas control valve control
solenoid valve circuit

1
EC-1254

1 — 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*2: Engine runs on after turning ignition switch OFF.

EC-1060

EC-1269

ZD30DDTi

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

*a, *b

AC AD

LOW IDLE

HI IDLE

POOR ACCELERATION

LACK OF POWER

KNOCK/DETONATION

HESITATION/SURGING/FLAT SPOT

WHEN DECELERATING

ENGINE STALL
DURING DRIVING

AT IDLE

*a, *b

Feature of symptom, Check point

Start signal circuit

Reference page

Warranty symptom code

HARD TO START WHEN ENGINE IS HOT

NO START (without first firing)

NO START (with first firing)

Malfunction

SYSTEM — ENGINE CONTROL system

HARD TO START WHEN ENGINE IS COLD

HARD/NO START/RESTART
(EXCP. HA)

SYMPTOM

EC-1230

PNP switch circuit

EC-1233

ENGINE CONTROL

*c
Accelerator position switch (Idle) circuit
Accelerator position switch (Full) circuit

*a, *c

1
EC-1125

*a, *b

Ignition switch circuit

*4
EC-1125

1
EC-1077

*a
Power supply for ECM circuit

EC-1077
*b

1 — 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*3: Start control does not function.
*4: Accelerator position sensor NG signal is output.
*5: Engine does not stop.

EC-1061

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

ZD30DDTi

*a, *b

Feature of symptom, Check point

Fuel cut

Can be detected by CONSULT-II?

DEAD BATTERY (UNDER CHARGE)

ABNORMAL SMOKE COLOR
WHITE SMOKE

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

IDLING VIBRATION

BLACK SMOKE
AP

Reference page

Start signal circuit

AG AH AJ AK AL AM

Malfunction indicator lamp illuminates.

Warranty symptom code

ROUGH IDLE/HUNTING

Malfunction

SYSTEM — ENGINE CONTROL system

SLOW/NO RETURN TO IDLE

SYMPTOM

EC-1230

*a, *b
PNP switch circuit

EC-1233

ENGINE CONTROL

*c
Accelerator position switch (Idle) circuit
Accelerator position switch (Full) circuit

*a, *c
EC-1125
*b

*a, *b

*4
EC-1125

*a
Ignition switch circuit

EC-1077
*b

Power supply for ECM circuit

1
*b

EC-1062

EC-1077

ZD30DDTi

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

LOW IDLE

HI IDLE

POOR ACCELERATION

LACK OF POWER

KNOCK/DETONATION

AC AD

Feature of symptom, Check point

HESITATION/SURGING/FLAT SPOT

WHEN DECELERATING

ENGINE STALL
DURING DRIVING

AT IDLE

Reference page

Warranty symptom code

HARD TO START WHEN ENGINE IS HOT

NO START (without first firing)

NO START (with first firing)

Malfunction

SYSTEM — ENGINE CONTROL system

HARD TO START WHEN ENGINE IS COLD

HARD/NO
START/RESTART
(EXCP. HA)

SYMPTOM

*a, *b
EGR volume control valve circuit

EC-1207
*c
*a

*8
1

ENGINE CONTROL

Glow relay circuit

EC-1221
*b

*10

ECM relay (Self-shutoff) circuit

EC-1077
*b

ECM, Connector circuit

*a, *b

*11
2

EC-1117,
1187, 1200

*12

Air conditioner relay circuit

EC-1275
*b

*13

*a, *c

*13

Air conditioner switch circuit

EC-1275
*b

*14

1 — 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*8: Does not stop operating.
*9: Glow lamp does not turn on.
*10: Glow lamp does not turn off. *11: Ground short makes engine unable to stop.
*12: Air conditioner does not operate.
*13: Air conditioner does not stop operating.
*14: Air conditioner does not work.

EC-1063

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
Symptom Matrix Chart (Cont’d)

ZD30DDTi

Feature of symptom, Check point

Reference page

Fuel cut

Can be detected by CONSULT-II?

DEAD BATTERY (UNDER CHARGE)

ABNORMAL SMOKE COLOR
WHITE SMOKE

BLACK SMOKE

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

IDLING VIBRATION

AG AH AJ AK AL AM

Malfunction indicator lamp illuminates.

Warranty symptom code

ROUGH IDLE/HUNTING

Malfunction

SYSTEM — ENGINE CONTROL system

SLOW/NO RETURN TO IDLE

SYMPTOM

*a, *b
EGR volume control valve circuit

EC-1207
*c

*8
1

ENGINE CONTROL

Glow relay circuit

EC-1221
*b

*10

ECM relay (Self-shutoff) circuit

ECM, Connector circuit

EC-1077
*b

*a, *b

*11
2

EC-1117,
1187, 1200

*12

Air conditioner relay circuit

EC-1275
*b

*13

*a, *c

*13

Air conditioner switch circuit

EC-1275
*b

*14

1 — 5: The numbers refer to the order of inspection.
*a: Open
*b: Short
*c: Ground short
*d: Noise
*8: Does not stop operating.
*9: Glow lamp does not turn on.
*10: Glow lamp does not turn off.
*11: Ground short makes engine unable to stop.
*12: Air conditioner does not operate.
*13: Air conditioner does not stop operating.
*14: Air conditioner does not work.

EC-1064

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ZD30DDTi

CONDITION

SPECIFICATION

CMPSzRPM-PUMP

+ Tachometer: Connect
+ Run engine and compare tachometer indication with the CONSULT-II value.

Almost the same speed as the
CONSULT-II value.

COOLAN TEMP/S

+ Engine: After warming up

More than 70°C (158°F)

VHCL SPEED SE

+ Turn drive wheels and compare speedometer indication with the CONSULT-II value

Almost the same speed as the
CONSULT-II value

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully released

0.40 — 0.60V

ACCEL POS SEN

Accelerator pedal: fully depressed

Approx. 4.5V

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully depressed

Except above

OFF

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully released

Accelerator pedal: slightly open

OPEN

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully released

OFF ACCEL SW

Accelerator pedal: slightly open

OFF

SPILL/V

+ Engine: After warming up

Approx. 13°CA

BATTERY VOLT

+ Ignition switch: ON (Engine stopped)

11 — 14V

P/N POSI SW

+ Ignition switch: ON

START SIGNAL

+ Ignition switch: ON → START → ON

AIR COND SIG

+ Engine: After warming up, idle the
engine

FULL ACCEL SW

ACCEL SW (FC)

BRAKE SW

+ Ignition switch: ON

IGN SW

+ Ignition switch: ON → OFF

WARM UP SW

+ Ignition switch: ON

Shift lever: Park/Neutral

Except above

OFF
OFF → ON → OFF

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

Brake pedal: depressed

Brake pedal: released

Engine: After warming up
Air conditioner switch: OFF
Shift lever: Neutral position
No-load

Heat up switch: ON

Heat up switch: OFF

OFF

Idle

1.6 — 2.0V

Idle

OFF

MAS AIR/FL SE

+
+
+
+

DECELER F/CUT

+ Engine: After warming up

INJ TIMG C/V

+ Engine: After warming up, idle the engine.

AIR COND RLY

+ Engine: After warming up, idle the
engine

GLOW RLY

OFF
ON → OFF

Approx. 50 — 70%

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

+ Refer to EC-1221.
+ When cooling fan is stopped.

OFF

+ When cooling fan operates.

COOLING FAN

EC-1065

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
CONSULT-II Reference Value in Data Monitor
Mode (Cont’d)
MONITOR ITEM

EGR VOL CON/V

VNT S/V 1

CONDITION
+
+
+
+

Engine: After warming up
Air conditioner switch: “OFF”
Shift lever: Neutral position
No-load

After 1 minute of idling

More than 10 steps

Revving engine from idle to 3,200 rpm

0 step

+
+
+
+

Engine: After warming up
Air conditioner switch: “OFF”
Shift lever: Neutral position
No-load

Idle

Approx. 56%

2,000 rpm

Approx. 20%

BARO SEN

+ Ignition switch: ON

SWRL CON S/V 1

+ Lift up the vehicle
+ Engine: After warming up let it idle for
more than 1 second.
+ Air conditioner switch: “OFF”
+ No-load

EXH/GAS REG V*

SPECIFICATION

+
+
+
+

Altitude
Approx. 0 m (0 ft): Approx. 100.62
kPa (1.0062 bar, 1.026 kg/cm2,
14.59 psi)
Approx. 1,000 m (3,281 ft): Approx.
88.95 kPa (0.8895 bar, 0.907
kg/cm2, 12.90 psi)
Approx. 1,500 m (4,922 ft): Approx.
83.16 kPa (0.8316 bar, 0.848
kg/cm2, 12.06 psi)
Approx. 2,000 m (6,562 ft): Approx.
78.36 kPa (0.7836 bar, 0.799
kg/cm2, 11.36 psi)
Shift lever: Except “P” and “Neutral” positions

Shift lever: Neutral position

OFF

Vehicle: Stopped
Engine speed: Below 1,200 rpm
Engine coolant temperature: Below 87°C (189°F)
Heat up switch: ON

Except above

OFF

*: This item is applicable for cold area models. On other models, “OFF” is always displayed.

EC-1066

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ZD30DDTi

Major Sensor Reference Graph in Data
Monitor Mode
The following are the major sensor reference graphs in “DATA MONITOR” mode.

ACCEL POS SEN, “CKPSzRPM (TDC)”, “MAS AIR/FL SE”
Below is the data for “ACCEL POS SEN”, “CKPSzRPM (TDC)” and “MAS AIR/FL SE” when revving engine
quickly up to 3,000 rpm under no load after warming up engine to the normal operating temperature.
Each value is for reference, the exact value may vary.

SEF321Y

EC-1067

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ZD30DDTi

ECM Terminals and Reference Value
PREPARATION
1. ECM is located behind the instrument lower panel. For this
inspection, remove the driver’s side instrument lower cover.

SEF519VA

2. Remove ECM harness protector.

AEC913

SEF367I

Be sure ECM unit is properly grounded before checking.

SEF665S

EC-1068

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)

ECM HARNESS CONNECTOR TERMINAL LAYOUT

SEF064P

ECM INSPECTION TABLE
Remarks: Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Engine is running.
2

R/W

Intake air control valve
control solenoid valve

DATA (DC Voltage and Pulse
Signal)
BATTERY VOLTAGE
(11 — 14V)

Ignition switch “OFF”
For a few seconds after turning ignition
switch “OFF”

Approximately 0.1V

Ignition switch “ON”
Ignition switch “OFF”
4

B/Y

ECM relay (Self-shutoff)

Approximately 0.25V

For a few seconds after turning ignition
switch “OFF”
Ignition switch “OFF”
A few seconds passed after turning ignition
switch “OFF”

EC-1069

BATTERY VOLTAGE
(11 — 14V)

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)
Approximately 5.7V

Engine is running.
Warm-up condition
Idle speed

SEF255Z

Y/B

Tachometer
Approximately 6V

Engine is running.
Warm-up condition
Engine speed is 2,000 rpm

SEF256Z

Engine is running.

BR/Y

Exhaust gas control
valve control solenoid
valve

Engine speed is below 1,200 rpm
Engine coolant temperature is below 87°C
(189°F)
Stop the vehicle
Heat up switch is “ON”
Engine is running.
Except the above condition
Engine is running.
Cooling fan is not operating

Approximately 0.1V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

Cooling fan relay
Engine is running.
Approximately 0.1V
Cooling fan is operating
Engine is running.
Air conditioner switch is “OFF”

Y/L

Air conditioner relay

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Both air conditioner switch and blower fan
switch are “ON”
(Compressor is operating)

Approximately 0.1V

Ignition switch “ON”
Approximately 1V
Glow lamp is “ON”
16

L/W

Glow lamp
Ignition switch “ON”
Glow lamp is “OFF”

EC-1070

BATTERY VOLTAGE
(11 — 14V)

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)

Ignition switch “ON”
Approximately 0V
Brake pedal fully released
17

G/Y

Stop lamp switch
Ignition switch “ON”
Brake pedal depressed

Malfunction indicator
lamp

Ignition switch “ON”

Approximately 1V

Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Idle speed

LG/R

R/W

Engine coolant temperature sensor

Engine is running.

Approximately 0 — 4.8V
Output voltage varies with
engine coolant temperature

Ignition switch “ON”

Approximately 0V

Ignition switch “START”

BATTERY VOLTAGE
(11 — 14V)

Start signal

Engine is running.
Air conditioner switch is “OFF”
21

LG/B

Air conditioner switch

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Both air conditioner switch and blower fan
switch are “ON”
(Compressor is operating)

Approximately 0.1V

Ignition switch “ON”

P/B

Park/Neutral position
switch

Gear position is “Neutral” (M/T models)
Gear position is “P” or “N” (A/T models)
Ignition switch “ON”
Except the above gear position

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”
0.4 — 0.6V
23

Accelerator position sensor

Accelerator pedal fully released
Ignition switch “ON”
Approximately 4.5V
Accelerator pedal fully depressed
Voltage goes high up once in
a few seconds
Engine is running.

PU/W

A/T signal No. 1

Warm-up condition
Idle speed

SEF448Z

EC-1071

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)
0 — Approximately 4.8V

Engine is running.
Lift up the vehicle
In 1st gear position
Vehicle speed is 10 km/h (6 MPH)

SEF257Z

L/OR

Vehicle speed sensor
Approximately 2.2V
Engine is running.
Lift up the vehicle
In 2nd gear position
Vehicle speed is 30 km/h (19 MPH)

SEF258Z

Ignition switch “ON”
Accelerator pedal fully released
29

R/L

BATTERY VOLTAGE
(11 — 14V)

Accelerator switch (F/C)
Ignition switch “ON”
Approximately 0V
Accelerator pedal depressed
Engine is running.
Warm-up condition
Idle speed

Approximately 0V

A/T signal No. 3
Engine is running.
Warm-up condition
Engine speed is 2,000 rpm
Ignition switch “ON”

R/L

Accelerator position
switch (Idle)

Accelerator pedal fully released

Approximately 7.7V

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”
Approximately 0V
Accelerator pedal depressed
Ignition switch “ON”
Approximately 0V

W/G

Accelerator position
switch (Full)

Accelerator pedal released
Ignition switch “ON”
Accelerator pedal fully depressed

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
33

G/Y

Electronic control fuel
injection pump

Warm-up condition
Idle speed

EC-1072

Approximately 2.5V

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)

Engine is running.
35

Mass air flow sensor

Warm-up condition
Idle speed

1.6 — 2.0V

Voltage goes high up once in
a few seconds
Engine is running.
37

P/B

A/T signal No. 2

Warm-up condition
Idle speed

SEF448Z

B/Y

Ignition switch “OFF”

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch

Engine is running.

39
43

B
B

ECM ground

R/B

Electronic control fuel
injection pump

L/G

Y/G

Y/R

Approximately 0V
Idle speed
Engine is running.
Warm-up condition
Idle speed
Engine is running.

Data link connector

Idle speed (CONSULT-II is connected and
turned on)

Approximately 2.5V

Approximately 0V
Approximately 0V
Less than 9V
Approximately 0V

Engine is running.
Warm-up condition
Idle speed

SEF333Y

Crankshaft position sensor (TDC)

Approximately 0V

Engine is running.
Warm-up condition
Engine speed is 2,000 rpm

SEF334Y

EC-1073

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)

Engine is running.
46

Charge air pressure sensor

B/W

Crankshaft position sensor (TDC) ground

G/R

Accelerator position sensor power supply

Ignition switch “ON”

Approximately 5V

Sensor’s power supply

Ignition switch “ON”

Approximately 5V

Warm-up condition
Idle speed

Approximately 2.0V

Engine is running.
Warm-up condition
Idle speed

Approximately 0V

Engine is running.
50

Sensors’ ground

L/W

Accelerator position sensor ground

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Warm-up condition
Idle speed

Approximately 0V

Engine is running.

L/R

Warm-up condition
Idle speed

Approximately 0V

Approximately 0.1V
Idle speed
Approximately 1.0V
Idle speed
Engine is running.

L/B

Swirl control valve control solenoid valve

Warm-up condition
At idle speed for more than 1 second
Lift up the vehicle
Gear position is in positions other than “P”
and “Neutral”

Approximately 0.1V

Engine is running.
Idle speed
Lift up the vehicle
Gear position is in “P” or “Neutral”
56
61
116

W
W
W

Power supply for ECM

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

BATTERY VOLTAGE
(11 — 14V)
Voltage goes high up once in
a few seconds

Engine is running.
58

L/OR

A/T signal No. 4

Warm-up condition
Idle speed

SEF448Z

EC-1074

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)

Ignition switch “ON”
Approximately 0V
Heat up switch is “ON”
59

BR/W

Heat up switch
Ignition switch “ON”
Heat up switch is “OFF”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”
0.4 — 0.6V
68

B/W

Accelerator position sensor signal output

Accelerator pedal fully released
Ignition switch “ON”
Approximately 4.5V
Accelerator pedal fully depressed
Approximately 6.8V

Engine is running.
Warm-up condition
Idle speed

101

R/B

Variable nozzle turbocharger control solenoid
valve

SEF253Z

Approximately 11V

Engine is running.
Warm-up condition
Engine speed is 2,000 rpm

SEF254Z

Engine is running.
102

G/R

Current return
Idle speed

103
105
109
115

L/Y
L/W
L
R/L

EGR volume control
valve

106
112
118

B
B
B

ECM ground

111

LG/B

Glow relay

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Warm-up condition
Idle speed

0.1 — 14V

Engine is running.
Approximately 0V
Idle speed
Refer to “GLOW CONTROL SYSTEM”, EC-1221.

EC-1075

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT

ZD30DDTi

Description
Intermittent incidents (I/I) may occur. In many cases, the problem resolves itself (the part or circuit function
returns to normal without intervention). It is important to realize that the symptoms described in the customer’s complaint often do not recur on DTC visits. Realize also that the most frequent cause of I/I occurrences
is poor electrical connections. Because of this, the conditions under which the incident occurred may not be
clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indicate the
specific problem area.

COMMON I/I REPORT SITUATIONS
STEP in Work Flow

Situation

The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than “0”.

III

The symptom described by the customer does not recur.

DTC does not appear during the DTC Confirmation Procedure.

The Diagnostic Procedure for XXXX does not indicate the problem area.

Diagnostic Procedure
1

INSPECTION START

Erase DTCs. Refer to “HOW TO ERASE DTC”, EC-1032.
c GO TO 2.
2

CHECK GROUND TERMINALS

Check ground terminals for corroding or loose connection.
Refer to GI section (“GROUND INSPECTION”, “Circuit Inspection”).
OK or NG
OK

c GO TO 3.

c Repair or replace.

SEARCH FOR ELECTRICAL INCIDENT

Perform GI section, “Incident Simulation Tests”.
OK or NG
OK

c INSPECTION END

c Repair or replace.

EC-1076

TROUBLE DIAGNOSIS FOR POWER SUPPLY

ZD30DDTi

Main Power Supply and Ground Circuit
ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”
Ignition switch “OFF”
4

B/Y

ECM relay (Self-shutoff)

Approximately 0.25V

For a few seconds after turning ignition switch
“OFF”
Ignition switch “OFF”
A few seconds passed after turning ignition
switch “OFF”

B/Y

Ignition switch “OFF”

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch

Engine is running.

39
43

B
B

ECM ground

56
61
116

W
W
W

Power supply for ECM

102

G/R

Current return

Approximately 0V
Idle speed

Ignition switch “ON”

Engine is running.
Idle speed
106
112
118

B
B
B

BATTERY VOLTAGE
(11 — 14V)

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

Engine is running.
ECM ground

Approximately 0V
Idle speed

EC-1077

ZD30DDTi
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)

WIRING DIAGRAM

TEC096M

EC-1078

ZD30DDTi
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)

TEC097M

EC-1079

ZD30DDTi
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)

DIAGNOSTIC PROCEDURE
1

INSPECTION START

Start engine.
Is engine running?
Yes or No
Yes

c GO TO 14.

c GO TO 2.

CHECK ECM POWER SUPPLY CIRCUIT-I

1. Turn ignition switch “ON”.
2. Check voltage between ECM terminal 38 and ground with CONSULT-II or tester.

SEF397Y

OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M51, F6
+ Fuse block (J/B) connector M2
+ 10A fuse
+ Harness for open or short between ECM and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
4

CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminals 39, 43, 106, 112, 118 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

EC-1080

ZD30DDTi
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
5

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-3
+ Harness for open or short between ECM and engine ground
c Repair open circuit or short to ground or short to power in harness or connectors.
6

CHECK ECM POWER SUPPLY CIRCUIT-II

1. Reconnect ECM harness connector.
2. Turn ignition switch “ON” and then “OFF”.
3. Check voltage between ECM terminals 56, 61, 116 and ground with CONSULT-II or tester.

SEF288Z

OK or NG
OK

c Check electronic control fuel injection pump power supply circuit. Refer to “Diagnostic
Procedure”, EC-1169.

NG (Battery voltage does not
exist.)

GO TO 7.

NG (Battery voltage exists for
more than a few seconds.)

GO TO 13.

EC-1081

ZD30DDTi
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
7

CHECK ECM POWER SUPPLY CIRCUIT-III

1. Disconnect ECM relay.

SEF225Z

2. Check voltage between relay terminals 1, 3 and ground with CONSULT-II or tester.

SEF289Z

OK or NG
OK

c GO TO 9.

c GO TO 8.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E104, M86 or E127, M21
+ 20A fuse
+ Harness for open or short between ECM relay and battery
c Repair open circuit or short to ground or short to power in harness or connectors.
9

CHECK OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 4 and ECM relay terminal 2. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 11.

c GO TO 10.

EC-1082

ZD30DDTi
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
10

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Harness for open or short between ECM and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.
11

CHECK ECM POWER SUPPLY CIRCUIT-IV

1. Check harness continuity between ECM terminals 56, 61, 116 and ECM relay terminal 5. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 13.

c GO TO 12.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M50, F5
+ Harness for open or short between ECM and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.
13

CHECK ECM RELAY

1. Apply 12V direct current between ECM relay terminals 1 and 2.
2. Check continuity between ECM relay terminals 3 and 5, 7 and 6.

SEF296X

OK or NG
OK

c GO TO 14.

c Replace ECM relay.

EC-1083

ZD30DDTi
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
14

CHECK ECM POWER SUPPLY CIRCUIT-V

1. Reconnect all harness connectors disconnected.
2. Turn ignition switch “ON”.
3. Check voltage between ECM terminal 102 and ground with CONSULT-II or tester.

SEF290Z

OK or NG
OK

c GO TO 16.

c GO TO 15.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Fuse block (J/B) connector M2
+ 10A fuse
+ Harness for open or short between ECM and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
16

CHECK ECM POWER SUPPLY CIRCUIT-VI

1. Turn ignition switch “OFF”.
2. Disconnect ECM relay.

SEF225Z

3. Disconnect ECM harness connector.
4. Check harness continuity between ECM terminals 56, 61, 116 and ECM relay terminal 5. Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 18.

c GO TO 17.

EC-1084

ZD30DDTi
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)
17

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M50, F5
+ Harness for open or short between ECM and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.
18

CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminals 39, 43, 106, 112, 118 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 20.

c GO TO 19.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-3
+ Harness for open or short between ECM and engine ground
c Repair open circuit or short to ground or short to power in harness or connectors.
20

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1085

ZD30DDTi

DTC 0102 MASS AIR FLOW SEN
Component Description

SEF987W

The mass air flow sensor (MAFS) is placed in the stream of
intake air. It measures the intake air flow rate by measuring a
part of the entire intake air flow. It consists of a hot wire that is
supplied with electric current from the ECM. The temperature of
the hot wire is controlled by the ECM a certain amount. The heat
generated by the hot wire is reduced as the intake air flows
around it. The more air, the greater the heat loss.
Therefore, the ECM must supply more electric current to maintain the temperature of the hot wire as air flow increases. The
ECM detects the air flow by means of this current change.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION
+
+
+
+

MAS AIR/FL SE

Engine: After warming up
Air conditioner switch: “OFF”
Shift lever: Neutral position
No-load

SPECIFICATION

Idle

1.6 — 2.0V

ECM Terminals and Reference Value
Specification data are reference values, and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
35

Mass air flow sensor

Sensor’s power supply

1.6 — 2.0V

Warm-up condition
Idle speed
Ignition switch “ON”

Approximately 5V

Engine is running.
50

Sensor’s ground

Approximately 0V

Warm-up condition
Idle speed

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ An excessively high or low voltage from the sensor is sent to
ECM.

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Mass air flow sensor

EC-1086

DTC 0102 MASS AIR FLOW SEN

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”, and wait at least 6 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and wait at least 3 seconds.
If DTC is detected, go to “Diagnostic Procedure”, EC-1089.

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON”, and wait at least 6 seconds.
2) Start engine and wait at least 3 seconds.
3) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1089.

EC-1087

DTC 0102 MASS AIR FLOW SEN

ZD30DDTi

Wiring Diagram

TEC098M

EC-1088

DTC 0102 MASS AIR FLOW SEN

ZD30DDTi

Diagnostic Procedure
1

CHECK MAFS POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect mass air flow sensor harness connector.

SEF226Z

3. Turn ignition switch “ON”.
4. Check voltage between mass air flow sensor terminals 2, 4 and gund with CONSULT-II or tester.

SEF297X

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E230, F12
+ Harness connectors M50, F5
+ Harness for open or short between mass air flow sensor and ECM
+ Harness for open or short between mass air flow sensor and ECM relay
c Repair open circuit or short to ground or short to power in harness or connector.

EC-1089

DTC 0102 MASS AIR FLOW SEN
Diagnostic Procedure (Cont’d)
3

ZD30DDTi

CHECK MAFS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEF227Z

3. Check harness continuity between mass air flow sensor terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E230, F12
+ Harness connectors M51, F6
+ Harness connectors E106, M88
+ Harness for open or short between mass air flow sensor and ECM
+ Harness for open or short between mass air flow sensor and TCM (Transmission control module)
c Repair open circuit or short to ground or short to power in harness or connectors.
5

CHECK MAFS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between mass air flow sensor terminal 1 and ECM terminal 35. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E230, F12
+ Harness for open or short between mass air flow sensor and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1090

DTC 0102 MASS AIR FLOW SEN
Diagnostic Procedure (Cont’d)
7

CHECK MASS AIR FLOW SENSOR

1. Reconnect harness connectors disconnected.
2. Start engine and warm it up to normal operating temperature.
3. Check voltage between ECM terminal 35 (Mass air flow sensor signal) and ground.

SEF400Y

4. If the voltage is out of specification, disconnect MAFS harness connector and connect it again.
Then repeat above check.
OK or NG
OK

c GO TO 8.

c Replace mass air flow sensor.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1091

ZD30DDTi

DTC 0103 COOLANT TEMP SEN
Description

The engine coolant temperature sensor is used to detect the
engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the
engine coolant temperature input. The sensor uses a thermistor
which is sensitive to the change in temperature. The electrical
resistance of the thermistor decreases as temperature
increases.
SEF594K

SEF012P

Engine coolant temperature °C (°F)

Voltage* (V)

Resistance (kΩ)

−10 (14)

4.4

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.3

0.68 — 1.00

90 (194)

1.0

0.236 — 0.260

*: These data are reference values and measured between ECM terminal 19
(Engine coolant temperature sensor) and ground.

CAUTION:
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may damage the ECM’s transistor.
Use a ground other than ECM terminals, such as the ground.

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ An excessively high or low voltage from the sensor is entered
to ECM.

+ Harness or connectors (The sensor circuit is open or shorted.)
+ Engine coolant temperature sensor

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If DTC is detected, go to “Diagnostic Procedure”, EC-1094.

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON” and wait at least 5 seconds.
2) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
4) If DTC is detected, go to “Diagnostic Procedure”, EC-1094.

EC-1092

DTC 0103 COOLANT TEMP SEN

ZD30DDTi

Wiring Diagram

TEC099M

EC-1093

DTC 0103 COOLANT TEMP SEN

ZD30DDTi

Diagnostic Procedure
1

CHECK ECTS POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect engine coolant temperature sensor harness connector.

SEF228Z

3. Turn ignition switch “ON”.
4. Check voltage between ECTS terminal 2 and ground with CONSULT-II or tester.

SEF401Y

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E230, F12
+ Harness for open or short between engine control temperature sensor and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.
3

CHECK ECTS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Check harness continuity between ECTS terminal 1 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

EC-1094

DTC 0103 COOLANT TEMP SEN
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E230, F12
+ Harness connectors F6, M51
+ Harness connectors M88, E106
+ Harness for open or short between engine coolant temperature sensor and ECM
+ Harness for open or short between engine coolant temperature sensor and TCM (Transmission control module)
c Repair open circuit or short to ground or short to power in harness or connectors.
5

CHECK ENGINE COOLANT TEMPERATURE SENSOR

1. Remove engine coolant temperature sensor from the engine.
2. Check resistance between ECTS terminals 1 and 2 as shown in the figure.

SEF304X

OK or NG
OK

c GO TO 6.

c Replace engine coolant temperature sensor.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1095

ZD30DDTi

DTC 0104 VEHICLE SPEED SEN
Description

The vehicle speed sensor is installed in the transaxle. It contains
a pulse generator which provides a vehicle speed signal to the
speedometer. The speedometer then sends a signal to the ECM.

AEC110

ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

DATA (DC Voltage and
Pulse Signal)

CONDITION

0 — Approximately 4.8V
Engine is running.
Lift up the vehicle
In 1st gear position
Vehicle speed is 10 km/h (6 MPH)
SEF257Z

L/OR

Vehicle speed sensor
Approximately 2.2V
Engine is running.
Lift up the vehicle
In 2nd gear position
Vehicle speed is 30 km/h (19 MPH)
SEF258Z

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible Cause)

+ The almost 0 km/h (0 MPH) signal from vehicle speed sensor
is sent to ECM even when vehicle is being driven.

+ Harness or connector
(The vehicle speed sensor circuit is open or shorted.)
+ Vehicle speed sensor

EC-1096

DTC 0104 VEHICLE SPEED SEN

ZD30DDTi

Overall Function Check
Use this procedure to check the overall function of the vehicle
speed sensor circuit. During this check, a DTC might not be
confirmed.

WITH CONSULT-II

SEF864Y

1) Lift up the vehicle.
2) Start engine.
3) Read vehicle speed sensor signal in “DATA MONITOR”
mode with CONSULT-II.
The vehicle speed on CONSULT-II should be able to
exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position.
4) If NG, go to “Diagnostic Procedure”, EC-1099.

WITHOUT CONSULT-II
1)
2)
3)
4)
SEF811R

Lift up the vehicle.
Start engine.
Rotate drive wheel by hand.
Check voltage between ECM terminal 26 and ground with
tester.
Voltage should vary between 0 — 4.8V.
5) If NG, go to “Diagnostic Procedure”, EC-1099.

EC-1097

DTC 0104 VEHICLE SPEED SEN

ZD30DDTi

Wiring Diagram

TEC100M

EC-1098

DTC 0104 VEHICLE SPEED SEN

ZD30DDTi

Diagnostic Procedure
1

CHECK VEHICLE SPEED SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector and combination meter harness connector.
3. Check harness continuity between ECM terminal 26 and combination meter terminal 26. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Joint connector-1
+ Harness for open or short between ECM and combination meter
c Repair open circuit or short to ground or short to power in harness or connectors.
3

CHECK SPEEDOMETER FUNCTION

Make sure that speedometer functions properly.
OK or NG
OK

c GO TO 5.

c GO TO 4.

CHECK SPEEDOMETER CIRCUIT FOR OPEN AND SHORT

Check the following.
+ Harness connectors E70, E201
+ Harness connectors M86, E104 or M21, E127
+ Harness for open or short between combination meter and vehicle speed sensor
OK or NG
OK

c Check vehicle speed sensor and combination meter. Refer to EL section.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1099

ZD30DDTi

DTC 0203 ACCEL POS SW (F/C)
Description

The accelerator switch is installed to the accelerator pedal
assembly. The switch senses accelerator position and sends an
ON-OFF signal to the ECM. The ECM uses the signal to control
the fuel cut operation at deceleration for better fuel efficiency.

SEF687V

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
ACCEL SW (FC)
DECELER F/CUT

CONDITION

SPECIFICATION

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully released

Accelerator pedal: slightly open

OPEN

+ Engine: After warming up

Idle

OFF

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”
Accelerator pedal fully released
29

R/L

BATTERY VOLTAGE
(11 — 14V)

Accelerator switch (F/C)
Ignition switch “ON”
Approximately 0V
Accelerator pedal depressed

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible Cause)

+ The OFF signal (short) is sent to the ECM for a certain period
of time even when the accelerator pedal is not being
depressed.

+ Harness or connectors
(The switch circuit is shorted.)
+ Accelerator switch (F/C)

EC-1100

DTC 0203 ACCEL POS SW (F/C)

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II
1) Turn ignition switch “ON”.
2) Select “DATA MONITOR” mode with CONSULT-II.
3) Fully depress and fully release accelerator pedal, and wait 15
seconds.
4) Repeat step 3 at least 29 times.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1103.

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON”.
2) Fully depress and fully release accelerator pedal, and then
wait 15 seconds.
3) Repeat step 2 at least 29 times.
4) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
5) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
6) If DTC is detected, go to “Diagnostic Procedure”, EC-1103.

EC-1101

DTC 0203 ACCEL POS SW (F/C)

ZD30DDTi

Wiring Diagram

TEC101M

EC-1102

DTC 0203 ACCEL POS SW (F/C)

ZD30DDTi

Diagnostic Procedure
1

CHECK ACCELERATOR SWITCH (F/C) GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.
3. Disconnect accelerator switch (F/C) harness connector.

SEF688V

4. Check harness continuity between accelerator switch (F/C) terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M51, F6 (RHD models)
+ Joint connector-3
+ Harness for open or short between accelerator switch (F/C) and engine ground
c Repair open circuit or short to ground or short to power in harness or connectors.
3

CHECK ACCELERATOR SWITCH (F/C) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 29 and accelerator switch (F/C) terminal 1. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M51, F6 (RHD models)
+ Harness for open or short between ECM and accelerator switch (F/C)
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1103

DTC 0203 ACCEL POS SW (F/C)
Diagnostic Procedure (Cont’d)
5

CHECK ACCELERATOR SWITCH (F/C)

Check continuity between accelerator switch (F/C) connector terminals 1 and 3 under the following conditions.

SEF274Z

OK or NG
OK

c GO TO 6.

c Replace accelerator pedal assembly.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1104

ZD30DDTi

DTC 0208 OVER HEAT
Description
SYSTEM DESCRIPTION
Sensor

Input signal to ECM

Vehicle speed sensor

Vehicle speed

Engine coolant temperature sensor

Engine coolant temperature

Air conditioner switch

Air conditioner “ON” signal

ECM function
Cooling fan control

Actuator

Cooling fan relay

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air conditioner ON signal. The control system has 2-step control [ON/OFF].

OPERATION

SEF450Z

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

AIR COND SIG

COOLING FAN

CONDITION
+ Engine: After warming up, idle
the engine

SPECIFICATION

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

+ When cooling fan is stopped.

OFF

+ When cooling fan operates.

EC-1105

ZD30DDTi

DTC 0208 OVER HEAT

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Cooling fan is not operating
14

Cooling fan relay
Engine is running.
Approximately 0.1V
Cooling fan is operating

On Board Diagnosis Logic
This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Malfunction is detected when …

Check Items (Possible Cause)

+ Cooling fan does not operate properly (Overheat).
+ Cooling fan system does not operate properly (Overheat).
+ Engine coolant was not added to the system using the proper
filling method.

+ Harness or connectors
(The cooling fan circuit is open or shorted.)
+ Cooling fan
+ Radiator hose
+ Radiator
+ Radiator cap
+ Water pump
+ Thermostat
+ Fan belt
+ Engine coolant temperature sensor
For more information, refer to “MAIN 12 CAUSES OF
OVERHEATING”, EC-1116.

CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the engine oil.
1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure
to use coolant with the proper mixture ratio. Refer to MA section (“Anti-freeze Coolant Mixture
Ratio”, “RECOMMENDED LUBRICANTS AND FLUIDS”).
2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.

EC-1106

DTC 0208 OVER HEAT

ZD30DDTi

Overall Function Check

AEC640

WITH CONSULT-II

SEF111X

1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
“Diagnostic Procedure”, EC-1109.
2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to
“Diagnostic Procedure”, EC-1109.
3) Turn ignition switch “ON”.
4) Perform “COOLING FAN” in “ACTIVE TEST” mode with
CONSULT-II and make sure that cooling fans operate when
touching “HIGH” or “LOW”.
If NG, go to “Diagnostic Procedure”, EC-1109.

WITHOUT CONSULT-II

MEC475B

1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
“Diagnostic Procedure”, EC-1109.
2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to
“Diagnostic Procedure”, EC-1109.
3) Disconnect engine coolant temperature sensor harness connector.
4) Connect 150Ω resistor to engine coolant temperature sensor
harness connector.
5) Start engine and make sure that cooling fan operates.
Be careful not to overheat engine.
6) If NG, go to “Diagnostic Procedure”, EC-1109.

EC-1107

DTC 0208 OVER HEAT

ZD30DDTi

Wiring Diagram

TEC102M

EC-1108

DTC 0208 OVER HEAT
Diagnostic Procedure
1

INSPECTION START

Do you have CONSULT-II?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

CHECK COOLING FAN OPERATION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II.

SEF646X

3. Make sure that cooling fan-1 operates.
OK or NG
OK

c GO TO 12.

c GO TO 4.

EC-1109

ZD30DDTi

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
3

CHECK COOLING FAN OPERATION

Without CONSULT-II
1. Turn ignition switch “OFF”.
2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Ω resistor to engine coolant temperature sensor harness connector.
4. Restart engine and make sure that cooling fan operates.

MEC475B

OK or NG
OK

c GO TO 12.

c GO TO 4.

EC-1110

ZD30DDTi

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

CHECK COOLING FAN POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect cooling fan relay-1.

SEF690V

3. Turn ignition switch “ON”.
4. Check voltage between cooling fan relay-1 terminals 2, 5 and ground with CONSULT-II or tester.

SEF291Z

OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Fuse block (J/B) connector E112
+ 10A fuse or 20A fuse
+ 30A fusible links
+ Harness for open or short between cooling fan relay-1 and fuse
+ Harness for open or short between cooling fan relay-1 and battery
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1111

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
6

ZD30DDTi

CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect cooling fan motor-1 harness connector.

SEF691V

3. Check harness continuity between cooling fan relay-1 terminal 3 and cooling fan motor-1 terminals 1, 3, cooling fan motor-1 terminals 2, 4 and body ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK COOLING FAN OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 14 and cooling fan relay-1 terminal 1. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 9.

c GO TO 8.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M52, F7
+ Harness for open or short between cooling fan relay-1 and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1112

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
9

CHECK COOLING FAN RELAY-1

Check continuity between cooling fan relay-1 terminals 3 and 5 under the following conditions.

SEF608X

OK or NG
OK

c GO TO 10.

c Replace cooling fan relay.

CHECK COOLING FAN MOTOR-1

Supply battery voltage between the following terminals and check operation.

SEF292Z

OK or NG
OK

c GO TO 11.

c Replace cooling fan motor.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1113

ZD30DDTi

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
12

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops.
Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher than the specified pressure may cause radiator damage.

SLC754A

Pressure should not drop.
OK or NG
OK

c GO TO 14.

c GO TO 13.

DETECT MALFUNCTIONING PART

Check the following for leak.
+ Hose
+ Radiator
+ Water pump (Refer to LC section, “Water Pump”.)
c Repair or replace.
14

CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief pressure.

SLC755A

Radiator cap relief pressure:
79 — 98 kPa (0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2, 11 — 14 psi)
OK or NG
OK

c GO TO 15.

c Replace radiator cap.

EC-1114

ZD30DDTi

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
15

ZD30DDTi

CHECK THERMOSTAT

1. Remove thermostat.
2. Check valve seating condition at normal room temperatures.
It should seat tightly.
3. Check valve opening temperature and valve lift.

SLC343

Valve opening temperature:
82°C (180°F) [standard] (Models for cold areas)
76.5°C (170°F) [standard] (Models for except cold areas)
Valve lift:
More than 10 mm/95°C (0.394 in/203°F)
4. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to LC section, “Thermostat”.
OK or NG
OK

c GO TO 16.

c Replace thermostat.

CHECK ENGINE COOLANT TEMPERATURE SENSOR

1. Remove engine coolant temperature sensor.
2. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure.

SEF304X

OK or NG
OK

c GO TO 17.

c Replace engine coolant temperature sensor.

EC-1115

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
17

ZD30DDTi

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-1116.
c INSPECTION END

Main 12 Causes of Overheating
Engine

Step

Inspection item

OFF

+
+
+
+

Equipment

Standard

Reference page

+ Visual

No blocking

+ Coolant mixture

+ Coolant tester

30 — 50% coolant mixture

See “RECOMMENDED
FLUIDS AND LUBRICANTS” in MA section.

+ Coolant level

+ Visual

Coolant up to MAX level
in reservoir tank and
radiator filler neck

See “Changing Engine
Coolant”, “ENGINE MAINTENANCE” in MA section.

+ Radiator cap

+ Pressure tester

78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0
kg/cm2, 11 — 14 psi)
59 — 98 kPa (0.59 — 0.98
bar, 0.6 — 1.0 kg/cm2,
9 — 14 psi) (Limit)

See “System Check”,
“ENGINE COOLING SYSTEM” in LC section.

ON*2

+ Coolant leaks

+ Visual

No leaks

See “System Check”,
“ENGINE COOLING SYSTEM” in LC section.

ON*2

+ Thermostat

+ Touch the upper and
lower radiator hoses

Both hoses should be hot. See “Thermostat” and
“Radiator”, “ENGINE
COOLING SYSTEM” in
LC section.

ON*1

+ Cooling fan

+ Visual

Operating

OFF

+ Combustion gas leak

+ Color checker chemical Negative
tester 4 gas analyzer

—

ON*3

+ Coolant temperature
gauge

+ Visual

—

Blocked
Blocked
Blocked
Blocked

radiator
condenser
radiator grille
bumper

Gauge less than 3/4
when driving

—

See “DTC 0208 OVER
HEAT”, EC-1105.

+ Coolant overflow to res- + Visual
ervoir tank

No overflow during driving See “Changing Engine
and idling
Coolant”, “ENGINE MAINTENANCE” in MA section.

OFF*4

+ Coolant return from res- + Visual
ervoir tank to radiator

Should be initial level in
reservoir tank

See “ENGINE MAINTENANCE” in MA section.

OFF

+ Cylinder head

+ Straight gauge feeler
gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD” in EM section.

+ Cylinder block and pistons

+ Visual

No scuffing on cylinder
walls or piston

See “Inspection”, “CYLINDER BLOCK” in EM section.

*1: Engine running at idle.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.

EC-1116

DTC 0301 ECM 2, DTC 0901 ECM 12

ZD30DDTi

Description
The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the
engine.

SEC220B

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)
+ ECM
(ECCS-D control module)

+ ECM calculation function is malfunctioning.

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and wait at least 2 seconds.
If DTC is detected, go to “Diagnostic Procedure”, EC-1118.

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Start engine and wait at least 2 seconds.
3) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1118.

EC-1117

DTC 0301 ECM 2, DTC 0901 ECM 12
Diagnostic Procedure
1

INSPECTION START

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform “DTC Confirmation Procedure”, EC-1117, again.
5. Is the malfunction displayed again?
Without CONSULT-II
1. Turn ignition switch “ON”.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory.
3. Perform “DTC Confirmation Procedure”, EC-1117, again.
4. Perform “Diagnostic Test Mode II (Self-diagnostic results)”.
5. Is the DTC 0301 or 0901 displayed again?
Yes or No
Yes

c Replace ECM.

c INSPECTION END

EC-1118

ZD30DDTi

DTC 0402 P9zFUEL TEMP SEN

ZD30DDTi

Description
SYSTEM DESCRIPTION

SEF437Y

The ECM and the electronic control fuel injection pump control
unit (abbreviated as the injection pump control unit) perform the
real time communication (signal exchange).
The ECM transmits the signals of the target fuel injection
amount, target fuel injection timing, and engine speed, etc., and
receives the signals of the pump speed and fuel temperature,
etc. from the injection pump control unit.
By those signals, the injection pump controls the optimum fuel
injection amount and injection timing of the spill valve and timing control valve.
Injection pump control unit has an on board diagnostic system,
which detects malfunctions related to sensors or actuators builtinto electronic control fuel injection pump. These malfunction
information are transferred through the line (circuit) from injection
pump control unit to ECM.

FUEL INJECTION AMOUNT CONTROL
In accordance with the target fuel injection amount signal from
the ECM, the injection amount is controlled by controlling the spill
valve in the injection pump and by changing the needle opening
time.

FUEL INJECTION TIMING CONTROL
Based on the target fuel injection timing signal from the ECM, the
injection timing is controlled in accordance with the timer spring
by performing the duty control of the timing control valve in the
injection pump and by adjusting the pressure of the timer piston
high pressure chamber.

FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel temperature.

CAM RING POSITION SENSOR
The sensor detects the passing of the protrusion on the sensor
wheel in the injection pump by the semiconductor magnetic
resistance element sensor. The cam ring position sensor synchronizes with the cam ring, and detects the actual advance
amount. The injection pump control unit measures the injection
pump revolution by the signal of the cam ring position sensor.

EC-1119

ZD30DDTi

DTC 0402 P9zFUEL TEMP SEN

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

SPILL/V

+ Engine: After warming up

Approx. 13°CA

INJ TIMG C/V

+ Engine: After warming up,
idle the engine.

Approx. 50 — 70%

DECELER F/CUT

+ Engine: After warmIdle
ing up

OFF

+ Ignition switch: ON

Altitude
Approx. 0 m (0 ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2,
11.36 psi)

BARO SEN

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
33

G/Y

Electronic control fuel
injection pump

R/B

Electronic control fuel
injection pump

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Approximately 2.5V

Warm-up condition
Idle speed
Engine is running.

L/R

Approximately 2.5V

Warm-up condition
Idle speed

Approximately 0.1V
Idle speed
Approximately 0.35V
Idle speed

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible cause)

+ An improper voltage signal from fuel temperature sensor
(Built-into electronic control fuel injection pump) is sent to
injection pump control unit.

+ Harness or connectors
(Electronic control fuel injection pump circuit is open or
shorted.)
+ Electronic control fuel injection pump

EC-1120

DTC 0402 P9zFUEL TEMP SEN

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II
1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Select “DATA MONITOR” mode with CONSULT-II.
3) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
4) If DTC is detected, go to “Diagnostic Procedure”, EC-1123.
SEF817Y

WITHOUT CONSULT-II
1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
3) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1123.

EC-1121

DTC 0402 P9zFUEL TEMP SEN

ZD30DDTi

Wiring Diagram

TEC113M

EC-1122

DTC 0402 P9zFUEL TEMP SEN

ZD30DDTi

Diagnostic Procedure
1

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect electronic control fuel injection pump harness connector.

SEF229Z

3. Turn ignition switch “ON”.
4. Check voltage between electronic control fuel injection pump terminal 7 and ground.

SEF438Y

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M50, F5
+ Harness connectors F4, EC4
+ Harness for open or short between electronic control fuel injection pump and ECM
+ Harness for open or short between electronic control fuel injection pump and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.
3

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Check harness continuity between electronic control fuel injection pump terminal 6 and ground. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

EC-1123

DTC 0402 P9zFUEL TEMP SEN
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F4, EC4
+ Harness for open or short between electronic control fuel injection pump and engine ground
c Repair open circuit or short to ground or short to power in harness or connectors.
5

CHECK COMMUNICATION LINE FOR OPEN AND SHORT

1. Check continuity between the following terminals. Refer to Wiring Diagram.

MTBL0444

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F4, EC4
+ Harness for open or short between electronic control fuel injection pump and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.
7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
OK or NG
OK

c Replace electronic control fuel injection pump.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1124

ZD30DDTi

DTC 0403 ACCEL POS SENSOR
Description

The accelerator position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. The ECM uses the signal to determine
the amount of fuel to be injected.
The accelerator position switch detects Off-accelerator switch signal and Full-accelerator switch signal and
send these signals to the ECM. The ECM will then determine engine idle conditions. These signals are also
used for diagnosing the accelerator position sensor.

SEF861SA

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
ACCEL POS SEN

FULL ACCEL SW

OFF ACCEL SW

CONDITION

SPECIFICATION

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: released

0.40 — 0.60V

Accelerator pedal: depressed

Approx. 4.5V

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully depressed

Except above

OFF

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully released

Accelerator pedal: slightly open

OFF

EC-1125

ZD30DDTi

DTC 0403 ACCEL POS SENSOR

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”
0.4 — 0.6V
23

Accelerator position sensor

Accelerator pedal fully released
Ignition switch “ON”
Approximately 4.5V
Accelerator pedal fully depressed
Ignition switch “ON”

R/L

Accelerator position switch
(Idle)

Accelerator pedal fully released

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”
Approximately 0V
Accelerator pedal depressed
Ignition switch “ON”
Approximately 0V

W/G

Accelerator position switch
(Full)

Accelerator pedal released
Ignition switch “ON”
Accelerator pedal fully depressed

G/R

Accelerator position sensor power supply

L/W

Accelerator position sensor ground

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)
Approximately 5V

Engine is running.
51

Approximately 0V

Warm-up condition
Idle speed

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ The relation between sensor and switch signal is not in the
normal range during the specified accelerator position.

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Accelerator position sensor
+ Accelerator position switch
+ Accelerator switch (F/C)

EC-1126

DTC 0403 ACCEL POS SENSOR

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Depress and release fully accelerator pedal slowly.
If DTC is detected, go to “Diagnostic Procedure”, EC-1130.

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON”.
2) Depress and release fully accelerator pedal slowly.
3) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1130.

EC-1127

DTC 0403 ACCEL POS SENSOR

ZD30DDTi

Wiring Diagram

TEC103M

EC-1128

DTC 0403 ACCEL POS SENSOR
Wiring Diagram (Cont’d)

ZD30DDTi

TEC107M

EC-1129

DTC 0403 ACCEL POS SENSOR
Diagnostic Procedure
1

CHECK OVERALL FUNCTION-I

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “ACCEL POS SEN” in “DATA MONITOR” mode with CONSULT-II.
3. Check “ACCEL POS SEN” signal under the following conditions.

SEF278Z

Without CONSULT-II
1. Turn ignition switch “ON”.
2. Check voltage between ECM terminal 23 and ground under the following conditions.

SEF279Z

OK or NG
OK

c GO TO 2.

c GO TO 3.

EC-1130

ZD30DDTi

DTC 0403 ACCEL POS SENSOR
Diagnostic Procedure (Cont’d)
2

CHECK OVERALL FUNCTION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “FULL ACCEL SW” and “OFF ACCEL SW” in “DATA MONITOR” mode with CONSULT-II.
3. Check “FULL ACCEL SW” and “OFF ACCEL SW” signal under the following conditions.

SEF416Y

Without CONSULT-II
1. Turn ignition switch “ON”.
2. Check voltage between ECM terminals 31, 32 and ground under the following conditions.

SEF417Y

OK or NG
OK

c INSPECTION END

c GO TO 14.

EC-1131

ZD30DDTi

DTC 0403 ACCEL POS SENSOR
Diagnostic Procedure (Cont’d)
3

CHECK ACCELERATOR POSITION SENSOR POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect accelerator position sensor harness connector.

SEF694V

3. Turn ignition switch “ON”.
4. Check voltage between accelerator position sensor terminal 1 and ground with CONSULT-II or tester.

SEF816Y

OK or NG
OK

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F7, M52 (RHD models)
+ Harness for open or short between ECM and accelerator position sensor
c Repair harness or connectors.

EC-1132

ZD30DDTi

DTC 0403 ACCEL POS SENSOR
Diagnostic Procedure (Cont’d)
5

ZD30DDTi

CHECK ACCELERATOR POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screw.

SEF227Z

3. Check harness continuity between accelerator position sensor terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F7, M52 (RHD models)
+ Harness for open or short between ECM and accelerator position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.
7

CHECK ACCELERATOR POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 23 and accelerator position sensor terminal 2. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 9.

c GO TO 8.

DETECT MALFUNCTIONING PART

EC-1133

DTC 0403 ACCEL POS SENSOR
Diagnostic Procedure (Cont’d)
9

CHECK ACCELERATOR POSITION SENSOR

With CONSULT-II
1. Reconnect all disconnected harness connectors.
2. Turn ignition switch “ON”.
3. Select “DATA MONITOR” mode with CONSULT-II.
4. Check the indication of “ACCEL POS SEN” under the following conditions.

SEF818Y

OK or NG
OK

c GO TO 11.

c Replace accelerator pedal assembly.

CHECK ACCELERATOR POSITION SENSOR

Without CONSULT-II
1. Reconnect all disconnected harness connectors.
2. Turn ignition switch “ON”.
3. Check voltage between ECM terminal 23 and ground under the following conditions.

SEF407Y

OK or NG
OK

c GO TO 12.

c Replace accelerator pedal assembly.

RESET ACCELERATOR POSITION SENSOR IDLE POSITION MEMORY

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “OFF ACCEL PO SIG” in “ACTIVE TEST” mode with CONSULT-II.
3. Touch “CLEAR”.
c GO TO 13.

EC-1134

ZD30DDTi

DTC 0403 ACCEL POS SENSOR
Diagnostic Procedure (Cont’d)
12

RESET ACCELERATOR POSITION SENSOR IDLE POSITION MEMORY

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Let engine idle for 10 minutes.
c GO TO 13.
13

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END
14

CHECK ACCELERATOR POSITION SWITCH POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect accelerator position switch harness connector.

SEF708V

3. Turn ignition switch “ON”.
4. Check voltage between accelerator position switch terminal 5 and ground with CONSULT-II or tester.

SEF346X

OK or NG
OK

c GO TO 16.

c GO TO 15.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M50, F5 (LHD models)
+ Harness for open or short between accelerator position switch and ECM relay
+ Harness for open or short between accelerator position switch and ECM
c Repair harness or connectors.

EC-1135

ZD30DDTi

DTC 0403 ACCEL POS SENSOR
Diagnostic Procedure (Cont’d)
16

ZD30DDTi

CHECK ACCELERATOR POSITION SWITCH INPUT SIGNAL CIRCUIT-I FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between accelerator position switch terminal 6 and ECM terminal 31. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 18.

c GO TO 17.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7 (RHD models)
+ Harness for open or short between ECM and accelerator position switch
c Repair open circuit or short to ground or short to power in harness or connectors.
18

CHECK ACCELERATOR POSITION SWITCH INPUT SIGNAL CIRCUIT-II FOR OPEN AND SHORT

1. Check harness continuity between accelerator position switch terminal 4 and ECM terminal 32. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 20.

c GO TO 19.

DETECT MALFUNCTIONING PART

CHECK ACCELERATOR POSITION SWITCH

Check continuity between accelerator position switch terminals 4 and 5, 5 and 6 under the following conditions.

SEF418Y

OK or NG
OK (With CONSULT-II)

c GO TO 21.

OK (Without CONSULT-II)

c GO TO 22.

c Replace accelerator pedal assembly.

EC-1136

DTC 0403 ACCEL POS SENSOR
Diagnostic Procedure (Cont’d)
21

RESET ACCELERATOR POSITION SENSOR IDLE POSITION MEMORY

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “OFF ACCEL PO SIG” in “ACTIVE TEST” mode with CONSULT-II.
3. Touch “CLEAR”.
c GO TO 23.

RESET ACCELERATOR POSITION SENSOR IDLE POSITION MEMORY

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Let engine idle for 10 minutes.
c GO TO 23.
23

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1137

ZD30DDTi

DTC 0406 INT AIR VOL

ZD30DDTi

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ An excessively high voltage from the mass air flow sensor is
sent to ECM when engine is running.

+
+
+
+
+
+

Air duct
Charge air cooler
Variable nozzle turbocharger control system
Variable nozzle turbocharger
Mass air flow sensor
Harness or connectors
(The mass air flow sensor circuit is shorted.)

DTC Confirmation Procedure
NOTE:
If DTC 0406 “INT AIR VOL” displayed with DTC 0102 “MASS
AIR FLOW SEN”, perform trouble diagnosis for DTC 0102
“MASS AIR FLOW SEN” first. (See EC-1086.)

WITH CONSULT-II
1)
2)
3)
4)
5)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and warm it up to normal operating temperature.
Drive vehicle.
Maintain the engine speed more than 4,000 rpm for at least
10 seconds.
6) If DTC is detected, go to “Diagnostic Procedure”, EC-1139.

WITHOUT CONSULT-II
SEF817Y

1) Start engine and warm it up to normal operating temperature.
2) Drive vehicle.
3) Maintain the engine speed more than 4,000 rpm for at least
10 seconds.
4) Stop vehicle.
5) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
6) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
7) If DTC is detected, go to “Diagnostic Procedure”, EC-1139.

EC-1138

DTC 0406 INT AIR VOL

ZD30DDTi

Diagnostic Procedure
1

CHECK INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK

c GO TO 2.

c Repair or replace.

CHECK VARIABLE NOZZLE TURBOCHARGER OVERALL FUNCTION

1. Start engine and let it idle.
2. Make sure that variable nozzle turbocharger control actuator rod moves when revving engine up to 3,000 rpm and returning to
idle.

SEF320Z

OK or NG
OK

c GO TO 3.

c Go to “Diagnostic Procedure” in “VARIABLE NOZZLE TURBOCHARGER CONTROL SOLENOID VALVE”, EC-1264.

CHECK MASS AIR FLOW SENSOR

1. Start engine and warm it up to normal operating temperature.
2. Check voltage between ECM terminal 35 (Mass air flow sensor signal) and ground.

SEF400Y

3. If the voltage is out of specification, disconnect MAFS harness connector and connect it again.
Then repeat above check.
OK or NG
OK

c GO TO 4.

c Replace mass air flow sensor.

CHECK INTERMIT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1139

DTC 0407 CRANK POS SEN (TDC)

ZD30DDTi

Description
The crankshaft position sensor (TDC) monitors engine speed by
means of signals from the sensing plate (with three protrusions)
installed to the crankshaft pulley. The data signal output is
detected at ATDC 70° and sent to the ECM. The sensor signal
is used for fuel injection control and fuel injection timing control.

SEF231Z

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

+ Tachometer: Connect
CKPSzRPM (TDC) + Run engine and compare tachometer indication with the CONSULT-II
value.

Almost the same speed as the
CONSULT-II value.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and
Pulse Signal)
Approximately 0V

Engine is running.
Warm-up condition
Idle speed

SEF333Y

Crankshaft position sensor
(TDC)

Approximately 0V
Engine is running.
Warm-up condition
Engine speed is 2,000 rpm

SEF334Y

Engine is running.
47

B/W

Crankshaft position sensor
(TDC) ground

Warm-up condition
Idle speed

EC-1140

Approximately 0V

DTC 0407 CRANK POS SEN (TDC)

ZD30DDTi

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ An improper signal from the sensor is sent to ECM during
engine running and cranking.

+ Harness or connectors
(The sensor circuit is open.)
+ Crankshaft position sensor (TDC)

DTC Confirmation Procedure
Before performing the following procedure, confirm that
battery voltage is more than 10V.

WITH CONSULT-II
1) Turn ignition switch “ON” and select “DATA MONITOR”
mode with CONSULT-II.
2) Crank engine for at least 1 second.
3) Start engine and run it for at least 2 seconds at idle speed.
4) If DTC is detected, go to “Diagnostic Procedure”, EC-1143.
SEF817Y

WITHOUT CONSULT-II
1) Crank engine for at least 1 second.
2) Start engine and run it for at least 2 seconds at idle speed.
3) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1143.

EC-1141

DTC 0407 CRANK POS SEN (TDC)

ZD30DDTi

Wiring Diagram

TEC104M

EC-1142

DTC 0407 CRANK POS SEN (TDC)

ZD30DDTi

Diagnostic Procedure
1

CHECK CRANKSHAFT POSITION SENSOR (TDC) GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEF227Z

3. Disconnect crankshaft position sensor (TDC) harness connector and ECM harness connector.

SEF230Z

4. Check harness continuity between ECM terminal 47 and terminal 2. Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 2.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK CRANKSHAFT POSITION SENSOR (TDC) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between terminal 1 and ECM terminal 44. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 3.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK CRANKSHAFT POSITION SENSOR SHIELD CIRCUIT

1. Check harness continuity between crankshaft position sensor (TDC) terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

EC-1143

DTC 0407 CRANK POS SEN (TDC)
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-4
+ Harness for open or short between crankshaft position sensor (TDC) and engine ground
c
5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK CRANKSHAFT POSITION SENSOR (TDC) INSTALLATION

Check the clearance between crankshaft position sensor (TDC) and protrusion on the crankshaft pulley.

JEF293Z

OK or NG
OK

c GO TO 6.

c GO TO 7.

REINSTALL CRANKSHAFT POSITION SENSOR (TDC)

1. Remove crankshaft position sensor (TDC).
2. Install crankshaft position sensor (TDC) properly.

JEF294Z

c INSPECTION END

EC-1144

DTC 0407 CRANK POS SEN (TDC)
Diagnostic Procedure (Cont’d)
7

CHECK CRANKSHAFT POSITION SENSOR (TDC)-I

1. Loosen the fixing bolt and remove the crankshaft position sensor (TDC).
2. Visually check the sensor for chipping.

SEF232Z

OK or NG
OK

c GO TO 8.

c Replace crankshaft position sensor (TDC).

CHECK CRANKSHAFT POSITION SENSOR (TDC)-II

1. Disconnect crankshaft position sensor (TDC) harness connector.
2. Check resistance between crankshaft position sensor (TDC) terminals 1 and 2.

SEF295Z

OK or NG
OK

c GO TO 9.

c Replace crankshaft position sensor (TDC).

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1145

ZD30DDTi

DTC 0502 BATTERY VOLTAGE

ZD30DDTi

On Board Diagnosis Logic
The ECM checks if battery voltage is within the tolerance range for the engine control system.
Malfunction is detected when …

Check Items (Possible Cause)

+ An abnormally high voltage from the battery is sent to ECM.

+
+
+
+

Incorrect jump starting
Battery
Alternator
ECM

DTC Confirmation Procedure
With CONSULT-II
1) Check the following.
+ Jumper cables are connected for jump starting.
+ Battery or alternator has been replaced.
If the result is “Yes” for one item or more, skip the following steps and go to “Diagnostic Procedure”,
EC-1146.
2) Check that the positive battery terminal is connected to battery properly. If NG, reconnect it properly.
3) Check that the alternator functions properly. Refer to EL section (“CHARGING SYSTEM”).
4) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II.
5) Wait one minute.
6) If DTC is detected, go to “Diagnostic Procedure”, EC-1146.
If DTC is not detected, go to next step.
7) Start engine and wait one minute at idle.
If DTC is detected, go to “Diagnostic Procedure”, EC-1146.

Without CONSULT-II
1) Check the following.
+ Jumper cables are connected for jump starting.
+ Battery or alternator has been replaced.
If the result is “Yes” for one item or more, skip the following steps and go to “Diagnostic Procedure”,
EC-1146.
2) Check that the positive battery terminal is connected to battery properly. If NG, reconnect it properly.
3) Check that the alternator functions properly. Refer to EL section (“CHARGING SYSTEM”).
4) Turn ignition switch “ON” and wait one minute.
5) Turn ignition switch “OFF”, wait 5 seconds and then turn “ON”.
6) Perform “Diagnostic Test Mode II (Self-diagnostic result)” with ECM.
7) If DTC is detected, go to “Diagnostic Procedure”, EC-1146.
If DTC is not detected, go to next step.
Start engine and wait one minute at idle.
9) Turn ignition switch “OFF”, wait 5 seconds and then turn “ON”.
10) Perform “Diagnostic Test Mode II (Self-diagnostic result)” with ECM.
11) If DTC is detected, go to “Diagnostic Procedure”, EC-1146.

Diagnostic Procedure
1

INSPECTION START

Are jumper cables connected for the jump starting?
Yes or No
Yes

c GO TO 3.

c GO TO 2.

EC-1146

DTC 0502 BATTERY VOLTAGE
Diagnostic Procedure (Cont’d)
2

CHECK BATTERY AND ALTERNATOR

Check that the proper type of battery and alternator is installed.
Refer to EL section (“BATTERY” and “CHARGING SYSTEM”).
OK or NG
OK

c GO TO 5.

c Replace with a proper one.

CHECK JUMPER CABLES INSTALLATION

Check that the jumper cables are connected in the correct sequence.

SEF488Z

OK or NG
OK

c GO TO 4.

c Reconnect jumper cables properly.

CHECK BATTERY FOR BOOSTER

Check that the battery for the booster is a 12V battery.
OK or NG
OK

c GO TO 5.

c Change the vehicle for booster.

PERFORM DTC CONFIRMATION PROCEDURE AGAIN

Perform “DTC Confirmation Procedure”, EC-1146, again.
OK or NG
OK

c GO TO 6.

c Replace ECM.

CHECK ELECTRICAL PARTS DAMAGE

Check the following for damage.
+ Wiring harness and harness connectors for burn
+ Fuses for short
OK or NG
OK

c INSPECTION END

c Repair or replace malfunctioning part.

EC-1147

ZD30DDTi

DTC 0504 A/T COMM LINE
System Description

These circuit lines are used to control the smooth shifting up and down of A/T during the hard acceleration/
deceleration.
Voltage signals are exchanged between ECM and TCM (Transmission control module).

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Voltage goes high up
once in a few seconds
24
37
58

PU/W
P/B
L/OR

A/T signal No. 1
A/T signal No. 2
A/T signal No. 4

Engine is running.
Warm-up condition
Idle speed

SEF448Z

Engine is running.
Approximately 0V

Warm-up condition
Idle speed
30

A/T signal No. 3
Engine is running.
Approximately 7.7V

Warm-up condition
Engine speed is 2,000 rpm

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ ECM receives incorrect voltage from TCM (Transmission control module) continuously.

+ Harness or connectors
[The circuit between ECM and TCM (Transmission control
module) is open or shorted.]

EC-1148

DTC 0504 A/T COMM LINE

ZD30DDTi

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously conducted,
always turn ignition switch “OFF” and wait at least 5 seconds
before conducting the next test.

With CONSULT-II

SEF817Y

1)
2)
3)
4)

Start engine.
Select “DATA MONITOR” mode with CONSULT-II.
Set selector lever to “D” position.
Accelerate up to 60 km/h (37 MPH) gradually on the accelerator pedal.
Do not accelerate with shift down.
5) Stop the vehicle with engine running.
6) If DTC is detected, go to “Diagnostic Procedure”, EC-1151.

Overall Function Check
Use this procedure to check the overall function of the A/T control circuit. During this check, a DTC might not be confirmed.

Without CONSULT-II

SEF301Z

1) Start engine.
2) Read the voltage signal between ECM terminals 24, 30, 37,
58 and ground with an oscilloscope.
3) Verify that the oscilloscope screen shows the signal wave as
shown under “ECM Terminals and Reference Value” on the
previous page.
4) If NG, go to “Diagnostic Procedure”, EC-1151.

EC-1149

DTC 0504 A/T COMM LINE

ZD30DDTi

Wiring Diagram

TEC109M

EC-1150

DTC 0504 A/T COMM LINE
Diagnostic Procedure
1

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector and TCM (Transmission control module) harness connector.

SEF519VA

SEF792V

3. Check harness continuity between the following terminals. Refer to Wiring Diagram.

MTBL0532

Continuity should exist.
OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E106, M88
+ Harness connectors M51, F6
+ Harness connectors E104, M86 (RHD models)
+ Harness for open or short between ECM and TCM (Transmission control module)
c Repair harness or connectors.

EC-1151

ZD30DDTi

DTC 0504 A/T COMM LINE
Diagnostic Procedure (Cont’d)
3

ZD30DDTi

CHECK INPUT SIGNAL CIRCUIT

1. Check harness continuity between ECM terminal 24 and ground, ECM terminal 30 and ground, ECM terminal 37 and ground,
ECM terminal 58 and ground. Refer to Wiring Diagram.
Continuity should not exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and TCM (Transmission control module).
c Repair open circuit short to ground or short to power in harness.
5

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1152

DTC 0701 P1zCAM POS SEN

ZD30DDTi

Description
SYSTEM DESCRIPTION

SEF437Y

FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel temperature.

EC-1153

ZD30DDTi

DTC 0701 P1zCAM POS SEN

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

SPILL/V

+ Engine: After warming up

Approx. 13°CA

INJ TIMG C/V

+ Engine: After warming up,
idle the engine.

Approx. 50 — 70%

DECELER F/CUT

+ Engine: After warmIdle
ing up

OFF

+ Ignition switch: ON

Altitude
Approx. 0 m (0 ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2,
11.36 psi)

BARO SEN

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
G/Y

Electronic control fuel
injection pump

R/B

Electronic control fuel
injection pump

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Approximately 2.5V

Warm-up condition
Idle speed
Engine is running.

L/R

Approximately 2.5V

Warm-up condition
Idle speed

Approximately 0.1V
Idle speed
Approximately 0.35V
Idle speed

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible cause)

+ An improper voltage signal from cam position sensor (Builtinto electronic control fuel injection pump) is sent to injection
pump control unit.

+ Harness or connectors
(Electronic control fuel injection pump circuit is open or
shorted.)
+ Electronic control fuel injection pump

EC-1154

DTC 0701 P1zCAM POS SEN

ZD30DDTi

EC-1155

DTC 0701 P1zCAM POS SEN

ZD30DDTi

Wiring Diagram

TEC113M

EC-1156

DTC 0701 P1zCAM POS SEN

ZD30DDTi

Diagnostic Procedure
1

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect electronic control fuel injection pump harness connector.

SEF229Z

3. Turn ignition switch “ON”.
4. Check voltage between electronic control fuel injection pump terminal 7 and ground.

SEF438Y

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP GROUND CIRCUIT FOR OPEN AND SHORT

c GO TO 5.

c GO TO 4.

EC-1157

DTC 0701 P1zCAM POS SEN
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

CHECK COMMUNICATION LINE FOR OPEN AND SHORT

1. Check continuity between the following terminals. Refer to Wiring Diagram.

MTBL0444

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
OK or NG
OK

c Replace electronic control fuel injection pump.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1158

DTC 0702 P2zTDC PULSE SIG

ZD30DDTi

Description
SYSTEM DESCRIPTION

SEF437Y

FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel temperature.

EC-1159

ZD30DDTi

DTC 0702 P2zTDC PULSE SIG

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

SPILL/V

+ Engine: After warming up

Approx. 13°CA

INJ TIMG C/V

+ Engine: After warming up,
idle the engine.

Approx. 50 — 70%

DECELER F/CUT

+ Engine: After warmIdle
ing up

OFF

+ Ignition switch: ON

Altitude
Approx. 0 m (0 ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2,
11.36 psi)

BARO SEN

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
33

G/Y

Electronic control fuel
injection pump

R/B

Electronic control fuel
injection pump

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Approximately 2.5V

Warm-up condition
Idle speed
Engine is running.

L/R

Approximately 2.5V

Warm-up condition
Idle speed

Approximately 0.1V
Idle speed
Approximately 0.35V
Idle speed

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible cause)

+ Injection pump control unit input signal [Crankshaft position
sensor (TDC) signal] processing function is malfunctioning.

+ Harness or connectors
(Electronic control fuel injection pump circuit is open or
shorted.)
+ Electronic control fuel injection pump

EC-1160

DTC 0702 P2zTDC PULSE SIG

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II

SEF817Y

1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Select “DATA MONITOR” mode with CONSULT-II.
3) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
4) If DTC 0407 is detected, go to “Diagnostic procedure”,
EC-1143.
If DTC 0702 is detected, go to “Diagnostic Procedure”,
EC-1163.

WITHOUT CONSULT-II
1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
3) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
5) If DTC 0407 is detected, go to “Diagnostic Procedure”,
EC-1143.
If DTC 0702 is detected, go to “Diagnostic Procedure”,
EC-1163.

EC-1161

DTC 0702 P2zTDC PULSE SIG

ZD30DDTi

Wiring Diagram

TEC113M

EC-1162

DTC 0702 P2zTDC PULSE SIG

ZD30DDTi

Diagnostic Procedure
1

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect electronic control fuel injection pump harness connector.

SEF229Z

3. Turn ignition switch “ON”.
4. Check voltage between electronic control fuel injection pump terminal 7 and ground.

SEF438Y

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP GROUND CIRCUIT FOR OPEN AND SHORT

c GO TO 5.

c GO TO 4.

EC-1163

DTC 0702 P2zTDC PULSE SIG
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

CHECK COMMUNICATION LINE FOR OPEN AND SHORT

1. Check continuity between the following terminals. Refer to Wiring Diagram.

MTBL0444

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
OK or NG
OK

c Replace electronic control fuel injection pump.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1164

DTC 0703 P3zPUMP COMM LINE

ZD30DDTi

Description
SYSTEM DESCRIPTION

SEF437Y

FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel temperature.

EC-1165

ZD30DDTi

DTC 0703 P3zPUMP COMM LINE

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

SPILL/V

+ Engine: After warming up

Approx. 13°CA

INJ TIMG C/V

+ Engine: After warming up,
idle the engine.

Approx. 50 — 70%

DECELER F/CUT

+ Engine: After warmIdle
ing up

OFF

+ Ignition switch: ON

Altitude
Approx. 0 m (0 ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2,
11.36 psi)

BARO SEN

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
G/Y

Electronic control fuel
injection pump

R/B

Electronic control fuel
injection pump

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Approximately 2.5V

Warm-up condition
Idle speed
Engine is running.

L/R

Approximately 2.5V

Warm-up condition
Idle speed

Approximately 0.1V
Idle speed
Approximately 0.35V
Idle speed

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible cause)

+ Injection pump control unit receives incorrect voltage signal
from ECM continuously.

+ Harness or connectors
(Electronic control fuel injection pump circuit is open or
shorted.)
+ Electronic control fuel injection pump

EC-1166

DTC 0703 P3zPUMP COMM LINE

ZD30DDTi

EC-1167

DTC 0703 P3zPUMP COMM LINE

ZD30DDTi

Wiring Diagram

TEC113M

EC-1168

DTC 0703 P3zPUMP COMM LINE

ZD30DDTi

Diagnostic Procedure
1

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect electronic control fuel injection pump harness connector.

SEF229Z

3. Turn ignition switch “ON”.
4. Check voltage between electronic control fuel injection pump terminal 7 and ground.

SEF438Y

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP GROUND CIRCUIT FOR OPEN AND SHORT

c GO TO 5.

c GO TO 4.

EC-1169

DTC 0703 P3zPUMP COMM LINE
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

CHECK COMMUNICATION LINE FOR OPEN AND SHORT

1. Check continuity between the following terminals. Refer to Wiring Diagram.

MTBL0444

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
OK or NG
OK

c Replace electronic control fuel injection pump.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1170

DTC 0704 P4zSPILL/V CIRC, DTC 0706 P6zSPILL VALVE

ZD30DDTi

Description
SYSTEM DESCRIPTION

SEF437Y

FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel temperature.

EC-1171

DTC 0704 P4zSPILL/V CIRC, DTC 0706 P6zSPILL VALVE

ZD30DDTi

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

SPILL/V

+ Engine: After warming up

Approx. 13°CA

INJ TIMG C/V

+ Engine: After warming up,
idle the engine.

Approx. 50 — 70%

DECELER F/CUT

+ Engine: After warmIdle
ing up

OFF

+ Ignition switch: ON

Altitude
Approx. 0 m (0 ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2,
11.36 psi)

BARO SEN

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
G/Y

Electronic control fuel
injection pump

R/B

Electronic control fuel
injection pump

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Approximately 2.5V

Warm-up condition
Idle speed
Engine is running.

L/R

Approximately 2.5V

Warm-up condition
Idle speed

Approximately 0.1V
Idle speed
Approximately 0.35V
Idle speed

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible cause)

+ Spill valve (Built-into electronic control fuel injection pump)
does not function properly.

+ Harness or connectors
(Electronic control fuel injection pump circuit is open or
shorted.)
+ Electronic control fuel injection pump

EC-1172

DTC 0704 P4zSPILL/V CIRC, DTC 0706 P6zSPILL VALVE

ZD30DDTi

EC-1173

DTC 0704 P4zSPILL/V CIRC, DTC 0706 P6zSPILL VALVE

ZD30DDTi

Wiring Diagram

TEC113M

EC-1174

DTC 0704 P4zSPILL/V CIRC, DTC 0706 P6zSPILL VALVE

ZD30DDTi

Diagnostic Procedure
1

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect electronic control fuel injection pump harness connector.

SEF229Z

3. Turn ignition switch “ON”.
4. Check voltage between electronic control fuel injection pump terminal 7 and ground.

SEF438Y

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP GROUND CIRCUIT FOR OPEN AND SHORT

c GO TO 5.

c GO TO 4.

EC-1175

DTC 0704 P4zSPILL/V CIRC, DTC 0706 P6zSPILL VALVE
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

CHECK COMMUNICATION LINE FOR OPEN AND SHORT

1. Check continuity between the following terminals. Refer to Wiring Diagram.

MTBL0444

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
OK or NG
OK

c Replace electronic control fuel injection pump.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1176

DTC 0705 P5zPUMP C/MODULE

ZD30DDTi

Description
SYSTEM DESCRIPTION

SEF437Y

FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel temperature.

EC-1177

ZD30DDTi

DTC 0705 P5zPUMP C/MODULE

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

SPILL/V

+ Engine: After warming up

Approx. 13°CA

INJ TIMG C/V

+ Engine: After warming up,
idle the engine.

Approx. 50 — 70%

DECELER F/CUT

+ Engine: After warmIdle
ing up

OFF

+ Ignition switch: ON

Altitude
Approx. 0 m (0 ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2,
11.36 psi)

BARO SEN

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
G/Y

Electronic control fuel
injection pump

R/B

Electronic control fuel
injection pump

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Approximately 2.5V

Warm-up condition
Idle speed
Engine is running.

L/R

Approximately 2.5V

Warm-up condition
Idle speed

Approximately 0.1V
Idle speed
Approximately 0.35V
Idle speed

On Board Diagnosis Logic
Malfunction is detected when ….
+ Injection pump control unit does not function properly.

Check Items (Possible cause)
+ Electronic control fuel injection pump

EC-1178

DTC 0705 P5zPUMP C/MODULE

ZD30DDTi

WITHOUT CONSULT-II

SEF817Y

1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
3) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1179.

Diagnostic Procedure
1

INSPECTION START

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform “DTC Confirmation Procedure”, EC-1179, again.
5. Is the malfunction displayed again?
Without CONSULT-II
1. Turn ignition switch “ON”.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory.
3. Perform “DTC Confirmation Procedure”, EC-1179, again.
4. Perform “Diagnostic Test Mode II (Self-diagnostic results)”.
5. Is the DTC 0705 displayed again?
Yes or No
Yes

c Replace electronic control fuel injection pump.

c INSPECTION END

EC-1179

DTC 0707 P7zF/INJ TIMG FB

ZD30DDTi

Description
SYSTEM DESCRIPTION

SEF437Y

FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel temperature.

EC-1180

ZD30DDTi

DTC 0707 P7zF/INJ TIMG FB

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

SPILL/V

+ Engine: After warming up

Approx. 13°CA

INJ TIMG C/V

+ Engine: After warming up,
idle the engine.

Approx. 50 — 70%

DECELER F/CUT

+ Engine: After warmIdle
ing up

OFF

+ Ignition switch: ON

Altitude
Approx. 0 m (0 ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2,
11.36 psi)

BARO SEN

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
G/Y

Electronic control fuel
injection pump

R/B

Electronic control fuel
injection pump

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Approximately 2.5V

Warm-up condition
Idle speed
Engine is running.

L/R

Approximately 2.5V

Warm-up condition
Idle speed

Approximately 0.1V
Idle speed
Approximately 0.35V
Idle speed

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible cause)

+ Fuel injection timing control system does not function properly.

+ Harness or connectors
(Electronic control fuel injection pump circuit is open or
shorted.)
+ Electronic control fuel injection pump
+ Improper fuel quality
+ “INJ TIMING” in “ACTIVE TEST” mode with CONSULT-II.*

*: When using this item, DTC may be detected. If so, erase it because it is not a malfunction.

EC-1181

DTC 0707 P7zF/INJ TIMG FB

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II

SEF817Y

1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Select “DATA MONITOR” mode with CONSULT-II.
3) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
4) Keep engine speed at more than 2,000 rpm for at least 10
seconds.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1184.

WITHOUT CONSULT-II
1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
3) Keep engine speed at more than 2,000 rpm for at least 10
seconds.
4) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
5) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
6) If DTC is detected, go to “Diagnostic Procedure”, EC-1184.

EC-1182

DTC 0707 P7zF/INJ TIMG FB

ZD30DDTi

Wiring Diagram

TEC113M

EC-1183

DTC 0707 P7zF/INJ TIMG FB
Diagnostic Procedure
1

INSPECTION START

1. Turn ignition switch “OFF”.
2. Perform “Air Bleeding”, EC-1031, and “DRAINING WATER” in MA section.
c GO TO 2.
2

PERFORM DTC CONFIRMATION PROCEDURE AGAIN

Perform “DTC Confirmation Procedure”, EC-1182 again.
OK or NG
OK

c INSPECTION END

c GO TO 3.

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect electronic control fuel injection pump harness connector.

SEF229Z

3. Turn ignition switch “ON”.
4. Check voltage between electronic control fuel injection pump terminal 7 and ground.

SEF438Y

OK or NG
OK

c GO TO 5.

c GO TO 4.

EC-1184

ZD30DDTi

DTC 0707 P7zF/INJ TIMG FB
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP GROUND CIRCUIT FOR OPEN AND SHORT

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

CHECK COMMUNICATION LINE FOR OPEN AND SHORT

1. Check continuity between the following terminals. Refer to Wiring Diagram.

MTBL0444

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 9.

c GO TO 8.

DETECT MALFUNCTIONING PART

EC-1185

DTC 0707 P7zF/INJ TIMG FB
Diagnostic Procedure (Cont’d)
9

ZD30DDTi

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
OK or NG
OK

c Replace electronic control fuel injection pump.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1186

ZD30DDTi

DTC 0802 ECM 10
Description

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the
engine.

SEC220B

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ An excessively high or low voltage from the absolute pressure
sensor (built-into ECM) is sent to ECM.

+ ECM
(ECCS-D control module)

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and wait at least 2 seconds.
If DTC is detected, go to “Diagnostic Procedure”, EC-1188.

WITHOUT CONSULT-II
SEF817Y

EC-1187

DTC 0802 ECM 10
Diagnostic Procedure
1

INSPECTION START

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform “DTC Confirmation Procedure”, EC-1187, again.
5. Is the malfunction displayed again?
Without CONSULT-II
1. Turn ignition switch “ON”.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory.
3. Perform “DTC Confirmation Procedure”, EC-1187, again.
4. Perform “Diagnostic Test Mode II (Self-diagnostic results)”.
5. Is the DTC 0802 displayed again?
Yes or No
Yes

c Replace ECM.

c INSPECTION END

EC-1188

ZD30DDTi

DTC 0804 ECM 11
Description

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the
engine.

SEC220B

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ ECM input signal processing function is malfunctioning.

+ ECM
(ECCS-D control module)

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 1 second.
If DTC is detected, go to “Diagnostic Procedure”, EC-1190.

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON” and wait at least 1 second.
2) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
4) If DTC is detected, go to “Diagnostic Procedure”, EC-1190.

EC-1189

DTC 0804 ECM 11
Diagnostic Procedure
1

INSPECTION START

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform “DTC Confirmation Procedure”, EC-1189, again.
5. Is the malfunction displayed again?
Without CONSULT-II
1. Turn ignition switch “ON”.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory.
3. Perform “DTC Confirmation Procedure”, EC-1189, again.
4. Perform “Diagnostic Test Mode II (Self-diagnostic results)”.
5. Is the DTC 0802 displayed again?
Yes or No
Yes

c Replace ECM.

c INSPECTION END

EC-1190

ZD30DDTi

DTC 0807 ECM 14
Description

The stop lamp switch is installed to brake pedal bracket. The
switch senses brake pedal position and sends an ON-OFF signal to the ECM. The ECM uses the signal to control the fuel
injection control system.

SEF275Z

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”
Approximately 0V
Brake pedal fully released
17

G/Y

Stop lamp switch
Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Brake pedal depressed

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ An irregular voltage signal from the switch is sent to ECM.

+ Harness or connectors
(The stop lamp switch circuit is open or shorted.)
+ Stop lamp switch

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Depress and release brake pedal more than 10 times.
If DTC is detected, go to “Diagnostic Procedure”, EC-1193.

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON”.
2) Depress and release brake pedal more than 10 times.
3) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1193.

EC-1191

DTC 0807 ECM 14

ZD30DDTi

Wiring Diagram

TEC121M

EC-1192

DTC 0807 ECM 14
Diagnostic Procedure
1

CHECK STOP LAMP SWITCH CIRCUIT

1. Turn ignition switch “ON”.
2. Check the stop lamp when depressing and releasing the stop lamp switch.

MTBL0443

OK or NG
OK

c GO TO 4.

c GO TO 2.

CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect stop lamp switch harness connector.

SEF275Z

3. Turn ignition switch “ON”.
4. Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester.

SEF435Y

OK or NG
OK

c GO TO 4.

c GO TO 3.

EC-1193

ZD30DDTi

DTC 0807 ECM 14
Diagnostic Procedure (Cont’d)
3

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Fuse block (J/B) connector M3
+ 10A fuse
+ Harness for open and short between stop lamp switch and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
4

CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Disconnect stop lamp switch harness connector.

SEF275Z

4. Check harness continuity between ECM terminal 17 and stop lamp switch terminal 2. Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Harness for open or short between ECM and stop lamp switch
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1194

DTC 0807 ECM 14
Diagnostic Procedure (Cont’d)
6

CHECK STOP LAMP SWITCH

Check continuity between stop lamp switch terminals 1 and 2 under the following conditions.

SEF276Z

OK or NG
OK

c GO TO 7.

c Replace stop lamp switch.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1195

ZD30DDTi

DTC 0902 ECM RLY

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”
Ignition switch “OFF”
4

B/Y

ECM relay (Self-shutoff)

Approximately 0.25V

For a few seconds after turning ignition switch
“OFF”
Ignition switch “OFF”
A few seconds passed after turning ignition
switch “OFF”

56
61
116

B/Y

W
W
W

Ignition switch “OFF”

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch

Power supply for ECM

BATTERY VOLTAGE
(11 — 14V)

On Board Diagnosis Logic
Malfunction is detected when ….

Check Items (Possible Cause)

+ An irregular voltage signal from the ECM relay is sent to
ECM.

+ Harness or connectors
(ECM relay circuit is open or shorted.)
+ ECM relay

DTC Confirmation Procedure
WITH CONSULT-II
1) Turn ignition switch “ON”.
2) Select “DATA MONITOR” mode with CONSULT-II.
3) Turn ignition switch “OFF”, wait at least 20 seconds and then
turn “ON”.
4) If DTC is detected, go to “Diagnostic Procedure”, EC-1198.

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON”.
2) Turn ignition switch “OFF”, wait at least 20 seconds and then
turn “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
4) If DTC is detected, go to “Diagnostic Procedure”, EC-1198.

EC-1196

DTC 0902 ECM RLY

ZD30DDTi

Wiring Diagram

TEC123M

EC-1197

DTC 0902 ECM RLY

ZD30DDTi

Diagnostic Procedure
1

CHECK ECM POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect ECM relay.

SEF225Z

3. Check voltage between ECM terminals 1, 3 and ground with CONSULT-II or tester.

SEF289Z

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
1. Harness connectors E104, M86 or E127, M21
2. 20A fuse
3. Harness for open and short between ECM relay and battery
c Repair open circuit or short to ground or short to power in harness or connectors.
3

CHECK ECM INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminals 56, 61, 116 and ECM relay terminal 5. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

EC-1198

DTC 0902 ECM RLY
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M50, F5
+ Harness for open or short between ECM and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.
5

CHECK ECM OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 4 and ECM relay terminal 2. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Harness for open or short between ECM and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.
7

CHECK ECM RELAY

1. Apply 12V direct current between ECM relay terminals 1 and 2.
2. Check continuity between ECM relay terminals 3 and 5, 6 and 7.

SEF296X

OK or NG
OK

c GO TO 8.

c Replace ECM relay.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1199

ZD30DDTi

DTC 0903 ECM 15
Description

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the
engine.

SEC220B

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ ECM input signal processing function is malfunctioning.

+ ECM
(ECCS-D control module)

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Turn ignition switch “OFF”, wait at least 20 seconds and then
turn “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
4) If DTC is detected, go to “Diagnostic Procedure”, EC-1201.

EC-1200

DTC 0903 ECM 15
Diagnostic Procedure
1

INSPECTION START

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform “DTC Confirmation Procedure”, EC-1200, again.
5. Is the malfunction displayed again?
Without CONSULT-II
1. Turn ignition switch “ON”.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory.
3. Perform “DTC Confirmation Procedure”, EC-1200, again.
4. Perform “Diagnostic Test Mode II (Self-diagnostic results)”.
5. Is the DTC 0903 displayed again?
Yes or No
Yes

c Replace ECM.

c INSPECTION END

EC-1201

ZD30DDTi

DTC 0905 TURBO PRESSURE
Component Description

The charge air pressure sensor detects pressure in the exit side
of the charge air cooler. The sensor output voltage to the ECM
increases as pressure increases. The charge air pressure sensor is not used to control the engine system under normal conditions.

SEF340VA

SEF627RA

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
46

Charge air pressure sensor

Approximately 2.0V

Warm-up condition
Idle speed

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ An excessively high or low voltage from the sensor is sent to
ECM.

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Charge air pressure sensor

EC-1202

DTC 0905 TURBO PRESSURE

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 1 second.
If DTC is detected, go to “Diagnostic Procedure”, EC-1205.

WITHOUT CONSULT-II
SEF817Y

EC-1203

DTC 0905 TURBO PRESSURE

ZD30DDTi

Wiring Diagram

TEC119M

EC-1204

DTC 0905 TURBO PRESSURE

ZD30DDTi

Diagnostic Procedure
1

CHECK CHARGE AIR PRESSURE SENSOR POWER SUPPLY CIRCUIT

1. Stop engine.
2. Disconnect charge air pressure sensor harness connector.

SEF283Z

3. Turn ignition switch “ON”.
4. Check voltage between charge air pressure sensor terminal 1 and ground with CONSULT-II or tester.

SEF306Z

OK or NG
OK

c GO TO 2.

c Repair harness or connectors.

CHECK CHARGE AIR PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Check harness continuity between charge air pressure sensor terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F6, M51 (A/T models)
+ Harness connectors M88, E106 (A/T models)
+ Harness for open or short between ECM and charge air pressure sensor
+ Harness for open or short between TCM (Transmission control module) and charge air pressure sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1205

DTC 0905 TURBO PRESSURE
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

CHECK CHARGE AIR PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 46 and charge air pressure sensor terminal 2. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK CHARGE AIR PRESSURE SENSOR

1. Remove charge air pressure sensor with its harness connector connected.
2. Turn ignition switch “ON”.
3. Use pump to apply pressure to charge air pressure sensor as shown in the figure.
CAUTION:
+ Always calibrate the pressure pump gauge when using it.
+ Inspection should be done at room temperature [10 — 30°C (50 — 86°F)].
4. Check the output voltage between charge air pressure sensor terminal 2 and engine ground.

SEF449Z

OK or NG
OK

c GO TO 6.

c Replace charge air pressure sensor.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1206

DTC 1003 EGR VOLUME CONT/V

ZD30DDTi

Description
SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Electronic controlled fuel injection pump

Fuel injection signal

Crankshaft position sensor (TDC)

Engine speed

Vehicle speed sensor

Vehicle speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Throttle position sensor

Throttle position

Battery

Battery voltage

Mass air flow sensor

Amount of intake air

Air conditioner switch

Air conditioner operation

Electrical load

Electrical load signal

PNP switch

Park/Neutral position signal

ECM Function

EGR volume control

Actuator

EGR volume control valve

This system controls flow rate of EGR led from exhaust manifold
to intake manifold. The opening of the EGR by-pass passage in
the EGR volume control valve changes to control the flow rate.
A built-in step motor moves the valve in steps corresponding to
the ECM output pulses. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is
determined by considering various engine conditions.
The EGR volume control valve remains close under the following conditions.
+ Engine stopped
+ Engine starting
+ Low engine coolant temperature
+ Excessively high engine coolant temperature
+ High engine speed
+ Wide open throttle
+ Low battery voltage

SEF908Y

EC-1207

ZD30DDTi

DTC 1003 EGR VOLUME CONT/V
Description (Cont’d)
COMPONENT DESCRIPTION
EGR volume control valve

The EGR volume control valve uses a step motor to control the flow
rate of EGR from exhaust manifold. This motor has four winding
phases. It operates according to the output pulse signal of the ECM.
Two windings are turned ON and OFF in sequence. Each time an
ON pulse is issued, the valve opens or closes, changing the flow
rate. When no change in the flow rate is needed, the ECM does not
issue the pulse signal. A certain voltage signal is issued so that the
valve remains at that particular opening.

SEF411Y

CONSULT-II Reference Value in Data Monitor Mode
Specification data are reference values.
MONITOR ITEM

EGR VOL CON/V

CONDITION
+
+
+
+

Engine: After warming up
Air conditioner switch: “OFF”
Shift lever: Neutral position
No-load

SPECIFICATION

After 1 minute at idle

More than 10 steps

Revving engine up to 3,200 rpm
quickly

0 step

WIRE
COLOR
L/Y
L/W
L
R/L

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
EGR volume control valve

Warm-up condition
Idle speed

0.1 — 14V

DTC Confirmation Procedure
WITH CONSULT-II
1) Start engine and warm it up to normal operating temperature.
2) Select “DATA MONITOR” mode with CONSULT-II.
3) Turn ignition switch “OFF”, and immediately turn “ON” within
1 second.
4) Start engine and let it idle.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1210.
SEF817Y

WITHOUT CONSULT-II
1) Start engine and warm it up to normal operating temperature.
2) Turn ignition switch “OFF”, and immediately turn “ON” within
1 second.
3) Start engine and let it idle.
4) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
5) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
6) If DTC is detected, go to “Diagnostic Procedure”, EC-1210.

EC-1208

DTC 1003 EGR VOLUME CONT/V

ZD30DDTi

Wiring Diagram

TEC116M

EC-1209

DTC 1003 EGR VOLUME CONT/V
Diagnostic Procedure
1

CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-I

1. Turn ignition switch “OFF”.
2. Disconnect EGR volume control valve harness connector.

SEF277Z

3. Turn ignition switch “ON”.
4. Check voltage between EGR volume control valve terminals 2, 5 and ground with CONSULT-II or tester.

SEF412Y

OK or NG
OK

c GO TO 7.

c GO TO 2.

EC-1210

ZD30DDTi

DTC 1003 EGR VOLUME CONT/V
Diagnostic Procedure (Cont’d)
2

ZD30DDTi

CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-II

1. Turn ignition switch “OFF”.
2. Disconnect ECM relay.

SEF225Z

3. Check harness continuity between ECM relay terminal 7 and EGR volume control valve terminals 2 and 5. Refer to Wiring Diagram.
Continuity should exist.
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M50, F5
+ Harness for open or short between EGR volume control valve and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.
4

CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-III

Check voltage between ECM relay terminal 6 and ground with CONSULT-II or tester.

SEF297Z

OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ 10A fuse
+ Harness for open or short between ECM relay and battery
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1211

DTC 1003 EGR VOLUME CONT/V
Diagnostic Procedure (Cont’d)
6

ZD30DDTi

CHECK ECM RELAY

1. Apply 12V direct current between ECM relay terminals 1 and 2.
2. Check continuity between ECM relay terminals 3 and 5, 6 and 7.

SEF296X

OK or NG
OK

c GO TO 7.

c Replace ECM relay.

CHECK EGR VOLUME CONTROL VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminals and EGR volume control valve terminals as follows.
Refer to Wiring Diagram.

MTBL0442

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1212

DTC 1003 EGR VOLUME CONT/V
Diagnostic Procedure (Cont’d)
8

ZD30DDTi

CHECK EGR VOLUME CONTROL VALVE-I

Check resistance between EGR volume control valve terminal 2 and terminals 1, 3, terminal 5 and terminals 4, 6.

SEF414Y

OK or NG
OK (With CONSULT-II)

c GO TO 9.

OK (Without CONSULT-II)

c GO TO 10.

c Replace EGR volume control valve.

CHECK EGR VOLUME CONTROL VALVE-II

With CONSULT-II
1. Remove EGR volume control valve.
2. Reconnect ECM harness connector and EGR volume control valve harness connector.
3. Turn ignition switch “ON”.
4. Perform “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II.
5. Check that EGR volume control valve shaft moves smoothly forward and backward according to the valve opening steps.

SEF819Y

OK or NG
OK

c GO TO 11.

c Replace EGR volume control valve.

EC-1213

DTC 1003 EGR VOLUME CONT/V
Diagnostic Procedure (Cont’d)
10

ZD30DDTi

CHECK EGR VOLUME CONTROL VALVE-II

Without CONSULT-II
1. Remove EGR volume control valve.
2. Reconnect ECM harness connector and EGR volume control valve harness connector.
3. Turn ignition switch “ON” and “OFF”.
4. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position.

SEF560W

OK or NG
OK

c GO TO 11.

c Replace EGR volume control valve.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1214

DTC 1004 FUEL CUT SYSTEM1

ZD30DDTi

Description
SYSTEM DESCRIPTION

SEF437Y

FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel temperature.

EC-1215

ZD30DDTi

DTC 1004 FUEL CUT SYSTEM1

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

SPILL/V

+ Engine: After warming up

Approx. 13°CA

INJ TIMG C/V

+ Engine: After warming up,
idle the engine.

Approx. 50 — 70%

DECELER F/CUT

+ Engine: After warmIdle
ing up

OFF

+ Ignition switch: ON

Altitude
Approx. 0 m (0 ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2,
11.36 psi)

BARO SEN

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
G/Y

Electronic control fuel
injection pump

R/B

Electronic control fuel
injection pump

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

Approximately 2.5V

Warm-up condition
Idle speed
Engine is running.

L/R

Approximately 2.5V

Warm-up condition
Idle speed

Approximately 0.1V
Idle speed
Approximately 0.35V
Idle speed

On Board Diagnosis Logic
Malfunction is detected when ….
+ Fuel cut control system does not function properly.

Check Items (Possible cause)
+ Harness or connectors
(Electronic control fuel circuit is open or shorted.)
+ Electronic control fuel

EC-1216

DTC 1004 FUEL CUT SYSTEM1

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II

SEF817Y

1) Turn ignition switch “ON” and wait at least 2 seconds.
2) Select “DATA MONITOR” mode with CONSULT-II.
3) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
4) Turn ignition switch “OFF”, wait at least 5 seconds and then
turn “ON”.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-1219.

EC-1217

DTC 1004 FUEL CUT SYSTEM1

ZD30DDTi

Wiring Diagram

TEC113M

EC-1218

DTC 1004 FUEL CUT SYSTEM1

ZD30DDTi

Diagnostic Procedure
1

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect electronic control fuel injection pump harness connector.

SEF229Z

3. Turn ignition switch “ON”.
4. Check voltage between electronic control fuel injection pump terminal 7 and ground.

SEF438Y

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

CHECK ELECTRONIC CONTROL FUEL INJECTION PUMP GROUND CIRCUIT FOR OPEN AND SHORT

c GO TO 5.

c GO TO 4.

EC-1219

DTC 1004 FUEL CUT SYSTEM1
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

DETECT MALFUNCTIONING PART

CHECK COMMUNICATION LINE FOR OPEN AND SHORT

1. Check continuity between the following terminals. Refer to Wiring Diagram.

MTBL0444

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
OK or NG
OK

c Replace electronic control fuel injection pump.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1220

ZD30DDTi

GLOW CONTROL SYSTEM
Description
SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position
sensor (TDC)

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

ECM
Function

Actuator

Glow
control

Glow lamp,
Glow relay
↓
Glow plugs

When engine coolant temperature is more than approximately
75°C (167°F), the glow relay turns off, inactivating the quick-glow
control until coolant temperature drops below approximately
55°C (131°F).
When coolant temperature is lower than approximately 75°C
(167°F):
+ Ignition switch ON
After ignition switch has turned to ON, the glow relay turns
ON for a certain period of time in relation to engine coolant
temperature, allowing current to flow through glow plug.
+ Cranking
The glow relay turns ON, allowing current to flow through
glow plug.
+ Starting
After engine has started, current continues to flow through
glow plug (after-glow mode) for a certain period in relation to
engine coolant temperature.
When engine speed exceeds approximately 4,800 rpm, current flow through glow plug is interrupted.
The glow indicator lamp turns ON for a certain period of time in
relation to engine coolant temperature at the time glow relay is
turned ON.

COMPONENT DESCRIPTION
Glow plug
+ The glow plug is provided with a ceramic heating element to
obtain a high-temperature resistance. It glows in response to
a signal sent from the ECM, allowing current to flow through
the glow plug via the glow relay.

SEF376Y

+ This engine uses two types of glow plugs.
Type A has a blue or yellow paint mark.
Type B has no paint mark.
The location of the paint mark is shown in the figure.
WARNING:
Do not use two types of glow plugs at the same time.

SEF280Z

EC-1221

GLOW CONTROL SYSTEM

ZD30DDTi

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”
Approximately 1V
Glow indicator lamp is “ON”
16

L/W

Glow indicator lamp
Ignition switch “ON”
Glow indicator lamp is “OFF”

111

LG/B

Glow relay

Refer to “SYSTEM DESCRIPTION”, EC-1221.

EC-1222

BATTERY VOLTAGE
(11 — 14V)

GLOW CONTROL SYSTEM

ZD30DDTi

Wiring Diagram

TEC105M

EC-1223

GLOW CONTROL SYSTEM

ZD30DDTi

Diagnostic Procedure
1

INSPECTION START

Check fuel level, fuel supplying system, starter motor, etc.
OK or NG
OK

c GO TO 2.

c Correct.

CHECK INSTALLATION

Check that all glow plug connecting plate nuts are installed properly.

SEF233Z

OK or NG
OK (With CONSULT-II)

c GO TO 3.

OK (Without CONSULT-II)

c GO TO 4.

c Install properly.

CHECK GLOW INDICATOR LAMP OPERATION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II.
3. Confirm that “COOLAN TEMP/S” indicates below 75°C (167°F). If it indicates above 75°C (167°F), cool down engine.

SEF013Y

4. Turn ignition switch “OFF”, wait at least 5 seconds and then turn “ON”.
5. Make sure that glow indicator lamp is turned “ON” for 1.5 seconds or more after turning ignition switch “ON”, and then turned
“OFF”.
OK or NG
OK

c GO TO 5.

c GO TO 6.

EC-1224

GLOW CONTROL SYSTEM
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

CHECK GLOW INDICATOR LAMP OPERATION

Without CONSULT-II
1. Turn ignition switch “ON”.
2. Confirm that the voltage between ECM terminal 19 and ground is above 1.36V. If it is below 1.36V, cool down engine.

SEF430Y

3. Turn ignition switch “OFF”, wait at least 5 seconds and then turn “ON”.
4. Make sure that glow indicator lamp is turned “ON” for 1.5 seconds or more after turning ignition switch “ON”, and then turned
“OFF”.
OK or NG
OK

c GO TO 5.

c GO TO 6.

5
1.
2.
3.
4.

CHECK GLOW CONTROL SYSTEM OVERALL FUNCTION
Turn ignition switch “OFF”.
Set voltmeter probe between glow plug and engine body.
Turn ignition switch “ON”.
Check the voltage between glow plug and engine body under the following conditions.

SEF234Z

OK or NG
OK

c INSPECTION END

c GO TO 11.

EC-1225

GLOW CONTROL SYSTEM
Diagnostic Procedure (Cont’d)
6
1.
2.
3.
4.

ZD30DDTi

CHECK GLOW INDICATOR LAMP POWER SUPPLY CIRCUIT
Turn ignition switch “OFF”.
Disconnect combination meter harness connector M32.
Turn ignition switch “ON”.
Check voltage between combination meter terminal 9 and ground with CONSULT-II or tester.

SEF296Z

OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
1. Fuse block (J/B) connector M3
2. 10A fuse
3. Harness for open or short between combination meter and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
8

CHECK GLOW INDICATOR LAMP OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1.
2.
3.
4.

Turn ignition switch “OFF”.
Disconnect ECM harness connector.
Disconnect combination meter harness connector M34.
Check harness continuity between ECM terminal 16 and combination meter terminal 30. Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
1. Harness connectors M51, F6
2. Harness for open or short between combination meter and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.
10

CHECK COMBINATION METER

Check combination meter and glow indicator lamp. Refer to EL section (“METER AND GAUGES”).
OK or NG
OK

c GO TO 18.

c Repair or replace combination meter or glow indicator lamp.

EC-1226

GLOW CONTROL SYSTEM
Diagnostic Procedure (Cont’d)
11

CHECK GLOW RELAY POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect glow relay.

SEF235Z

3. Check voltage between glow relay terminals 1, 3 and ground with CONSULT-II or tester.

SEF451Z

OK or NG
OK

c GO TO 13.

c GO TO 12.

DETECT MALFUNCTIONING PART

Check the following.
+ 100A fusible link
+ Harness for open or short between glow relay and battery
c Repair harness or connectors.
13

CHECK GLOW RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 111 and glow relay terminal 2. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 15.

c GO TO 14.

EC-1227

ZD30DDTi

GLOW CONTROL SYSTEM
Diagnostic Procedure (Cont’d)
14

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M51, F6
+ Harness for open or short between glow relay and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.
15

CHECK HARNESS CONTINUITY BETWEEN GLOW RELAY AND GLOW PLUG FOR OPEN AND SHORT

1. Disconnect glow plug harness connector.
2. Check harness continuity between glow relay terminal 5 and glow plug harness connector. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 16.

c Repair open circuit or short to ground or short to power in harness or connectors.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E67, E223
+ Harness connectors E225, E241
+ Harness for open or short between glow relay and glow plug
c Repair open circuit or short to ground or short to power in harness or connectors.
17

CHECK GLOW RELAY

Check continuity between glow relay terminals 3 and 5 under the following conditions.

SEF433Y

OK or NG
OK

c GO TO 18.

c Replace glow relay.

EC-1228

GLOW CONTROL SYSTEM
Diagnostic Procedure (Cont’d)
18

CHECK GLOW PLUG

1. Remove glow plug connecting plate.
2. Check glow plug resistance.

SEF236Z

NOTE:
+ Do not bump glow plug heating element. If it is bumped, replace glow plug with a new one.
+ If glow plug is dropped from a height of 10 cm (3.94 in) or higher, replace with a new one.
+ If glow plug installation hole is contaminated with carbon, remove it with a reamer or suitable tool.
+ Hand-tighten glow plug by turning it two or three times, then tighten using a tool to specified torque.
: 15 — 20 Nzm (1.5 — 2.1 kg-m, 11 — 15 ft-lb)
OK or NG
OK

c GO TO 19.

c Replace glow plug.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1229

ZD30DDTi

START SIGNAL

ZD30DDTi

Wiring Diagram

TEC106M

EC-1230

START SIGNAL

ZD30DDTi

Diagnostic Procedure
1

CHECK START SIGNAL OVERALL FUNCTION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

SEF604X

Without CONSULT-II
Check voltage between ECM terminal 20 and ground under the following conditions.

SEF415Y

OK or NG
OK

c INSPECTION END

c GO TO 2.

CHECK START SIGNAL INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector and ignition switch harness connector.
3. Check harness continuity between ECM terminal 20 and ignition switch terminal 6. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ 7.5A fuse
+ Fuse block (J/B) connectors M3, E112
+ Harness for open or short between ECM and ignition switch
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1231

START SIGNAL
Diagnostic Procedure (Cont’d)
4

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1232

ZD30DDTi

PARK/NEUTRAL POSITION (PNP) SWITCH

ZD30DDTi

Description
When the gear position is in “Neutral”, neutral position is “ON”. ECM detects the position because the continuity of the line (the “ON” signal) exists.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
P/N POSI SW

CONDITION
+ Ignition switch: ON

SPECIFICATION

Shift lever: Park/Neutral

Except above

OFF

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”

P/B

Park/Neutral position
switch

Gear position is “Neutral” (M/T models)
Gear position is “P” or “N” (A/T models)
Ignition switch “ON”
Except the above gear position

EC-1233

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

PARK/NEUTRAL POSITION (PNP) SWITCH

ZD30DDTi

Wiring Diagram

TEC108M

EC-1234

PARK/NEUTRAL POSITION (PNP) SWITCH
Diagnostic Procedure
FOR M/T MODELS
1

CHECK OVERALL FUNCTION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II.
3. Check “P/N POSI SW” signal under the following conditions.

SEF049Y

Without CONSULT-II
1. Turn ignition switch “ON”.
2. Check voltage between ECM terminal 22 and ground under the following conditions.

SEF419Y

OK or NG
OK

c INSPECTION END

c GO TO 2.

EC-1235

ZD30DDTi

PARK/NEUTRAL POSITION (PNP) SWITCH
Diagnostic Procedure (Cont’d)
2

ZD30DDTi

CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect park/neutral position (PNP) switch harness connector.

SEF281Z

3. Check harness continuity between PNP switch terminal 2 and body ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E202, E69
+ Harness for open or short between PNP switch and body ground
c Repair open circuit or short to ground or short to power in harness or connectors.
4

CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 22 and PNP switch terminal 1. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F7, M52
+ Harness connectors M21, E127
+ Harness connectors E70, E201
+ Harness for open or short between PNP switch and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.
6

CHECK PARK/NEUTRAL POSITION SWITCH

Refer to MT section (“POSITION SWITCH CHECK”).
OK or NG
OK

c GO TO 7.

c Replace park/neutral position switch.

EC-1236

PARK/NEUTRAL POSITION (PNP) SWITCH
Diagnostic Procedure (Cont’d)
7

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

FOR A/T MODELS
1

CHECK OVERALL FUNCTION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II.
3. Check “P/N POSI SW” signal under the following conditions.

SEF049Y

Without CONSULT-II
1. Turn ignition switch “ON”.
2. Check voltage between ECM terminal 22 and ground under the following conditions.

SEF419Y

OK or NG
OK

c INSPECTION END

c GO TO 2.

EC-1237

ZD30DDTi

PARK/NEUTRAL POSITION (PNP) SWITCH
Diagnostic Procedure (Cont’d)
2

CHECK PNP SWITCH CIRCUIT

With CONSULT-II
1. Select “A/T” and then select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II.
2. Check “P/N POSI SW” signal under the following conditions.

SEF049Y

OK or NG
OK

c GO TO 9.

c GO TO 4.

CHECK PNP SWITCH CIRCUIT

Without CONSULT-II
1. Turn ignition switch “OFF”.
2. Disconnect TCM (Transmission control module) harness connector.

SEF792V

3. Turn ignition switch “ON”.
4. Check voltage between TCM terminal 36 and ground under the following conditions.

SEF298Z

OK or NG
OK

c GO TO 9.

c GO TO 4.

EC-1238

ZD30DDTi

PARK/NEUTRAL POSITION (PNP) SWITCH
Diagnostic Procedure (Cont’d)
4
1.
2.
3.
4.

ZD30DDTi

CHECK PNP SWITCH POWER SUPPLY CIRCUIT
Turn ignition switch “OFF”.
Disconnect PNP switch harness connector.
Turn ignition switch “ON”.
Check voltage between PNP switch terminal 3 and ground with CONSULT-II or tester.

SEF299Z

OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Fuse block (J/B) connector E112
+ 7.5A fuse
+ Harness for open or short between PNP switch and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
6

CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT-I

1. Turn ignition switch “OFF”.
2. Disconnect TCM (Transmission control module) harness connector.
3. Check harness continuity between TCM terminal 36 and PNP switch terminals 7, 9 under the following conditions.

SEF300Z

4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

EC-1239

PARK/NEUTRAL POSITION (PNP) SWITCH
Diagnostic Procedure (Cont’d)
7

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Diode E103
+ Harness for open or short between PNP switch and TCM (Transmission control module)
c Repair open circuit or short to ground or short to power in harness or connectors.
8

CHECK PARK/NEUTRAL POSITION (PNP) SWITCH

Refer to “TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS” in AT section.
OK or NG
OK

c GO TO 9.

c Replace park/neutral position (PNP) switch.

CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT-II

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 22 and TCM terminal 14. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 11.

c GO TO 10.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F7, M52
+ Harness connectors M21, E127
+ Harness for open or short between ECM and TCM (Transmission control module)
c Repair open circuit or short to ground or short to power in harness or connectors.
11

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1240

ZD30DDTi

HEAT UP SWITCH
Component Description

The heat up switch is located on the lower side of the instrument
panel. This switch is used to speed up the heater’s operation
when the engine is cold.
When the ECM received the heat up switch “ON” signal, the
ECM increases the engine idle speed to 1,100 to 1,200 rpm to
warm up engine quickly.
This system works when all conditions listed below are met.
SEF803V

Heat up switch

Engine coolant temperature

Below 105°C (221°F)

Shift lever

“P” or “N”

Accelerator pedal

Fully released

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
WARM UP SW

CONDITION
+ Ignition switch: ON

SPECIFICATION

Heat up switch: ON

Heat up switch: OFF

OFF

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse
Signal)

Ignition switch “ON”
0V
Heat up switch is “OFF”.
59

BR/W

Heat up switch
Ignition switch “ON”
Heat up switch is “ON”.

EC-1241

BATTERY VOLTAGE
(11 — 14V)

HEAT UP SWITCH

ZD30DDTi

Wiring Diagram

TEC110M

EC-1242

HEAT UP SWITCH
Diagnostic Procedure
1

INSPECTION START

Do you have CONSULT-II?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

CHECK OVERALL FUNCTION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Check “WARM UP SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

SEF302Z

OK or NG
OK

c INSPECTION END

c GO TO 4.

CHECK OVERALL FUNCTION

Without CONSULT-II
1. Turn ignition switch “ON”.
2. Check voltage between ECM terminal 59 and ground under the following conditions.

SEF303Z

OK or NG
OK

c INSPECTION END

c GO TO 4.

EC-1243

ZD30DDTi

HEAT UP SWITCH
Diagnostic Procedure (Cont’d)
4
1.
2.
3.
4.
5.

ZD30DDTi

CHECK HEAT UP SWITCH POWER SUPPLY CIRCUIT
Turn heat up switch “OFF”.
Turn ignition switch “OFF”.
Disconnect heat up switch harness connector.
Turn ignition switch “ON”.
Check voltage between heat up switch terminal 6 and ground with CONSULT-II or tester.

SEF304Z

OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Fuse block (J/B) connector M3
+ 10A fuse
+ Harness for open or short between heat up switch and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
6

CHECK HEAT UP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 59 and heat up switch terminal 5. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M51, F6
+ Harness for open or short between heat up switch and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1244

HEAT UP SWITCH
Diagnostic Procedure (Cont’d)
8

CHECK HEAT UP SWITCH

Check continuity between heat up switch terminals 5 and 6 under the following conditions.

SEF305Z

OK or NG
OK

c GO TO 9.

c Replace heat up switch.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1245

ZD30DDTi

SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE

ZD30DDTi

Description
SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Ignition switch

Start signal

Crankshaft position sensor (TDC)

Engine speed

PNP switch

Park/Neutral position signal

Engine coolant temperature sensor

Engine coolant temperature

ECM
Function

Actuator

Swirl
control
valve
control

Swirl control valve control solenoid valve
↓ Vacuum signal
Swirl control valve actuator
↓ Swirl control valve

This system has a swirl control valve in the throttle body.
While idling and during low engine speed operation, the swirl
control valve closes. Thus the velocity of the air in the intake
passage increases, promoting the vaporization of the fuel and
producing a swirl in the combustion chamber.
Because of this operation, this system tends to increase the
burning speed of the gas mixture, improve fuel consumption, and
increase the stability in running conditions.
Also, except when idling and during low engine speed operation,
this system opens the swirl control valve. In this condition, this
system tends to increase power by improving intake efficiency
via reduction of intake flow resistance, intake flow.
The solenoid valve controls swirl control valve’s shut/open condition. This solenoid valve is operated by the ECM.
PNP switch

Engine speed

Less than
1,250 rpm

Engine coolant temperature

Swirl control
valve control
solenoid valve

Swirl control
valve

Less than
50°C (122°F)

OFF

Open

More than
50°C (122°F)

Closed

Less than
50°C (122°F)

OFF

Open

More than
50°C (122°F)

OFF

Open

—

OFF

Open

OFF
More than
1,250 rpm

—

SEF452Z

EC-1246

SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE
Description (Cont’d)

ZD30DDTi

COMPONENT DESCRIPTION
Swirl control valve control solenoid valve
The swirl control valve control solenoid valve responds to signals
from the ECM. When the ECM sends an ON (ground) signal, the
solenoid valve is bypassed to apply vacuum pump vacuum to the
swirl control valve actuator. This operation closes the swirl control valve. When the ECM sends an OFF signal, the vacuum
signal is cut and the swirl control valve opens.
SEF284Z

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

SWRL CONT S/V

CONDITION
+ Lift up the vehicle
+ Engine: After warming up, let it
idle for more than 1 second.
+ Air conditioner switch: OFF
+ No-load

SPECIFICATION

Shift lever: Except “P” and “Neutral”
ON
position
Shift lever: “Neutral” position

OFF

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse
Signal)

Engine is running.

L/B

Swirl control valve control
solenoid valve

Warm-up condition
At idle speed for more than 1 second.
Lift up the vehicle
Gear position is except “P” and “Neutral”

Approximately 0.1V

Engine is running.
Idle speed
Lift up the vehicle
Gear position is “P” or “Neutral”

EC-1247

BATTERY VOLTAGE
(11 — 14V)

SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE

ZD30DDTi

Wiring Diagram

TEC117M

EC-1248

SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE

ZD30DDTi

Diagnostic Procedure
1

INSPECTION START

Do you have CONSULT-II?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

CHECK OVERALL FUNCTION

With CONSULT-II
1. Start engine and let it idle.
2. Select “SWIRL CONT S/V 1” in “ACTIVE TEST” mode with CONSULT-II.
3. Touch “ON” and “OFF” alternately on CONSULT-II screen.
4. Make sure that swirl control valve actuator rod moves according to “SWIRL CONT S/V 1” indication.

SEF307Z

OK or NG
OK

c INSPECTION END

c GO TO 4.

CHECK OVERALL FUNCTION

Without CONSULT-II
1. Lift up the vehicle.
2. Start engine and warm it up to normal operating temperature.
3. Run engine at idle speed.
4. Make sure that swirl control valve actuator rod moves when shifting the shift lever to “P” or “Neutral” position and then to positions other than “P” and “Neutral”.

SEF308Z

OK or NG
OK

c INSPECTION END

c GO TO 5.

EC-1249

SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

CHECK VACUUM SOURCE

With CONSULT-II
1. Turn ignition switch “OFF”.
2. Disconnect vacuum hose connected to swirl control valve actuator.
3. Start engine and let it idle.
4. Select “SWIRL CONT S/V 1” in “ACTIVE TEST” mode with CONSULT-II.
5. Touch “ON” and “OFF” alternately on CONSULT-II screen.
6. Check vacuum hose for vacuum existence under the following conditions.

SWIRL CONT S/V 1

Vacuum
Should exist
Should not exist

SEF309Z

OK or NG
OK

c GO TO 7.

c GO TO 6.

CHECK VACUUM SOURCE

Without CONSULT-II
1. Turn ignition switch “OFF”.
2. Disconnect vacuum hose connected to swirl control valve actuator.
3. Lift up the vehicle.
4. Start engine and warm it up to normal operating temperature.
5. Run engine at idle speed
6. Check vacuum hose for vacuum existence under the following conditions.

SEF310Z

OK or NG
OK

c GO TO 7.

c GO TO 6.

EC-1250

SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
6

ZD30DDTi

CHECK SWIRL CONTROL VALVE ACTUATOR

1. Turn ignition switch “OFF”.
2. Install a vacuum pump to swirl control valve actuator.
3. Make sure that the swirl control valve actuator rod moves smoothly when applying vacuum of −93.3 kPa (−933 mbar, −700
mmHg, −27.6 inHg) and releasing it.

SEF311Z

OK or NG
OK

Repair or replace vacuum hoses and vacuum gallery.

Replace swirl control valve actuator.

CHECK VACUUM HOSE

1. Turn ignition switch “OFF”.
2. Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.

SEF109L

OK or NG
OK

c GO TO 8.

c Repair or replace vacuum hoses and vacuum gallery.

EC-1251

SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
8

ZD30DDTi

CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect swirl control valve control solenoid valve harness connector.

SEF284Z

3. Turn ignition switch “ON”.
4. Check voltage between swirl control valve control solenoid valve terminal 2 and ground with CONSULT-II or tester.

SEF312Z

OK or NG
OK

GO TO 10.

GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Fuse block (J/B) connector M2
+ 10A fuse
+ Harness for open or short between swirl control valve control solenoid valve and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
10

CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 54 and swirl control valve control solenoid valve terminal 1. Refer to Wiring
Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 11.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1252

SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
11

CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE

With CONSULT-II
1. Reconnect all disconnected harness connectors.
2. Turn ignition switch “ON”.
3. Select “SWIRL CONT S/V 1” in “ACTIVE TEST” mode with CONSULT-II.
4. Check air passage continuity of swirl control valve control solenoid valve under the following conditions.

SEF313Z

Without CONSULT-II
1. Apply 12V direct current between swirl control valve control solenoid valve terminals.
2. Check air passage continuity of swirl control valve control solenoid valve under the following conditions.

SEF335X

OK or NG

GO TO 12.

Replace swirl control valve control solenoid valve.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1253

ZD30DDTi

INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE

ZD30DDTi

Description
Vibration when stopping the engine can be controlled by cutting
intake air right before the fuel is cut. The intake air control valve
control solenoid valve controls the ON-OFF load of the intake air
control valve actuator. As a result, the intake air control valve
control solenoid valve will be turned ON when the ignition switch
is turned OFF with the engine running and when the engine
stalls. After the engine has stopped, the intake air control valve
control solenoid valve will return to fully open.
SEF284Z

WIRE
COLOR

ITEM

CONDITION

Engine is running.
2

R/W

Intake air control valve
control solenoid valve

DATA (DC Voltage)

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “OFF”
Approximately 0.1V
For a few seconds after engine stops

EC-1254

INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE

ZD30DDTi

Wiring Diagram

TEC122M

EC-1255

INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure
1

CHECK OVERALL FUNCTION

1. Start engine and let it idle.
2. Make sure that intake air control valve actuator rod moves when turning ignition switch “OFF”.

SEF315Z

OK or NG
OK

c INSPECTION END

c GO TO 2.

2
1.
2.
3.
4.

CHECK VACUUM SOURCE
Turn ignition switch “OFF”.
Disconnect vacuum hose connected to intake air control valve actuator.
Start engine and let it idle.
Check vacuum hose for vacuum existence under the following conditions.

SEF316Z

OK or NG
OK

c GO TO 3.

c GO TO 4.

EC-1256

ZD30DDTi

INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
3

ZD30DDTi

CHECK INTAKE AIR CONTROL VALVE ACTUATOR

4. Turn ignition switch “OFF”.
5. Install a vacuum pump to intake air control valve actuator.
6. Make sure that the intake air control valve actuator rod moves smoothly when applying vacuum of −93.3 kPa (−933 mbar, −700
mmHg, −27.56 psi) and releasing it.

SEF317Z

OK or NG
OK

c Repair or replace vacuum hoses and vacuum gallery.

c Replace intake air control valve actuator.

CHECK VACUUM HOSE

3. Turn ignition switch “OFF”.
4. Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.

SEF109L

OK or NG
OK

c GO TO 5.

c Repair or replace vacuum hoses and vacuum gallery.

EC-1257

INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
5

ZD30DDTi

CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT-I

1. Turn ignition switch “OFF”.
2. Disconnect intake air control valve control solenoid valve harness connector.

SEF284Z

3. Turn ignition switch “ON”.
4. Check voltage between intake air control valve control solenoid valve terminal 2 and ground with CONSULT-II or tester.

SEF312Z

OK or NG
OK

c GO TO 11.

c GO TO 6.

EC-1258

INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
6

ZD30DDTi

CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT-II

1. Turn ignition switch “OFF”.
2. Disconnect ECM relay.

SEF225Z

3. Check harness continuity between intake air control valve control solenoid valve terminal 2 and ECM relay terminal 7. Refer to
Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M50, F5
+ Harness for open or short between intake air control valve control solenoid valve and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.
8

CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT-III

Check voltage between ECM relay terminal 6 and ground with CONSULT-II or tester.

SEF297Z

OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M21, E127
+ 10A fuse
+ Harness for open or short between ECM relay and battery
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1259

INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
10

ZD30DDTi

CHECK ECM RELAY

1. Apply 12V direct current between ECM relay terminals 1 and 2.
2. Check continuity between ECM relay terminals 3 and 5, 6 and 7.

SEF296X

OK or NG
OK

c GO TO 13.

c Replace ECM relay.

CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN OR
SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 2 and intake air control valve control solenoid valve terminal 1. Refer to Wiring
Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 12.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE

1. Apply 12V direct current between intake air control valve control solenoid valve terminals.
2. Check air passage continuity of intake air control valve control solenoid valve under the following conditions.

SEF335X

OK or NG

GO TO 13.

Replace intake control valve control solenoid valve.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1260

VARIABLE NOZZLE TURBOCHARGER CONTROL
SOLENOID VALVE

ZD30DDTi

Description
The load from the variable nozzle turbocharger control solenoid
valve controls the actuator. By changing the variable nozzle vane
opening through the rods, the intake air volume is adjusted.

SEF453Z

The variable nozzle turbocharger control solenoid valve is moved
by ON/OFF pulse from the ECM. The longer the ON pulse, the
charge air pressure rises.

SEF287Z

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

VNT S/V 1

CONDITION
+
+
+
+

Engine: After warming up
Air conditioner switch: “OFF”
Shift lever: Neutral position
No-load

SPECIFICATION

Idle

Approx. 56%

2,000 rpm

Approx. 20%

EC-1261

VARIABLE NOZZLE TURBOCHARGER CONTROL
SOLENOID VALVE

ZD30DDTi

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 6.8V
Engine is running.
Warm-up condition
Idle speed

101

R/B

Variable nozzle turbocharger control solenoid
valve

SEF253Z

Approximately 11V
Engine is running.
Warm-up condition
Engine speed is 2,000 rpm

SEF254Z

EC-1262

VARIABLE NOZZLE TURBOCHARGER CONTROL
SOLENOID VALVE

ZD30DDTi

Wiring Diagram

TEC120M

EC-1263

VARIABLE NOZZLE TURBOCHARGER CONTROL
SOLENOID VALVE

ZD30DDTi

Diagnostic Procedure
1

CHECK OVERALL FUNCTION

1. Start engine and let it idle.
2. Make sure that variable nozzle turbocharger control actuator rod moves when revving engine up to 3,000 rpm and returning to
idle.

SEF320Z

OK or NG
OK

c INSPECTION END

c GO TO 2.

2
1.
2.
3.
4.

CHECK VACUUM SOURCE
Turn ignition switch “OFF”.
Disconnect vacuum hose connected to variable nozzle turbocharger control actuator.
Start engine and let it idle.
Check vacuum hose for vacuum existence.

SEF321Z

OK or NG
OK

c GO TO 3.

c GO TO 5.

EC-1264

VARIABLE NOZZLE TURBOCHARGER CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
3

ZD30DDTi

CHECK VARIABLE NOZZLE TURBOCHARGER CONTROL ACTUATOR

1. Turn ignition switch “OFF”.
2. Install a vacuum pump to variable nozzle turbocharger control actuator.
3. Make sure that the variable nozzle turbocharger control actuator rod moves smoothly when applying vacuum of −53.3 kPa (−533
mbar, −400 mmHg, −15.75 inHg) and releasing it.

SEF322Z

OK or NG
OK

c GO TO 4.

c Replace turbocharger assembly.

CHECK VACUUM HOSE

1. Turn ignition switch “OFF”.
2. Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.

SEF109L

OK or NG
OK

c GO TO 9.

c Repair or replace vacuum hoses and vacuum gallery.

EC-1265

VARIABLE NOZZLE TURBOCHARGER CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
5

ZD30DDTi

CHECK VACUUM HOSE

1. Turn ignition switch “OFF”.
2. Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.

SEF109L

OK or NG
OK

c GO TO 6.

c Repair or replace vacuum hoses and vacuum gallery.

CHECK VARIABLE NOZZLE TURBOCHARGER CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect variable nozzle turbocharger control solenoid valve harness connector.

SEF287Z

3. Turn ignition switch “ON”.
4. Check voltage between variable nozzle turbocharger control solenoid valve terminal 2 and ground with CONSULT-II or tester.

SEF314Z

OK or NG
OK

c GO TO 8.

c GO TO 7.

EC-1266

VARIABLE NOZZLE TURBOCHARGER CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
7

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M21, E127
+ Harness connectors E69, E202
+ Fuse block (J/B) connector M2
+ 10A fuse
+ Harness for open or short between variable nozzle turbocharger control solenoid valve and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
8

CHECK VARIABLE NOZZLE TURBOCHARGER CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN OR SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 101 and variable nozzle turbocharger control solenoid valve terminal 1. Refer
to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E230, F12
+ Harness for open or short between variable nozzle turbocharger control solenoid valve and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-1267

VARIABLE NOZZLE TURBOCHARGER CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
10

ZD30DDTi

CHECK VARIABLE NOZZLE TURBOCHARGER CONTROL SOLENOID VALVE

1. Disconnect variable nozzle turbocharger control solenoid valve harness connector.

SEF287Z

2. Apply 12V direct current between variable nozzle turbocharger control solenoid valve terminals.
3. Check air passage continuity of variable nozzle turbocharger control solenoid valve under the following conditions.

SEF454Z

OK or NG
OK

c GO TO 11.

c Replace variable nozzle turbocharger control solenoid valve.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1268

EXHAUST GAS CONTROL VALVE CONTROL
SOLENOID VALVE

ZD30DDTi

Description

SEF285Z

With the heat up switch ON, engine speed is increased and the
exhaust gas control valve is closed, which helps to promote
heating and improve heating performance.
The exhaust gas control valve control solenoid valve responds
to signals from the ECM. When the ECM sends an ON (ground)
signal, the solenoid valve is bypassed to apply vacuum pump
vacuum to the exhaust gas control valve actuator. This operation
closes the exhaust gas control valve. When the ECM sends an
OFF signal, the vacuum signal is cut and the exhaust gas control valve opens.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

EXH/GAS REG V

CONDITION
+
+
+
+

SPECIFICATION

Vehicle: Stopped
Engine speed: Below 1,200 rpm
Engine coolant temperature: Below 87°C (189°F)
Heat up switch: ON

Except above

OFF

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

BR/Y

Exhaust gas control valve
control solenoid valve

Engine speed is below 1,200 rpm
Engine coolant temperature is below 87°C
(189°F)
Stop the vehicle
Heat up switch is “ON”
Engine is running.
Except the above condition

EC-1269

Approximately 0.1V

BATTERY VOLTAGE
(11 — 14V)

EXHAUST GAS CONTROL VALVE CONTROL
SOLENOID VALVE

ZD30DDTi

Wiring Diagram

TEC118M

EC-1270

EXHAUST GAS CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure
1

INSPECTION START

Do you have CONSULT-II?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

CHECK OVERALL FUNCTION-I

With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II.
3. Make sure that “COOLAN TEMP/S” indication is below 60°C (140°F). If out of range, cool down the engine.
NOTE:
The following procedure should be performed before the engine coolant temperature reaches 87°C (189°F).
4. Disconnect vacuum hose connected to exhaust gas control valve actuator.
5. Start engine and let it idle.
6. Check vacuum hose for vacuum existence under the following conditions.

SEF318Z

OK or NG
OK

c GO TO 4.

c GO TO 5.

EC-1271

ZD30DDTi

EXHAUST GAS CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
3

ZD30DDTi

CHECK OVERALL FUNCTION-I

Without CONSULT-II
7. Turn ignition switch “ON”.
8. Make sure that voltage between ECM terminal 19 and ground is more than 1.88V. If out of range, cool down the engine.
NOTE:
The following procedure should be performed before the voltage becomes less than 1.06V.
9. Disconnect vacuum hose connected to exhaust gas control valve actuator.
10. Start engine and let it idle.
11. Check vacuum hose for vacuum existence under the following conditions.

SEF318Z

OK or NG
OK

c GO TO 4.

c GO TO 5.

4
1.
2.
3.
4.

CHECK OVERALL FUNCTION-II
Turn ignition switch “OFF”.
Remove exhaust gas control valve actuator from exhaust tube.
Install a vacuum pump to exhaust gas control valve actuator.
Make sure that the exhaust gas control valve moves smoothly when applying vacuum of −86.6 to −93.3 kPa (−866 to −933
mbar, −650 to −700 mmHg, −25.59 to −27.56 inHg) and releasing it.

SEF319Z

OK or NG
OK

c INSPECTION END

c Replace exhaust gas control valve assembly.

EC-1272

EXHAUST GAS CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
5

ZD30DDTi

CHECK VACUUM HOSE

1. Turn ignition switch “OFF”.
2. Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.

SEF109L

OK or NG
OK

c GO TO 6.

c Repair or replace vacuum hoses and vacuum gallery.

CHECK EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect exhaust gas control valve control solenoid valve harness connector.

SEF285Z

3. Turn ignition switch “ON”.
4. Check voltage between exhaust gas control valve control solenoid valve terminal 2 and ground with CONSULT-II or tester.

SEF312Z

OK or NG
OK

c GO TO 8.

c GO TO 7.

EC-1273

EXHAUST GAS CONTROL VALVE CONTROL
SOLENOID VALVE
Diagnostic Procedure (Cont’d)
7

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M21, E127
+ Fuse block (J/B) connector M2
+ 10A fuse
+ Harness for open or short between exhaust gas control valve control solenoid valve and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.
8

CHECK EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN
OR SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 11 and exhaust gas control valve control solenoid valve terminal 1. Refer to
Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M21, E127
+ Harness connectors M50, F5
+ Harness for open or short between exhaust gas control valve control solenoid valve and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.
10

CHECK EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE

1. Apply 12V direct current between exhaust gas control valve control solenoid valve terminals.
2. Check air passage continuity of exhaust gas control valve control solenoid valve under the following conditions.

SEF335X

OK or NG
OK

c GO TO 11.

c Replace exhaust gas control valve control solenoid valve.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-1076.
c INSPECTION END

EC-1274

AIR CONDITIONER CONTROL

ZD30DDTi

Wiring Diagram

TEC111M

EC-1275

MI & DATA LINK CONNECTORS

ZD30DDTi

Wiring Diagram

TEC112M

EC-1276

ZD30DDTi

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

Unit: rpm

Engine

ZD30DDTi

Idle speed

750±25

Maximum engine speed

4,300

Injection Pump Numbers
Engine

Part number

Pump assembly number

ZD30DDTi

16700 VG100

109342-4023

Injection Nozzle
Unit: kPa (bar, kg/cm2, psi)

Initial injection pressure

Used

19,026 (190.3, 194, 2,759)

New

19,516 — 20,497 (195.2 — 205.0, 199 — 209, 2,830 — 2,972)

Limit

16,182 (161.8, 165, 2,346)

Engine Coolant Temperature Sensor
Temperature °C (°F)

Resistance kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.00

90 (194)

0.236 — 0.260

Crankshaft Position Sensor (TDC)
Resistance [at 20°C (68°F)] Ω

1,287 — 1,573

Glow Plug
Resistance [at 20°C (68°F)] Ω

Approximately 0.5

Accelerator Position Sensor
Throttle valve conditions

Resistance between terminals 2 and 3 kΩ [at 25°C (77°F)]

Completely closed

Approximately 0.5

Partially open

0.5 — 4

Completely open

Approximately 4

EGR Volume Control Valve
Resistance [at 25°C (77°F)] Ω

13 — 17

EC-1277

ELECTRICAL SYSTEM
SECTION

When you read wiring diagrams:
+ Read GI section, “HOW TO READ WIRING DIAGRAMS”.
When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT”.
+ Check for any service bulletins before servicing the vehicle.

MODIFICATION NOTICE:
+ Power window (driver’s side only) with an interruption detection function has been adopted.
+ ID code entry procedure of multi-remote control system has been changed.
+ NATS (Nissan Anti-Theft System) has been adopted on ZD engine model.

CONTENTS
PRECAUTIONS AND PREPARATION …………… 1003
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 1003
POWER SUPPLY ROUTING…………………………. 1004
Schematic ……………………………………………….. 1004
Wiring Diagram — POWER —…………………… 1005
GROUND DISTRIBUTION/LHD MODELS………. 1013
Engine Room Harness………………………………. 1013
Engine Control Harness…………………………….. 1016
Main Harness…………………………………………… 1017
Body Harness ………………………………………….. 1020
Body No. 2 Harness …………………………………. 1022
Back Door and Rear Window Defogger
Harness…………………………………………………… 1023
GROUND DISTRIBUTION/RHD MODELS ……… 1024
Engine Room Harness………………………………. 1024
Engine Control Harness…………………………….. 1027
Main Harness…………………………………………… 1028
Body Harness ………………………………………….. 1031
Body No. 2 Harness …………………………………. 1033
Back Door and Rear Window Defogger
Harness…………………………………………………… 1034
BATTERY……………………………………………………. 1035
Service Data and Specifications (SDS)……….. 1035
STARTING SYSTEM ……………………………………. 1036
Wiring Diagram — START —/M/T Models…… 1036
Wiring Diagram — START —/A/T Models …… 1037
Construction …………………………………………….. 1038

Service Data and Specifications (SDS)……….. 1039
CHARGING SYSTEM …………………………………… 1040
Wiring Diagram — CHARGE……………………… 1040
Construction …………………………………………….. 1041
Service Data and Specifications (SDS)……….. 1041
COMBINATION SWITCH ……………………………… 1042
Check ……………………………………………………… 1042
STEERING SWITCH…………………………………….. 1043
Check ……………………………………………………… 1043
HEADLAMP — Daytime Light System — …….. 1044
Wiring Diagram — DTRL — ………………………. 1044
PARKING, LICENSE AND TAIL LAMPS ……….. 1046
Wiring Diagram — TAIL/L —/LHD Models…… 1046
Wiring Diagram — TAIL/L —/RHD Models ….. 1048
STOP LAMP ……………………………………………….. 1050
Wiring Diagram — STOP/L —……………………. 1050
BACK-UP LAMP………………………………………….. 1051
Wiring Diagram — BACK/L —/RHD Models … 1051
FRONT FOG LAMP……………………………………… 1052
Wiring Diagram — F/FOG — …………………….. 1052
REAR FOG LAMP ……………………………………….. 1053
Wiring Diagram — R/FOG — …………………….. 1053
CORNERING LAMP …………………………………….. 1054
Wiring Diagram — CORNER —/LHD Models. 1054
System Description/RHD Models ……………….. 1055
Wiring Diagram — CORNER —/RHD Models1056
Trouble Diagnoses/RHD Models ………………… 1057

ELECTRICAL SYSTEM
TURN SIGNAL AND HAZARD WARNING
LAMPS ……………………………………………………….. 1058
Wiring Diagram — TURN — ……………………… 1058
ILLUMINATION……………………………………………. 1060
Schematic ……………………………………………….. 1060
Wiring Diagram — ILL — ………………………….. 1061
INTERIOR ROOM LAMP………………………………. 1067
System Description …………………………………… 1067
Wiring Diagram — ROOM/L —/LHD Models .. 1068
Wiring Diagram — ROOM/L —/RHD Models.. 1070
Trouble Diagnoses……………………………………. 1072
METER AND GAUGES ………………………………… 1073
Wiring Diagram — METER —/LHD Models…. 1073
Wiring Diagram — METER —/RHD Models … 1075
WARNING LAMPS ………………………………………. 1078
Schematic ……………………………………………….. 1078
Wiring Diagram — WARN — …………………….. 1080
WARNING CHIME ……………………………………….. 1091
System Description …………………………………… 1091
Wiring Diagram — CHIME —/LHD Models….. 1092
Wiring Diagram — CHIME —/RHD Models …. 1093
Trouble Diagnoses……………………………………. 1094
Electrical Components Inspection ………………. 1097
FRONT WIPER AND WASHER …………………….. 1098
Wiring Diagram — WIPER —…………………….. 1098
HEADLAMP WIPER AND WASHER ……………… 1099
Wiring Diagram — HLC — ………………………… 1099
HORN …………………………………………………………. 1100
Wiring Diagram — HORN —……………………… 1100
REAR WINDOW DEFOGGER……………………….. 1101
System Description …………………………………… 1101
Wiring Diagram — DEF —/LHD Models ……… 1102
Wiring Diagram — DEF —/RHD Models……… 1104
Trouble Diagnoses……………………………………. 1106
Electrical Components Inspection ………………. 1107
AUDIO ………………………………………………………… 1108
Wiring Diagram — REMOTE — …………………. 1108
AUDIO ANTENNA ……………………………………….. 1109
Wiring Diagram — P/ANT —/RHD Models ….. 1109
AUTOMATIC SPEED CONTROL DEVICE
(ASCD) ……………………………………………………….. 1110
Schematic ……………………………………………….. 1110
Wiring Diagram — ASCD — ……………………… 1111
POWER WINDOW ……………………………………….. 1115
System Description …………………………………… 1115
Schematic ……………………………………………….. 1116
Wiring Diagram — WINDOW —…………………. 1117
Trouble Diagnoses……………………………………. 1122
POWER DOOR LOCK — Super Lock — ………. 1124
Component Parts and Harness Connector
Location…………………………………………………… 1124
System Description …………………………………… 1125
Schematic ……………………………………………….. 1127
Wiring Diagram — S/LOCK —/LHD Models … 1128

Wiring Diagram — S/LOCK —/RHD Models… 1133
Trouble Diagnoses……………………………………. 1138
MULTI-REMOTE CONTROL SYSTEM …………… 1149
System Description …………………………………… 1149
Wiring Diagram — MULTI —/LHD Models…… 1150
Wiring Diagram — MULTI —/RHD Models ….. 1152
Trouble Diagnoses……………………………………. 1154
ID Code Entry Procedure ………………………….. 1156
Remote Controller Battery Replacement……… 1157
SUPER LOCK CONTROL UNIT ……………………. 1159
Description ………………………………………………. 1159
Schematic ……………………………………………….. 1160
Input/Output Operation Signal ……………………. 1162
NATS (Nissan Anti-Theft System) ……………….. 1163
Component Parts and Harness Connector
Location…………………………………………………… 1163
System Description …………………………………… 1164
System Composition …………………………………. 1165
Wiring Diagram — NATS —………………………. 1166
Wiring Diagram — NATS —/LHD Models……. 1167
Wiring Diagram — NATS —/RHD Models …… 1168
CONSULT-II…………………………………………….. 1169
Trouble Diagnoses……………………………………. 1172
How to Replace NATS IMMU…………………….. 1183
LOCATION OF ELECTRICAL UNITS…………….. 1185
Engine Compartment ………………………………… 1185
Passenger Compartment — LHD Models ……. 1186
Passenger Compartment — RHD Models …… 1188
HARNESS LAYOUT …………………………………….. 1191
How to Read Harness Layout ……………………. 1191
Main Harness/LHD Models………………………… 1192
Main Harness/RHD Models ……………………….. 1196
Engine Room Harness/LHD Models……………. 1200
Engine Room Harness/RHD Models …………… 1204
Engine Harness ……………………………………….. 1208
Engine Control Harness…………………………….. 1209
Body Harness/LHD Models ……………………….. 1210
Body Harness/RHD Models……………………….. 1214
Body No. 2 Harness/LHD Models ………………. 1218
Body No. 2 Harness/RHD Models………………. 1220
Chassis Harness………………………………………. 1222
Room Lamp Harness………………………………… 1223
Front Door Harness (Driver side) ……………….. 1224
Front Door Harness (Passenger side)…………. 1225
Back Door Harness and Rear Window
Defogger Harness…………………………………….. 1226
WIRING DIAGRAM CODES (CELL CODES)….. 1227
Wiring Diagram Codes (Cell Codes) …………… 1227

PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and
Air Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.

EL-1003

POWER SUPPLY ROUTING
Schematic

TEL201M

EL-1004

POWER SUPPLY ROUTING
Wiring Diagram — POWER —
BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

TEL202M

EL-1005

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL480A

EL-1006

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL203M

EL-1007

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL204M

EL-1008

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)
ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON”

TEL606B

EL-1009

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)
IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START”

TEL205M

EL-1010

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL206M

EL-1011

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL207M

EL-1012

GROUND DISTRIBUTION/LHD MODELS
Engine Room Harness

CEL081M

EL-1013

GROUND DISTRIBUTION/LHD MODELS
Engine Room Harness (Cont’d)

CEL082M

EL-1014

GROUND DISTRIBUTION/LHD MODELS
Engine Room Harness (Cont’d)

CEL083M

EL-1015

GROUND DISTRIBUTION/LHD MODELS
Engine Control Harness

CEL085M

EL-1016

GROUND DISTRIBUTION/LHD MODELS
Main Harness

CEL086M

EL-1017

GROUND DISTRIBUTION/LHD MODELS
Main Harness (Cont’d)

CEL232A

EL-1018

GROUND DISTRIBUTION/LHD MODELS
Main Harness (Cont’d)

CEL087M

EL-1019

GROUND DISTRIBUTION/LHD MODELS
Body Harness

CEL088M

EL-1020

GROUND DISTRIBUTION/LHD MODELS
Body Harness (Cont’d)

CEL247A

EL-1021

GROUND DISTRIBUTION/LHD MODELS
Body No. 2 Harness

CEL248A

EL-1022

GROUND DISTRIBUTION/LHD MODELS
Back Door and Rear Window Defogger Harness

CEL249A

EL-1023

GROUND DISTRIBUTION/RHD MODELS
Engine Room Harness

CEL089M

EL-1024

GROUND DISTRIBUTION/RHD MODELS
Engine Room Harness (Cont’d)

CEL090M

EL-1025

GROUND DISTRIBUTION/RHD MODELS
Engine Room Harness (Cont’d)

CEL091M

EL-1026

GROUND DISTRIBUTION/RHD MODELS
Engine Control Harness

CEL093M

EL-1027

GROUND DISTRIBUTION/RHD MODELS
Main Harness

CEL094M

EL-1028

GROUND DISTRIBUTION/RHD MODELS
Main Harness (Cont’d)

CEL804

EL-1029

GROUND DISTRIBUTION/RHD MODELS
Main Harness (Cont’d)

CEL095M

EL-1030

GROUND DISTRIBUTION/RHD MODELS
Body Harness

CEL096M

EL-1031

GROUND DISTRIBUTION/RHD MODELS
Body Harness (Cont’d)

CEL097M

EL-1032

GROUND DISTRIBUTION/RHD MODELS
Body No. 2 Harness

CEL082A

EL-1033

GROUND DISTRIBUTION/RHD MODELS
Back Door and Rear Window Defogger Harness

CEL098M

EL-1034

BATTERY
Service Data and Specifications (SDS)
ZD30
Applied model
Type
Capacity V-AH

EL-1035

Standard

Option

115D31L

110D26L × 2

12-80

12-75

STARTING SYSTEM
Wiring Diagram — START —/M/T Models

TEL208M

EL-1036

STARTING SYSTEM
Wiring Diagram — START —/A/T Models

TEL209M

EL-1037

STARTING SYSTEM
Construction

MEL656K

EL-1038

STARTING SYSTEM
Service Data and Specifications (SDS)
STARTER
S13-551A

S14-407A

Type

HITACHI
Reduction
ZD30

Applied model
Standard
System voltage

Option

11.0

No-load
Terminal voltage
Current
Revolution

A
rpm

Less than 160
More than 3,300

More than 3,400

Minimum diameter of commutator
mm (in)

35.5 (1.398)

Minimum length of brush mm (in)

11.0 (0.433)

Brush spring tension
N (kg, lb)

28.4 — 34.3 (2.9 — 3.5, 6.4 — 7.7)

Clearance between bearing metal
and armature shaft
mm (in)

—

Clearance “!” between pinion
front edge and pinion stopper
mm (in)

—

Movement “!” in height of pinion
assembly
mm (in)

0.3 — 2.0 (0.012 — 0.079)

EL-1039

CHARGING SYSTEM
Wiring Diagram — CHARGE —

TEL210M

EL-1040

CHARGING SYSTEM
Construction

MEL658K

Service Data and Specifications (SDS)
ALTERNATOR
LR190-752
Type
HITACHI
Applied model

ZD30

Nominal rating

V-A

Ground polarity

12-90
Negative

Minimum revolution under noload
(When 13.5V is applied)
rpm
Hot output current
(When 13.5V is applied)
A/rpm
Regulated output voltage

Less than 1,000
More than 23/1,300
More than 65/2,500
More than 87/5,000

14.1 — 14.7

Minimum length of brush mm (in)

6.0 (0.236)

Brush spring pressure
N (g, oz)
Slip ring minimum outer diameter
mm (in)
Rotor (Field coil) resistance

EL-1041

Ω

1.0 — 3.43 (102 — 350, 3.60 — 12.34)
26.0 (1.024)
2.67

COMBINATION SWITCH
Check

CEL099M

EL-1042

STEERING SWITCH
Check
WITH ASCD AND AUDIO SWITCH

CEL205A

EL-1043

HEADLAMP — Daytime Light System —
Wiring Diagram — DTRL —

TEL675B

EL-1044

HEADLAMP — Daytime Light System —
Wiring Diagram — DTRL — (Cont’d)

TEL211M

EL-1045

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/LHD Models

TEL637A

EL-1046

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/LHD Models
(Cont’d)

TEL213M

EL-1047

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/RHD Models

TEL214M

EL-1048

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/RHD Models
(Cont’d)

TEL215M

EL-1049

STOP LAMP
Wiring Diagram — STOP/L —

TEL217M

EL-1050

BACK-UP LAMP
Wiring Diagram — BACK/L —/RHD Models

TEL218M

EL-1051

FRONT FOG LAMP
Wiring Diagram — F/FOG —

TEL219M

EL-1052

REAR FOG LAMP
Wiring Diagram — R/FOG —

TEL220M

EL-1053

CORNERING LAMP
Wiring Diagram — CORNER —/LHD Models

TEL221M

EL-1054

CORNERING LAMP
System Description/RHD Models
The cornering lamp operation is controlled by the lighting switch which is built into the combination switch
and cornering lamp relay unit.
Power is supplied at all times
+ to lighting switch terminal V
11
+ through 10A fuse [No. 15 , located in the fuse block (J/B)].

Lighting operation by lighting switch
When lighting switch is in 1ST (or 2ND) position, power is supplied
3
+ to cornering lamp relay unit terminal V
+ through lighting switch terminal V
12 .
With the ignition switch in the ON or START position, power is supplied to cornering lamp relay unit termi2
nal V
+ through 7.5A fuse [No. 11 , located in the fuse block (J/B)].
RH turn
When the turn signal lever is moved to the RH position, ground is supplied
6
+ to cornering lamp relay unit terminal V
2 and V
1
+ through turn signal lamp switch terminals V
+ through body grounds E25 and E40 .
Power is supplied
5 of the cornering lamp relay unit
+ from terminal V
3 .
+ to front combination lamp RH terminal V
4 of front combination lamp RH through body grounds E25 and E40 .
Ground is supplied to terminal V
The RH cornering lamp illuminates until the turn signal lever returns to NEUTRAL position.
LH turn
When the turn signal lever is moved to the LH position, ground is supplied
8
+ to cornering lamp relay unit terminal V
3 and V
1
+ through turn signal lamp switch terminals V
+ through body grounds E25 and E40 .
Power is supplied
+ from terminal V
10 of the cornering lamp relay unit
3 .
+ to front combination lamp LH terminal V
4 of front combination lamp LH through body grounds E25 and E40 .
Ground is supplied to terminal V
The LH cornering lamp illuminates until the turn signal lever returns to NEUTRAL position.

EL-1055

CORNERING LAMP
Wiring Diagram — CORNER —/RHD Models

TEL222M

EL-1056

CORNERING LAMP
Trouble Diagnoses/RHD Models
Symptom

Possible cause

Cornering lamps do not operate but 1. 10A fuse
turn signal lamps operate.
2. Lighting switch circuit
3. Lighting switch
4. Cornering lamp relay unit

Repair order
1. Chack 10A fuse [No. 15 , located in fuse block (J/B).]
Verify battery voltage is present at terminal V
11 of lighting switch.
2. Check harness for open or short between lighting
switch and cornering lamp relay unit.
3. Check lighting switch.
4. Replace the cornering lamp relay unit.

LH cornering lamp does not operate 1. Bulb
but RH cornering operates.
2. Cornering lamp LH circuit

1. Check bulb
2. Check harness for open or short between cornering
lamp LH and cornering lamp relay unit.
3. Cornering lamp ground LH circuit 3. Check harness for open or short between cornering
lamp LH and ground.

RH cornering lamp does not operate 1. Bulb
but LH cornering operates.
2. Cornering lamp RH circuit

1. Check bulb
2. Check harness for open or short between cornering
lamp RH and cornering lamp relay unit.
3. Cornering lamp ground RH circuit 3. Check harness for open or short between cornering
lamp RH and ground.

EL-1057

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —

TEL223M

EL-1058

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN — (Cont’d)

TEL224M

EL-1059

ILLUMINATION
Schematic

TEL287M

EL-1060

ILLUMINATION
Wiring Diagram — ILL —

TEL418A

EL-1061

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL419A

EL-1062

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL288M

EL-1063

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL600B

EL-1064

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL422A

EL-1065

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL601B

EL-1066

INTERIOR ROOM LAMP
System Description
POWER SUPPLY AND GROUND
Power is supplied at all times:
+ through 10A fuse [No. 20 , located in the fuse block (J/B)]
1
+ to front and rear interior room lamp terminal V
+ through 7.5A fuse [No. 24 , located in the fuse block (J/B)]
2 and
+ to key switch terminal V
1 .
+ to super lock control unit terminal V
When the key is removed from ignition key cylinder, power is interrupted:
1
+ through key switch terminal V
+ to super lock control unit terminal V
18 .
With the ignition key switch in the ON or START position, power is supplied:
+ through 10A fuse [No. 25 , located in the fuse block (J/B)]
+ to super lock control unit terminal V
17 .
Ground is supplied:
+ to super lock control unit terminal V
16
+ through body grounds terminals M30 and M19 (LHD models) or M98 (RHD models).
When the front driver side door is opened, ground is supplied:
+ through body grounds B23 and M19 (LHD models) or M98 (RHD models).
3
+ to front door switch (driver side) terminal V
1
+ from front door switch (driver side) terminal V
+ to super lock control unit terminal V
30 .
When any other door is opened, ground is supplied to super lock control unit terminal V
31 in the same manner as the driver door switch.
When the front driver side door is unlocked, the super lock control unit receives a ground signal:
+ through body grounds terminals M30 and M19 (LHD models) or M98 (RHD models).
5
+ to front door lock actuator (driver side) (door unlock sensor) terminal V
2
+ from front door lock actuator (driver side) (door unlock sensor) terminal V
+ to super lock control unit terminal V
28 .
When a signal, or combination of signals is received by the super lock control unit, ground is supplied:
+ through super lock control unit terminal V
26
2 .
+ to front interior room lamp terminal V
With power and ground supplied, the front interior room lamp illuminates.

INTERIOR ROOM LAMP TIMER OPERATION
When front interior room lamp switch is in the “DOOR” position, the super lock control unit keeps the front
interior room lamp illuminated for about 30 seconds when:
+ unlock signal is supplied from driver’s door unlock sensor while all doors are closed and key is out of
ignition key cylinder
+ key is removed from ignition key cylinder while all doors are closed
+ driver’s door is opened and then closed while key is out of the ignition key cylinder. (However, if the
driver’s door is closed with the key inserted in the ignition key cylinder after the driver’s door is opened
with the key removed, the timer is operated.)
The timer is canceled when:
+ driver’s door is locked or
+ ignition switch is turned ON.

ON-OFF CONTROL
When the driver side door, front passenger door, rear LH or RH door, back door LH or RH is opened, the
interior room lamp turns on while the interior room lamp switch is in the “DOOR” position.

EL-1067

INTERIOR ROOM LAMP
Wiring Diagram — ROOM/L —/LHD Models

TEL230M

EL-1068

INTERIOR ROOM LAMP
Wiring Diagram — ROOM/L —/LHD Models
(Cont’d)

TEL231M

EL-1069

INTERIOR ROOM LAMP
Wiring Diagram — ROOM/L —/RHD Models

TEL232M

EL-1070

INTERIOR ROOM LAMP
Wiring Diagram — ROOM/L —/RHD Models
(Cont’d)

TEL233M

EL-1071

INTERIOR ROOM LAMP
Trouble Diagnoses
DIAGNOSTIC PROCEDURE
SYMPTOM: Front interior room lamp does not turn on when
any door is opened, or timer does not operate
properly.
Does room lamp turn on when room lamp
switch is in “ON” position?

No
c

+ Bulb
+ 10A fuse [No. 20 ,
located in the fuse block
(J/B)]
+ Harness for open or
short between fuse and
front interior room lamp
+ Front interior room lamp
ground condition

Yes
SEL120X

Does key warning chime operate properly?

No
c

Yes
SEL121X

CHECK ROOM LAMP OUTPUT SIGNAL.
1. Turn front interior room lamp switch to
“DOOR” position.
2. Disconnect super lock control unit connector.
3. Check voltage between super lock control unit terminal V
26 and ground.
Battery voltage should exist.

Check the following.

NG
c

Check “WARNING
CHIME” system.
(Refer to EL-1094.)

Check harness for open or
short between front interior
room lamp and super lock
control unit.

OK
.

CHECK DOOR SWITCH INPUT SIGNAL.
1. Connect super lock control unit connector.
2. Check voltage between super lock control unit terminals V
30 , V
31 and ground.
Terminals
⊕
30
V

31
V

Condition

Voltage
[V]

Driver side door
is opened.

Driver side door
is closed.

Approx.
5

At least one
door is opened.

@
Ground

Ground

All doors are
closed.

OK
.

Replace control unit.

EL-1072

Approx.
5

NG
c

Check the following.
+ Door switch
+ Door switch ground condition
+ Harness for open or
short between super
lock control unit and
door switch

METER AND GAUGES
Wiring Diagram — METER —/LHD Models

TEL236M

EL-1073

METER AND GAUGES
Wiring Diagram — METER —/LHD Models
(Cont’d)

TEL237M

EL-1074

METER AND GAUGES
Wiring Diagram — METER —/RHD Models

TEL238M

EL-1075

METER AND GAUGES
Wiring Diagram — METER —/RHD Models
(Cont’d)

TEL239M

EL-1076

METER AND GAUGES
NOTE

EL-1077

WARNING LAMPS
Schematic

TEL240M

EL-1078

WARNING LAMPS
Schematic (Cont’d)

TEL241M

EL-1079

WARNING LAMPS
Wiring Diagram — WARN —

TEL566B

EL-1080

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL567B

EL-1081

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL242M

EL-1082

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL702A

EL-1083

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL243M

EL-1084

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL570B

EL-1085

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL571B

EL-1086

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL706A

EL-1087

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL573B

EL-1088

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)
LHD MODELS

TEL244M

EL-1089

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)
RHD MODELS

TEL245M

EL-1090

WARNING CHIME
System Description
The warning chime is combined with the super lock control unit.
Both the ignition key and light warning chime will not sound, when ignition switch in the ON or START position (when power supply exists at super lock control unit terminal V
17 ).

IGNITION KEY WARNING CHIME
With the key in the ignition key cylinder, the ignition switch in the OFF or ACC position, and the driver’s door
open and locked, the warning chime will sound. Power is supplied
1
+ from key switch terminal V
+ to super lock control unit terminal V
18 .
Ground is supplied
1
+ through driver front door switch terminal V
+ to super lock control unit terminal V
30 , and
2
+ through front door lock actuator assembly (driver side) (unlock sensor) terminal V
+ to super lock control unit terminal V
28 .

LIGHT WARNING CHIME
With ignition switch in the OFF or ACC position, driver’s door open, and lighting switch in 1ST or 2ND
position, warning chime will sound. Power is supplied
+ from combination switch terminal V
12
+ to super lock control unit terminal V
19 .
Ground is supplied
1
+ through driver front door switch terminal V
+ to super lock control unit terminal V
30 .

EL-1091

WARNING CHIME
Wiring Diagram — CHIME —/LHD Models

TEL247M

EL-1092

WARNING CHIME
Wiring Diagram — CHIME —/RHD Models

TEL248M

EL-1093

WARNING CHIME
Trouble Diagnoses
EL-1094

EL-1095

EL-1096

DIAGNOSTIC PROCEDURE 2
(Key switch input signal check)

DIAGNOSTIC PROCEDURE 3
(Door unlock sensor check)

DIAGNOSTIC PROCEDURE 4

REFERENCE PAGE

DIAGNOSTIC PROCEDURE 1
(Lighting switch input signal check)

SYMPTOM CHART

SYMPTOM
Light warning chime does not activate.

Ignition key warning chime does not
activate.

All warning chimes do not activate.

DIAGNOSTIC PROCEDURE 1
(Lighting switch input signal check)
CHECK LIGHTING SWITCH INPUT SIGNAL.
Check voltage between super lock control
unit terminal V
19 and ground.

SEL122X

Condition of lighting
switch

Voltage [V]

1ST or 2ND

Approx. 12

OFF

OK
.

Go to DIAGNOSTIC PROCEDURE 4.

EL-1094

NG
c

Check the following.
+ Harness for open or
short between super
lock control unit and
combination switch
(RHD models)
+ Harness for open or
short between super
lock control unit and
7.5A fuse (LHD models)

WARNING CHIME
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 2
(Key switch input signal check)
CHECK KEY SWITCH INPUT SIGNAL.
Check voltage between super lock control
unit terminal V
18 and ground.

SEL123X

Condition of key switch

Voltage [V]

Key is inserted.

Approx. 12

Key is withdrawn.

NG
c

Go to DIAGNOSTIC PROCEDURE 4.

Check the following.
+ Key switch
Refer to “Electrical Components Inspection” (EL1097).
+ 7.5A fuse [No. 24 ,
located in fuse block
(J/B)]
+ Harness for open or
short between key
switch and fuse
+ Harness for open or
short between super
lock control unit and key
switch

DIAGNOSTIC PROCEDURE 3
(Door unlock sensor check)
CHECK DOOR UNLOCK SENSOR
INPUT SIGNAL.
Check voltage between super lock control
unit terminal V
28 and ground.
Terminals
SEL175X

⊕

28
V

Ground

Condition

Voltage
[V]

Locked

Approx. 5

Unlocked

OK
.

Go to DIAGNOSTIC PROCEDURE 4.

EL-1095

NG
c

Check the following.
+ Door unlock sensor
Refer to “Electrical Components Inspection” (EL1097).
+ Harness for open or
short between super
lock control unit and
door unlock sensor

WARNING CHIME
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 4
CHECK POWER SUPPLY CIRCUIT FOR
SUPER LOCK CONTROL UNIT.
Check voltage between super lock control
1 ,V
unit terminals V
17 and ground.
Terminals
⊕

1
V
17
V

Ground
Ground

NG
c

Ignition switch position
OFF

ACC

Approx. 12V
0V

Approx. 12V

Check the following.
+ 10A fuse [No. 25 ,
located in the fuse block
(J/B)]
+ 7.5A fuse [No. 24 ,
located in the fuse block
(J/B)]
+ Harness for open or
short between super
lock control unit and
fuse

OK
.

CHECK GROUND CIRCUIT FOR SUPER
LOCK CONTROL UNIT.
Check continuity between super lock control unit terminal V
16 and ground.
Continuity should exist.

NG
c

Repair harness or connectors.

OK
.
SEL124X

CHECK DOOR SWITCH INPUT SIGNAL.
Check voltage between super lock control
unit terminal V
30 and ground.
Condition of driver’s door

Voltage [V]

Driver side door is closed.

Approx. 12

Driver side door is open.

OK
.

Replace super lock control unit.
SEL125X

SEL126X

EL-1096

NG
c

Check the following.
+ Driver side door switch
Refer to “Electrical Components Inspection” (EL1097).
+ Door switch ground circuit
+ Harness for open or
short between super
lock control unit and
door switch

WARNING CHIME
Electrical Components Inspection
KEY SWITCH (insert)
Check continuity between terminals when key is inserted in ignition key cylinder and key is removed from ignition key cylinder.
Terminal No.
1 -V
2
V

Condition

Continuity

Key is inserted.

Yes

Key is removed.

SEL015WB

DRIVER SIDE DOOR SWITCH
Check continuity between terminals when door switch is pushed
and released.
Terminal No.
1 -V
3
V

Condition

Continuity

Door switch is pushed.

Door switch is released.

Yes

SEL039X

DRIVER SIDE DOOR UNLOCK SENSOR
Check continuity between door unlock sensor terminals with the
door locked and unlocked.
Terminal No.
2 -V
5
V

SEL814UD

EL-1097

Condition

Continuity

Locked

Unlocked

Yes

FRONT WIPER AND WASHER
Wiring Diagram — WIPER —

TEL575B

EL-1098

HEADLAMP WIPER AND WASHER
Wiring Diagram — HLC —

TEL289M

EL-1099

HORN
Wiring Diagram — HORN —

TEL577B

EL-1100

REAR WINDOW DEFOGGER
System Description
The rear window defogger system is controlled by the super lock control unit. The rear window defogger
operates only for approximately 15 minutes.
Power is supplied at all times
3
+ to rear window defogger relay terminal V
+ through 15A fuse (No. 43 , located in the fuse and fusible link box),
6
+ to rear window defogger relay terminal V
+ through 20A fuse (No. 44 , located in the fuse and fusible link box) and
1
+ to super lock control unit terminal V
+ through 7.5A fuse [No. 24 , located in the fuse block (J/B)].
With the ignition switch in the ON or START position, power is supplied
1
+ to the rear window defogger relay terminal V
+ through 7.5A fuse [No. 8 , located in the fuse block (J/B)] and
+ to super lock control unit terminal V
17
+ through 10A fuse [No. 25 , located in the fuse block (J/B)].
2 of the rear window defogger switch through body grounds.
Ground is supplied to terminal V
When the rear window defogger switch is turned ON, ground is supplied
1 of the rear window defogger switch
+ through terminal V
+ to super lock control unit terminal V
35 .
27 of the super lock control unit then supplies ground to the rear window defogger relay terminal
Terminal V
2 .
V
With power and ground supplied, the rear window defogger relay is energized.
Power is supplied
5 and V
7 of the rear window defogger relay
+ through terminals V
+ to the rear window defogger and door mirror defogger (with door mirror defogger).
The rear window defogger has an independent ground.
With power and ground supplied, the rear window defogger filaments heat and defog the rear window.
When the system is activated, the rear window defogger indicator illuminates in the rear window defogger
switch.
Power is supplied
3 of the rear window defogger switch
+ to terminal V
5 of the rear window defogger relay.
+ from terminal V
4 of the rear window defogger switch is grounded through body grounds.
Terminal V

EL-1101

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/LHD Models

TEL249M

EL-1102

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/LHD Models
(Cont’d)

TEL674B

EL-1103

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/RHD Models

TEL251M

EL-1104

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/RHD Models
(Cont’d)

TEL252M

EL-1105

REAR WINDOW DEFOGGER
Trouble Diagnoses
SYMPTOM: Rear window defogger does not activate, or
does not go off after activating.
CHECK REAR WINDOW DEFOGGER
OUTPUT SIGNAL.
1. Turn ignition switch to ON position.
2. Check voltage between super lock control unit harness terminal V
27 and
ground.
SEL127X

Condition

OK
c

Check the following.
+ Rear window defogger
relay
(Refer to EL-1107.)
+ Rear window defogger
circuit
+ Rear window defogger
filament
[Refer to “Filament
Check” in Service
Manual (SM7E2Y61G1).]

Check the following.
+ 7.5A fuse [No. 8 ,
located in the fuse block
(J/B)]
+ Rear window defogger
relay
+ Harness for open or
short between super
lock control unit and
rear window defogger
relay
+ Harness for open or
short between rear window defogger relay and
fuse

Check the following.
+ Rear window defogger
switch
(Refer to EL-1107.)
+ Harness for open or
short between super
lock control unit and
rear window defogger
switch
+ Rear window defogger
switch ground circuit

Check the following.
+ 10A fuse [No. 25
located in the fuse block
(J/B)]
+ Harness for open or
short between super
lock control unit and
fuse

Repair harness or connectors.

Voltage [V]

Rear window defogger
switch is released.

Approx. 12

Rear window defogger
switch is pushed.

NG
.

1. Disconnect super lock control unit connector.
2. Turn ignition switch to ON position.
3. Check voltage between super lock control unit terminal V
27 and ground.
Battery voltage should exist.
OK

SEL128X

CHECK REAR WINDOW DEFOGGER
SWITCH INPUT SIGNAL.
Check continuity between super lock control unit terminal V
35 and ground.
SEL129X

Condition of
defogger switch

Continuity

Rear window defogger
switch is pushed.

Yes

Rear window defogger
switch is released.

OK
.

CHECK IGNITION INPUT SIGNAL.
Check voltage between super lock control
unit terminal V
17 and ground.
Condition

SEL130X

Voltage [V]

Ignition switch is “ON”.

Approx. 12

Ignition switch is “OFF”.

OK
.

CHECK SUPER LOCK CONTROL UNIT
GROUND CIRCUIT.
Check continuity between super lock control unit terminal V
16 and ground.
Continuity should exist.
OK
.

Replace super lock control unit.
SEL131X

EL-1106

REAR WINDOW DEFOGGER
Electrical Components Inspection
REAR WINDOW DEFOGGER RELAY
3 and V
5 ,V
6 and V
7 .
Check continuity between terminals V
Condition

Continuity

12V direct current supply between
1 and V
2
terminals V

Yes

No current supply

SEC202B

REAR WINDOW DEFOGGER SWITCH
Check continuity between terminals when rear window defogger
switch is pushed and released.
Terminals

1 — 2

V V

SEL430TG

EL-1107

Condition

Continuity

Rear window defogger
switch is pushed

Yes

Rear window defogger
switch is released

AUDIO
Wiring Diagram — REMOTE —

TEL581B

EL-1108

AUDIO ANTENNA
Wiring Diagram — P/ANT —/RHD Models

TEL290M

EL-1109

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Schematic

TEL582B

EL-1110

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram — ASCD —

TEL464A

EL-1111

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram — ASCD — (Cont’d)

TEL583B

EL-1112

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram — ASCD — (Cont’d)

TEL584B

EL-1113

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram — ASCD — (Cont’d)

TEL467A

EL-1114

POWER WINDOW
System Description
OUTLINE
Power window system consists of
+ CPU (combined with power window main switch)
+ four power window regulators
When ignition switch is in the “ON” position, power window can be operated depending on power window
sub/main switch condition.

OPERATIVE CONDITION
+Power windows can be raised or lowered with each sub-switch or the power window main switch located
on the driver’s door trim when ignition switch is in the “ON” position and power window lock switch on the
driver’s door trim is unlocked.
+ When power window lock switch is locked, no windows can be raised or lowered except for driver’s side
window.
+ When ignition switch is in the “ON” position, to fully open/close the driver’s side window, press down/
pull up completely on the automatic switch (main switch) and release it; it needs not be held. The window will automatically open/close all the way. To stop the window, pull up/press down then release the
switch.
+ After turning ignition switch to OFF, the driver’s side window can be raised or lowered for 15 minutes.
The timer control for supplying power after turning ignition switch to OFF will be canceled when the driver’s side door is open and then closed.

INTERRUPTION DETECTION FUNCTION
CPU (combined with power window main switch) monitors the power window regulator motor operation and
the power window position (full closed or other) for driver’s power window by the signals from encoder and
limit switch in front power window regulator (driver’s side).
When CPU (combined with power window main switch) detects interruption during the following close
operation in the driver’s side door,
+ automatic close operation when ignition switch is in the “ON” position
+ automatic close operation during power window timer operation
+ manual close operation during power window timer operation
CPU (combined with power window main switch) controls driver’s power window regulator motor for open
and the power window will be lowered about 150 mm (5.91 in).

EL-1115

POWER WINDOW
Schematic

TEL585B

EL-1116

POWER WINDOW
Wiring Diagram — WINDOW —

TEL254M

EL-1117

POWER WINDOW
Wiring Diagram — WINDOW — (Cont’d)

TEL255M

EL-1118

POWER WINDOW
Wiring Diagram — WINDOW — (Cont’d)

TEL256M

EL-1119

POWER WINDOW
Wiring Diagram — WINDOW — (Cont’d)
LHD WAGON MODELS

TEL257M

EL-1120

POWER WINDOW
Wiring Diagram — WINDOW — (Cont’d)
RHD WAGON MODELS

TEL258M

EL-1121

POWER WINDOW
Trouble Diagnoses
Symptom

Possible cause

Repair order
1. Check 7.5A fuse [No. 8 , located in fuse block (J/B)],
40A fusible link (letter e , located in fuse and fusible
link box) and M123 circuit breaker. Turn ignition switch
“ON” and verify battery positive voltage is present at
5 and V
terminals V
13 of power window main switch.
switch 2. Check ground circuit of power window main switch.

None of the power windows can be 1. 7.5A fuse, 40A fusible link and
M123 circuit breaker
operated using any switch.

2. Power window main
ground circuit
3. Power window main switch

3. Check power window main switch.

Driver side power window cannot be 1. Driver side power window regula- 1. Check harness between power window main switch
and power window regulator for open or short circuit.
tor circuit
operated but other windows can be
2. Driver side power window regula- 2. Check driver side power window regulator.
operated.
tor
3. Check power window main switch.
3. Power window main switch
Passenger power window cannot be 1. M92 circuit breaker
operated.
2. Power supply of power window
relay
3. Power window relay ground circuit
4. Power window relay
5. Power window sub-switches
6. Passenger side power window
regulators
7. Power window main switch
8. Power window circuit

1. Check M92 circuit breaker. Verify battery positive volt3 of power window relay.
age is present at terminal V
2. Check harness between 7.5A fuse and power window
relay.
3. Check power window ground circuit.

Passenger power window cannot be 1. Power window main switch
operated using power window main
switch but can be operated by power
window sub-switch.

1. Check power window main switch.

Driver side power window auto func- 1. Power window main switch
tion cannot be operated properly.
2. Encoder and limit switch

1. Check power window main switch.
2. Check encoder and limit switch. (EL-1123)

Timer control for supplying power 1. Driver side door switch circuit.
after turning ignition switch to OFF
does not operate properly.
2. Driver side door switch
3. Ignition switch ON signal circuit

1-1. Check harness between driver side door switch and
power window main switch.
1-2. Check ground circuit of driver side door switch.
2. Check driver side door switch.
3. Check ignition switch ON signal circuit to power window main switch.
4. Check power window main switch.

4. Power window main switch

EL-1122

4. Check power window relay.
5. Check power window sub-switch.
6. Check passenger side power window regulator.
7. Check power window main switch.
8-1. Check harness between power window relay and
power window sub-switch.
8-2. Check harnesses between power window main
switch and power window sub-switch for open/
short circuit.
8-3. Check harnesses between power window subswitch and power window regulator for open/
short circuit.

POWER WINDOW
Trouble Diagnoses (Cont’d)
ENCODER AND LIMIT SWITCH CHECK
CHECK DRIVER SIDE DOOR WINDOW
SLIDE MECHANISM
Check the following.
+ Obstacles in window, glass molding,
etc.
+ Worn or deformed glass molding
+ Door sash tilted too far inward or outward
+ Door window regulator

NG
c

Remove obstacles or
repair door window slide
mechanism.

SEL641W
.

CHECK POWER SUPPLY TO LIMIT
SWITCH
1. Disconnect driver side power window
regulator connector.
2. Turn ignition switch ON.
3. Check voltage between power window
9 and ground.
main switch terminal V
Approx. 5V should exist.

NG
c

Replace power window
main switch.

OK
.

CHECK LIMIT SWITCH OPERATION
1. Turn ignition switch OFF.
2. Connect driver side power window
regulator connector.
3. Turn ignition switch ON.
4. Check voltage between power window
9 and ground
main switch terminal V
during power window closing operation.
Terminal No.

9
V

Condition

Voltage (DCV)

Approx. 15 mm (0.59
in) below the full
closed position to full
closed position

Approx. 5

Other positions

Approx. 0

SEL642W

OK
c

CHECK ENCODER
Measure voltage between
power window main switch
terminal V
16 and ground
with oscilloscope when
power window is in automatic closing operation. If
result is NG, replace
power window regulator
motor (front driver side).
If result is OK, replace
power window main
switch.

NG
.

RESET LIMIT SWITCH
Reset limit switch. Refer to BT section.
Then check voltage between power win9 and ground
dow main switch terminal V
during power window closing operation at
least ten times.
Terminal No.

9
V

Condition

Voltage (DCV)

Approx. 15 mm (0.59
in) below the full
closed position to full
closed position

Approx. 5

Other positions

Approx. 0

NG
c

Replace power window
regulator (front driver side).

OK
.

CHECK ENCODER
Measure voltage between power window
main switch terminal V
16 and ground with
oscilloscope when power window is in
automatic closing operation.
OK
.

Replace power window main switch.

EL-1123

POWER DOOR LOCK — Super Lock —
Component Parts and Harness Connector
Location

SEL625X

EL-1124

SEL831U

OPERATION
Power door lock/unlock and super lock set/release operation by door key cylinder
+With the key inserted into front door key cylinder, turning it to LOCK will lock all doors and set super lock.
(Super lock will not be set while key is inserted in the ignition key cylinder.)
+ With the key inserted into front door key cylinder, turning it to UNLOCK will unlock all doors and release
super lock.

Power door lock/unlock and super lock set/release operation by multi-remote controller
+Pressing multi-remote controller LOCK button will lock all doors and set super lock. (Super lock will not be
set while key is inserted in the ignition key cylinder.)
+ Pressing multi-remote controller UNLOCK button once will unlock the driver door and release super lock.
If an unlock signal is sent from the remote controller again within 5 seconds, all other doors will be
unlocked.

Power door lock and super lock release operation (by NATS IMMU signal)
+When the super lock is set, turning ignition key switch to ON will release super lock, and all doors will unlock
once, but then immediately lock again.

Power door lock/unlock operation using the lock and unlock switch
+ With lock and unlock switch set to LOCK, all doors will lock.
+ With lock and unlock switch set to UNLOCK, all doors will unlock.
Lock and unlock switch operation cannot control the super lock.

EL-1125

POWER DOOR LOCK — Super Lock —
System Description (Cont’d)
Key reminder system
+If the ignition key is in the ignition key cylinder and the driver door is open, setting lock knob on driver door,
key or multi-remote controller to “LOCK” locks the door once but then immediately unlocks all doors. (Signal from unlock sensor driver side)

System initialization
+System initialization is required when battery cables are reconnected. Conduct one of the followings to
release super lock once;
— insert the key into ignition key cylinder and turn it to ON.
— LOCK/UNLOCK operation using door key cylinder or multi-remote controller.

EL-1126

POWER DOOR LOCK — Super Lock —
Schematic

TEL261M

EL-1127

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models

TEL262M

EL-1128

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL263M

EL-1129

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL264M

EL-1130

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL265M

EL-1131

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL266M

EL-1132

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models

TEL267M

EL-1133

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL268M

EL-1134

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL269M

EL-1135

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL270M

EL-1136

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL271M

EL-1137

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses
PRELIMINARY CHECK
CHECK-IN
.

Open all windows and remove
key from ignition key cylinder.
.

No (All doors)

Does power door lock operate
properly?

Power door lock does not operate by using:
— any switch.
……………………………………………………………..
— both door key cylinders.
……………………………………………………………..
— door lock and unlock switch.

Yes

SYMPTOM 1

SYMPTOM 2

SYMPTOM 3

SYMPTOM 4

SYMPTOM 5

SYMPTOM 6

SYMPTOM 9

SYMPTOM 7

SYMPTOM 8

SYMPTOM 9

No (Specific door)
.

No (All doors)

Does super lock set by using
door key cylinder?

Super lock does not set by using:
— both door key cylinders.
……………………………………………………………..
— one of door key cylinders.

Yes
No (Specific door)
.

Does super lock release by using
door key cylinder or IGN key
switch?

No (All doors)
c

Super lock does not release by using:
— one or both door key cylinders.
……………………………………………………………..
— IGN key switch.

Yes
No (Specific door)
.

Does super lock set/release by
using multi-remote controller?
(If equipped)

No
c

Check “MULTIREMOTE
CONTROL”
system.

Yes
.

Insert key to ignition key cylinder,
open driver’s door and lock the
door using door lock and unlock
switch.
.

Does key reminder system operate properly?

No
c

Yes
.

INSPECTION END

After performing preliminary check, go to symptom chart on the next page.

EL-1138

SYMPTOM 10

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
Before starting trouble diagnoses below, perform preliminary check, EL-1138.
Symptom numbers in the symptom chart correspond with those of Preliminary check.

SYMPTOM CHART

Power door lock does not operate
with both door key cylinders.

Power door lock does not operate
with door lock and unlock switch.

Specific door lock actuator does
not operate.

Super lock cannot be set by both
door key cylinders.

Super lock cannot be set by one of
door key cylinders.

*Super lock cannot be released by
one or both door key cylinders.

*Super lock cannot be released by
ignition key switch. (Signal from
NATS IMMU and ignition switch)

Specific super lock actuator does
not operate.

*Key reminder system does not
operate.

Procedure 7
(NATS release signal check)

Procedure 6
(Driver’s door switch check)

Procedure 5
(Super lock actuator check)

Procedure 4
(Door lock actuator check)

Procedure 9
(Ignition switch “ON” circuit check)

Power door lock does not operate
using any switch.

Procedure 8
(Key switch check)

Procedure 3
(Door lock and unlock switch check)

Procedure 2
(Door key cylinder switch check)

Procedure 1
(Door unlock sensor check)

SYMPTOM

EL-1140 EL-1141 EL-1142 EL-1143 EL-1144 EL-1145 EL-1146 EL-1147 EL-1148 EL-1148
Power supply and ground circuit check

REFERENCE PAGE

X
X
X
X

X
X

X: Applicable
*: Make sure the power door lock system operates properly.

EL-1139

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
POWER SUPPLY AND GROUND CIRCUIT CHECK
Main power supply circuit check
Terminals

Ignition switch position

⊕

OFF

ACC

Ground

Battery
voltage

V
10
V

Ground

SEL132X

Ground circuit check
Terminals

Continuity

16 — Ground
V

Yes

SEL133X

EL-1140

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 1
(Door unlock sensor check)
CHECK DOOR UNLOCK SENSOR
INPUT SIGNAL.
Check voltage between super lock control
unit terminals V
28 or V
29 and ground.
Terminals

Condition

⊕

Driver
side

28
V

Ground

Passenger
side

29
V

SEL134X

OK
c

Door unlock sensor is OK.

Voltage
[V]

Approx.
5
Unlocked
0
Approx.
Locked
5
Ground
Unlocked
0
Locked

Refer to wiring diagram in EL-1130
(LHD), EL-1135 (RHD).
NG
.

SEL814UB

CHECK DOOR UNLOCK SENSOR.
1. Disconnect door unlock sensor connector.
2. Check continuity between door unlock
sensor terminals.
Terminals
2 -V
5
V

Condition
Locked
Unlocked

Continuity
No
Yes

OK
.

Check the following.
+ Door unlock sensor ground circuit
+ Harness for open or short between control unit and door unlock sensor

EL-1141

NG
c

Replace door lock actuator
assembly.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 2
(Door key cylinder switch check)

CHECK DOOR KEY CYLINDER SWITCH
INPUT SIGNAL (LOCK/UNLOCK SIGNAL).
Check voltage between super lock control
unit terminal V
24 or V
25 and ground.
Terminals
@

⊕

Key position

24
V

Ground

25
V

Ground

OK
c

Door key cylinder switch is
OK.

Replace door key cylinder
switch.

Voltage
[V]

Between
neutral
0
and lock
Other
Approx. 5
positions
Between
neutral
0
and
unlock
Other
Approx. 5
positions

SEL135X

NG
.

CHECK DOOR KEY CYLINDER
SWITCH.
1. Disconnect door key cylinder switch
connector.
2. Check continuity between door key cylinder switch terminals.
Terminals
Front LH:
1 -V
2
V
Front RH:
3 -V
2
V
Front LH:
3 -V
2
V
Front RH:
1 -V
2
V

Key position
Neutral
Between
neutral and
lock
Neutral
Between
neutral and
unlock

Continuity
No
Yes
No
Yes

OK
.

SEL875WA

Check the following.
+ Door key cylinder switch ground circuit
+ Harness for open or short between
super lock control unit and door key
cylinder switch

EL-1142

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 3
(Door lock and unlock switch check)
CHECK DOOR LOCK AND UNLOCK
SWITCH INPUT SIGNAL.
Check voltage between control unit terminal V
20 or V
23 and ground.
Terminals
SEL626X
20 — Ground
V

Door lock and
unlock switch
condition
Lock
N and Unlock
Unlock

23 — Ground
V

N and Lock

OK
c

Door lock and unlock
switch is OK.

Voltage
(V)
0
Battery
voltage
0
Battery
voltage

NG
.

CHECK DOOR LOCK AND UNLOCK
SWITCH.
1. Disconnect door lock and unlock switch
connector.
2. Check continuity between each door
lock and unlock switch terminals.
Power window main switch
[Door lock and unlock switch (with
power window)]
Condition

SEL627X

Unlock
N
Lock

Terminals
18

17
j

No continuity
j

19
j
j

Door lock and unlock switch (without
power window)
Condition
Lock
N
Unlock

Terminals
2
j
No continuity

3
j
j

OK
.
SEL628X

Check the following.
+ Ground circuit for power window main
switch [Door lock and unlock switch
(with power window)] or door lock and
unlock switch (without power window)
+ Harness for open or short between
power window main switch [Door lock
and unlock switch (with power window)]
or door lock and unlock switch (without
power window) and control unit connector

EL-1143

NG
c

Replace power window
main switch (with power
window) or door lock and
unlock switch (without
power window).

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 4
(Door lock actuator check)
CHECK OUTPUT SIGNAL FOR DOOR
LOCK ACTUATOR.
Check voltage for door lock actuator.
Door lock actuator driver
Door lock/unlock
switch condition
SEL137X

Unlock → Lock
Lock → Unlock

Terminals
⊕
@
14
Ground
V
11
Ground
V

NG
c

Door lock actuator is OK.

Voltage
(V)
Battery
voltage

Door lock actuator passenger, rear
and back
Door lock/unlock
switch condition
Unlock → Lock
Lock → Unlock

SEL138X

Terminals
⊕
@
14
Ground
V
4
Ground
V

Voltage
(V)
Battery
voltage

Refer to wiring diagram in EL-1132
(LHD), EL-1137 (RHD).
OK
.

CHECK DOOR LOCK ACTUATOR.
1. Disconnect door lock actuator connector.
2. Apply 12V direct current to door lock
actuator and check operation.
Door lock actuator operation

SEL818UB

Door lock actuator operation

Terminals
⊕
@

Unlocked → Locked
Locked → Unlocked

6
3
V
V
3
6
V
V

Back door lock actuator operation

Terminals
⊕
@

Unlocked → Locked
Locked → Unlocked

3
1
V
V
1
3
V V

NG
SEL827UB

Replace door lock actuator assembly.

SEL434VA

EL-1144

OK
c

Check harness between
control unit and door lock
actuator.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 5
[Super lock actuator (in door lock actuator assembly)
check]
CHECK OUTPUT SIGNAL FOR SUPER
LOCK ACTUATOR.
Check voltage for super lock actuator.

SEL139X

Door key cylinder switch condition
Lock (Set)
Unlock
(Released)

Terminals

NG
c

Super lock actuator is OK.

Voltage
(V)

⊕

6
V
3
V

Ground
Ground

Approx. 12

Put the system in set condition before
checking release signal.
Refer to wiring diagram in EL-1131
(LHD), EL-1136 (RHD).
OK
.

CHECK SUPER LOCK ACTUATOR.
1. Disconnect door lock actuator assembly connector.
2. Set lever A in Lock position.
3. Apply 12V direct current to door lock
actuator assembly and check operation.
Super lock
actuator operation

Terminals
⊕
@

Connection from
lever B to lever
A

Released → Set
Set → Released

1
4
V
V
4
1
V V

Disconnect
Connect

SEL820UB

NG
.

Replace door lock actuator assembly.

EL-1145

OK
c

Check harness between
control unit and door lock
actuator assembly.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 6
(Driver’s door switch check)

CHECK DOOR SWITCH INPUT SIGNAL.
Check voltage between super lock control
unit terminal V
30 and ground.

SEL140X

Condition
Any door is opened.
Driver’s door is
closed.

OK
c

Door switch is OK.

Voltage [V]
0
Approx. 12

Refer to wiring diagram in EL-1129
(LHD), EL-1134 (RHD).
NG
.

CHECK DOOR SWITCH.
1. Disconnect door switch connector.
2. Check continuity between door switch
terminals.
SEL141X

Terminals Condition Continuity
Driver
side door
switch

1 V
ground

Closed

Open

Yes

OK
.

Check the following.
+ Driver side door switch ground condition
+ Harness for open or short between control unit and door switch

EL-1146

NG
c

Replace door switch.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 7
(NATS release signal check)
No

Does engine start properly?

Check NATS system.

Yes
.

SEL142X

CHECK NATS SIGNAL CIRCUIT.
1. Disconnect super lock control unit connector and NATS IMMU connector.
2. Check continuity between super lock
control unit terminal V
34 and NATS
3 .
IMMU terminal V
Continuity should exist.
3. Check continuity between super lock
control unit terminal V
34 and ground.
Continuity should not exist.
Refer to wiring diagram in EL-1128
(LHD), EL-1133 (RHD).

NG
c

Repair harness.

OK
.

CHECK NATS RELEASE SIGNAL.
1. Connect super lock control unit connector and NATS IMMU connector.
2. Check voltage between super lock control unit terminal V
34 and ground.
Ignition switch condition

SEL143X

OFF
More than 20 seconds after ignition
switch turned ON
For 20 seconds after ignition switch
turned ON

OK
.

Replace super lock control unit.

EL-1147

Voltage
[V]
5

Pulse

NG
c

Check NATS system.

POWER DOOR LOCK — Super Lock —
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 8
(Key switch check)
CHECK KEY SWITCH INPUT SIGNAL.
Check voltage between super lock control
unit terminal V
18 and ground.

SEL144X

Condition of key switch

Voltage [V]

Key is inserted.

Approx. 12

Key is withdrawn.

OK
c

Key switch is OK.

Refer to wiring diagram in EL-1128
(LHD), EL-1133 (RHD).
NG
.

CHECK KEY SWITCH POWER SUPPLY.
1. Disconnect key switch connector.
2. Check voltage between key switch har2 and ground.
ness terminal V
Battery voltage should exist.

NG
c

SEL197X

CHECK KEY SWITCH.
Check continuity between key switch terminals.
Terminals

SEL015WB

2
-V

Condition

Continuity

Key is
inserted.

Yes

Key is withdrawn.

NG
c

Check the following.
+ 7.5A fuse [No. 24 ,
located in fuse block
(J/B)]
+ Harness for open or
short between key
switch and fuse

Replace key switch.

OK
.

Check harness for open or short between
control unit and key switch.

DIAGNOSTIC PROCEDURE 9
(Ignition switch “ON” circuit check)
Terminals

SEL145X

Ignition switch position

⊕

OFF

ACC

17
V

Ground

Battery
voltage

If NG, check the following.
+ 10A fuse [No. 25 , located in the fuse block (J/B)]
+ Harness for open or short

EL-1148

MULTI-REMOTE CONTROL SYSTEM
System Description
FUNCTION
Multi-remote control system has the following function.
+ Door lock
+ Door unlock
+ Hazard reminder

LOCK OPERATION
When the LOCK signal is input to multi-remote control unit (the antenna of the system is combined with
multi-remote control unit), ground is supplied
5
+ through multi-remote control unit terminal V
+ to super lock control unit terminal V
32 .
Then super lock control unit locks all doors and set super lock. (Super lock will not be set while key is inserted
in the ignition key cylinder.)

UNLOCK OPERATION
When the UNLOCK signal is input to multi-remote control unit (the antenna of the system is combined with
multi-remote control unit) once, ground is supplied
6
+ through multi-remote control unit terminal V
+ to super lock control unit terminal V
33 .
Then super lock control unit unlocks driver’s door and release super lock on all doors.
If the UNLOCK signal is sent to the multi-remote control unit again within 5 seconds, all other doors will be
unlocked.

HAZARD REMINDER
When the doors are locked or unlocked (signal from front door unlock sensor LH) by multi-remote controller,
power is supplied
3 and V
8
+ through multi-remote control unit terminals V
+ to the hazard warning lamps
Then hazard warning lamp flashes as follows.
+ Lock operation: Flash once
+ Unlock operation: Flash twice

MULTI-REMOTE CONTROLLER ID CODE ENTRY
A maximum of four remote controllers can be entered. Any attempt to enter a remote controller will erase
all ID codes previously entered. Therefore, be sure to receive all remote controllers from the vehicle owner
when any ID code entry is performed.
To enter ID code entry, the following signals must be input to the multi-remote control unit.
+ Ignition switch ON signal
+ Battery power supply
+ Signal from remote controller
For detailed procedure, refer to “ID Code Entry Procedure” in EL-1156.

EL-1149

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/LHD Models

TEL274M

EL-1150

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/LHD Models
(Cont’d)

TEL275M

EL-1151

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/RHD Models

TEL278M

EL-1152

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/RHD Models
(Cont’d)

TEL279M

EL-1153

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses
SYMPTOM CHART
Symptom
No doors can be locked or unlocked by remote control operation. (See NOTE.)

Possible cause

Diagnoses/service order

1. Check power door lock operation.
2. Check remote controller battery. Refer to “Remote
controller battery check” in EL section of Service
Manual (SM7E-2Y61G1).
Ignition power supply circuit for 3. Check harness for open or short between multi-remote
control unit and super lock control unit.
multi-remote control unit
4 of
4. Make sure battery voltage is present at terminal V
Power supply circuit for multi-remulti-remote control unit while ignition switch is in IGN
mote control unit
position.
Ground circuit for multi-remote 5. Make sure battery voltage is present at terminal
2 of multi-remote control unit.
control unit
V
1 of multi-remote
Remote controller
6. Check continuity between terminal V
control unit and ground.
7. Replace remote controller. Refer to EL-1156.

1. Power door lock system
2. Remote controller battery
3. Door lock/unlock circuit
4.

5.
6.
7.

Hazard reminder does not operate 1. Hazard reminder output to haz- 1. Check hazard reminder output to hazard warning
3 and V
8 of multi-remote control
properly.
ard warning lamps
lamps at terminals V
unit.
2. Hazard reminder circuit
2. Check the harness for open or short between hazard
warning lamps and multi-remote control unit.
3. Driver’s door unlock sensor
3. Check driver’s door unlock sensor signal at terminal
7 of multi-remote control unit.
V
The new ID of remote controller
cannot be entered.

1. Remote controller battery
2. Ignition power supply circuit
for multi-remote control unit
3. Driver’s door unlock sensor
4. Remote controller

1. Check remote controller battery. Refer to “Remote
controller battery check” in EL section of Service
Manual (SM7E-2Y61G1).
4 of
2. Make sure battery voltage is present at terminal V
multi-remote control unit while ignition switch is in IGN
position.
3. Check driver’s door unlock sensor signal at terminal
7 of multi-remote control unit.
V
4. Replace remote controller. Refer to EL-1156.

Refer to “MULTI-REMOTE CONTROL UNIT INSPECTION TABLE” on next page to check the control unit
signals.
NOTE:
+ The lock operation of multi-remote control system does not activate with the ignition key ON position.

EL-1154

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses (Cont’d)
MULTI-REMOTE CONTROL UNIT INSPECTION TABLE
Terminal
No.

Connections

Ground

Power source (BAT)

Hazard warning lamp RH

Ignition power supply

Condition

Voltage (V)
(approximate
values)

—

Remote controller LOCK/UNLOCK button is pushed
(All doors are closed and key is not in ignition key cylinder.)

Other than above condition

0
OFF

ON or START

Ignition switch

Lock signal (to super lock control
unit)

Unlock signal (to super lock control
unit)

Driver side door unlock sensor

Hazard warning lamp LH

Remote controller LOCK button is pushed
(All doors are closed and key is not in ignition key cylinder.)

Other than above condition

Remote controller UNLOCK button is pushed
(Key is not in ignition key cylinder.)

Other than above condition

5
Locked

Unlocked

Driver side door
Remote controller LOCK/UNLOCK button is pushed
(All doors are closed and key is not in ignition key cylinder.)

Other than above condition

SEL147X

EL-1155

MULTI-REMOTE CONTROL SYSTEM
ID Code Entry Procedure
Activation of the registration mode:
The vehicle must have been unlocked by either the multi-remote controller or a transponder OK signal (TPOK)
from the vehicle’s immobilizer.
Preparation: — Make sure all doors unlock.
— Make sure all multi-remote controllers to be registered are available.
— Make sure the batteries of all multi-remote controllers are in a good condition.
— Make sure all transmitting sources are out of the neighbourhood of the vehicle.
— Make sure the battery of the vehicle is in a good condition.

Switch ignition-switch exactly six times from the “LOCK” to the “ON” position within 10 seconds and return the
ignition switch to the “LOCK” position (leaving the key in the ignition switch).
.

After 2 seconds the registration mode is activated. The turn signal lamps will flash twice.
OK
.

Proceed with the registration mode.
NOTE
The registration mode is operated when: + The ignition-switch is turned to the “ON” position.
+ 4 multi remote controllers have been learned.
+ No multi-remote controller or ignition switch input is received within 120 seconds.

Registration mode
Press and hold the “UNLOCK” button of the multi-remote controller.

Press the “LOCK” button 3 times.
.

Release the “UNLOCK” button.

c
.

Do you want to register another multi-remote controller? (max. 4)
No

If the multi-remote controller
code is registered correctly,
the turn signal lamp will flash
once.

Yes

After registration of the requested No. of multi-remote controller(s),
confirm the ID-code(s) by switching the ignition switch to the “ON”
position.

Take the ignition key out of the ignition switch and confirm the functioning of all multi-remote controllers by locking and unlocking the
vehicle with each of the multi-remote controllers.
.

End

EL-1156

If the multi-remote controller
registration is performed
correctly, the turn signal lamp
will flash twice.

NG
c
m

MULTI-REMOTE CONTROL SYSTEM
Remote Controller Battery Replacement

SEL241X

EL-1157

MULTI-REMOTE CONTROL SYSTEM
NOTE

EL-1158

SUPER LOCK CONTROL UNIT
Description
The following systems are controlled by the super lock control unit.
+ Warning chime
+ Rear window defogger timer
+ Power door lock (super lock)
+ Interior room lamp timer
For detailed description and wiring diagrams, refer to the relevant pages for the each system. The control
unit receives data from the switches, control units and sensors to control their corresponding system relays
and actuators.
System

Input

Output

Power door lock (super lock)

Door switches
Key switch (Insert)
Door key cylinder switch (lock/unlock)
Ignition switch (ON)
Door unlock sensors
Multi-remote control signals (lock/unlock)
NATS IMMU signal (Anti-theft cancel)

Door lock actuator
Super lock actuator

Warning chime

Key switch (Insert)
Ignition switch (ON)
Lighting switch (1st and 2nd)
Front door switch (Driver side)
Door unlock sensor (Driver side)

Warning chime

Rear window defogger timer

Ignition switch (ON)
Rear window defogger switch

Rear window defogger relay

Interior room lamp timer

Door switches
Door unlock sensor (Driver side)
Ignition switch (ON)
Key switch (Insert)

Interior lamp

EL-1159

SUPER LOCK CONTROL UNIT
Schematic

TEL285M

EL-1160

SUPER LOCK CONTROL UNIT
Schematic (Cont’d)

TEL286M

EL-1161

SUPER LOCK CONTROL UNIT
Input/Output Operation Signal
SUPER LOCK CONTROL UNIT INSPECTION TABLE
Operated condition

Voltage
(Approximate
values)

—

12V

Terminal
No.

Wire
color

Power source (Fuse)

L/Y

Super lock actuators

Key inserted into front door key cylinder, turning it to
UNLOCK
(Key is not in ignition key cylinder.)

L/R

Passenger door lock actuator

Door lock & unlock switch

12V

L/W

Super lock actuators

Key inserted into front door key cylinder, turning it to
LOCK
(When super lock is in release condition)

W/R

Power source (C/B)

L/R

Driver door lock actuator

Door lock & unlock switch

Door lock actuators

Door lock & unlock switch

Connections

Unlocked

—

Ground

12V
12V

Free

Locked

12V

—

B/W

Ignition switch (ON)

Ignition key is in “ON” position

Ignition key switch (Insert)

key inserted → key removed from IGN key cylinder

12V → 0V

L/B

Lighting switch (1ST)

1ST, 2ND positions: ON → OFF

12V → 0V

Door lock/unlock switches

Neutral → Locked

5V → 0V

Door lock/unlock switches

Neutral → Unlocked

5V → 0V

R/Y

Door key cylinder lock switch

OFF (Neutral) → ON (Locked)

5V → 0V

Y/G

Door key cylinder unlock switch

OFF (Neutral) → ON (Unlocked)

5V → 0V

R/W

Interior room lamp

When interior lamp is operated with
driver’s door is unlocked.
(Lamp switch in “DOOR” position)

12V

Locked

12V

Unlocked

B/W

Rear window defogger relay

OFF → ON (Ignition key is in “ON” position)

12V → 0V

L/W

Driver door unlock sensor

Driver door: Locked → Unlocked

12V → 0V

Passenger door unlock sensor

Passenger and back door: Locked → Unlocked

5V → 0V

R/Y

Driver door switch

OFF (Closed) → ON (Open)

12V → 0V

R/B

All door switches

OFF (Closed) → ON (Open)

12V → 0V

B/R

Lock signal (from multi-remote control unit)

B/Y

Remove controller LOCK button is pushed
(Key is not in ignition key cylinder.)

Other than above condition

Remove controller UNLOCK button is pushed
(When super lock is in release condition)

Other than above condition

12V

Anti-theft cancel signal

When super lock is in set condition with driver and
passenger door is locked, insert the key into ignition
key cylinder and turn it to ON.

Rear window defogger switch

OFF → ON

Unlock signal (from multi-remote
control unit)

EL-1162

5V → 0V

NATS (Nissan Anti-Theft System)
Component Parts and Harness Connector
Location

SEL168X

NOTE:
If customer reports a “No Start” condition, request ALL KEYS to be brought to the Dealer is case of
a NATS malfunction.

EL-1163

NATS (Nissan Anti-Theft System)
System Description
NATS has the following immobilizer functions:
+ Since only NATS ignition keys, whose ID nos. have been registered into the ECM and IMMU of NATS,
allow the engine to run, operation of a stolen vehicle without a NATS registered key is prevented by
NATS.
That is to say, NATS will immobilize the engine if someone tries to start it without the registered key of
NATS.
+ This version of NATS has dongle unit to improve its anti-theft performance (RHD models). Dongle unit
has its own ID which is registered into NATS IMMU. So it dongle unit is replaced, initialization must be
carried out.
+ When malfunction of dongle unit is detected:
— The security indicator lamp illuminates for about 15 minutes after ignition switch is turned to ON.
— When dongle unit has a malfunction and the indicator lamp is illuminated, engine can not be started.
However, engine can be started only one time when security indicator turns off in about 15 minutes
after ignition switch is turned to ON.
+ Both of the originally supplied ignition key IDs have been NATS registered.
If requested by the vehicle owner, a maximum of five key IDs can be registered into the NATS components.
+ The NATS security indicator (NATS security ind.) blinks when the ignition switch is in “OFF” or “ACC”
position. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.
+ When NATS detects trouble, the security indicator lamp lights up as follows.
Condition
IGN ON and

With Dongle

Without Dongle

MIL

Security Indicator

MIL

Security Indicator

NATS malfunction
(except dongle unit) is
detected

—

1. 6 times blinking
2. Staying ON after ignition switch is turned
ON

—

Staying ON

Only malfunction of
dongle unit is detected.

—

Staying ON for about
15 minutes after ignition
switch is turned ON.

—

Malfunction of NATS
and engine related parts
are detected

Staying ON

1. 6 times blinking
2. Staying ON after ignition switch is turned
ON

Staying ON

Only engine related part
malfunction is detected

Staying ON

—

Staying ON

—

Just after initialization of
NATS

—

6 times blinking

NATS trouble diagnoses, system initialization and additional registration of other NATS ignition key IDs
must be carried out using CONSULT-II hardware and CONSULT-II NATS software.
Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.
When servicing a malfunction of the NATS (indicated by lighting up of security Indicator Lamp)
or registering another NATS ignition key ID no., it is necessary to re-register original key identification. Therefore, be sure to receive ALL KEYS from vehicle owner.

EL-1164

NATS (Nissan Anti-Theft System)
System Composition
The immobilizer function of the NATS consists of the following:
+ NATS ignition key
+ NATS immobilizer control unit (NATS IMMU), located in the ignition key cylinder
+ Engine control module (ECM)
+ Dongle unit (RHD models)
+ NATS security indicator

SEL148XA

EL-1165

NATS (Nissan Anti-Theft System)
Wiring Diagram — NATS —

TEL280M

EL-1166

NATS (Nissan Anti-Theft System)
Wiring Diagram — NATS —/LHD Models

TEL281M

EL-1167

NATS (Nissan Anti-Theft System)
Wiring Diagram — NATS —/RHD Models

TEL294M

EL-1168

NATS (Nissan Anti-Theft System)
CONSULT-II
CONSULT-II INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Insert NATS program card into CONSULT-II.
Program card
EEN99A
3. Connect CONSULT-II to Data link connector which is located
behind the fuse box cover.

4. Turn ignition switch ON.
5. Touch “START”.

SEL149X

6. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT-II Operation
Manual, NATS.

SEL150X

EL-1169

NATS (Nissan Anti-Theft System)
CONSULT-II (Cont’d)
CONSULT-II DIAGNOSTIC TEST MODE FUNCTION
CONSULT-II DIAGNOSTIC TEST
MODE

Description

C/U INITIALIZATION

When replacing any of the following components, C/U initialization is necessary.
[NATS ignition key/IMMU/ECM/Dongle unit]

SELF-DIAG RESULTS

Detected items (screen terms) are as shown in the chart below.

NOTE:
When any initialization is performed, all ID previously registered will be erased. So all NATS ignition
keys must be registered again.
The engine cannot be started with an unregistered key. In this case, the system may show “DIFFERENCE OF KEY” or “LOCK MODE” as a self-diagnostic result on the CONSULT-II screen.
When initialization is performed (for RHD models), security indicator will flash six times to demonstrate recognition of dongle unit ID.

HOW TO READ SELF-DIAGNOSTIC RESULTS

SEL151X

EL-1170

NATS (Nissan Anti-Theft System)
CONSULT-II (Cont’d)
SELF-DIAGNOSTIC RESULTS ITEM CHART
Detected items (Screen terms)

Description

Reference page

ECM INT CIRC-IMMU

The malfunction of ECM internal circuit of IMMU communication line is
detected.

EL-1175

CHAIN OF ECM-IMMU

Communication impossible between ECM and IMMU.
(In rare case, “CHAIN OF ECM-IMMU” might be stored during key registration procedure, even if the system is not malfunctioning.)

EL-1176

DIFFERENCE OF KEY

IMMU can receive the key ID signal but the result of ID verification
between key ID and IMMU is NG.

EL-1178

CHAIN OF IMMU-KEY

IMMU cannot receive the key ID signal. Otherwise, the registered ID signal from dongle unit cannot be received when the IMMU requests the
ID.

EL-1179

ID DISCORD, IMM-ECM

The result of ID verification between IMMU and ECM is NG. System initialization is required.

EL-1180

DON’T ERASE BEFORE CHECKING ENG DIAG

Engine trouble data and NATS trouble data have been detected in ECM.

EL-1172

LOCK MODE

When the starting operation is carried out 5 or more times consecutively
under the following conditions, NATS will shift the mode to one which
prevents the engine from being started.
+ unregistered ignition key is used
+ IMMU or ECM malfunctioning

EL-1181

EL-1171

NATS (Nissan Anti-Theft System)
Trouble Diagnoses
WORK FLOW
*NOTE: In rare case, “CHAIN OF ECM-IMMU” might be stored as a selfdiagnostic result during key registration procedure, even if the system is not malfunctioning.

CHECK IN
.

Listen to customer complaints or request. (Get symptoms)
NOTE:
If customer reports a “No start” condition, request ALL
KEYS to be brought to the Dealer in case of a NATS malfunction.
KEY SERVICE REQUEST (Additional key ID registration)

TROUBLE
.

Verify the security indicator.

INITIALIZATION
(Refer to CONSULT-II operation
manual NATS.)

Using the CONSULT-II program card for NATS check the

c “SELF-DIAG RESULTS” with CONSULT-II.

Self-diagnostic results referring to NATS, but no information
about engine self-diagnostic results is displayed on CONSULTII.
.

Self-diagnostic results referring to NATS and “DON’T ERASE
BEFORE CHECKING ENG DIAG” are displayed on CONSULTII.
(This means that engine trouble data has been detected in
ECM.)

Turn ignition switch “OFF”.
.

Repair NATS.
(If necessary, carry out “C/U INITIALIZATION” with CONSULTII.*)

Turn ignition switch “OFF”.

Turn ignition switch “ON”.

Repair NATS according to self-diagnostic results referring to
NATS.
(If necessary, carry out “C/U INITIALIZATION” with CONSULTII.*)
.

Erase the NATS “SELF-DIAG RESULTS” by using CONSULT-II.
(Touch “ERASE”)

Do not erase the NATS “SELF-DIAG RESULTS” by using
CONSULT-II.

Start the engine.

Check the engine “SELF-DIAG RESULTS” with CONSULT-II by
using the CONSULT-II generic program card.
b
(Engine diagnostic software included)
.

Verify no lighting up of the security indicator.

Repair engine control system (Refer to EC section.) when selfdiagnostic results except “NATS MALFUNCTION” are detected.
When only “NATS MALFUNCTION” is detected, erase the selfdiagnostic results and go to the next step.

CHECK OUT

Start the engine. Does the engine start properly?
OK

Perform running test with CONSULT-II in engine “SELF-DIAG
RESULTS” mode.

Erase the NATS and engine “SELF-DIAG RESULTS” by using
the CONSULT-II program card for NATS and generic program
card.

NG Verify “NO DTC” displayed on the CONSULT-II screen.

Start the engine.

OK
.

CHECK OUT

EL-1172

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
SYMPTOM MATRIX CHART 1
(Self-diagnosis related item)
SYMPTOM

Displayed “SELF-DIAG
RESULTS” on CONSULT-II
screen.
ECM INT CIRC-IMMU

CHAIN OF ECM-IMMU

DIAGNOSTIC PROCEDURE
(Reference page)
PROCEDURE 1
(EL-1175)

PROCEDURE 2
(EL-1176)

+ Security indicator lighting
up*
+ Engine does not start

SYSTEM
(Malfunctioning
part or mode)
ECM

In rare case, “CHAIN OF
ECM-IMMU might be stored
during key registration
procedure, even if the system is not malfunctioning.

—

Open circuit in battery voltage line of IMMU circuit

Open circuit in ignition line
of IMMU circuit

Open circuit in ground line
of IMMU circuit

Open circuit in communication line between IMMU and
ECM

Short circuit between IMMU
and ECM communication
line and battery voltage line

Short circuit between IMMU
and ECM communication
line and ground line

ECM

DIFFERENCE OF KEY

CHAIN OF IMMU-KEY

+ Security indicator lighting
up*
+ Engine hard to start

ID DISCORD, IMM-ECM

LOCK MODE
+ MIL staying ON
+ Security indicator lighting
up*

DON’T ERASE BEFORE
CHECKING ENG DIAG

PROCEDURE 3
(EL-1178)

PROCEDURE 4
(EL-1179)

PROCEDURE 5
(EL-1180)
PROCEDURE 6
(EL-1181)
WORK FLOW
(EL-1172)

REFERENCE PART NO.
OF ILLUSTRATION ON
DIAGNOSTIC SYSTEM
DIAGRAM

IMMU

Unregistered key

IMMU

Malfunction of key ID chip

IMMU

Open circuit in ground line
of dongle unit circuit

Open or short circuit in
communication line between
IMMU and dongle unit

Dongle unit

System initialization has not
yet been completed.

ECM

LOCK MODE

Engine trouble data and
NATS trouble data have
been detected in ECM

—

*: When NATS detects trouble, the security indicator lights up while ignition key is in the “ON” position.
*: When the vehicle is equipped with dongle unit, the security indicator blinks 6 times just after ignition switch is turned to ON. Then
the security indicator will light up while ignition key is in the ON position.

EL-1173

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
SYMPTOM MATRIX CHART 2
(Non self-diagnosis related item)
SYMPTOM

Security ind. does not light up.

DIAGNOSTIC PROCEDURE
(Reference page)

PROCEDURE 7
(EL-1182)

Security ind. does not blink
just after initialization even if
the vehicle is equipped with
dongle unit.
Security ind. does not blink
just after ignition switch is
turned to ON when some malfunction related to NATS is
detected even if the vehicle is
equipped with dongle unit.

PROCEDURE 8
(EL-1183)

SYSTEM
(Malfunctioning part or mode)

REFERENCE PART NO. OF
ILLUSTRATION ON DIAGNOSTIC SYSTEM DIAGRAM

Security ind.

—

Open circuit between Fuse and NATS IMMU

—

Continuation of initialization mode

—

NATS IMMU

NATS might be initialized without connecting
dongle unit properly.

—

Open circuit in ground line of dongle unit circuit

Open or short circuit in communication line
between IMMU and dongle unit

Dongle unit

DIAGNOSTIC SYSTEM DIAGRAM

SEL028X

EL-1174

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 1
Self-diagnostic results:
“ECM INT CIRC-IMMU” displayed on CONSULT-II screen

Confirm SELF-DIAGNOSTIC RESULTS “ECM INT CIRC-IMMU” displayed on CONSULT-II screen.
Ref. part No. B.

SEL152X

Replace ECM.

Perform initialization with CONSULT-II.
For the operation of initialization, refer to “CONSULT-II operation
manual NATS”.

EL-1175

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 2
Self-diagnostic results:
“CHAIN OF ECM-IMMU” displayed on CONSULT-II screen
*: In rare case, “CHAIN OF
ECM-IMMU” might be
stored during key registration procedure, even if the
system is not malfunctioning.

Confirm SELF-DIAGNOSTIC
RESULTS “CHAIN OF ECMIMMU”* displayed on CONSULT-II
screen.
OK
SEL153X
.

CHECK POWER SUPPLY CIRCUIT FOR
IMMU.
8 of
Check voltage between terminal V
IMMU and ground.
Voltage: Battery voltage

NG
c

.
SEL154X

CHECK IGN SW. ON SIGNAL.
7 of
Check voltage between terminal V
IMMU and ground while ignition switch is
in the “ON” position.
Voltage: Battery voltage

NG
c

SEL155X

CHECK GROUND CIRCUIT FOR IMMU.
Check harness continuity between IMMU
4 and ground.
terminal V
Continuity should exist.

Check the following:
+ 20A fuse (No. 50 ,
located in the fuse and
fusible link box)
+ Harness for open or
short between fuse and
IMMU connector
Ref. part No. C1

Check the following:
+ 10A fuse [No. 25 ,
located in the fuse
block (J/B)]
+ Harness for open or
short between fuse and
IMMU connector
Ref. part No. C2

Repair harness.
Ref. part No. C3

Repair harness.
Ref. part No. C4

OK
.

CHECK COMMUNICATION ON OPEN
CIRCUIT.
Check harness continuity between the
following ECM terminal and IMMU terminal.
ECM terminal V
55 or IMMU terminal
1
V

Continuity should exist.
SEL156X

OK
.

A
V

SEL157X

EL-1176

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
A
V

CHECK COMMUNICATION LINE BATTERY SHORT CIRCUIT.
1. Disconnect ECM connector and IMMU
connector.
2. Turn ignition switch to ON.
3. Check voltage between ECM terminal
1 and ground.
55 or IMMU terminal V
V
No voltage should exist.

NG
c

Repair harness.
Ref. part No. C4

SEL158X

OK
.

CHECK COMMUNICATION LINE
GROUND SHORT CIRCUIT.
1. Disconnect ECM connector and IMMU
connector.
2. Turn ignition switch OFF.
3. Check continuity between ECM termi1 and
nal V
55 or IMMU terminal V
ground.
Continuity should not exist.

OK
SEL159X
.

SIGNAL FROM ECM TO IMMU CHECK
1. Check the signal between ECM terminal V
55 and ground with CONSULT-II
or oscilloscope when ignition switch is
turned “ON”.
2. Make sure signals which are shown in
the figure below can be detected during 750 msec. just after ignition switch
is turned “ON”.
OK
.
SEL193X

+ IMMU is malfunctioning.
1. Replace IMMU. Ref. part No. A
2. Perform initialization with CONSULTII. For the initialization procedure,
refer to “CONSULT-II operation
manual NATS”.

EL-1177

NG
c

+ ECM is malfunctioning.
1. Replace ECM. Ref.
part No. B
2. Perform initialization
with CONSULT-II.
For the initialization
procedure, refer to
“CONSULT-II operation
manual NATS”.

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 3
Self-diagnostic results:
“DIFFERENCE OF KEY” displayed on CONSULT-II screen
Confirm SELF-DIAGNOSTIC
RESULTS “DIFFERENCE OF
KEY” displayed on CONSULT-II
screen.
OK
SEL163X

PERFORM INITIALIZATION.
Perform initialization with CONSULT-II.
Re-register all NATS ignition key IDs.
For the initialization procedure, refer to
“CONSULT-II operation manual NATS”.
Initialization
completed

SEL566W

Start engine.
.

END.
(The ignition key was unregistered.)
Ref. part No. D

EL-1178

Initialization
with CONSULT-II
incomplete or
failed

+ IMMU is malfunctioning.
c 1. Replace
IMMU.
Ref. part No.
A
2. Perform initialization with
CONSULT-II.
For the initialization
procedure,
refer to “CONSULT-II operation manual
NATS”.

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 4
Self-diagnostic results:
“CHAIN OF IMMU-KEY” displayed on CONSULT-II screen
Confirm SELF-DIAGNOSTIC
RESULTS “CHAIN OF IMMUKEY” displayed on CONSULT-II
screen.
OK
SEL165X

CHECK NATS IGNITION KEY ID CHIP.
Start engine with another registered
NATS ignition key.
Does the engine start?

Yes
c

Is this vehicle equipped with dongle unit
(RHD models)?

No
c

SEL160X

yes

CHECK HARNESS CONNECTOR CONNECTION.
Check the following harness connector
connection. M29 , M121
Does the engine start?

Yes
c

+ Ignition key ID chip is
malfunctioning.
1. Replace the ignition
key.
Ref. part No. E
2. Perform initialization
with CONSULT-II.
For the initialization
procedure, refer to
“CONSULT-II operation
manual NATS”.
+ IMMU is malfunctioning.
1. Replace IMMU.
Ref part No. A
2. Perform initialization
with CONSULT-II.
For the initialization
procedure, refer to
“CONSULT-II operation
manual NATS”.
System is OK.
(The malfunction is caused
by improper connector
connection.)

SEL161X
.

CHECK GROUND CIRCUIT FOR
DONGLE UNIT.
Check continuity between dongle unit ter1 and ground.
minal V
Continuity should exist.

No
c

Repair harness.
Ref. part No. C6

Repair harness.
Ref. part No. C5

Yes
.

SEL162X

CHECK INTERFACE CIRCUIT.
1. Check continuity between IMMU termi2 and dongle unit terminal V
7
nal V
(Open circuit check)
Continuity should exist.
2. Check continuity between IMMU termi2 and ground. (Short circuit
nal V
check)
Continuity should not exist.
Yes
.

Dongle unit is malfunctioning.
1. Replace dongle unit. Ref. part No. G
2. Perform initialization with CONSULT-II.
For the initialization procedure, refer to
“CONSULT-II operation manual NATS”.

EL-1179

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 5
Self-diagnostic results:
“ID DISCORD, IMM-ECM” displayed on CONSULT-II screen
Confirm SELF-DIAGNOSTIC
RESULTS “ID DISCORD, IMMECM*” displayed on CONSULT-II
screen.

SEL166X

SEL566W
.

Start engine. (END)
(System initialization was not completed.
Ref. part No. F)

EL-1180

* “ID DISCORD, IMM-ECM”:
Registered ID of IMMU is
in discord with that of
ECM.

Initialization
with CONSULT-II
incomplete or
failed

+ ECM is malfunctioning.
c 1. Replace ECM.
Ref. part No.
B
2. Perform initialization with
CONSULT-II.
For the initialization
procedure,
refer to “CONSULT-II operation manual
NATS”.

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 6
Self-diagnostic results:
“LOCK MODE” displayed on CONSULT-II screen
Confirm SELF-DIAGNOSTIC RESULTS
“LOCK MODE” is displayed on CONSULT-II screen.
.
SEL167X

1. Turn the ignition switch to OFF position.
2. Turn the ignition key switch to ON
position with a registered key.
(Do not start engine.) Wait 5 seconds.
3. Return the key to the OFF position.
4. Repeat steps 2 and 3 twice (total of
three cycles).
5. Start the engine.
Does the engine start?

Yes
c

System is OK.
(Now the system is
escaped from “LOCK
MODE”.)

No
.
SEL566W

CHECK NATS IMMU INSTALLATION.
Refer to “How to Replace NATS IMMU” in
EL-1183.

NG
c

Reinstall NATS IMMU correctly.

OK
.

PERFORM INITIALIZATION.
Perform initialization with CONSULT-II.
For the initialization procedure, refer to
“CONSULT-II operation manual NATS”.
Can the system be initialized?
Note: If the initialization is incompleted or
failed, CONSULT-II shows
message on the screen.
No
.

Go to DIAGNOSTIC PROCEDURE 4,
EL-1179 to check “CHAIN OF IMMUKEY”.

EL-1181

Yes
c

System is OK.

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 7
“SECURITY IND. DOES NOT LIGHT UP”
Check 7.5A fuse [No. 24 , located in the
fuse block (J/B)].

NG
c

Replace fuse.

OK
.

NATS INITIALIZATION
1) Install the 7.5A fuse.
2) Perform initialization with CONSULT-II.
For the operation of
initialization, refer to “CONSULT-II operation manual
NATS”.

Turn ignition switch “OFF”.

Start engine and turn ignition switch
“OFF”.

Check the security ind. lighting.

OK
c

END

NG
.

Check voltage between security ind. con1 and ground.
nector terminal V
Voltage: Battery voltage

NG
c

Check harness for open or
short between fuse and
security ind.

OK
.
SEL931UA

CHECK INDICATOR LAMP.

NG
c

Repair harness.

OK
.

CHECK NATS IMMU FUNCTION.
1. Connect NATS IMMU connector.
2. Disconnect security ind. connector.
3. Check continuity between NATS IMMU
6 and ground.
terminal V
Continuity should exist intermittently.
OK

SEL164X

Check harness for open or short between
security indicator and NATS IMMU.

EL-1182

NG
c

NATS IMMU is malfunctioning. Replace IMMU.

Perform initialization with CONSULT-II.
For the operation
of initialization,
refer to “CONSULT-II operation
manual NATS”.

NATS (Nissan Anti-Theft System)
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 8
CHECK GROUND CIRCUIT FOR
DONGLE UNIT.
Check continuity between dongle unit ter1 and ground.
minal V
Continuity should exist.

No
c

Repair harness.
Ref. part No. C6

Repair harness.
Ref. part No. C5

Yes
.
SEL160X

CHECK INTERFACE CIRCUIT.
1. Check continuity between IMMU termi2 and dongle unit terminal V
7 .
nal V
(Open circuit check)
Continuity should exist.
2. Check continuity between IMMU termi2 and ground. (Short circuit
nal V
check)
Continuity should exist.

Yes
.
SEL161X

Dongle unit is malfunctioning.
1. Replace dongle unit.
Ref. part No. G
2. Perform initialization with CONSULT-II.
For the initialization procedure, refer to
“CONSULT-II operation manual NATS”.

SEL162X

How to Replace NATS IMMU
NOTE:
+ If NATS IMMU is not installed correctly, NATS system
will not operate properly and SELF-DIAG RESULTS on
CONSULT-II screen will show “LOCK MODE”.

SEL096WD

EL-1183

NATS (Nissan Anti-Theft System)
NOTE

EL-1184

LOCATION OF ELECTRICAL UNITS
Engine Compartment

CEL101M

EL-1185

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — LHD Models

CEL102M

EL-1186

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — LHD Models
(Cont’d)

CEL103M

EL-1187

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — RHD Models

CEL104M

EL-1188

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — RHD Models
(Cont’d)

CEL105M

EL-1189

LOCATION OF ELECTRICAL UNITS
NOTE

EL-1190

HARNESS LAYOUT
How to Read Harness Layout
Example:
G2

B/6

: ASCD ACTUATOR

Connector color / Cavity
Connector number
Grid reference

The following Harness Layouts use a map style grid to help locate connectors on the drawings:
+ Main Harness
+ Engine Room Harness (Engine Compartment)
To use the grid reference
1)Find the desired connector number on the connector list.
2) Find the grid reference.
3) On the drawing, find the crossing of the grid reference letter column and number row.
4) Find the connector number in the crossing zone.
5) Follow the line (if used) to the connector.
CONNECTOR SYMBOL
Main symbols of connector (in Harness Layout) are indicated in the below.
Water proof type

Standard type

Connector type
Male

Female

—

Male

+ Cavity: Less than 4
+ Relay connector
+ Cavity: From 5 to 8
+ Cavity: More than 9
+ Ground terminal etc.

—

EL-1191

Female

HARNESS LAYOUT
Main Harness/LHD Models

CEL106M

EL-1192

HARNESS LAYOUT
Main Harness/LHD Models (Cont’d)

CEL107M

EL-1193

HARNESS LAYOUT
Main Harness/LHD Models (Cont’d)

CEL108M

EL-1194

HARNESS LAYOUT
NOTE

EL-1195

HARNESS LAYOUT
Main Harness/RHD Models

CEL109M

EL-1196

HARNESS LAYOUT
Main Harness/RHD Models (Cont’d)

CEL110M

EL-1197

HARNESS LAYOUT
Main Harness/RHD Models (Cont’d)

CEL111M

EL-1198

HARNESS LAYOUT
NOTE

EL-1199

HARNESS LAYOUT
Engine Room Harness/LHD Models

CEL112M

EL-1200

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)

CEL113M

EL-1201

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)
PASSENGER COMPARTMENT

CEL114M

EL-1202

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)

CEL115M

EL-1203

HARNESS LAYOUT
Engine Room Harness/RHD Models

CEL118M

EL-1204

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)

CEL119M

EL-1205

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)
PASSENGER COMPARTMENT

CEL120M

EL-1206

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)

CEL121M

EL-1207

HARNESS LAYOUT
Engine Harness

CEL123M

EL-1208

HARNESS LAYOUT
Engine Control Harness

CEL125M

EL-1209

HARNESS LAYOUT
Body Harness/LHD Models
WAGON

CEL126M

EL-1210

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)

CEL127M

EL-1211

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)
HARDTOP

CEL128M

EL-1212

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)

CEL129M

EL-1213

HARNESS LAYOUT
Body Harness/RHD Models
WAGON

CEL130M

EL-1214

HARNESS LAYOUT
Body Harness/RHD Models (Cont’d)

CEL131M

EL-1215

HARNESS LAYOUT
Body Harness/RHD Models (Cont’d)
HARDTOP

CEL132M

EL-1216

HARNESS LAYOUT
Body Harness/RHD Models (Cont’d)

CEL133M

EL-1217

HARNESS LAYOUT
Body No. 2 Harness/LHD Models
WAGON

CEL226A

EL-1218

HARNESS LAYOUT
Body No. 2 Harness/LHD Models (Cont’d)
HARDTOP

CEL134M

EL-1219

HARNESS LAYOUT
Body No. 2 Harness/RHD Models
WAGON

CEL135M

EL-1220

HARNESS LAYOUT
Body No. 2 Harness/RHD Models (Cont’d)
HARDTOP

CEL136M

EL-1221

HARNESS LAYOUT
Chassis Harness

CEL250A

EL-1222

HARNESS LAYOUT
Room Lamp Harness

CEL137M

EL-1223

HARNESS LAYOUT
Front Door Harness (Driver side)
LHD MODELS

CEL245A

RHD MODELS

CEL138M

EL-1224

HARNESS LAYOUT
LHD MODELS

Front Door Harness (Passenger side)

CEL246A

RHD MODELS

CEL139M

EL-1225

HARNESS LAYOUT
Back Door Harness and Rear Window
Defogger Harness

CEL251A

EL-1226

WIRING DIAGRAM CODES (CELL CODES)
Wiring Diagram Codes (Cell Codes)
Use the chart below to find out what each wiring diagram code
stands for.
Refer to the wiring diagram code in the alphabetical index to find
the location (Page number) of each wiring diagram.
Code

Section

Wiring Diagram Name

Code

Section

Wiring Diagram Name

A/C,A

Auto Air Conditioner

HLC

Headlamp Wiper and Washer

A/C,M

Manual Air Conditioner

HORN

Horn

A/CCUT

Air Conditioner Control

IGN

Ignition Control System

A/T

ILL

Illumination

ABS

Anti-lock Brake System

INJPMP

ACC/SW

Accelerator Switch (FC)

Electronic Control Fuel Injection
Pump

ACL/SW

Accelerator Position Switch

INT/V

Intake Air Control Valve Control
Solenoid Valve

APS

Accelerator Position Sensor

MAFS

Mass Air Flow Sensor

ASCD

Automatic Speed Control Device

AT/C

A/T Control

MAIN

Main Power Supply and Ground Circuit

BACK/L

Back-up Lamp

BCDD

BCDD System

METER

Speedometer, Tachometer, Temp.,
Oil and Fuel Gauges

BOOST

Turbo Charger Boost Sensor

MIL/DL

Mil and Data Link Connectors

BRK/SW

Brake Switch Signal

MULTI

Multi-remote Control System

CHARGE

Charging System

NATS

Nissan Anti-Theft System

CHIME

Warning Chime

P/ANT

Power Antenna

CHOKE

Automatic Choke

PNP/SW

Park/Neutral Position Switch

Power Supply Routing

CKPS

Crankshaft Position Sensor (OBD)

POWER

COOL/B

Cool Box

R/COOL

Rear Cooler System

COOL/F

Cooling Fan Control

R/FOG

Rear Fog Lamp

CORNER

Cornering Lamp

R/HEAT

Rear Heater System

DEF

Rear Window Defogger

REMOTE

Audio (Remote Control Switch)

DIFF/L

Differential Lock Control System

ROOM/L

Interior Room Lamp

DTRL

Headlamp — With Daytime Light
System

S/LOCK

Power Door Lock — Super Lock

S/SIG

Start Signal

ECMRLY

ECM Relay

S/TANK

Sub Fuel Tank Control System

ECTS

Engine Coolant Temperature Sensor

SHIFT

A/T Shift Lock System

EGVC/V

EGR Volume Control Valve

SRS

Supplemental Restraint System

EXH

Exhaust Gas Control Valve Control
Solenoid Valve

STAB

Stabilizer Release Device

START

Starting System

F/FOG

Front Fog Lamp

STOP/L

Stop Lamp

F/PUMP

Fuel Pump

FCUT

Fuel Cut System

SWL/V

Swirl Control Valve Control Solenoid
Valve

FICD

IACV-FICD Solenoid Valve

TAIL/L

Parking, License and Tail Lamps

FIPOT

ISC-FI POT

FPCM

Fuel Pump Control Module

TURN

Turn Signal and Hazard Warning
Lamps

GLOW

Quick Glow System

VSS

Vehicle Speed Sensor

HEATER

Heater System

WARN

Warning Lamps

HEATUP

Heat up Switch

EL-1227

WIRING DIAGRAM CODES (CELL CODES)
Wiring Diagram Codes (Cell Codes) (Cont’d)
Code

Section

Wiring Diagram Name

VNT

Variable Nozzle Turbocharger Control Solenoid Valve

WINCH

Electrical Winch

WINDOW

Power Window

WIPER

Front Wiper and Washer

EL-1228

ENGINE MECHANICAL
SECTION

MODIFICATION NOTICE:
ZD engine
+ ZD30DDTi engine has newly been added.

CONTENTS
ZD
PRECAUTIONS …………………………………………… 1003
Parts Requiring Angular Tightening…………….. 1003
Liquid Gasket Application Procedure ………….. 1003
PREPARATION …………………………………………… 1004
Special Service Tools ……………………………….. 1004
Commercial Service Tools…………………………. 1006
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………….. 1008
NVH Troubleshooting Chart — Engine Noise . 1009
MEASUREMENT OF COMPRESSION
PRESSURE…………………………………………………. 1010
INTERCOOLER …………………………………………… 1011
Removal and Installation …………………………… 1011
INTAKE MANIFOLD …………………………………….. 1012
Removal and Installation …………………………… 1012
Inspection………………………………………………… 1013
CATALYST AND TURBOCHARGER …………….. 1014
Removal and Installation …………………………… 1014
Inspection………………………………………………… 1015
EXHAUST MANIFOLD …………………………………. 1018
Removal and Installation …………………………… 1018
Inspection………………………………………………… 1019
ROCKER COVER ………………………………………… 1020
Removal and Installation …………………………… 1020
OIL PAN & OIL STRAINER ………………………….. 1022
Removal and Installation …………………………… 1022
VACUUM PUMP ………………………………………….. 1025
Removal and Installation …………………………… 1025
TIMING CHAIN ……………………………………………. 1027
Removal and Installation …………………………… 1027
Removal ………………………………………………….. 1027
Installation ……………………………………………….. 1029

CAMSHAFT ………………………………………………… 1031
Removal and Installation …………………………… 1031
Removal ………………………………………………….. 1031
Inspection………………………………………………… 1032
Installation ……………………………………………….. 1034
VALVE CLEARANCE INSPECTIONS AND
ADJUSTMENTS…………………………………………… 1036
Inspection………………………………………………… 1036
Adjustments …………………………………………….. 1037
TIMING GEAR …………………………………………….. 1039
Removal and Installation …………………………… 1039
Removal ………………………………………………….. 1040
Inspection………………………………………………… 1042
Installation ……………………………………………….. 1047
OIL SEAL REPLACEMENT ………………………….. 1051
CYLINDER HEAD………………………………………… 1053
Removal and Installation …………………………… 1053
Removal ………………………………………………….. 1053
Inspection………………………………………………… 1054
Installation ……………………………………………….. 1055
Disassembly…………………………………………….. 1058
Inspection………………………………………………… 1059
Assembly…………………………………………………. 1062
ENGINE REMOVAL……………………………………… 1064
Precautions ……………………………………………… 1064
Removal ………………………………………………….. 1064
Installation ……………………………………………….. 1066
Inspection………………………………………………… 1066
CYLINDER BLOCK ……………………………………… 1067
Selection Procedure for Selective Part
Combination …………………………………………….. 1068
Disassembly…………………………………………….. 1068
Inspection………………………………………………… 1072

Assembly…………………………………………………. 1081
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1085
General Specifications ………………………………. 1085
Compression Pressure ……………………………… 1085
Cylinder Head ………………………………………….. 1085
Valve ………………………………………………………. 1085
Valve Seat……………………………………………….. 1088

Camshaft and Camshaft Bearing ……………….. 1090
Cylinder Block ………………………………………….. 1091
Piston, Piston Ring and Piston Pin……………… 1091
Connecting Rod ……………………………………….. 1092
Crankshaft……………………………………………….. 1093
Available Main Bearing ……………………………… 1093
Available Connecting Rod Bearing……………… 1094
Miscellaneous Components……………………….. 1095

EM-1002

PRECAUTIONS

Parts Requiring Angular Tightening
+ Use an angle wrench for the final tightening of the cylinder
head bolts.
+ Do not use a torque value for final tightening.
+ The torque value for these parts are for a preliminary step.
+ Ensure thread and seat surfaces are clean and coated with
engine oil.

Liquid Gasket Application Procedure
1. Use a scraper to remove old liquid gasket from mating
surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.)
+ Be sure liquid gasket diameter is as specified.

SEM164F

3. Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and
engine coolant.

AEM080

EM-1003

PREPARATION
Special Service Tools
Tool number
Tool name

Description

ST0501S000
Engine stand assembly
1 ST05011000
V
Engine stand
2 ST05012000
V
Base

Disassembling and assembling

NT042

KV10106500
Engine stand shaft

NT028

KV11106101
Engine sub-attachment

NT819

KV10115600
Valve oil seal drift

Installing valve oil seal
Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)

NT603

KV10107902
Valve oil seal puller
1 KV10116100
V
Valve oil seal puller
adapter

Removing valve oil seal

NT605

KV101056S0
Ring gear stopper
1 KV10105630
V
Adapter
2 KV10105610
V
Plate

Preventing crankshaft from
rotating

a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)

NT617

EM-1004

PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name

Description

KV101151S0
Lifter stopper set
1 KV10115110
V
Camshaft pliers
2 KV10115120
V
Lifter stopper

Changing shims

NT041

KV101092S0
Valve spring compressor
1 KV10109210
V
Compressor
2 KV10109220
V
Adapter

Disassembling and assembling valve components

NT718

ED19600620
Compression gauge adapter

Checking compression pressure

NT820

ST16610000
Pilot bushing puller

Removing crankshaft pilot bushing

NT045

KV10111100
Seal cutter

Removing steel oil pan and rear timing chain
case

NT046

WS39930000
Tube presser

Pressing the tube of liquid gasket

NT052

KV10112100
Angle wrench

Tightening bolts for bearing cap, cylinder head,
etc.

NT014

EM-1005

PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name

Description

KV10109300
Pulley holder

a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.

NT628

KV111045S1
Balancer shaft bearing
replacer set
1 KV11104510
V
Replacer bar
2 KV11104521
V
Guide plate
3 KV11104530
V
Adapter
(Front bearing)
4 ST15243000
V
Drift

Removing and installing balancer shaft bearing

NT258

Commercial Service Tools
Tool name

Description

Valve seat cutter set

Finishing valve seat dimensions

NT048

Piston ring compressor

Installing piston assembly into cylinder bore

NT044

Piston ring expander

Removing and installing piston ring

NT030

Standard Universal

Removing and installing transmission mount

NT808

EM-1006

PREPARATION
Commercial Service Tools (Cont’d)
Tool name

Description

Deep socket (12 mm)

Removing and installing glow plugs

NT821

EM-1007

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING

SEM290G

EM-1008

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING

NVH Troubleshooting Chart — Engine Noise
Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location of
noise

Top of
engine
Rocker
cover
Cylinder
head

Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil pan

Front of
engine
Timing gear
cover

Type of
noise

Before
After
warm-up warm-up

When
starting

When
idling

When
racing

While
driving

Source of
noise

Check item

Reference
page

Ticking or
clicking

—

Tappet
noise

Valve clearance

MA section
(“Adjusting
Intake &
Exhaust
Valve
Clearance”,
“ENGINE
MAINTENANCE”)

Rattle

—

Camshaft
bearing
noise

Camshaft bushing clearance
Camshaft runout

EM-1032,
1032

Slap or
knock

—

Piston pin
noise

Piston and piston pin clearance
Connecting rod bushing
clearance

EM-1072,
1074

Piston slap
noise

Piston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsion

EM-1076,
1073, 1073,
1074

Connecting rod bushing
clearance (Small end)
Connecting rod bearing
clearance (Big end)

EM-1074,
1078

Slap or rap

—

Knock

Connecting
rod bearing
noise

Knock

—

Main bearing noise

Main bearing oil clearance
Crankshaft runout

EM-1079,
1077

Tapping or
ticking

—

Timing gear
noise

Timing gear backlash

EM-1042

Squeaking
or fizzing

—

Other drive
belts (Sticking or slipping)

Creaking

Other drive
belts (Slipping)

Front of
engine

Squall
Creak

A: Closely related

B: Related

—

C: Sometimes related

—: Not related

EM-1009

MA section
(“Checking
Drive Belts”,
“ENGINE
MAINTEIdler pulley bearing operation NANCE”)
Drive belts deflection

Water pump
Water pump bearing operabearing
tion
noise

LC section
(“Water
Pump
Inspection”,
“ENGINE
COOLING
SYSTEM”)

MEASUREMENT OF COMPRESSION PRESSURE
TROUBLESHOOTING

SEM318G

1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC section, “Fuel Pressure
Release”.
+ Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and for error detection at the end of this operation.
4. Disconnect the negative battery terminal.
5. Remove the following parts.
+ Intercooler cover
+ Intercooler
+ Throttle body
+ Rocker cover
6. To prevent fuel from being injected during inspection, remove
fuel injection pump fuse [ENG CONT (20A)] from fuse box on
the right side of engine compartment.
7. Remove glow plugs from all the cylinders.
+ Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
+ Carefully remove glow plugs to prevent any damage or
breakage.
+ Handle with care to avoid applying any shock to glow plugs.
8. Install adapter (SST) to installation holes of glow plugs and
connect compression gauge for diesel engine.
: 15 — 19 Nzm (1.5 — 2.0 kg-m, 11 — 14 ft-lb)
9. Connect battery negative terminal.
10. Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine
rpm. Repeat the above steps for each cylinder.
+ Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm

SEM334G

Standard

Minimum

2,942 (29.42, 30.0, 427)/ 2,452 (24.52, 25.0, 356)/
200
200

Difference limit between
cylinders
294 (2.94, 3.0, 43)/200

+ When engine rpm is out of the specified range, check the
specific gravity of battery liquid. Measure again under corrected conditions.
+ If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower surfaces) and measure again.
11. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect battery negative terminal.
c. Replace glow plug oil seals and install glow plugs.
d. Install fuel injection pump fuse [ENG CONT (20A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for
items of self-diagnosis. Refer to EC section, “Trouble Diagnosis — Index”.

EM-1010

INTERCOOLER

Removal and Installation

SEM291G

CAUTION:
To avoid damaging intercooler core when flushing intercooler with high pressure water, apply water straight to the
core face.

EM-1011

INTAKE MANIFOLD

Removal and Installation

SEM292G

REMOVAL
1. Remove the following parts.
+ Drain engine coolant. Refer to MA section, “Changing Engine
Coolant”.
+ Remove engine cover. Refer to the figure at left.
+ Remove intercooler.
+ Remove air hose (on throttle body side).
+ Remove injection tube.
+ Remove or relocate wires/harnesses and tubes/pipes.

EM-1012

INTAKE MANIFOLD
Removal and Installation (Cont’d)

2. Remove intake manifold in the reverse order of that shown
in the figure.

SEM293G

Inspection
Clean surface of intake manifold.
Use a reliable straightedge and feeler gauge to check the flatness of intake manifold surface.
Intake manifold surface flatness:
Limit 0.2 mm (0.008 in)

SEM294G

INSTALLATION
1. Tighten intake manifold in the numerical order shown in the
figure.
: 25 — 28 Nzm (2.5 — 2.9 kg-m, 18 — 20 ft-lb)
2. Install in the reverse order of removal.

EM-1013

CATALYST AND TURBOCHARGER

Removal and Installation

SMA for deletion of water feed hole of
turbocharger. Engine serial number
>ZD-104114A
SMA for engine serial number
>ZD-089395

SEM295G

REMOVAL
1.
+
+
+

SEM296G

Remove the following parts.
Undercover
Under guard
Engine coolant (drain)
Refer to MA section, “Changing Engine Coolant”.
+ Battery (on left side) (for cold areas)
+ Exhaust front tube
Refer to FE section, “Removal and Installation”, “EXHAUST
SYSTEM”.
+ Remove wires, harnesses, tubes and pipes.

EM-1014

CATALYST AND TURBOCHARGER
Removal and Installation (Cont’d)

2. Remove catalyst.
CAUTION:
Do not disassemble catalyst.

Inspection
TURBOCHARGER

SEM297G

CAUTION:
When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in the
following passages in order to prevent a secondary failure:
Suction side: Between turbocharger and intercooler
Exhaust side: Between turbocharger and catalytic
converter

Rotor shaft
+ Check that the rotor shaft rotates smoothly without any resistance when it is rotated by your fingertips.
+ Check that the rotor shaft is not loose when it is moved vertically or horizontally.
Standard value for rotor shaft oil clearance:
0.086 — 0.177 mm (0.0034 — 0.0070 in)

SEM298G

EM-1015

CATALYST AND TURBOCHARGER
Inspection (Cont’d)

Rotor shaft end play
Place a dial gauge at the rotor shaft end in the axial direction to
measure the end play.
Standard: 0.044 — 0.083 mm (0.0017 — 0.0033 in)

SEM299G

Turbine wheel
+ Check that there is no oil adhesion.
+ Check that there is no carbon accumulation.
+ Check that blades of the turbine wheel are not bent or broken.
+ Check that the turbine wheel does not interfere with the turbine housing.

SEM300G

Compressor wheel
+ Check that there is no oil adhesion inside the air inlet.
+ Check that the compressor wheel does not interfere with the
compressor housing.
+ Check that the wheel is not bent or broken.

SEM310G

VNT control actuator

SEM311G

+ Connect the handy pump to the actuator, and check that the
rod strokes smoothly in compliance with the following pressure.
+ First, apply the inspection negative pressure of about −66.7
kPa (−667 mbar, −500 mmHg, 19.69 inHg), and then measure the values while reducing the negative pressure to 0.
Standard (Vacuum pressure/rod stroke amount):
−46.9±1.3 kPa (−469±13 mbar, −352±10 mmHg,
−13.86±0.39 inHg)/0.2 mm (0.008 in)
−30.8±0.7 kPa (−308±7 mbar, −231±5 mmHg,
−9.09±0.20 inHg)/5.0 mm (0.197 in)
Approximately −22.7 kPa (−227 mbar, −170 mmHg,
−6.69 inHg)/Rod stroke end

EM-1016

CATALYST AND TURBOCHARGER
Inspection (Cont’d)
Trouble diagnosis of turbocharger

Preliminary check:
Check that the VNT control valve system has no malfunction.
Refer to EC section, “ECM Terminals and Reference Value” in
“TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”.
+ Check that the engine oil level is between MIN and MAX of
the dipstick. (When the engine oil amount is more than MAX,
the oil flows into the inlet duct through the blow-by gas
passage, and the turbocharger is misjudged failure.)
+ Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
+ Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
+ If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Symptom (when each inspection item
meets each inspection result)

Inspection item

Inspection result
Oil leakage

Smoke

Noise

Insufficient
power/
acceleration
failure

Oil leaks.

Carbon is accumulated.

Friction with housing.

Inside the air inlet is seriously contaminated by oil.

Friction with housing.

Turbine wheel

Blades are bent or broken.

Compressor wheel

Blades are bent or broken.
There is resistance when the rotor shaft
is rotated by your fingertips.
After checking both turbine and compressor,
inspect rotor shaft end play.

The rotor shaft sometimes does not
rotate by your fingertips.
There is too much play in the bearing.

Oil return port

Carbon or sludge is accumulated in the
waste oil hole.

Operation of VNT control actuator

+ The actuator does not operate
smoothly when vacuum pressure is
gradually applied.
+ Stroke amount is not in compliance
with the vacuum pressure.

: Large possibility
j: Medium possibility
n: Small possibility

INSTALLATION
1. Install catalyst.
: 29 — 39 Nzm (2.9 — 3.3 kg-m, 21 — 23 ft-lb)
Place the protruding area of the gasket between the turbocharger and the exhaust outlet upwards, and install the lipped
side to the turbocharger side. Refer to the figure, EM-1014.
2. Install in the reverse order of removal.

EM-1017

EXHAUST MANIFOLD

Removal and Installation

SEM312G

REMOVAL
1. Remove the following parts.
+ Refer to “PREPARATIVE WORK” in “CATALYST AND
TURBOCHARGER”, EM-1014.
+ Remove catalytic converter.
+ Remove turbocharger.

2. Loosen nuts holding the exhaust manifold in the reverse
order of that shown in the figure.

SEM313G

EM-1018

EXHAUST MANIFOLD

Inspection
EXHAUST MANIFOLD
Check distortion on mounting surface with straightedge and
feeler gauge.
Limit: 0.2 mm (0.008 in)

FEM034

INSTALLATION
1. Tighten exhaust manifold holding nuts in the numerical order
shown in the figure.
: 40 — 44 Nzm (4.0 — 4.5 kg-m, 29 — 32 ft-lb)
NOTE:
Install gasket so that the protruding tab (mark for correct
installation) is positioned on the side of No. 1 port (front
side). Refer to component structure diagram on the previous page.
2. Install in the reverse order of removal.

EM-1019

ROCKER COVER

Removal and Installation

SEM315G

REMOVAL
1.
+
+
+
+
+

Remove the following parts.
Engine cover
Intercooler
Air inlet pipe
Throttle body
Wires, harnesses, tubes and pipes

2. Loosen holding bolts in the reverse order of that shown in the
figure and remove.
3. Remove rocker cover to the direction of glow plug tilt.
4. Remove glow plug oil seals.

SEM316G

EM-1020

ROCKER COVER
Removal and Installation (Cont’d)

INSTALLATION
1. Temporarily tighten holding bolts in the numerical order
shown in the figure.

SEM317G

2. Apply Three Bond 1207C (KP510 00150) to the area shown
in the figure.
3. Use a scraper to remove old liquid gasket.
4. Apply once more.
5. Apply engine oil to glow plug oil seals and install them.

FEM001

6. Tighten holding bolts in the numerical order shown in the
figure.
7. Re-tighten to the same torque in the same order as above.

SEM316G

8. Install in the reverse order of removal.

EM-1021

OIL PAN & OIL STRAINER

Removal and Installation

SEM319G

REMOVAL [OIL PAN (LOWER)]
1. Remove the following parts.
+ Remove undercover.
+ Extract the engine oil.

2. Loosen the installation bolts in the reverse order of that
shown in the figure and then remove.
3. Using a seal cutter (SST), cut the liquid gasket to separate
it.

SEM341G

EM-1022

OIL PAN & OIL STRAINER
Removal and Installation (Cont’d)

INSTALLATION [OIL PAN (LOWER)]

SEM159F

1. Install oil pan (Lower).
a. Use a scraper to remove all traces of liquid gasket from
mating surfaces.
+ Also remove traces of liquid gasket from mating surface of oil
pan (Upper).
+ Remove old liquid gasket from the bolt hole and thread.
b. Apply a continuous bead of liquid gasket to mating surface
of oil pan (Lower).
+ Use Genuine Liquid Gasket or equivalent.
+ Apply liquid gasket to the groove on the mating surface.
+ Allow 7 mm (0.28 in) clearance around bolt holes.
c. Apply liquid gasket to inner sealing surface as shown in figure.
+ Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in).
+ Attaching should be done within 5 minutes after coating.
2. Tighten the installation bolts in the order shown in the figure.
3. Install in the reverse order of removal.

SEM345GA

REMOVAL [OIL PAN (UPPER) AND OIL STRAINER]
1.
+
+
+
+

SEM346G

Remove the following parts.
Engine cover
Under covers
Stabilizer; Refer to FA section in original Service Manual.
Exhaust front tube and its bracket; Refer to FE section in
original Service Manual.
+ Front propeller shaft and rear propeller shaft; Refer to PD
section in original Service Manual.
+ Starter motor; Refer to EL section in original Service Manual.
+ A/T or M/T assembly with transfer; Refer to AT section or MT
section in original Service Manual.
NOTE:
As there is a converter/clutch housing side oil pan (upper)
installation bolt as well, the transmission will also need to
be removed.
2. Loosen the installation bolts in the reverse order of that
shown in the figure and then remove.
3. Using a seal cutter (SST), cut the liquid gasket to separate it.
4. Remove oil strainer

SEM159F

INSTALLATION [OIL PAN (UPPER) AND OIL STRAINER]

SEM347GA

1. Clean oil strainer if any object is attached, and install oil
strainer.
2. Install oil pan (Upper).
a. Use a scraper to remove all traces of liquid gasket from
mating surfaces.
+ Also remove traces of liquid gasket from mating surface of
cylinder block, front cover and oil pan (Lower).
+ Remove old liquid gasket from the bolt hole and thread.
b. Apply a continuous bead of liquid gasket to mating surface
of oil pan (Upper).

EM-1023

OIL PAN & OIL STRAINER
Removal and Installation (Cont’d)
+
+
+
c.
+
+
3.
4.

Use Genuine Liquid Gasket or equivalent.
Apply liquid gasket to the groove on the mating surface.
Allow 7 mm (0.28 in) clearance around bolt holes.
Apply liquid gasket to inner sealing surface as shown in figure.
Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in).
Attaching should be done within 5 minutes after coating.
Tighten the installation bolts in the order shown in the figure.
Then tighten in the same order to the torque stated.
The torque of the installation bolts will differ depending on
position.
Measurement below the neck of the installation bolt:
40 mm (1.57 in) (Bolt No. 15, 17 in the figure)
50 mm (1.97 in) (Bolt No. 21 in the figure)
20 mm (Others)
Install in the reverse order of removal.

EM-1024

VACUUM PUMP

Removal and Installation

SEM320G

REMOVAL
1.
+
+
+
+
+
+
+
2.
SEM321G

Remove the following parts.
Radiator under side
Radiator shroud
Cooling fan
Chain cover front side
A/T cooler hose (Disconnect)
Vacuum hose
Intercooler cover (When removing vacuum tank)
Remove the installation bolts and pull the vacuum pump from
the engine front directly.
3. If it is difficult to remove from the spline shaft connection, tap
lightly with a plastic hammer.

EM-1025

VACUUM PUMP
Removal and Installation (Cont’d)

INSPECTION

SEM322G

1. Remove the vacuum hose. Connect the vacuum gauge
through the 3-way connector. Otherwise, remove the welch
valve of the vacuum pipe and attach the vacuum gauge
directly. (The illustration shows the second method.)
+ Remove an appropriate part to measure the vacuum pump
load pressure directly and install the vacuum gauge. Refer to
the figure.
2. Start the engine, and measure the load pressure with the
engine idling.
Vacuum pressure:
Standard
−93.3 to −101.3 kPa (−933 to −1,013 mbar, −700 to
−760 mmHg, −27.56 to −29.92 inHg)
3. If outside the standard value, make sure that there is no
intake of air within the circuit and measure again.
4. Replace the vacuum pump if still outside the standard value.

INSTALLATION
+ Install in the reverse order of removal.

EM-1026

TIMING CHAIN

Removal and Installation

FEM003

CAUTION:
As the internal mechanism of the idler gear must first of all,
and always, be set by a bolt when removing the timing chain
before removing the fuel injection pump and timing gear,
follow the procedures on EM-1039, “Removal of timing
chain after setting idler gear”, “Electronic controlled fuel
injection pump”.
+ This chapter will deal with the summary of removing the timing chain before removing the camshaft and cylinder head.

Removal
1.
+
+
+
+
+
+
+
+
+
+
+
+

Remove the following parts.
Engine cover
Intercooler
Air inlet pipe
Throttle body
Rocker cover
Spill tube
Coolant (Drain)
Radiator upper hose
Water outlet
Radiator shroud
Cooling fan
Auxilary belt

EM-1027

TIMING CHAIN
Removal (Cont’d)
+
+
2.
+
+

Vacuum pipe
Vacuum pump
Move the following parts.
TDC sensor harness
Power steering oil pump

3. Remove the chain cover.
+ Remove the holding bolts A to C shown in the figure.
CAUTION:
While the chain cover is removed, be careful not to allow
entry of dust or foreign objects.

FEM004

4. Set the No. 1 cylinder to the TDC.
1) Turn the crankshaft pulley clockwise, and match the timing
indicator of the gear case to the timing mark of the crankshaft
pulley.

SEM342G

2) Make sure that the cam sprocket match mark is in the position shown in the figure.
+ If the match mark is not in position, turn the crankshaft pulley once more and position it.
+ When removing at No. 1 cylinder TDC, each sprocket and
chain is fitted using the match mark, therefore there is no
need to apply any match marks beforehand.

FEM005

FEM006

5. Remove the chain tensioner.
1) Loosen upper and lower holding bolts.
2) Holding the chain tensioner in your hand, remove the upper
holding bolt and release the spring tension.
3) Remove the lower holding bolt, then remove the chain tensioner.
+ The chain tensioner does not have a mechanism which prevents the ejection of the plunger. (It does have a mechanism
which prevents the plunger from returning.)
CAUTION:
Be careful not to drop the plunger and spring.

EM-1028

TIMING CHAIN
Removal (Cont’d)

SEM335G

6. Remove the timing chain slack guide.
7. Remove the timing chain with cam sprocket.
+ Loosen the cam sprocket holding bolt by fixing the hexagonal portion of the intake manifold side camshaft with a
spanner, etc.
+ If the spill tube is not removed, fix the hexagonal portion of
the exhaust manifold side camshaft.
CAUTION:
Do not loosen the holding bolt by using the tension of the
chain.
8. Remove the timing chain tension guide.

Installation
1. Install the timing chain tension guide.
2. Install the cam sprocket and the timing chain together.
+ Install by aligning the sprocket and timing chain match
marks.
+ Tighten the cam sprocket holding bolt by fixing the hexagonal portion of the camshaft.
CAUTION:
Do not tighten in the holding bolt using the tension of the
chain.
3. Install the timing chain slack guide.
CAUTION:
When the holding bolt is tightened to the specified torque,
there is a gap between the guide and bolt. Do not overtighten.

FEM007

4. Install the chain tensioner.
1) With the chain tensioner in the position shown in the figure
(with the plunger on the outer side), temporarily tighten the
holding bolt.
2) Press the plunger into the tensioner body while pressing on
the clips which prevent the plunger from returning.
3) Install the upper side holding bolt while holding the plunger
down with your finger and rotating it 180 degrees.
4) Tighten the holding bolt to the specified torque.
FEM008

FEM009

5. Install the chain cover.
1) Before installing chain cover, remove all traces of liquid gasket from mating surface using a scraper.
2) Apply a continuous bead of liquid gasket to chain cover.
+ Use Genuine Liquid Gasket or equivalent.
a. Coat of liquid gasket should be maintained within 2.0 to
3.0 mm (0.079 to 0.118 in) dia. range.
b. Attach chain cover to gear case within 5 minutes after
coating.
c. Wait at least 30 minutes before refilling engine oil or
starting engine.

EM-1029

TIMING CHAIN
Installation (Cont’d)

3) Install the chain cover.
+ The dimension below the neck of the holding bolt will vary
depending on the part.
Dimension below the neck:
A: 20 mm (0.79 in)
B: 50 mm (1.97 in)
C: 60 mm (2.36 in)

FEM004

6. Install by following all removal procedures in reverse.
CAUTION:
+ Arrange the TDC sensor harness in the position shown
in the figure.
+ Make sure that the harness has no deflection around the
vicinity of the crankshaft pulley when installing the
clamp.

SEM349G

EM-1030

CAMSHAFT

Removal and Installation

SEM350G

+ This engine will have a different valve arrangement from
normal DOHC 4-valve type engines. As both camshafts on
this engine have intake and exhaust cams, in this chapter
they are named as follows:
Camshaft (Right side): Intake manifold side camshaft
Camshaft (Left side): Exhaust manifold side camshaft
+ The same parts are used for the right and left sides.
+ Refer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
FEM010

Removal
1. Set the No. 1 cylinder at TDC, then remove the chain case,
timing chain and other parts in connection. Refer to “TIMING
CHAIN”, EM-1027.
2. Remove the cam gear.
+ Loosen the cam gear installation bolt by fixing the hexagonal portion of the camshaft.
+ The idler gear cannot be removed at this point as the gear
case is in the way. (The cylinder head can be removed as a
single unit.)
FEM011

EM-1031

CAMSHAFT
Removal (Cont’d)

FEM012

3. Remove injection tube and injection nozzle assembly. Refer
to EC section, “Injection Tube and Injection Nozzle” in
“BASIC SERVICE PROCEDURE”.
4. Remove the camshaft.
+ Place distinguishing marks on the right and left sides with
paint.
+ Loosen and remove the installation bolt in reverse order
shown in the figure.
5. Remove the adjusting shim and valve lifter.
+ Remove by taking notice of the installation position, and
place outside engine in order to prevent confusion.

Inspection
VISUAL CHECK OF CAMSHAFT
+ Check the camshaft for one sided wear or scratches.
+ Replace the camshaft if there are abnormalities.

CAMSHAFT RUNOUT
+ Prepare V-block on a flat surface and secure camshaft journals No. 1 and No. 5.
+ Set the dial gauge vertically on journal No. 3.
+ Rotate camshaft in one direction by hand, then read needle
movement on dial indicator.
Camshaft bend value is 1/2 of needle movement.
Limit: 0.02 mm (0.0008 in)

FEM013

HEIGHT OF CAM NOSE
Measure by using a micrometer.
Standard:
Intake
40.488±0.02 mm (1.5940±0.0008 in)
Exhaust
40.850±0.02 mm (1.6083±0.0008 in)

FEM014

CAMSHAFT OIL CLEARANCE
Measure by using a micrometer.
Cam journal outer diameter:
Standard
29.931 — 29.955 mm (1.1784 — 1.1793 in) dia.

FEM015

EM-1032

CAMSHAFT
Inspection (Cont’d)

CAMSHAFT BRACKET INNER DIAMETER
+ Install camshaft bracket and tighten bolts to the specified
torque.
+ Measure inner diameter of camshaft bracket using an inside
micrometer.
Standard: 30.000 — 30.021 mm (1.1811 — 1.1819 in) dia.

CAMSHAFT OIL CLEARANCE CALCULATIONS

FEM016

Oil clearance = Cam bracket inner diameter − Cam journal outer
diameter
Standard: 0.045 — 0.090 mm (0.0018 — 0.0035 in) dia.
+ If it exceeds the standard value, refer to the standard value
of each unit, then replace the camshaft and/or cylinder head.
+ As the camshaft bracket is manufactured with the cylinder
head, it is impossible to replace only the camshaft bracket.

CAMSHAFT END PLAY
+ Set the dial gauge to the front end of the camshaft. Measure
the end play by moving the camshaft in the direction of the
axle.
Standard: 0.065 — 0.169 mm (0.0026 — 0.0067 in)
Limit: 0.2 mm (0.0079 in)
+ If end play exceeds the limit, replace camshaft and measure
camshaft end play again.
+ If end play still exceeds the limit after replacing camshaft,
replace cylinder head.
FEM017

VISUAL INSPECTION OF VALVE LIFTER
Check lifter side for any signs of wear or damage. Replace if
there are any abnormalities.

VISUAL INSPECTION OF ADJUSTING SHIM
Check cam nose contact and sliding surfaces for wear and
scratches. Replace if there are any abnormalities.

VALVE LIFTER CLEARANCE
Measure the outer diameter of the valve lifter with a micrometer.
Standard: 34.450 — 34.465 mm (1.3563 — 1.3569 in) dia.

FEM018

EM-1033

CAMSHAFT
Inspection (Cont’d)

VALVE LIFTER BORE DIAMETER
Measure the bore diameter of the cylinder head valve lifter with
an inside micrometer.
Standard: 34.495 — 34.515 mm (1.3581 — 1.3589 in) dia.

FEM019

VALVE LIFTER CLEARANCE CALCULATIONS
Clearance = Valve lifter bore diameter − Valve lifter outer diameter
Standard: 0.030 — 0.065 mm (0.0012 — 0.0026 in)
If it exceeds the standard value, refer to the outer diameter and
bore diameter standard values and replace valve lifter and/or
cylinder head.

Installation
1. Install the valve lifter and adjusting shim.
+ Make sure that these are installed in the same position as
before the removal process.
2. Install the camshaft.
+ Follow the distinguishing marks that were placed on in the
removal process.
+ Face the key in the direction shown in the figure.
FEM020

3. Install the camshaft bracket.
+ Refer to the camshaft bracket upper side journal No. and
install.
+ Looking from the exhaust manifold side (left side of engine),
install in the direction that the journal number can be read
correctly.
+ Place baffle plate onto upper face of No. 1 camshaft bracket,
and tighten together.

FEM021

4. Tighten the installation bolts in numerical order in the figure.
1) Tighten to 10 to 14 Nzm (1.0 to 1.5 kg-m, 8 to 10 ft-lb).
+ Make sure that the thrust portion of the camshaft is fitted
properly in the head installation side.
2) Tighten to 20 to 23 Nzm (2.0 to 2.4 kg-m, 15 to 17 ft-lb).

FEM012

EM-1034

CAMSHAFT
Installation (Cont’d)

5. Install the cam gear.
+ Align the match marks, and install the idler gear and each
cam gear to the position shown in the figure.
+ Tighten the cam gear installation bolt by fixing the hexagonal portion of the camshaft.

FEM023

6. Install the timing chain, all other related parts and chain
cover.
Refer to “TIMING CHAIN”, EM-1027.
7. After installing the timing chain, check and adjust the valve
clearance before installing the spill tube.
Refer to “VALVE CLEARANCE”, EM-1036.
8. Install in the reverse order of removal.

EM-1035

VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTS
Inspection

FEM010

+ When the camshaft or parts in connection with valves are
removed or replaced, and a fault has occurred (poor starting,
idling, or other faults) due to the misadjustment of the valve
clearance, inspect as follows.
+ Inspect and adjust when the engine is cool (at normal temperature).
+ Be careful of the intake and exhaust valve arrangement. (The
valve arrangement is different from that in a normal engine.)
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
1. Remove the following parts.
+ Intercooler cover
+ Intercooler
+ Rocker cover
2. Set the No. 1 cylinder at TDC.
1) Rotate the crankshaft pulley clockwise, and align the TDC
mark of the crankshaft pulley with the timing indicator of the
TDC sensor bracket.

SEM342G

2) Confirm that the cam nose of the No. 1 cylinder and the
knock pin of the cam sprocket is in the position shown in the
figure.
+ Rotate the crankshaft pulley again if not in the position shown
in the figure.

FEM024

3. While referring to the figure, measure the valve clearance in
the circled area of the table below.
No. 1

No. 2

No. 3

No. 4

Measuring point
When the No. 1
cylinder is in the
TDC

INT

EXH

INT

EXH

INT

EXH

INT

EXH

+ The injection order is 1-3-4-2.
FEM025

+ Measure the valve clearance using a JIS high grade feeler
gauge when the engine is cool (at normal temperature).
Standard:
Intake and exhaust
0.35±0.05 mm (0.0138±0.0020 in)
4. Set the No. 4 cylinder at TDC by rotating the crankshaft
clockwise once.

FEM026

EM-1036

VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTS
Inspection (Cont’d)

5. While referring to the figure, measure the valve clearance in
the circled area of the table below.
No. 1

No. 2

No. 3

No. 4

Measuring point
INT
When the No. 4
cylinder is in the
TDC

EXH

INT

EXH

INT

EXH

INT

EXH

6. If the valve clearance is outside the specification, adjust as
follows.
FEM027

Adjustments

FEM028

+ Remove the adjusting shim for parts which are outside the
specified valve clearance.
1. Remove the spill tube.
2. Extract the engine oil on the upper side of the cylinder head
(for the air gun used in step 7).
3. Rotate the crankshaft to face the cam for adjusting shims that
are to be removed upward.
4. Grip the camshaft with camshaft pliers (SST), the using the
camshaft as a support point, push the adjusting shim downward to compress the valve spring.
CAUTION:
Do not damage the camshaft, cylinder head, or the outer
circumference of the valve lifter.

5. With the valve spring in a compressed state, remove the
camshaft pliers (SST) by securely setting the outer circumference of the valve lifter with the end of the lifter stopper
(SST).
+ Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as the camshaft will be damaged.

FEM029

6. Move the rounded hole of the adjusting shim to the front with
a very thin screwdriver.
+ When the adjusting shim on the valve lifter will not rotate
smoothly, restart from step 4 with the end of the lifter stopper (SST) touching the adjusting shim.
7. Remove the adjusting shim from the valve lifter by blowing
air through the rounded hole of the shim with an air gun.
CAUTION:
To prevent any remaining oil from being blown around, thoroughly wipe the area clean and wear protective goggles.
FEM030

EM-1037

VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTS
Adjustments (Cont’d)
8. Remove the adjusting shim by using a magnetic hand.

FEM031

FEM032

9. Measure the thickness of the adjusting shim using a
micrometer.
+ Measure near the center of the shim (the part that touches
the cam).
10. Select the new adjusting shim from the following methods.
Calculation method of the adjusting shim thickness:
t = t1 + (C1 − C2)
t = Adjusting shim thickness
t1 = Thickness of the removed shim
C1 = Measured valve clearance
C2 = Specified valve clearance
[when the engine is cool (at normal temperature)]
0.35 mm (0.0138 in)

+ New adjusting shims have the thickness stamped on the rear
side.

FEM033

Stamped

Shim thickness

2.35
2.40
.
.
.
3.05

2.35 (0.0925)
2.40 (0.0945)
.
.
.
3.05 (0.1201)

mm (in)

+ The thickness of the adjusting shim ranges from 2.35 to 3.05
mm (0.0925 to 0.1201 in), where in the space of 0.05 mm
(0.0020 in). There are 15 types of shims available.
11. Fix the selected adjusting shim to the valve lifter.
CAUTION:
Place the stamped side of the adjusting shim to the valve
lifter.
12. Compress the valve spring using the camshaft pliers and
remove the lifter stopper (SST).
13. Rotate the crankshaft 2 to 3 times by hand.
14. Confirm that the valve clearance is within the specification.

EM-1038

TIMING GEAR
Removal and Installation
2 idler gears are shown in this chapter. Idler gear (A) has scissors gear, and idler gear (B) does not.

SEM314GA

EM-1039

TIMING GEAR

Removal
1.
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
2.
3.

SEM376G

Remove the following parts.
Undercover
Engine oil (Drain)
Engine coolant (Drain)
Engine cover
Intercooler
Air inlet pipe
Air cleaner case
Throttle body
Swirl and intake air control valve control solenoid valve and
bracket
Vacuum tank
Glow plate
Rocker cover
Spill tube
Radiator shrouds (Rear and Lower)
Cooling fan
Radiator hose (Upper and Lower)
Auxiliary belt and auto tensioner.
Remove the alternator.
Remove the A/C compressor and bracket with piping connected. Move and support it at the LH side of engine bay with
a rope to avoid putting load on piping.
Refer to HA section in Nissan Service Manual (Supplement
I: Publication No. SM0E-Y61AE0E.)

4. Remove the chain cover, timing chain and other parts in
connection.
Before removing timing chain, remove injection pump
sprocket with No.1 cylinder being positioned at TDC. Refer
to the figure.
Refer to “TIMING CHAIN”, EM-1027.
CAUTION:
After removing timing chain, never rotate crankshaft, or the
piston will push the valve up and damage the valve.
+ Do not paint the match mark on the timing chain beforehand
as the No. 1 cylinder is set at the TDC during assembly.
5. Remove the TDC sensor.
CAUTION:
+ Do not drop or hit the sensor.
+ Store in a clean place free of iron filings, etc.
+ Do not place near any magnetic equipment.
6. Remove the water pump and its stud bolts.
Refer to “WATER PUMP” in LC section.
7. Remove the water inlet.

EM-1040

TIMING GEAR
Removal (Cont’d)

8. Remove the crankshaft pulley.
+ To fix the crankshaft, remove the starter motor and set ring
gear stopper (SST).
CAUTION:
+ Do not damage or magnetize the signal detection protrusions of the crankshaft pulley.
+ After removing timing chain, never rotate crankshaft, or
the piston will push the valve up and damage the valve.

FEM051

9. Remove the gear case.
+ Using the grooved places shown in the figure, remove the
gear case by using a screwdriver and a seal cutter (SST).
10. Remove the front oil seal from the gear case by using a
screwdriver.
CAUTION:
Do not damage the gear case.

FEM052

SEM377G

11. Fix the internal mechanism setting bolt [part No.: 81-2062028, screw dia.: M6, dimension below neck: 20 mm (0.79 in)]
to the bolt hole of the idler gear (A) and tighten to the specification.
: 2.5 — 3.4 Nzm (0.25 — 0.35 kg-m, 22 — 30 in-lb)
CAUTION:
+ Only use the genuine setting bolt, or the idler gear (A)
will be damaged.
+ Do not rotate the crankshaft as the head of the setting
bolts interferes with the gear case.
+ Do not remove the setting bolt from the idler gear (A)
until the timing chain and all of the parts in connection
have been installed.
+ If these bolts are not installed, internal mechanism will
disengage after the idler gear is removed. This will prohibit the idler gear from being reusable.

EM-1041

TIMING GEAR
Removal (Cont’d)

12. Remove the idler gears (A) and (B).
+ Check the backlash of each gear before removing. Refer to
“BACKLASH OF EACH GEAR”, “Inspection”.
CAUTION:
+ Do not loosen the internal mechanism setting bolt of the
idler gear (A). (The idler gear cannot be reused when the
internal mechanism is released.)
+ During removal of the idler gears (A) and (B), do not face
the rear side downward as the idler shaft will drop.
SEM348G

13. Set the fuel injection timing gear with the pulley holder (SST).
14. Remove injection pump timing gear.

SEM378G

15. Extract the balancer shaft taking care not to damage the
inner bushes of the cylinder block.
16. Remove the fuel injection pump.
17. Remove the front plate.

SEM352G

Inspection
BACKLASH OF EACH GEAR
Method using a fuse wire
+ Tighten the holding bolts of each gear to specification.
+ Place a wire in the biting area of the teeth between the gears
to be checked, rotate the crankshaft in the operating direction so that the wire is taken inwards.
+ Measure the crushed area of the wire with a micrometer.
FEM035

Method using dial gauge

FEM036

+ Tighten the holding bolts of each gear to specification.
+ Place the dial gauge on the tooth surface area of the gear to
be checked.
+ With the other gear in a set position, measure the dial gauge
value while moving the gear left and right.
Standard: 0.07 — 0.11 mm (0.0028 — 0.0043 in)
Limit: 0.20 mm (0.0079 in)
+ If it exceeds the limit, replace the gear and measure again.
+ If it exceeds the limit again, check for the installation condition of
the gear driving parts, wear of shaft and gear, and oil clearance.

EM-1042

TIMING GEAR
Inspection (Cont’d)
IDLER GEAR END PLAY

+ Tighten the holding bolts to the specification.
+ Measure the clearance between the gear plate and idler gear
using a feeler gauge.
Unit: mm (in)

Idler gear (A)
Idler gear (B)

Standard

Limit

0.06 — 0.12
(0.0024 — 0.0047)

0.15 (0.0059)

+ If it exceeds the limit, replace the idler gear, shaft, and gear
plate.

IDLER GEAR OIL CLEARANCE

FEM037

+ Measure the inner diameter (d1) of the idler gear shaft.
Standard:
Idler gear (A)
43.000 — 43.020 mm (1.6929 — 1.6937 in) dia.
Idler gear (B)
28.600 — 28.620 mm (1.1260 — 1.1268 in) dia.
+ Measure the outer diameter (d2) of the idler shaft.
Standard:
Idler gear (A)
42.959 — 42.975 mm (1.6913 — 1.6919 in) dia.
Idler gear (B)
28.567 — 28.580 mm (1.1247 — 1.1252 in) dia.
+ Calculate the oil clearance.
Clearance = d1 − d2
Unit: mm (in)
Standard
Idler gear (A)

0.025 — 0.061
(0.0010 — 0.0024)

Idler gear (B)

0.020 — 0.053
(0.0008 — 0.0021)

Limit

0.2 (0.0079)

+ If it exceeds the limit, refer to each standard specification and
replace the idler gear and/or shaft.

BALANCER SHAFT END PLAY
+ Measure the clearance between the plate and gear using a
feeler gauge.
Standard: 0.07 — 0.22 mm (0.0028 — 0.0087 in)
+ If it exceeds the specification, replace the balancer shaft
assembly.
+ As the gears are press-fitted, there are no setting for individual parts.

FEM038

EM-1043

TIMING GEAR
Inspection (Cont’d)

BALANCER SHAFT OIL CLEARANCE
Outer diameter of balancer shaft journal
Measure the outer diameter of the balancer shaft journal with a
micrometer.
Standard:
Front side
50.875 — 50.895 mm (2.0029 — 2.0037 in) dia.
Rear side
50.675 — 50.695 mm (1.9951 — 1.9959 in) dia.
FEM039

Inner diameter of balancer shaft bearing
Measure the inner diameter of the balancer shaft bearing using
a bore gauge.
Standard:
Front side
50.940 — 51.010 mm (2.0055 — 2.0083 in) dia.
Rear side
50.740 — 50.810 mm (1.9976 — 2.0004 in) dia.

Oil clearance calculations
FEM040

Oil clearance = Bearing inner diameter − Journal outer diameter
Standard: 0.045 — 0.135 mm (0.0018 — 0.0053 in)
Limit: 0.180 mm (0.0071 in)

BALANCER SHAFT BEARING REMOVAL AND
INSTALLATION

SEM993BA

1. Remove balancer shaft front bearing.

SEM380G

EM-1044

TIMING GEAR
Inspection (Cont’d)

2. Using Tool, remove balancer shaft rear bearing from engine.

SEM381G

3. Install the rear and front balancer shaft bearings.
+ Install from the cylinder block hole to the rear journal and
then the front journal.
+ Install the groove of the balancer shaft bearing facing the
front and the under right direction.
(Align the guide plate and bar knock pin and then force in the
balancer shaft bearing.)

SEM382G

+ Align the balancer shaft bearing groove with the knock pin of
the bar (SST) and install the balancer shaft bearing.)

SEM383G

+ On rear journals, so the bearing does not get out of position,
wrap tape around the bar.

EMV0514D

EM-1045

TIMING GEAR
Inspection (Cont’d)

+ Make an alignment mark 11.0±0.8 mm (0.433±0.031 in) from
the bar No. 2 engraved line with a marker pen. This alignB will be the point to where the rear bearing is
ment mark V
pushed.

SEM385G

+ Insert the bar with the bearing installed into the cylinder block
and install the guide plate (SST).
+ Align the guide plate with the ZD engraving and install the
bolts.
CAUTION:
Use a washer of the same thickness used on the front plate
to prevent the guide plate from bending.

SEM384G

B to the same posi+ Push the engraved bar alignment mark V
A .
tion of the guide plate tip V
+ After all the journals have been installed, make sure that all
the journal and cylinder block oil holes are aligned.

SEM386G

4. Install the front balancer shaft bearing.
+ Align the journal and cylinder block oil holes.
+ Use a drift (SST) to force in the tip of the journal to 8.0±0.3
mm (0.315±0.012 in) inside the cylinder block.
+ After installing the journal, make sure that the journal and
cylinder block oil holes are aligned.

SEM380G

EM-1046

TIMING GEAR

SEM387G

Installation

SEM206H

1. Install the front plate.
1) Install the O-ring and gasket to the cylinder block.
+ Apply liquid gasket uniformly and thinly to the front and
reverse sides of gasket.
Use Genuine Liquid Gasket or equivalent.
2) Install the front plate.
+ Before installing, apply liquid gasket to the mating surfaces
of the cylinder block and the oil pan (upper).
Use Genuine Liquid Gasket or equivalent.
+ Lightly tap with a hammer if the dowel pin cannot be inserted
easily.
CAUTION:
Make sure that the O-ring does not pop out.

SEM207H

2. Install the fuel injection pump.
+ After installing the front plate, align the 6 mm (0.24 in) dia.
hole of the pump flange and the 6 mm (0.24 in) dia. hole
position of the pump body.
3. Install each timing gear.
+ Align the match marks of the timing gears by referring to the
figure below.
1 ,V
2 ) shown
+ When installing timing gear, follow the order (V
in the dotted box in the figure below to facilitate installation.
FEM042

EM-1047

TIMING GEAR
Installation (Cont’d)

FEM043

4. Install the front oil seal to the gear case.
+ Apply engine oil to the fitting side.
+ Evenly insert the front oil seal using a drift [outer dia.: approx.
64 mm (2.52 in)] completely.
CAUTION:
Make sure the oil seal does not spill off the end side of the
gear case.

FEM044

5. Install the gear case.
1) Before installing gear case, remove all traces of liquid gasket from mating surface using a scraper.
2) Align gasket with dowel and install.

SEM353G

FEM045

3) Install the O-rings to the gear case.
+ The O-ring at the top position shown in the figure can be
installed in during cylinder head installation.
4) Apply a continuous bead of liquid gasket to gear case and oil
pan (upper).
+ Use Genuine Liquid Gasket or equivalent.
a. Coat of liquid gasket should be maintained within the
specified range as shown in the figure.
b. Attach gear case to cylinder block within 5 minutes after
coating.
c. Wait at least 30 minutes before refilling engine oil or
starting engine.

EM-1048

TIMING GEAR
Installation (Cont’d)

CAUTION:
Apply the liquid gasket around the bolt holes shown by the
arrows in the figure.

SEM208H

5) Install the gear case.
+ Insert the gear case diagonally to prevent it from dragging
over the liquid gasket applied on the timing gear case and the
oil pan (upper).
+ Align the dowel pin at the lower position of cylinder block with
the hole on the gear case side.
+ Tap the area around the dowel pin with a plastic hammer if
it cannot be inserted easily.
CAUTION:
Do not pop out the O-rings.
SEM209H

6) Install the holding bolt referring to the figure.
Dimension below neck:
A: 25 mm (0.98 in)
B: 30 mm (1.18 in)
C: 50 mm (1.97 in)
D: 80 mm (3.15 in)
E: 20 mm (0.79 in)
7) Install the holding bolts from the rear side of the front plate.

FEM046

6. Install the crankshaft pulley.
+ Insert by aligning the 2 sides of the oil pump with the 2 sides
of the shaft on the rear side of the crankshaft pulley.
CAUTION:
Do not damage the oil seal lip when inserting.
+ Refer to EM-1041, “Removal” for the crankshaft setting procedures when tightening the holding nut.
7. Install the water pump.
+ Install it before installing the TDC sensor. Refer to “Water
Pump” in LC section.

SEM349G

8. Install the TDC sensor.
+ Align the bracket knock pin with the hole on the gear case
side and tighten the holding bolt.
+ Confirm that the clearance between the end of the sensor
and the signal detection protrusion of the crankshaft pulley is
within the specification.
Standard: 1±0.8 mm (0.039±0.031 in)
+ Arrange the TDC sensor harness to the position shown in the
figure.
CAUTION:
Confirm that the harness has no deflection around the
crankshaft pulley when installing the clamp.

EM-1049

TIMING GEAR
Installation (Cont’d)

9. Install the timing chain, other parts in connection with the
timing chain, and the chain cover. Refer to EM-1027, “TIMING CHAIN”.

10. Remove the internal mechanism setting bolt of the idler gear
(A).
11. Apply liquid gasket to the plug thread.
12. Install in the reverse order of removal.

FEM047

EM-1050

OIL SEAL REPLACEMENT

VALVE OIL SEAL
1. Remove timing chain. Refer to EM-1027, “TIMING CHAIN”.
2. Remove injection nozzle assembly. Refer to “Injection Tube
and Injection Nozzle” in “BASIC SERVICE PROCEDURE” in
EC section.
3. Remove camshaft. Refer to EM-1031, “CAMSHAFT”.

SEM354G

4. Remove valve lifters and mark order No. on each lifter.
5. Replace valve oil seal according to the following procedure.
When replacing valve oil seal, set the corresponding piston
at TDC. Failure to do so causes the valve to drop into the
cylinder.
1) Set No. 1 cylinder at TDC.

SEM355G

2) Remove valve springs and valve oil seals for No. 1 and No.
4 cylinders. Valve spring seats should not be removed.

SEM356G

3) Install new valve oil seals for No. 1 and No. 4 cylinders as
illustrated. Reinstall valve springs. (pink paint side toward
cylinder head)
4) Install valve spring retainers on intake valves and valve rotators on exhaust valves, and remount valve assembly.
5) Set No. 2 cylinder at TDC.
6) Replace valve oil seals for No. 2 and No. 3 cylinders according to steps 2) and 3).
7) Install valve lifters in original positions.
SEM357G

CRANKSHAFT OIL SEAL INSTALLING DIRECTION
AND MANNER
+ When installing crankshaft oil seals, be careful to install
them correctly, as shown in the figure.
+ Wipe off excess oil after installing oil seal.

SEM715A

EM-1051

OIL SEAL REPLACEMENT

CRANKSHAFT FRONT OIL SEAL
1. Remove the front cover. Refer to “TIMING GEAR”.
2. Remove front oil seal with a suitable tool.

SEM358G

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

FEM044

CRANKSHAFT REAR OIL SEAL
1.
2.
3.
4.

Remove
Remove
Remove
Remove

oil pan assembly. Refer to EM-1022, “OIL PAN”.
clutch cover assembly.
flywheel and rear plate.
oil seal retainer assembly.

5. Apply a continuous bead of liquid gasket to rear oil seal
retainer.
a. Coat of liquid gasket should be maintained within 2.0 to
3.0 mm (0.079 to 0.118 in) dia. range.
b. Attach oil seal retainer to cylinder block within five minutes after coating.
c. Wait at least 30 minutes before refilling engine oil or
starting engine.
d. Use Genuine Liquid Gasket or equivalent.
SLC822

FEM053

EM-1052

CYLINDER HEAD

Removal and Installation

SEM359G

Removal

FEM054

1. Remove the following. (Refer to corresponding chapter for
detailed auxiliary work.)
+ Drain coolant
+ Rocker cover
+ Injection tube
+ Spill tube
+ High pressure injection nozzle assembly
+ Timing chain
+ Camshaft
+ Catalytic converter
+ Turbocharger assembly
+ Exhaust manifold
2. Remove mounting bolts of the gear case and water pump as
shown by arrows in the figure.
3. Remove oil return pipe from the rear side of cylinder head.
4. Remove intake manifold.

EM-1053

CYLINDER HEAD
Removal (Cont’d)

FEM055

SEM379G

5. Remove cylinder head assembly.
+ Loosen and remove mounting bolts in the reverse order
shown in the figure.
+ Lift up the cylinder head assembly to avoid interference with
dowel pins located between the block and head, and remove
cylinder head assembly.
CAUTION:
+ Do not drop the O-ring located between the front of cylinder head and the rear of gear case into the engine.
+ Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of the cylinder head, or, place wood blocks beneath both ends of
the cylinder head to keep the cylinder bottom from any
contact.

+ For glow plug removal, the following shall be noted.
CAUTION:
+ To avoid breakage, do not remove glow plug unless necessary.
+ Perform continuity test with glow plug installed.
+ Keep glow plug from any impact. (Replace if dropped
from a height 10 cm (3.94 in) or higher.)
+ Do not use air impact wrench.
6. Remove idler gear.
CAUTION:
While removing idler gear, keep the rear of idler gear facing
up to prevent idler shaft from falling.

Inspection

CYLINDER HEAD BOLT DEFORMATION
(ELONGATION)
+ Using micrometer, measure the outer diameters d1 and d2
of bolt thread as shown in the figure.
+ If the necking point can be identified, set it as measuring
point d2.
+ Calculate the difference between d1 and d2.
Limit: 0.15 mm (0.0059 in)
FEM056

IDLER GEAR END PLAY
+ Tighten mounting bolts to the specified torque.
+ Using feeler gauge, measure the clearance between gear
plate and idler gear.
Standard: 0.07 — 0.14 mm (0.0028 — 0.0055 in)
Limit: 0.2 mm (0.0079 in)
+ If the measured value exceeds the limit value, replace idler
gear, shaft, and gear plate.

EM-1054

CYLINDER HEAD
Inspection (Cont’d)
IDLER GEAR OIL CLEARANCE

+ Measure the inner diameter (d1) of idler gear shaft hole.
Standard: 26.000 — 26.020 mm (1.0236 — 1.0244 in)
+ Measure the outer diameter (d2) of idler shaft.
Standard: 25.967 — 25.980 mm (1.0223 — 1.0228 in)
+ Calculate gear clearance.
Clearance = d1 − d2
Standard: 0.023 — 0.053 mm (0.0009 — 0.0021 in)

FEM057

Installation
1. Install cylinder head gasket.
+ Cylinder head gasket to be installed is selected by its thickness through the following procedure.

When replacing gasket only
+ Install gasket with same thickness as the one removed.
+ Gasket thickness is identified by the number of notches
located on rear-left side.
FEM058

Grade

Gasket thickness*
mm (in)

No. of notches

0.65 (0.0256)

0.70 (0.0276)

*: Thickness of gasket tightened with head bolts

+ The number of notches can be checked at the position
shown in the figure before cylinder head is removed. (It is
necessary to remove exhaust manifold.)

When repairing/replacing the following

FEM059

+ When the top of cylinder block or crankshaft pin/journal is
ground, or
+ When cylinder block, piston, connecting rod, or crankshaft is
replaced
1) Move piston toward TDC.
2) Position dial indicator on cylinder block as shown in the
figure, and adjust the needle to “0”.
3) Move dial indicator stand aside, and position the dial indicator to the measuring point as shown in the figure.
4) Rotate crankshaft slowly, and read the value on dial indicator at piston’s maximum height.
5) Repeat above procedure at 2 positions of each cylinder (8
positions in total for 4 cylinders), and select the appropriate
gasket by comparing the maximum crown depression with
the table.

FEM060

EM-1055

CYLINDER HEAD
Installation (Cont’d)
Grade

Piston crown
depression

Gasket thickness*1

No. of notches

Less than −0.078
(−0.0031)*2

0.65 (0.0256)

More than −0.078
(−0.0031)*3

0.70 (0.0276)

*1: Thickness of gasket tightened with head bolts
*2: Indicates values such as −0.080 mm (−0.0031 in).
*3: Indicates values such as −0.075 mm (−0.0030 in).

2. Install idler gear and idler shaft.
+ Check that the counter marks with cam gear, “AA” and “BB”,
are located on the front side of the engine.
Refer to EM- 1053.
CAUTION:
Since idler gear cannot be installed or removed with cylinder head assembly mounted on the engine because of interference with gear case, make sure that there are no reverse
installations or uninstalled parts.

3.
1)
2)
3)

Install cylinder head assembly.
Attach gasket onto the rear of gear case.
Install O-ring to the rear of gear case.
Align cylinder head assembly with dowel pin of cylinder block
and install.
CAUTION:
+ Make sure the O-ring does not fall off. Be careful not to
drop the O-ring.
+ Do not damage gasket located at the front.
FEM061

4. Position cylinder head assembly close to the rear of the gear
case.
1) Install cylinder head bolts to the front and rear of cylinder
head respectively, and tighten to the specified torque.
: 40 — 49 Nzm (4.0 — 5.0 kg-m, 29 — 36 ft-lb)
2) Loosen cylinder head bolts completely.
3) Install gear case mounting bolts to 2 positions shown by
arrows in the figure, and tighten to the specified torque.
: Less than 9.8 Nzm (1.0 kg-m, 7 in-lb)
FEM062

FEM055

5. Tighten cylinder head bolts in the order indicated in the figure.
1) Apply engine oil to installation bolt threads and washers.
2) Tighten bolts to 98 to 102 Nzm (10.0 to 10.5 kg-m, 73 to 75
ft-lb).
3) Loosen bolts completely until the torque becomes 0 Nzm (0
kg-m, 0 in-lb).
CAUTION:
For procedure 3), loosen bolts in the reverse order as indicated in the figure.
4) Tighten bolts to 40 to 44 Nzm (4.0 to 4.5 kg-m, 29 to 32 ftlb).

EM-1056

CYLINDER HEAD
Installation (Cont’d)

5)Tighten bolts at the angle of 90 to 95° (target is 95°). (Angle
tightening)
6) Once again, tighten bolts at the angle of 90 to 95° (target is
95°). (Angle tightening)
CAUTION:
Perform the following procedure to check turning angle of
angle tightening, and do not judge by visual check.

ANGLE TIGHTENING PROCEDURE
With protractor
+ Make counter marks on the bolt head of cylinder head and
cylinder head surface with paint, and check the turning angle.

With angle wrench (SST)
+ Check the turning angle using angle indicator of angle
wrench.
6. Loosen gear case mounting bolts which were tightened in 3)
of procedure 4, retighten them to the specified torque.
FEM063

7. Install glow plug.
+ 2 different types (manufacturers) of glow plugs are provided
in parallel. (Refer to the figure for identification.)
+ Do not install 2 different types of glow plugs in the engine.
Make sure that the same glow plugs are installed.
+ Using reamer, remove the carbon adhering to the installation
hole of glow plug, and install glow plug.

FEM064

EM-1057

CYLINDER HEAD
Installation (Cont’d)

8. Install oil return pipe to the rear side of the cylinder head.
+ When reinstalling a stud bolt, apply Three Bond 1207C
(KP510 00150) to the thread of the bolt.

FEM081

Disassembly
1. Remove adjusting shims and valve lifters.
Check the installation positions, and keep them to avoid
being confused.
2. Using valve spring compressor (SST), compress valve
spring. Using magnetic hand, remove valve collets.
3. Remove valve spring retainers and valve springs.
4. Remove valves as pressing valve stems toward combustion
chamber.
SEM361G

+ Before removing the valve, check the valve guide clearance.
(Refer to next page.)
+ Check installation positions, and keep them to avoid being
confused.
+ Refer to the figure for intake/exhaust valve positions. (Intake
and exhaust valve driving cams are provided alternately for
each camshaft.)

FEM010

EM-1058

CYLINDER HEAD
Disassembly (Cont’d)

5. Remove valve oil seals using valve oil seal puller (SST).
6. Remove valve spring seats.
7. Before removing valve spring seats, perform valve seat contact check. (Refer to EM-1061.)
8. Before removing valve guides, perform valve guide clearance check. (Refer to below.)

FEM065

Inspection
CYLINDER HEAD DISTORTION
Using straightedge and feeler gauge, check the bottom of the
cylinder head for distortion.
Limit: 0.2 mm (0.008 in)

FEM066

VALVE DIMENSION
Using micrometer, measure the dimensions of each part.
Standard
Unit: mm (in)
Intake valve

Exhaust valve

113.5 (4.4685)

1.5 (0.0591)

φd

6.962 — 6.977
(0.2741 — 0.2747)

6.945 — 6.960
(0.2734 — 0.2740)

φD

31.9 — 32.1
(1.2559 — 1.2638)

29.9 — 30.1
(1.1772 — 1.1850)

45°00′ — 45°30′

FEM067

α (degree)

VALVE GUIDE CLEARANCE
+ Perform the inspection before removing valve guides.
+ Check that the valve stem diameter is within specifications.
+ Push valve approximately 25 mm (0.98 in) toward combustion chamber, move valve toward dial indicator to measure
valve movement.
+ Valve guide clearance is 1/2 of movement on dial indicator.

FEM068

EM-1059

CYLINDER HEAD
Inspection (Cont’d)

Unit: mm (in)
Standard

Limit

Intake

0.023 — 0.053
(0.0009 — 0.0021)

0.18 (0.0071)

Exhaust

0.040 — 0.070
(0.0016 — 0.0028)

0.10 (0.0039)

+ If the measured value exceeds the limit, replace valve guide.

VALVE GUIDE REPLACEMENT
+ There is no setup for oversized valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath.

FEM069

2. Using valve guide drift (multi-purpose tool: for 7.0 mm dia.),
tap valve guides out from the combustion chamber side.

FEM070

3. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath.
4. Using valve guide drift (multi-purpose tool: for 7.0 mm dia.),
press fit valve guides from camshaft side, referring to the
dimension shown in the figure.

FEM071

5. Using valve guide reamer (multi-purpose tool), perform
reaming to the press-fitted valve guides.
Reaming specifications:
Intake/Exhaust
7.000 — 7.015 mm (0.2756 — 0.2762 in)

FEM072

EM-1060

CYLINDER HEAD
Inspection (Cont’d)

VALVE SEAT CONTACT
Check valve for any evidence of pitting at valve contact surface,
and reseat or replace if worn out excessively.
+ When repairing valve seats, check valve and valve guide
for wear beforehand. If worn, replace them. Then correct
valve seat.
+ The cutting should be done with both hands for uniform
cutting.

FEM073

VALVE SEAT REPLACEMENT
+ When removing valve seat, replace it with oversized [0.5 mm
(0.0020 in)] valve seat.
1. Cut valve seat to make it thin, and pull it out.

FEM074

2. Machine cylinder head inner diameter at valve seat installation position.
Machining dimension:
Intake
33.500 — 33.515 mm (1.3189 — 1.3195 in) dia.
Exhaust
31.995 — 32.010 mm (1.2596 — 1.2602 in) dia.
3. Heat cylinder head to approximately 110 to 130°C (230 to
266°F) in oil bath.
4. After cooling valve seats sufficiently with dry ice, press fit it
to cylinder head.
CAUTION:
Do not touch the cooled valve seats directly by hand.

5. Using valve seat cutter (multi-purpose tool), finish processing referring to the dimensions shown in the figure.
CAUTION:
When using valve seat cutter, grasp cutter handle with both
hands, press cutter onto contacting face all around, and cut
thoroughly. If cutter is pressed unevenly or repeatedly, the
valve seat surface may be damaged.
6. Using compound, perform valve fitting.
7. Check again to make sure that contacting status is satisfactory.
FEM075

EM-1061

CYLINDER HEAD
Inspection (Cont’d)

For details, Refer to EM-1088, “Valve Seat” in “SERVICE DATA
AND SPECIFICATIONS (SDS)”.

FEM076

VALVE SPRING RIGHT ANGLE
Position a straightedge to valve spring, turn the spring, and measure the maximum clearance value between top surface of
spring and the straightedge
Limit: 2.4 mm (0.0945 in)

FEM077

VALVE SPRING FREE LENGTH AND COMPRESSIVE
LOAD
Using valve spring tester, check the following.
Free length: 55.43 mm (2.1823 in)
Installation height: 40.8 mm (1.6063 in)
Installation load: 180 — 206 N (18.4 — 21.0 kg, 40.6 46.3 lb)
Height at valve open: 32.3 mm (1.2717 in)
Load at valve open: 336 — 372 N (34.3 — 37.9 kg, 75.6 83.6 lb)
FEM078

Assembly
1. Install valve guides, referring to EM-1061, “VALVE SEAT
REPLACEMENT”.
2. Install valve seats, referring to EM-1061, “VALVE SEAT
CONTACT”.

3. Using valve oil seal drift (SST), install valve oil seals referring to the dimension shown in the figure.
+ The figure shows the dimension before valve spring seats
are installed.
4. Install valve spring seats.
5. Install valves.
+ Install the valves with bigger openings to intake valve side.
+ Note that valve layout here is different from that of conventional the engine.
FEM079

EM-1062

CYLINDER HEAD
Assembly (Cont’d)

FEM080

6. Install valve spring.
+ When installing valve spring, make sure that a smaller pitch
side (identification paint-applied side) faces the cylinder
head.
Identification color: pink
7. Install valve spring retainers.
8. Using valve spring compressor (SST), compress valve
springs. Using magnetic hand, install valve collets.
+ After installing valve collets, tap the stem end using a plastic hammer, and check the installation status.
9. Install valve lifters and adjusting shims to the same positions
as before.

EM-1063

ENGINE REMOVAL
Precautions

+ Do not perform operation unless it is perfectly safe.
+ Do not start operation unless the exhaust system and coolant are cooled down.
+ Lift the engine at the designated support points only.
+ Perform operations for the items other than the engine body,
referring to the applicable sections.

SEM362G

+ Refer to MT section and AT section for rear mount.

Removal
+ After removing transmission, hoist the engine and remove it.

Preparation
1.
2.
+
+
+
+
+
+
+
+
+
+
+

Drain coolant from radiator drain plugs.
Remove the following parts.
Engine hood
Undercover
Under protector
Battery
Intercooler cover
Intercooler
Radiator shroud
Radiator
Accessory belt
Cooling fan
Exhaust front tube

Engine room (Left)
3. Remove air duct and air cleaner case.
4. Disconnect vacuum hose to the vehicle on the engine.

EM-1064

ENGINE REMOVAL
Removal (Cont’d)

5. Disconnect harness connectors from alternator and air compressor.
6. Remove alternator.
7. After removing refrigerant, remove pipes of air compressor
and inlet/outlet.
8. Disconnect heating hose, install blank cap to hose to prevent
coolant from leaking.
9. Remove heating pipe.
10. Remove heat insulator.
11. Remove catalytic converter.

Engine room (Right)
12. Remove power steering reservoir tank from bracket, and fix
it to the vehicle with a rope.
CAUTION:
Keep the reservoir tank level when fixing to prevent oil leak.
13. Remove fuel feed and return hoses.
CAUTION:
Install blank caps immediately to avoid fuel leakage.
14. Remove all harness connectors on the engine, and move
harnesses to the side of the vehicle.

Vehicle underfloor
15. Remove starter motor.
16. Detach A/T oil cooler pipes from oil pan. (A/T model)
17. Remove rear propeller shaft.
18. Remove mounting bolts to secure the engine to transmission.
1) Remove torque converter installation bolt. (A/T model)
2) Lift transmission bottom with transmission jack, and remove
rear mount members from the vehicle.
3) Lower transmission with the jack, and remove upper mounting bolts securing the engine to transmission.
4) Lift transmission with the jack, and reinstall rear mount members to the vehicle.
5) Position the jack to the front side of transmission.
6) Remove remaining mounting bolts securing the engine to
transmission.

Removal operation
19. Remove air conditioner high pressure pipes at the rear of the
engine room.
+ This is due to some inconvenience in the rear slinger installation.
20. Install the engine slingers (standard service part) to front-left
and rear-right.
: 25 — 28 Nzm (2.5 — 2.9 kg-m, 18 — 20 ft-lb)

FEM082

WARNING:
For engines without engine slingers, attach proper slingers
and bolts described in the PARTS CATALOG.

EM-1065

ENGINE REMOVAL
Removal (Cont’d)

21. Hook hoists to slingers to secure the position.
22. Remove installation nuts for left and right engine mount insulators.

23. While adjusting position frequently, hoist and remove the
engine.
CAUTION:
+ While performing operation, check that all necessary
wires and pipes are disconnected.
+ Avoid interference with parts on the vehicle.

SEM363G

Installation
Install the engine in the reverse order of the removal procedure.
+ Keep each mount insulator from oil adherence and damage.
+ As for identification and installation direction of left and right
insulators, refer to stamping on the top surface. Refer to
EM-1064.
+ As for a location with positioning pin, insert the pin correctly
to the hole of mating part.
+ While keeping each mount insulator free from twisting,
tighten mounting bolts and nuts for the engine mount.

Inspection
+ Before starting the engine, check coolant level and grease
amount, and if necessary, refill them to the specified level.
+ Start the engine, and check that there is no abnormal noise
or vibration.
+ Warm up the engine to the sufficient temperature, and check
that there is no leakage of coolant, greases, fuel, or exhaust
gas.

EM-1066

CYLINDER BLOCK

SMA for VIN >JN1*ESY61U014001 (except Israel) or
>JN1*ESY615X806001 (Israel)

SEM360G

EM-1067

CYLINDER BLOCK
Selection Procedure for Selective Part
Combination
Location

Selective part combination

Item

Method

Cylinder block — piston

Piston and piston assembly
(Part No. is given to a piston
and piston pin as a set.)

Piston grade (Piston outer
diameter)

Refer to “Selective combination
chart”.

+ Identification grade stamped on each part represents initial
dimension of new part. This grade will not be applied to a
reused part.
+ Measure correct dimensions of a reused or modified part,
then refer to “Selective combination chart” in this manual to
identify the grade.
+ Refer to the applicable pages for measurement method for
each part, standards for reuse, and selecting method for
selective part combination.

Disassembly
1. Remove engine assembly from vehicle.
Refer to EM-1064, “ENGINE REMOVAL”.

2. Remove pilot bushing from flywheel using pilot bearing puller
(SST), if necessary (M/T model).
3. Install engine to engine stand (SST).

SEM364G

1) Remove flywheel (M/T model) or drive plate (A/T model).
+ Using ring gear stopper (SST), secure ring gear, and remove
mounting bolts.
CAUTION:
Do not disassemble flywheel.
+ Flywheel has a two-piece structure. When being pressed
forward/backward, or twisted in rotating direction, transmission-side mass will be moved with audible sound. This is not
a problem.
2) Remove pilot converter (A/T model) and rear plate.
SEM365G

EM-1068

CYLINDER BLOCK
Disassembly (Cont’d)

3) Install engine sub-attachment (SST) to the rear side of cylinder block.
+ Align knock pin on cylinder block with pin hole on attachment
to install engine sub-attachment.
+ Mounting bolts are provided with engine sub-attachment.
4) Install engine attachment (SST).
+ Use commercially available M12 mounting bolts and nuts (4
sets) with strength grade of 9T (minimum).

FEM083

FEM084

5) Hoist engine and install it to the engine stand (SST).
+ Engine attachment and engine sub-attachment can be
installed to engine stand before engine installation.
4. Drain engine oil and coolant from engine.
5. Remove the following parts and related parts. (Only major
parts are listed.)
+ Accessory belt
+ Catalytic converter
+ Turbocharger
+ Exhaust manifold
+ Injection tube
+ Intake manifold
+ Rocker cover
+ Oil pan (upper/lower)
+ Water pump
+ Thermostat and water pipes
+ Vacuum pump
+ Injection tube
+ Timing chain
+ Electronic high pressure fuel injection pump
+ Timing gear
+ High pressure injection nozzle assembly
+ Camshaft
+ Cylinder head
+ Oil cooler
+ Accessory and accessory brackets

6. Remove rear oil seal and retainer assembly.
+ Insert flat-bladed screwdriver between lower cylinder block
and rear oil seal retainer to remove the assembly.
+ No part No. is given to oil seal.

EM-1069

CYLINDER BLOCK
Disassembly (Cont’d)

7. Remove piston and connecting rod assembly.
+ Before removing piston and connecting rod assembly, check
connecting rod side clearance.
Refer to EM-1072,“CONNECTING ROD SIDE CLEARANCE”.
1) Move crankshaft pin to be removed to approximately BDC.
2) Remove connecting rod caps.
3) Using the grip of a hammer, press the piston and connecting rod assembly out to cylinder head side.
FEM085

CAUTION:
When removing the piston and connecting rod assembly,
prevent the big end of the connecting rod from interfering
with the oil jet.
8. Remove connecting rod bearings from connecting rods and
caps.
+ Keep them by cylinder to avoid confusion.

FEM086

9. Remove piston rings from pistons using piston ring expander
(multi-purpose tool).
CAUTION:
+ When removing, prevent pistons from being damaged.
+ Do not expand piston rings excessively. This may damage the piston rings.

FEM087

10. Remove pistons from connecting rods.
1) Using long nose pliers, remove snap rings.

FEM088

2) Using industrial dryer, heat pistons up to 60 to 70°C (140 to
158°F).

FEM089

EM-1070

CYLINDER BLOCK
Disassembly (Cont’d)

3) Using rod with outer diameter of 30 mm (1.18 in), press piston pins out.

FEM090

11. Remove lower cylinder block.
+ The lower cylinder block is the lower part of the cylinder
block, which works as the main bearing cap (beam) and oil
pan mounting face.
1) Remove mounting bolts for engine sub-attachment shown by
arrows in the figure.

FEM091

2) Loosen and remove mounting bolts in the reverse order
shown in the figure.

FEM092

3) Insert flat-bladed screwdriver into 5 locations shown by
arrows in the figure. Lift lower cylinder block evenly, and
remove liquid gasket.
CAUTION:
Prevent mating faces from being damaged.
4) When removing lower cylinder block, use slot to prevent
dowel pin from interfering with engine sub-attachment.
+ No part No. is given to lower cylinder block, because it is
machined with the cylinder block.
FEM093

12. Remove crankshaft.
13. Remove main bearings and thrust bearings from cylinder
block and lower cylinder block.
CAUTION:
Check mounting positions. Keep them to avoid confusion.

EM-1071

CYLINDER BLOCK
Inspection
CRANKSHAFT END PLAY

+ Using dial indicator, measure crankshaft travel amount by
moving the crankshaft forward or backward, or
+ Using feeler gauge, measure crankshaft travel amount with
the lower cylinder block removed.
Standard: 0.055 — 0.140 mm (0.0022 — 0.0055 in)
Limit: 0.250 mm (0.0098 in)
FEM094

+ If measured value exceeds the limit, select appropriate thrust
bearings.
Unit: mm (in)

FEM095

Grade symbol

Thickness of thrust bearing

2.275 — 2.325 (0.0896 — 0.0915)

2.300 — 2.350 (0.0906 — 0.0925)

2.325 — 2.375 (0.0915 — 0.0935)

OS 020

2.475 — 2.525 (0.0974 — 0.0994)

+ OS 020 has part No. of 12280 2W215 and OS 0.20 marked
on bearing surface.

CONNECTING ROD SIDE CLEARANCE
+ Using feeler gauge, measure side clearance between connecting rod and crank arm.
Standard: 0.10 — 0.22 (0.0039 — 0.0087 in)
Limit: 0.22 mm (0.0087 in)
+ If measured value exceeds the limit, replace connecting rod
and repeat measurement.
If measured value still exceeds the limit, replace crankshaft.

FEM096

PISTON TO PISTON PIN CLEARANCE
Piston pin hole inner diameter
Using inside micrometer, measure piston pin hole inner diameter.
Standard: 32.997 — 33.005 mm (1.2991 — 1.2994 in) dia.

FEM097

Piston pin outer diameter
Using micrometer, measure piston pin outer diameter.
Standard: 32.993 — 33.000 mm (1.2989 — 1.2992 in) dia.

FEM098

EM-1072

CYLINDER BLOCK
Inspection (Cont’d)
Calculation of piston to piston pin clearance

Piston pin clearance = Piston pin hole inner diameter − Piston pin
outer diameter
Standard: −0.003 (Tightening clearance) to 0.012 mm
(−0.0001 to 0.0005 in)
If out of specifications, replace piston and piston pin assembly.

PISTON RING SIDE CLEARANCE
+ Using feeler gauge, measure clearance between piston ring
and piston ring groove.
Unit: mm (in)
Standard

Limit

Top ring

0.05 — 0.07 (0.0020 — 0.0028)

0.5 (0.020)

Second ring

0.04 — 0.08 (0.0016 — 0.0031)

0.3 (0.012)

Oil ring

0.02 — 0.06 (0.0008 — 0.0024)

0.15 (0.0059)

FEM099

+ Align top ring and external surface of piston. Measure lower
side clearance of top ring with top ring pressed onto upper
side of ring groove.
+ If side clearance exceeds the limit, replace piston ring.
+ Check clearance again. If side clearance still exceeds the
limit, replace piston.

FEM100

PISTON RING END GAP
+ Check that cylinder bore diameter is within specifications.
Refer to EM-1075, “PISTON TO CYLINDER BORE CLEARANCE”.
+ Using piston, press piston ring to cylinder mid point, and
measure end gap.
Unit: mm (in)
Standard
Top ring
FEM101

Second ring

0.5 — 0.65 (0.0197 — 0.0256)

Oil ring

0.25 — 0.45 (0.0098 — 0.0177)

EM-1073

Limit

0.3 — 0.45 (0.0118 — 0.0177)
1.5 (0.059)

CYLINDER BLOCK
Inspection (Cont’d)

CONNECTING ROD BEND AND TORSION
Use connecting rod aligner to check bend and torsion.
Bend limit:
0.05 mm (0.0020 in)/100 mm (3.94 in)
Torsion limit:
0.05 mm (0.0020 in)/100 mm (3.94 in)

FEM102

Connecting rod big end inner diameter
Install connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Using inside
micrometer, measure connecting rod big end inner diameter.
Standard:
59.987 — 60.000 mm (2.3617 — 2.3622 in) dia.

FEM103

CONNECTING ROD BUSHING OIL CLEARANCE
(SMALL END)
Connecting rod small end inner diameter
Use inside micrometer to measure small end inner diameter.
Standard:
33.025 — 33.038 mm (1.3002 — 1.3007 in) dia.

FEM104

Piston pin outer diameter
Use micrometer to measure piston pin outer diameter.
Standard:
32.993 — 33.000 mm (1.2989 — 1.2992 in) dia.

FEM098

Calculation of connecting rod bushing clearance
Connecting rod small end bushing clearance = Connecting rod
small end inner diameter − Piston pin outer diameter
Standard:
0.025 — 0.045 mm (0.0010 — 0.0018 in)
+ If out of specifications, replace connecting rod and/or piston
and piston pin assembly.

EM-1074

CYLINDER BLOCK
Inspection (Cont’d)

+ New connecting rods are classified into 8 weight classes at
factory. The same class connecting rods are used on a
engine.

FEM106

Weight grade symbol

Weight class g (oz)

1,261 — 1,264 (44.5 — 44.6)

1,264 — 1,267 (44.6 — 44.7)

1,267 — 1,270 (44.7 — 44.8)

1,270 — 1,273 (44.8 — 44.9)

1,273 — 1,276 (44.9 — 45.0)

1,276 — 1,279 (45.0 — 45.1)

1,279 — 1,282 (45.1 — 45.2)

1,282 — 1,285 (45.2 — 45.3)

CYLINDER BLOCK TOP SURFACE DISTORTION
+ Using scraper, remove gasket installed onto cylinder block
surface. Remove contamination such as oil, scale, and carbon.
CAUTION:
Keep broken pieces of gasket clear of oil and coolant passages.
+ Use straightedge and feeler gauge to check block upper surface for distortion.
Limit: 0.1 mm (0.004 in)
FEM107

MAIN BEARING HOUSING INNER DIAMETER
+ Install main bearing caps without main bearings. Tighten
mounting bolts to the specified torque.
+ Use bore gauge to measure main bearing housing inner
diameter.
Standard:
74.981 — 75.000 mm (2.9520 — 2.9528 in) dia.
+ If out of specification, replace cylinder block and lower cylinder block.
FEM108

PISTON TO CYLINDER BORE CLEARANCE
Cylinder bore inner diameter

FEM109

+ Using bore gauge, measure cylinder inner diameters at 6
positions; top, middle, and bottom (A, B, C) in 2 directions (X,
Y).
Cylinder inner diameter (Standard):
96.000 — 96.030 mm (3.7795 — 3.7807 in) dia.
Wear limit: 0.2 mm (0.008 in)
Out-of-round limit (X — Y): 0.02 mm (0.0008 in)
Taper limit (A — C): 0.02 mm (0.0008 in)

EM-1075

CYLINDER BLOCK
Inspection (Cont’d)

+ If clearance exceeds the limit, or any flaws or seizures are
found on inner surface of cylinder, horn or bore the applicable cylinder.

FEM110

Piston outer diameter
Use micrometer to measure piston skirt outer diameter.
Measurement position:
10 mm (0.39 in) upper from the lower end of piston
Standard:
95.950 — 95.980 mm (3.7776 — 3.7787 in) dia.

FEM111

Calculation of piston to piston bore clearance
+ Calculate using piston skirt outer diameter and cylinder inner
diameter (direction X, position B).
Clearance = Cylinder inner diameter − Piston skirt outer
diameter
Specifications at room temperature [20°C (68°F)]:
0.040 — 0.060 mm (0.0016 — 0.0024 in)
+ If out of specification, replace piston and piston pin assembly.

SELECTIVE PISTON COMBINATION
When using new cylinder block
+ Confirm cylinder bore grade (1, 2, 3) on left upper surface of
cylinder block, and refer to “Selective combination chart”
below to select appropriate piston.
+ Part No. is given to a piston and piston pin as a set.

FEM112

When re-using an old cylinder block
1. Measure cylinder block bore inner diameter.
2. Referring to “Cylinder block bore inner diameter” in “Selective combination chart”, select appropriate piston according
to cylinder bore grade.

FEM113

EM-1076

CYLINDER BLOCK
Inspection (Cont’d)
Selective combination chart

Unit: mm (in)
Piston grade
j: Preferable combination
n: Allowable combination
X: NG combination
Cylinder
bore grade
(Cylinder
block bore
inner
diameter)

95.950 — 95.960
(3.7776 — 3.7779)

95.960 — 95.970
(3.7779 — 3.7783)

96.000 — 96.010
(3.7795 — 3.7799)

96.010 — 96.020
(3.7799 — 3.7803)

96.020 — 96.030
(3.7803 — 3.7807)

+ Piston grade 3 (95.980/95.970) is applicable at factory only.
+ New pistons are classified into 4 weight classes at factory.
The same class pistons are used on a engine.
Weight grade symbol

Weight class g (oz)

600 — 605 (21.2 — 21.3)

605 — 610 (21.3 — 21.5)

610 — 615 (21.5 — 21.7)

615 — 620 (21.7 — 21.9)

CRANKSHAFT JOURNAL OUTER DIAMETER
Use micrometer to measure journal outer diameter.
Standard: 70.907 — 70.920 mm (2.7916 — 2.7921 in) dia.

CRANKSHAFT PIN OUTER DIAMETER
Use micrometer to measure pin outer diameter.
Standard: 56.913 — 56.926 mm (2.2407 — 2.2412 in) dia.

FEM114

CRANKSHAFT OUT-OF-ROUND AND TAPER
+ Using micrometer, measure each journal and pin at 4 points
shown in the figure.
+ Out-of-round value is indicated by difference in dimensions
between directions A and B at points 1 and 2.
+ Taper value is indicated by difference in dimensions between
points 1 and 2 in directions A and B.
Out-of-round limit: 0.01 mm (0.0004 in)
Taper limit: 0.01 mm (0.0004 in)
FEM115

CRANKSHAFT RUNOUT
+ Place V-block onto surface plate to support journals at both
ends of crankshaft.
+ Position dial indicator vertically onto No. 3 journal.
+ Rotate crankshaft to read needle movement on dial indicator.
+ Crankshaft bend value is 1/2 of needle movement.
Limit: 0.03 mm (0.0012 in)

FEM116

EM-1077

CYLINDER BLOCK
Inspection (Cont’d)

CONNECTING ROD BEARING OIL CLEARANCE
Method by measurement

FEM103

+ Install connecting rod bearings to connecting rods and caps,
and tighten connecting nuts to the specified torque. Use
inside micrometer to measure connecting rod bearing inner
diameter.
Bearing clearance = Connecting rod bearing inner diameter
− Crankshaft pin outer diameter
Standard: 0.035 — 0.077 mm (0.0014 — 0.0030 in)
+ If out of specifications, check connecting rod big end inner
diameter and crankshaft pin outer diameter, and select
appropriate connecting rod bearing to adjust clearance to
specifications.
Refer to “Connecting rod bearing undersize list” on the next
page.

Method using plastigage

FEM118

+ Remove contamination such as oil, dust completely from
crankshaft pins and each bearing surface.
+ Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
+ Install connecting rod bearings to caps, and tighten connecting rod nuts to the specified torque.
CAUTION:
Never rotate crankshaft.
+ Remove connecting rod caps and bearings, and measure
plastigage width using scale on plastigage bag.
CAUTION:
If out of specification, take same action mentioned in
“Method by measurement”.

Undersize bearing usage
+ If bearing clearance is out of specifications for connecting rod
bearings in standard size, use undersize bearings.
+ When using undersize bearings, measure bearing inner
diameter with bearing installed, and grind pins to adjust clearance to specification.

EM-1078

CYLINDER BLOCK
Inspection (Cont’d)
Connecting rod bearing undersize list

Unit: mm (in)

FEM119

Size

Thickness

US 025

1.630 — 1.638 (0.0642 — 0.0645)

US 050

1.755 — 1.763 (0.0691 — 0.0694)

US 075

1.880 — 1.888 (0.0740 — 0.0743)

US 100

2.005 — 2.013 (0.0789 — 0.0793)

CAUTION:
When grinding crank pins to use undersize bearings, avoid
damaging corners of fillet.
Corner dimension (Standard):
Pin
3.3 — 3.7 mm (0.130 — 0.146 in)
Journal
2.8 — 3.2 mm (0.110 — 0.126 in)

MAIN BEARING OIL CLEARANCE
Method by measurement
+ Install main bearings to cylinder block and bearing caps, and
tighten bearing cap bolts to the specified torque. Measure
main bearing inner diameter.
Bearing clearance = Bearing inner diameter − Crankshaft
journal outer diameter
Standard: 0.035 — 0.083 mm (0.0014 — 0.0033 in)
+ If out of specification, check main bearing housing inner
diameter and crankshaft journal outer diameter, and select
appropriate main bearing to adjust clearance to specifications.
Refer to “Main bearing undersize list” on the next page.

Method using plastigage

FEM120

+ Remove contamination such as oil, dust completely from
crankshaft journals and each bearing surface.
+ Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
+ Install main bearings to caps, and tighten connecting rod nuts
to the specified torque.
CAUTION:
Never rotate crankshaft.
+ Remove bearing caps and bearings, and measure plastigage
width using scale on plastigage bag.

EM-1079

CYLINDER BLOCK
Inspection (Cont’d)

CAUTION:
If out of specification, take same action mentioned in
“Method by measurement”.

Undersize bearing usage
+ If bearing clearance is out of specifications for main bearings
in standard size, use undersize bearings.
+ When using undersize bearings, measure bearing inner
diameter with bearing installed, and grind crank journals to
adjust clearance to specification.

Main bearing undersize list
Unit: mm (in)

FEM119

Size

Thickness

US 025

2.130 — 2.138 (0.0839 — 0.0842)

US 050

2.255 — 2.263 (0.0888 — 0.0891)

US 075

2.380 — 2.388 (0.0937 — 0.0940)

US 100

2.505 — 2.513 (0.0986 — 0.0989)

CAUTION:
When grinding crank journals to use undersize bearings,
avoid damaging corners of fillet.
Corner dimension (Standard):
Pin
3.3 — 3.7 mm (0.130 — 0.146 in)
Journal
2.8 — 3.2 mm (0.110 — 0.126 in)

MAIN BEARING CRUSH HEIGHT
+ Tighten bearing caps to the specified torque with main bearings installed, and remove caps. The bearing end must then
be higher than the flat surface.
Standard: Crush height must exist.
+ If out of specification, replace main bearings.

SMA for double-mass flywheel inspection procedure
FEM122

EM-1080

CYLINDER BLOCK
Assembly

1. Blow air sufficiently to inside coolant passage, oil passage,
crankcase, and cylinder bore to remove foreign matter.

2. Install main bearings and thrust bearings.
1) Remove contamination, dust and oil from bearing mounting
positions on cylinder block and main bearing caps.
2) Install thrust bearings on both sides of No. 4 housing on cylinder block.
+ Install thrust bearings with oil groove facing to crankshaft arm
(outside).

FEM126

3) Being careful with the direction, install main bearings.
+ Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the lower cylinder block side.
+ While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply oil to rear surfaces, but clean them
completely.
+ Align stopper notches on bearings to install them.
+ Check that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
FEM127

3.
+
4.
+

Install crankshaft to cylinder block.
While rotating crankshaft by hand, check for smooth rotation.
Install lower cylinder block.
Apply a continuous bead of liquid gasket to lower cylinder
block as shown in the figure.
+ Using slots on engine sub-attachment, install the lower cylinder block to the cylinder block, avoiding interference of
dowel pins.

FEM128

5. Tighten lower cylinder mounting bolts to the torque shown
below in 3 consecutive steps in the order shown in the figure.
Unit: Nzm (kg-m, ft-lb)

FEM092

Main bolt (Nos. 1 — 10)

Sub-bolt (Nos. 11 — 20)

1st

20 (2.0, 14)

9.8 (1.0, 7)

2nd

98 (10, 72)

20 (2.0, 14)

3rd

167 — 176 (17 — 18, 123 — 130)

40 — 46 (4.0 — 4.7, 29 — 33)

+ Sub-bolt No. 17 has shorter length than that of other subbolts.

EM-1081

CYLINDER BLOCK
Assembly (Cont’d)

6. Install mounting bolts for engine sub-attachment shown by
arrows in the figure.
+ After tightening bolts to the specified torque, check crankshaft for smooth rotation.
+ Check crankshaft end play.
Refer to EM-1072, “CRANKSHAFT END PLAY”.

FEM091

7. Install pistons to connecting rod.
1) Using long nose pliers, install snap rings to grooves on piston rear side.
+ Fit snap rings correctly into grooves.
2) Install pistons to connecting rods.
+ Using industrial dryer, heat pistons up to approx. 60 to 70°C
(140 to 158°F) until piston pin can be pressed down by finger touch. Then insert piston pins into piston and connecting
rod from front side of piston toward rear.

FEM131

+ Assemble piston and connecting rod with front mark of piston crown and cylinder No. stamped on connecting rod being
positioned as shown in the figure.
3) Install snap rings to front side of pistons.
+ Refer to above 1) for precaution on snap ring installation.
+ After installation, check connecting rods for smooth movement.
8. Use piston ring expander (multi-purpose tool) to install piston
rings.
CAUTION:
When installing, prevent piston from being damaged.
+ Install top ring and second ring with stamped surfaces facing upward.
Identification stamp:
Top ring: R
Second ring: RN

FEM132

9. Install connecting rod bearings to connecting rods and caps.
+ While installing connecting rod bearings, apply engine oil to
bearing surfaces (inside). Do not apply oil to rear surfaces,
but clean them completely.
+ Align stoppers on connecting rod bearings with connecting
rod stopper notches to install connecting rod bearings.

FEM133

EM-1082

CYLINDER BLOCK
Assembly (Cont’d)

FEM134

10. Install piston and connecting rod assembly to crankshaft.
+ Move crankshaft pin to be removed to BDC.
+ Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
+ Using piston ring compressor (multi-purpose tool), install piston and connecting rod assembly with front mark on piston
crown facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, prevent the big end of connecting rod from interfering with oil
jet.
11. Install connecting rod caps and mounting nuts.
+ Align cylinder No. stamped on connecting rod with that on
cap to install connecting rod cap.
+ After tightening nuts, check crankshaft for smooth rotation.
+ Check connecting rod side clearance.
Refer to EM-1072, “CONNECTING ROD SIDE CLEARANCE”.

FEM131

12. Install rear oil seal and retainer assembly.
+ Apply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.

FEM053

13. Press fit pilot bushing into flywheel (M/T model).
1) Using drift with outer diameter of 35 mm, press fit spacer until
it is in contact with the flywheel to prevent displacement at
removal.
2) Using drift with outer diameter of 20 mm, press fit pilot bushing by the length shown in the figure.

SEM366G

14. Install rear plate.
+ Refer to the figure for gasket installation direction.

SEM367G

EM-1083

CYLINDER BLOCK
Assembly (Cont’d)

15. Install removed parts to engine in the reverse order of disassembly.
16. Remove engine from engine stand.

17. Install flywheel (M/T model) or drive plate (A/T model).
+ Install pilot converter, drive plate, and reinforcing plate in
direction shown in the figure.
+ Using the same method as disassembly, secure crankshaft
and tighten mounting bolts.

FEM137

+ Tighten mounting bolts for flywheel or drive plate in order
shown in the figure.

FEM138

EM-1084

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Cylinder arrangement

In-line 4
3

Displacement

cm (cu in)

Bore and stroke

mm (in)

2,953 (180.19)
96 x 102 (3.78 x 4.02)

Valve arrangement

DOHC

Firing order

1-3-4-2
Compression

Oil

Number of piston rings
Number of main bearings

Compression ratio

17.9

Compression Pressure
Unit: kPa (bar, kg/cm2, psi)/200 rpm

Compression pressure

Standard

2,942 (29.4, 30.0, 427)

Minimum

2,452 (24.5, 25.0, 356)

Differential limit between cylinders

294 (2.94, 3.0, 43)

Cylinder Head
Unit: mm (in)

Head surface distortion

Standard

Limit

Less than 0.03 (0.0012)

0.2 (0.008)

SEM368G

Valve
VALVE
Unit: mm (in)

FEM067

EM-1085

SERVICE DATA AND SPECIFICATIONS (SDS)
Valve (Cont’d)
Intake

31.9 — 32.1 (1.256 — 1.264)

Exhaust

29.9 — 30.1 (1.177 — 1.185)

Valve head diameter “D”
Intake

113.5 (4.4685)

Exhaust

113.5 (4.4685)

Valve length “L”
Intake

6.962 — 6.977 (0.2741 — 0.2747)

Exhaust

6.945 — 6.960 (0.2734 — 0.2740)

Valve stem diameter “d”
Intake
Valve seat angle “α”

45°00′ — 45°30′
Exhaust
Intake

1.5 (0.059)

Exhaust

1.5 (0.059)

Valve margin “T”
Valve stem end surface grinding limit

VALVE CLEARANCE

Less than 0.2 (0.008)

SMA for VIN >JN1*ESY61U014001 (except Israel) or
>JN1*ESY615X806001 (Israel)
Cold

Intake

0.30 — 0.40 (0.0118 — 0.0157)

Exhaust

0.30 — 0.40 (0.0118 — 0.0157)

*: Approximately 80°C (176°F)

AVAILABLE SHIMS
Thickness mm (in)

Identification mark

2.35 (0.0925)

2.35

2.40 (0.0945)

2.40

2.45 (0.0965)

2.45

2.50 (0.0984)

2.50

2.55 (0.1004)

2.55

2.60 (0.1024)

2.60

2.65 (0.1043)

2.65

2.70 (0.1063)

2.70

2.75 (0.1083)

2.75

2.80 (0.1102)

2.80

2.85 (0.1122)

2.85

2.90 (0.1142)

2.90

2.95 (0.1161)

2.95

3.00 (0.1181)

3.00

3.05 (0.1201)

3.05

SEM252G

EM-1086

Unit: mm (in)

SERVICE DATA AND SPECIFICATIONS (SDS)
Valve (Cont’d)
VALVE SPRING
Free height
Pressure

mm (in)
N (kg, lb) at height mm (in)

Out-of-square

mm (in)

55.43 (2.1823)
354 (36.1, 79.6) at 32.3 (1.2717)
2.4 (0.094)

VALVE LIFTER
Unit: mm (in)

Valve lifter outer diameter

34.450 — 34.465 (1.3563 — 1.3569)

Lifter guide inner diameter

34.495 — 34.515 (1.3581 — 1.3589)

Clearance between lifter and lifter guide

0.030 — 0.065 (0.0012 — 0.0026)

VALVE GUIDE
Unit: mm (in)

FEM071

Standard
Outer diameter

11.023 — 11.034 (0.4340 — 0.4344)

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

7.000 — 7.015 (0.2756 — 0.2762)
10.996 — 10.975 (0.4329 — 0.4321)

Interference fit of valve guide

0.027 — 0.059 (0.0011 — 0.0023)
Standard
Intake

0.023 — 0.053 (0.0009 — 0.0021)

Exhaust

0.040 — 0.070 (0.0016 — 0.0028)

Stem to guide clearance
Valve deflection limit

0.2 (0.0079)

Projection length

12.8 — 13.2 (0.5309 — 0.5197)

EM-1087

SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Seat

Unit: mm (in)

SEM374G

SEM373G

SEM375G

Cylinder head seat recess diameter
(D)

Standard

Service

Intake

33.000 — 33.015 (1.2992 — 1.2998)

33.500 — 33.515 (1.3189 — 1.3195)

Exhaust

31.495 — 31.510 (1.2400 — 1.2405)

31.995 — 32.010 (1.2596 — 1.2602)

Intake

0.050 — 0.078 (0.0020 — 0.0031)

Exhaust

0.040 — 0.066 (0.0016 — 0.0026)

Valve seat interference fit

EM-1088

SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Seat (Cont’d)

Intake

33.065 — 33.078 (1.3018 — 1.3023)

33.565 — 33.578 (1.3215 — 1.3220)

Exhaust

31.550 — 31.561 (1.2421 — 1.2426)

32.050 — 32.061 (1.2618 — 1.2622)

Intake

6.75 — 6.85 (0.2657 — 0.2697)

Exhaust

7.35 — 7.45 (0.2894 — 0.2933)

Valve seat outer diameter (d)

Height (h)
Intake

43.65 — 44.35 (1.7185 — 1.7461)

Exhaust

43.65 — 44.35 (1.7185 — 1.7461)

Depth (L)

EM-1089

SERVICE DATA AND SPECIFICATIONS (SDS)
Camshaft and Camshaft Bearing

Unit: mm (in)

Standard

Limit

0.045 — 0.090 (0.0018 — 0.0035)

0.09 (0.0035)

Inner diameter of camshaft bearing

30.000 — 30.021 (1.1811 — 1.1819)

—

Outer diameter of camshaft journal

29.931 — 29.955 (1.1784 — 1.1793)

—

0.02 (0.0008)

Less than 0.15 (0.0059)

—

0.065 — 0.169 (0.0026 — 0.0067)

0.2 (0.008)

Camshaft journal to bearing clearance

Camshaft runout [TIR*]
Camshaft sprocket runout [TIR*]
Camshaft end play
*: Total indicator reading

EM671

Intake

40.468 — 40.508 (1.5932 — 1.5948)

Exhaust

40.830 — 40.870 (1.6075 — 1.6091)

Cam height “A”
Wear limit of cam height

0.15 (0.0059)

Valve timing

SEM372G

Unit: degree
a

234

220

EM-1090

SERVICE DATA AND SPECIFICATIONS (SDS)
Cylinder Block

Unit: mm (in)

SEM370G

Standard

Less than 0.03 (0.0012)

Surface flatness
Limit

0.10 (0.0039)

Standard
Cylinder bore

Grade No. 1

96.000 — 96.010 (3.7795 — 3.7799)

Grade No. 2

96.010 — 96.020 (3.7799 — 3.7803)

Grade No. 3

96.020 — 96.030 (3.7803 — 3.7807)

Inner diameter
Wear limit

0.20 (0.0079)

Out-of-round (X − Y)

Less than 0.02 (0.0008)

Taper (A − B − C)

Less than 0.02 (0.0008)

Main journal inner diameter (Without bearing)

74.981 — 75.000 (2.9520 — 2.9528)

Difference in inner diamLimit
eter between cylinders

Less than 0.05 (0.0020)

Piston, Piston Ring and Piston Pin
AVAILABLE PISTON
Unit: mm (in)

SEM369G

Piston skirt diameter “A”

Standard

Grade No. 1

95.950 — 95.960 (3.7776 — 3.7779)

Grade No. 2

95.960 — 95.970 (3.7779 — 3.7783)

Grade No. 3

95.970 — 95.980 (3.7783 — 3.7787)

“a” dimension

10 (0.39)

Piston pin hole diameter

32.997 — 33.005 (1.2991 — 1.2994)

Piston clearance to cylinder block

0.040 — 0.060 (0.0016 — 0.0024)

EM-1091

ZD
SERVICE DATA AND SPECIFICATIONS (SDS)
Piston, Piston Ring and Piston Pin (Cont’d)

PISTON RING
Unit: mm (in)

Side clearance

End gap

Standard

Limit

Top

0.05 — 0.07 (0.0020 — 0.0028)

0.5 (0.020)

2nd

0.04 — 0.08 (0.0016 — 0.0031)

0.3 (0.012)

Oil ring

0.02 — 0.06 (0.0008 — 0.0024)

0.15 (0.0059)

Top

0.30 — 0.45 (0.0118 — 0.0177)

1.5 (0.059)

2nd

0.50 — 0.65 (0.0197 — 0.0256)

1.5 (0.059)

Oil (rail ring)

0.25 — 0.45 (0.0098 — 0.0177)

1.5 (0.059)

PISTON PIN
Unit: mm (in)

Piston pin outer diameter

32.993 — 33.000 (1.2989 — 1.2992)

Interference fit of piston pin to piston

−0.003 to 0.012 (−0.0001 to 0.0005)
Standard

0.025 — 0.045 (0.0010 — 0.0018)

Piston pin to connecting rod bushing clearance
Limit

0.045 (0.0018)

*: Values measured at ambient temperature of 20°C (68°F)

Connecting Rod
Unit: mm (in)

Center distance

154.5 (6.083)

Bend [per 100 (3.94)]

Limit

Torsion [per 100 (3.94)]

Limit

0.05 (0.0020)
0.05 (0.0020)

Connecting rod small end inner diameter

35.087 — 36.000 (1.3814 — 1.4173)

Piston pin bushing inner diameter*

33.025 — 33.038 (1.3002 — 1.3007)

Connecting rod big end inner diameter

59.987 — 60.000 (2.3617 — 2.3622)

Crankshaft journal bearing inner diameter*

70.955 — 70.990 (2.7935 — 2.7949)
Standard

0.10 — 0.22 (0.0039 — 0.0087)

Side clearance
Limit

0.22 (0.0087)

*: After installing in connecting rod

EM-1092

SERVICE DATA AND SPECIFICATIONS (SDS)
Crankshaft

Unit: mm (in)

Main journal dia. “Dm”
Pin journal dia. “Dp”

70.907 — 70.920 (2.7916 — 2.7921)
Grade No. 0

56.913 — 56.926 (2.2407 — 2.2412)

Center distance “r”

50.95 — 51.05 (2.0059 — 2.0098)

Out-of-round (X − Y)

Standard

Less than 0.01 (0.0004)

Taper (A − B)

Standard

Less than 0.01 (0.0004)

Standard

Less than 0.01 (0.0004)

Limit

Less than 0.03 (0.0012)

Runout [TIR*]
Standard

0.055 — 0.140 (0.0022 — 0.0055)

Free end play
Limit

0.25 (0.0098)

EM715

SEM645

*: Total indicator reading

Available Main Bearing
UNDERSIZE

FEM127

Size

Thickness “T” mm (in)

Standard

2.005 — 2.013 (0.0789 — 0.0793)

US 025

2.130 — 2.138 (0.0839 — 0.0842)

US 050

2.255 — 2.263 (0.0888 — 0.0891)

US 075

2.380 — 2.388 (0.0937 — 0.0940)

US 100

2.505 — 2.513 (0.0986 — 0.0989)

Width “W” mm (in)

25.74 — 26.00 (1.0134 — 1.0236)

EM-1093

Main journal diameter “Dm”

Grind so that bearing clearance is
the specified value.

SERVICE DATA AND SPECIFICATIONS (SDS)
Available Connecting Rod Bearing
CONNECTING ROD BEARING
Grade number

Thickness “T” mm (in)

Standard

1.505 — 1.513 (0.0593 — 0.0596)

US 025

1.630 — 1.638 (0.0642 — 0.0645)

US 050

1.755 — 1.763 (0.0691 — 0.0694)

US 075

1.880 — 1.888 (0.0740 — 0.0743)

US 100

2.005 — 2.013 (0.0789 — 0.0793)

Width “W” mm (in)

25.9 — 26.1 (1.020 — 1.028)

BALANCER SHAFT BUSH
Unit: mm (in)

SEM371G

Front

50.940 — 51.010 (2.0055 — 2.0083)

Rear

50.740 — 50.810 (1.9976 — 2.0004)

Front

53.980 — 54.010 (2.1252 — 2.1264)

Rear

53.780 — 53.810 (2.1173 — 2.1185)

Balancer shaft bearing journal diameter

Balancer shaft journal outer diameter
Standard

0.045 — 0.135 (0.0018 — 0.0053)

Balancer shaft journal oil clearance
Limit

0.180 (0.0071)

Front

54.090 — 54.130 (2.1295 — 2.1311)

Rear

53.890 — 53.930 (2.1216 — 2.1232)

Front

0.2 — 0.4 (0.008 — 0.016)

Rear

0.2 — 0.4 (0.008 — 0.016)

Balancer shaft bush outer diameter (d)

Thickness (t)

EM-1094

SERVICE DATA AND SPECIFICATIONS (SDS)
Miscellaneous Components

Unit: mm (in)

Flywheel runout [TIR]*

Less than 0.15 (0.0059)

Drive plate runout [TIR]*

Less than 0.1 (0.0039)

*: Total indicator reading

BEARING CLEARANCE
Unit: mm (in)

Main bearing clearance

Standard

0.035 — 0.083 (0.0014 — 0.0033)

Connecting rod bearing clearance

Standard

0.035 — 0.077 (0.0014 — 0.0030)

EM-1095

FRONT AXLE &
FRONT SUSPENSION

SECTION

MODIFICATION NOTICE:
Tightening torque of brake rotor bolt has been changed.

CONTENTS
FRONT AXLE — Drive Flange and
Free-running Hub ……………………………………….. 1002

FRONT AXLE — Drive Flange and Free-running Hub

SFA859BA

FA-1002

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
SECTION

MODIFICATION NOTICE:
+ The circuit diagram and wiring diagram have been changed.
+ ZD30DDTi engine has been added.
+ The accelerator control system for ZD30DDTi engine models is the same as for RD28ETi engine models. Refer to FE-3 in Service Manual [SM7E-1Y61G0 (01)].
+ The fuel tank and sub-fuel tank for ZD30DDTi engine models are the same as for TD42 engine models.
Refer to FE-22 and FE-25 in Service Manual [SM7E-1Y61G0 (01)].

CONTENTS
TROUBLE DIAGNOSES ………………………………. 1002
Circuit Diagram ………………………………………… 1002
Wiring Diagram — S/TANK — …………………… 1003

ZD
EXHAUST SYSTEM …………………………………….. 1007

TROUBLE DIAGNOSES
Circuit Diagram

TFE004M

FE-1002

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK —

TFE005M

FE-1003

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)

TFE014

FE-1004

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)

TFE019

FE-1005

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)

TFE006M

FE-1006

EXHAUST SYSTEM

JFE660A

FE-1007

FUSE BLOCK — Junction Box (J/B)
Terminal Arrangement

CEL140M

FUSE AND FUSIBLE LINK BOX
Terminal Arrangement

CEL141M

ELECTRICAL UNITS
Terminal Arrangement

CEL142M

Edition: February 2000
Release: February 2000 (01)
Publication No.: SM0E-Y61AE0E
Reference No.: 7711346024

QUICK REFERENCE INDEX

GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL

PATROL GR

ENGINE LUBRICATION &
COOLING SYSTEMS

MODEL Y61 SERIES

ENGINE CONTROL SYSTEM

ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEM

CLUTCH

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

TRANSFER

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

FRONT AXLE & FRONT SUSPENSION

REAR AXLE & REAR SUSPENSION

BRAKE SYSTEM

STEERING SYSTEM

RESTRAINT SYSTEM

BODY & TRIM

HEATER & AIR CONDITIONER

ELECTRICAL SYSTEM

ALPHABETICAL INDEX

IDX

NISSAN EUROPE S.A.S.
© 2000 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.

NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

GENERAL INFORMATION
SECTION

OUTLINE OF MODIFICATIONS:
+ Side air bag has been adopted.
+ Power window (driver’s side only) with an interruption detection function has been adopted.
+ ZD30DDTi engine has been adopted in place of RD28ETi engine.
+ CONSULT-II has been adopted.
+ ID code entry procedure of multi-remote control system has been changed.

APPLIED FROM:
For Europe:
JN1TESY61U0000001
JN1KESY61U0000001

For Israel:
JN1TESY611X800001
JN1KESY611X800001

CONTENTS
PRECAUTIONS AND PREPARATION …………… 1002
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 1002
Precautions for Fuel………………………………….. 1002
CONSULT-II CHECKING SYSTEM………………… 1003
Function and System Application ……………….. 1003
Nickel Metal Hydride Battery Replacement….. 1003
Checking Equipment…………………………………. 1004

CONSULT-II Data Link Connector (DLC)
Circuit ……………………………………………………… 1004
IDENTIFICATION INFORMATION …………………. 1005
Model Variation ………………………………………… 1005
Identification Number ………………………………… 1007
LIFTING POINTS AND TOW TRUCK TOWING. 1009
Screw Jack………………………………………………. 1009
Tow Truck Towing ……………………………………. 1010

Precautions for Fuel
DIESEL ENGINE*:
Diesel fuel of at least 50 cetane for ZD30DDTi engine
* If two types of diesel fuel are available, use summer or winter fuel properly according to the following temperature conditions.
+ Above −7°C (20°F) … Summer type diesel fuel.
+ Below −7°C (20°F) … Winter type diesel fuel.
CAUTION:
+ Do not use home heating oil, gasoline, or other alternate
fuels in your diesel engine. The use of those can cause
engine damage.
+ Do not use summer fuel at temperature below −7°C
(20°F). The cold temperature will cause wax to form in
the fuel. As a result, it may prevent the engine from running smoothly.
+ Do not add gasoline or other alternate fuels to diesel
fuel.

GI-1002

CONSULT-II CHECKING SYSTEM
Function and System Application
Diagnostic test mode

Function

ENGINE

A/T

ABS

AIR
BAG

NATS*

SMART
ENTRANCE

Self-diagnostic results

Self-diagnostic results can be read and
erased quickly.

—

Trouble diagnostic
record

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

—

ECU discriminated
No.

Classification number of a replacement ECU
can be read to prevent an incorrect ECU
from being installed.

—

Data monitor

Input/Output data in the ECU (ECM) can be
read.

—

DTC work support

This mode enables a technician to set operating conditions to confirm self-diagnosis
status/results.

—

Active test

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

—

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

—

A maximum of four IDs (identifications) can
REMO CONT ID SET be registered in the memory using the
remote controller. These IDs can be also be
UP
confirmed and erased as required.

—

x*1

ECU (ECM) part numECU (ECM) part number can be read.
ber
Control unit initialization

x: Applicable
*: NATS (Nissan Anti-Theft System)
*1: Right-hand drive models for Eruope only

Nickel Metal Hydride Battery Replacement

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

GI-1003

CONSULT-II CHECKING SYSTEM
Checking Equipment
When ordering the below equipment, contact your NISSAN distributor.
Tool name

Description

NISSAN CONSULT-II
1 CONSULT-II unit (Tester
V
internal software: Resident version 3.2.0) and
accessories
2 Program card AED99C
V
(Version 3.0) and
EEN99A (For NATS)
To confirm the best combination of those softwares, refer SGI100A
to CONSULT-II Operation
Manual.

NOTE:
+ The CONSULT-II must be used in conjunction with a program card.
CONSULT-II does not require loading (Initialization) procedure.
+ Be sure the CONSULT-II is turned off before installing or removing a program card.

CONSULT-II Data Link Connector (DLC)
Circuit

SOM397

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

Check item

CONSULT-II cannot access any
system.

+ CONSULT-II DLC power supply circuit (Terminal and ground circuit (Terminal 4)
(For detailed circuit, refer to EC section, “MIL & DATA LINK CONNECTORS”.)
+ CONSULT-II (DDL) cable

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

+ CONSULT-II program card (Check the appropriate CONSULT-II program card for the system.
Refer to “Checking Equipment” above.)
+ Power supply and ground circuit for the control unit of the system
(For detailed circuit, refer to wiring diagram for each system.)
+ Open or short circuit between the system and CONSULT-II DLC
(For detailed circuit, refer to wiring diagram for each system.)

GI-1004

IDENTIFICATION INFORMATION
Model Variation
Model

Rear seat arrangement
Destination

Steering
position

Hardtop

Station Wagon

2nd seat

2nd center split bench seat

Forward facing

3rd seat

Seatless

Engine
Front differential

Forward facing

H233B

Rear differential
Transmission

Transfer

FS5R50B

RE4R03A
FS5R50B

RHD

RE4R03A
FS5R50B

RE4R03A
FS5R50B
Europe

ZD30DDTi

RE4R03A

S
TX12A

FS5R50B
SE
LHD

RE4R03A

FS5R50B
SE
RE4R03A

H233B/H260

Grade
KWSSREFY61UEA

—

TWSSREFY61UEA

—

TWSSREAY61UEA

KWSSRFFY61UEA

—

TWSSRFFY61UEA

KWSSRFAY61UEA

—

TWSSRFAY61UEA

—

TWSSRHFY61UEA

—

TWSSRHAY61UEA

KWSSLEFY61UGA

KWSSLEFY61USP

TWSSLEFY61USP

TWSSLEFY61UGA

—

TWSSLEAY61UGA

KWSSLFFY61UGA

—

TWSSLFFY61USP

TWSSLFFY61UGA

—

TWSSLFFY61USA

KWSSLFAY61UGA

—

TWSSLFAY61UGA

—

TWSSLFAY61USA

—

TWSSLHFY61UGA

—

TWSSLHFY61USA

—

TWSSLHAY61UGA

—

TWSSLHAY61USA

GI-1005

IDENTIFICATION INFORMATION
Model Variation (Cont’d)
Prefix and suffix designations
T

Y61

A
A: 3rd seat forward facing
P: 3rd seat/Rear seat seatless

E: RHD for Europe
G: Central/South Europe
S: North Europe
U: Turbocharger engine
F: 5-speed floor shift manual transmission
A: 4-speed floor shift automatic transmission
E: S F: SE H: SE
L: LH drive R: RH drive
S: Long wheelbase (4WD)
WS: ZD30DDTi engine
T: Station Wagon
K: Hardtop

GI-1006

IDENTIFICATION INFORMATION
Identification Number
VEHICLE IDENTIFICATION NUMBER (Chassis number)
Prefix and suffix designations
For Israel
JN1

Y61

XXXXXX
Vehicle serial number

Manufacturing plant
X: Hiratuka
Model year
1: 2001 model year
S: Long wheelbase (4WD)
E: ZD30DDTi engine
T: Station Wagon K: Hardtop
JN1: Japan produced vehicle

For Europe (except for Israel)
JN1

Y61

XXXXXX
Vehicle serial number

0: Stopgap (no meaning)
U: Europe
S: Long wheelbase (4WD)
E: ZD30DDTi engine
T: Station Wagon K: Hardtop
JN1: Japan produced vehicle

GI-1007

IDENTIFICATION INFORMATION
Identification Number (Cont’d)
IDENTIFICATION PLATE

SGI126AA

ENGINE SERIAL NUMBER

SGI137A

GI-1008

Screw Jack

SGI016AA

GI-1009

LIFTING POINTS AND TOW TRUCK TOWING
Tow Truck Towing
TOWING HOOKS
The towing hooks are provided only for emergency.
+ Use the towing hooks only, not other parts of the vehicle.
Otherwise, the vehicle body will be damaged.
+ Use the towing hooks only to free a vehicle stuck in sand,
snow, mud, etc. Never tow the vehicle for long distances
using only the towing hooks.
+ The towing hook is under tremendous force when used to
free a stuck vehicle. Always pull the cable straight out from
the front or rear of the vehicle. Never pull on the hook at a
sideways angle.

SGI025AA

GI-1010

HEATER &
AIR CONDITIONER

SECTION

MODIFICATION NOTICE:
+ Wiring diagrams have been changed.
+ Cooler cycle for ZD30DDTi engine has been added.

CONTENTS
PRECAUTIONS AND PREPARATION …………… 1002
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 1002
Precautions for Refrigerant Connection ………. 1002

REAR COOLER

TROUBLE DIAGNOSES ………………………………. 1005
Wiring Diagram — HEATER —………………….. 1005
Wiring Diagram — R/HEAT —/LHD Models … 1006
Wiring Diagram — A/C, M —/ZD Engine …….. 1007

TROUBLE DIAGNOSES ………………………………. 1013
Wiring Diagram — R/COOL —/LHD Models
with Front Auto A/C ………………………………….. 1013
Wiring Diagram — R/COOL —/LHD Models
with Front Manual A/C ………………………………. 1015
Wiring Diagram — R/COOL —/RHD Models
with Front Auto A/C ………………………………….. 1017
Wiring Diagram — R/COOL —/RHD Models
with Front Manual A/C ………………………………. 1019

AUTO

MANUAL AND AUTO

TROUBLE DIAGNOSES ………………………………. 1009
Circuit Diagram ………………………………………… 1009
Wiring Diagram — A/C, A —/ZD Engine……… 1010

SERVICE PROCEDURES …………………………….. 1021
Refrigerant Lines………………………………………. 1021
Compressor Mounting……………………………….. 1023

MANUAL

Precautions for Refrigerant Connection
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
+Expansion valve to cooling unit

FEATURES OF NEW TYPE REFRIGERANT CONNECTION
+The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the
O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics.
+ The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby
facilitating piping connections.

SHA815E

HA-1002

PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont’d)
O-RING AND REFRIGERANT CONNECTION

RHA840H

O-Ring Part Numbers and Specifications
Connection
type

O-ring size

New

Part number

D mm (in)

W mm (in)

92471 N8210

6.8 (0.268)

1.85 (0.0728)

92470 N8200

6.07 (0.2390)

1.78 (0.0701)

92472 N8210

10.9 (0.429)

2.43 (0.0957)

92475 71L00

11.0 (0.433)

2.4 (0.094)

92473 N8210

13.6 (0.535)

2.43 (0.0957)

92475 72L00

14.3 (0.563)

2.3 (0.0906)

92474 N8210

16.5 (0.650)

2.43 (0.0957)

92477 N8200

17.12 (0.6740)

1.78 (0.0701)

8
Former
New
12
Former
New
16
Former
New
SHA814E

19
Former

WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system
is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove
it.
CAUTION
When replacing or cleaning refrigerant cycle components, observe the following.
+ When the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber.
+ When connecting tubes, always use a torque wrench and a back-up wrench.
+ After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
+ When installing an air conditioner in the vehicle, connect the pipes as the final stage of the
operation. Do not remove the seal caps of pipes and other components until just before required
for connection.

HA-1003

PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont’d)
+
+
+
+

+
+
+
+

Allow components stored in cool areas to warm to working area temperature before removing
seal caps. This prevents condensation from forming inside A/C components.
Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
Always replace used O-rings.
When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful
not to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0
O-ring must be closely attached to dented portion of tube.
When replacing the O-ring, be careful not to damage O-ring and tube.
Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure
that the O-ring is installed to tube correctly.
After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten
connections of seal seat to the specified torque.

HA-1004

TROUBLE DIAGNOSES

MANUAL

Wiring Diagram — HEATER —

THA021M

HA-1005

TROUBLE DIAGNOSES

MANUAL

Wiring Diagram — R/HEAT —/LHD Models

THA022M

HA-1006

TROUBLE DIAGNOSES

MANUAL

Wiring Diagram — A/C, M —/ZD Engine

THA027M

HA-1007

MANUAL
TROUBLE DIAGNOSES
Wiring Diagram — A/C, M —/ZD Engine
(Cont’d)

THA028M

HA-1008

TROUBLE DIAGNOSES

AUTO

Circuit Diagram
LHD MODELS

THA029M

HA-1009

TROUBLE DIAGNOSES

AUTO

Wiring Diagram — A/C, A —/ZD Engine

THA039M

HA-1010

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/ZD Engine
(Cont’d)

THA040M

HA-1011

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/ZD Engine
(Cont’d)

THA041M

HA-1012

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/LHD Models
with Front Auto A/C

THA270

HA-1013

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/LHD Models
with Front Auto A/C (Cont’d)

THA271

HA-1014

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/LHD Models
with Front Manual A/C

THA272

HA-1015

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/LHD Models
with Front Manual A/C (Cont’d)

THA273

HA-1016

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/RHD Models
with Front Auto A/C

THA042M

HA-1017

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/RHD Models
with Front Auto A/C (Cont’d)

THA043M

HA-1018

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/RHD Models
with Front Manual A/C

THA044M

HA-1019

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/RHD Models
with Front Manual A/C (Cont’d)

THA045M

HA-1020

SERVICE PROCEDURES

MANUAL AND AUTO

Refrigerant Lines
RHD MODELS WITH ZD ENGINE

RHA841H

HA-1021

SERVICE PROCEDURES
Refrigerant Lines (Cont’d)

MANUAL AND AUTO

LHD MODELS WITH ZD ENGINE

RHA842H

HA-1022

SERVICE PROCEDURES

MANUAL AND AUTO

Compressor Mounting

RHA893H

HA-1023

ALPHABETICAL INDEX
SECTION

IDX

ALPHABETICAL INDEX
A

A/T — Wiring diagram ……………………….. AT-1009
A/T control ……………………………………… EC-1148
A/T fluid temperature sensor …………….. AT-1081
A/T mode switch ……………………………… AT-1095
A/T self-diagnoses …………………………… AT-1028
A/T shift lock system — Wiring
diagram ………………………………………. AT-1117
A/T shift lock system ……………………….. AT-1116
A/T trouble diagnoses ……………………… AT-1036
APS — Wiring diagram ……………………… EC-1125
ASCD (automatic speed control
device) ……………………………………….. EL-1110
ASCD — Wiring diagram ……………………. EL-1111
AT/C — Wiring diagram …………………….. EC-1150
Accelerator control system ……………….. FE-1007
Accelerator position sensor ……………… EC-1125
Air bag disposal ……………………………… RS-1015
Air bag precautions ………………………….. GI-1002
Air bag …………………………………………… RS-1003
Air cleaner filter replacement …………… MA-1019
Air conditioner cut control ………………… EC-1021
Air flow meter — See Mass air flow
sensor ………………………………………… EC-1086
Alternator ……………………………………….. EL-1041
Angular tightening application ………….. EM-1003
Anti-lock brake system — Wiring
diagram ……………………………………… BR-1002
Audio ……………………………………………… EL-1108
Automatic speed control system — See
ASCD …………………………………………. EL-1110
Automatic transmission fluid
replacement ……………………………….. MA-1021

BACK/L — Wiring diagram …………………. EL-1051
BOOST — Wiring diagram …………………. EC-1204
Back-up lamp ………………………………….. EL-1051
Basic inspection ……………………………… EC-1049
Battery …………………………………………… EL-1035
Boring/horning cylinder block …………… EM-1075

CHARGE — Wiring diagram ………………. EL-1040
CKPS — Wiring diagram …………………… EC-1140
CONSULT for engine ………………………. EC-1038
CONSULT general information ………….. GI-1003
COOL/F — Wiring diagram ………………… EC-1105
CORNER — Wiring diagram ………………. EL-1054
Camshaft inspection ……………………….. EM-1032
Charging system ……………………………… EL-1040
Chassis and body maintenance ……….. MA-1020
Clutch operating cylinder ………………….. CL-1003
Collision diagnosis ………………………….. RS-1052
Combination meter ………………………….. EL-1073

Combination switch …………………………. EL-1042
Compression pressure ……………………. EM-1010
Compressor mounting ……………………… HA-1023
Connecting rod bearing clearance ……. EM-1078
Connecting rod bushing clearance ……. EM-1074
Connecting rod ………………………………. EM-1074
Control valve (A/T) ………………………….. AT-1148
Converter housing installation …………… AT-1128
Coolant mixture ratio ………………………. MA-1010
Coolant replacement ………………………. MA-1014
Cooling fan control ………………………….. EC-1105
Cornering lamp ……………………………….. EL-1054
Crankcase emission control system See Positive crankcase ventilation … EC-1022
Crankcase ventilation system — See
Positive crankcase ventilation ……….. EC-1022
Crankshaft position sensor (TDC) …….. EC-1140
Crankshaft …………………………………….. EM-1077
Cruise control — See ASCD ………………. EL-1110
Cylinder block boring ………………………. EM-1020
Cylinder block ………………………………… EM-1067
Cylinder head bolt tightening ……………. EM-1034
Cylinder head ………………………………… EM-1053

DEF — Wiring diagram ………………………. EL-1102
DTRL — Wiring diagram ……………………. EL-1044
Data link connector for Consult ………… EC-1038
Daytime light system ……………………….. EL-1044
Diagnosis sensor unit ……………………… RS-1008
Diagnostic trouble code (DTC) for
OBD system ……………………………….. EC-1032
Dome light — See Interior lamp ………….. EL-1067
Door mirror …………………………………….. BT-1007
Door trim ………………………………………… BT-1004
Drive belt inspection ……………………….. MA-1011
Drive plate runout …………………………… EM-1095
Dropping resistor (A/T) …………………….. AT-1086

ECCS-D control module .. EC-1068, 1117, 1189,
1191, 1196, 1200
ECM input/output signal …………………… EC-1068
ECTS — Wiring diagram ……………………. EC-1092
EGR — Wiring diagram …………………….. EC-1209
EGR volume control valve ……………….. EC-1207
Electrical unit ………………………………….. EL-1231
Electrical units location …………………….. EL-1185
Electronic fuel injection pump …. EC-1119, 1153,
1159, 1165, 1171, 1177, 1180, 1215
Engine control circuit diagram ………….. EC-1015
Engine control component parts
location ………………………………………. EC-1011
Engine control system diagram and
chart ………………………………………….. EC-1016

IDX-1002

ALPHABETICAL INDEX
Engine coolant temperature sensor
(ECTS) ………………………………………. EC-1092
Engine oil filter replacement …………….. MA-1013
Engine oil replacement ……………………. MA-1012
Engine removal ………………………………. EM-1064
Engine serial number ……………………….. GI-1008

F/FOG — Wiring diagram …………………… EL-1052
Final drive disassembly ………….. PD-1004, 1005
Fluid temperature sensor (A/T) …………. AT-1081
Fluids ……………………………………………. MA-1008
Flywheel runout ……………………………… EM-1095
Fog lamp, front ……………………………….. EL-1052
Fog lamp, rear ………………………………… EL-1053
Forward clutch ………………………………… AT-1167
Front axle ………………………………………. FA-1002
Front final drive disassembly (4WD) …. PD-1004
Front fog lamp ………………………………… EL-1052
Front passenger air bag ………………….. RS-1003
Front seat ………………………………………. BT-1006
Front washer …………………………………… EL-1098
Front wiper ……………………………………… EL-1098
Fuel cut control (at no load & high
engine speed) …………………………….. EC-1021
Fuel filter replacement …………………….. MA-1017
Fuel gauge ……………………………………… EL-1073
Fuel injection system ………………………. EC-1019
Fuel line inspection …………………………. MA-1018
Fuel precautions ………………………………. GI-1002
Fuse block ……………………………………… EL-1229
Fuse ………………………………………………. EL-1230
Fusible link ……………………………………… EL-1230

GLOW — Wiring diagram ………………….. EC-1221
Gauges ………………………………………….. EL-1073
Glow plug ………………………………………. EC-1221
Glow relay ……………………………………… EC-1221
Grease …………………………………. MA-1008, 1016
Ground distribution ………………………….. EL-1013

HEAT UP — Wiring diagram ………………
HEATER — Wiring diagram ………………..
HLC — Wiring diagram ……………………….
HORN — Wiring diagram ……………………
Harness layout …………………………………
Hazard warning lamp ……………………….
Headlamp washer …………………………….
Headlamp wiper ……………………………….
Headlamp ……………………………………….
Heat up switch ………………………………..
High clutch ………………………………………

EC-1242
HA-1005
EL-1099
EL-1100
EL-1191
EL-1058
EL-1099
EL-1099
EL-1044
EC-1241
AT-1165

Horn ………………………………………………. EL-1100
How to erase DTC for OBD system ….. EC-1032

ILL — Wiring diagram ………………………… EL-1061
Identification plate ……………………………. GI-1008
Idle speed ……………………………………… EC-1049
Illumination ……………………………………… EL-1060
Injection nozzle ………………………………. EC-1023
Intake manifold ………………………………. EM-1012
Interior lamp ……………………………………. EL-1067
Interior …………………………………………… BT-1004

Junction box (J/B) ……………………………. EL-1229

License lamp ………………………………….. EL-1046
Lifting points ……………………………………. GI-1009
Line pressure solenoid valve ……………. AT-1086
Line pressure test (A/T) …………………… AT-1044
Liquid gasket application …………………. EM-1003
Location of electrical units ………………… EL-1185
Low and reverse brake ……………………. AT-1171
Lubricants ……………………………………… MA-1008
Luggage room lamp ………………………… EL-1067

MAFS — Wiring diagram …………………… EC-1086
MAIN — Wiring diagram ……………………. EC-1077
MAJOR OVERHALL ………………………… AT-1129
METER — Wiring diagram …………………. EL-1073
Maintenance (engine) ……………………… MA-1011
Malfunction indicator lamp (MIL) ………. EC-1033
Manifold tightening torque (intake &
exhaust) …………………………………….. MA-1011
Mass air flow sensor (MAFS) …………… EC-1086
Meter ……………………………………………… EL-1073
Mirror, door …………………………………….. BT-1007
Mirror, outside ………………………………… BT-1007
Model variation ………………………………… GI-1005

NATS (Nissan Anti-theft System) ………. EL-1163
NATS — Wiring diagram ……………………. EL-1166
NVH troubleshooting (EM) ………………. EM-1008

IDX-1003

ALPHABETICAL INDEX
O

Oil change (capacity) ……………………….
Oil pan (engine) ………………………………
Oil pump (A/T) …………………………………
Oil seal replacement (engine) …………..
On board diagnostic system ……………..
Operating cylinder (clutch) ………………..
Outside mirror ………………………………….
Overdrive control switch ……………………
Overrun clutch solenoid valve ……………
Overrun clutch …………………………………
Oversize piston ……………………………….

MA-1008
EM-1022
AT-1144
EM-1051
EC-1032
CL-1003
BT-1007
AT-1095
AT-1075
AT-1167
EM-1075

P/ANT — Wiring diagram …………………… EL-1109
PCV (positive crankcase ventilation) …. EC-1022
PNP/SW — Wiring diagram ……………….. EC-1233
POWER — Wiring diagram ………………… EL-1005
Park/Neutral position switch …………….. EC-1233
Park/neutral position switch (A/T) ……… AT-1095
Parking lamp …………………………………… EL-1046
Pilot bushing replacement — See Pilot
converter ……………………………………. EM-1083
Piston pin inspection ………………………. EM-1072
Piston ring inspection ……………………… EM-1073
Piston to bore clearance …………………. EM-1076
Power antenna ……………………………….. EL-1109
Power supply routing ……………………….. EL-1004
Power window ………………………………… EL-1115
Pressure test (A/T) ………………………….. AT-1044
Priming pump …………………………………. EC-1049
Propeller shaft on vehicle service ……… PD-1003
Propeller shaft vibration …………………… PD-1003
Propeller shaft ………………………………… PD-1002

Quick-glow system ………………………….. EC-1221

R/COOL — Wiring diagram
(front auto A/C) ………………….. HA-1013, 1017
R/COOL — Wiring diagram (front
manual A/C) ……………………………….. HA-1019
R/HEAT — Wiring diagram ………………… HA-1006
ROOM/L — Wiring diagram ………………… EL-1068
Radio — See Audio …………………………… EL-1108
Rear cooler — Wiring diagram (front
auto A/C) …………………………… HA-1013, 1017
Rear cooler — Wiring diagram (front
manual A/C) ……………………………….. HA-1019
Rear fog lamp …………………………………. EL-1053
Rear heater — Wiring diagram …………… HA-1006

Rear window defogger ……………………..
Refrigerant lines ………………………………
Removal and installation (A/T) …………..
Reverse clutch …………………………………
Revolution sensor (A/T) ……………………
Room lamp — See Interior lamp ………….

EL-1101
HA-1021
AT-1127
AT-1161
AT-1065
EL-1067

S/LOCK — Wiring diagram …………………. EL-1128
S/TANK — Wiring diagram …………………. FE-1003
SHIFT — Wiring diagram …………………… AT-1117
SRS — See Supplemental Restraint
System ………………………………………. RS-1003
STAB — Wiring diagram ……………………. RA-1002
START — Wiring diagram ………………….. EL-1036
SWL/V — Wiring diagram ………………….. EC-1248
Screw jack ………………………………………. GI-1009
Seat belt pre-tensioner disposal ……….. RS-1015
Seat belt pre-tensioner ……………………. RS-1003
Seat, front ………………………………………. BT-1006
Self-diagnostic results ……………………… EC-1034
Shift lock system …………………………….. AT-1116
Shift schedule …………………………………. AT-1206
Shift solenoid valve A (A/T) ……………… AT-1071
Shift solenoid valve B (A/T) ……………… AT-1073
Side air bag ……………………………………. RS-1003
Speedometer ………………………………….. EL-1073
Spiral cable ……………………………………. RS-1009
Stabilizer release device — Wiring
diagram ……………………………………… RA-1002
Stabilizer release device ………………….. RA-1002
Stall test (A/T) ………………………………… AT-1041
Start signal …………………………………….. EC-1230
Starter ……………………………………………. EL-1039
Starting system ……………………………….. EL-1036
Steering switch ……………………………….. EL-1043
Stop lamp ………………………………………. EL-1050
Super lock …………………………….. EL-1124, 1159
Supplemental Restraint System ……….. RS-1003
Supplemental restraint system — Wiring
diagram …………………………….. RS-1024, 1028
Swirl control valve control solenoid
valve ………………………………………….. EC-1246
Symptom matrix chart ……………………… EC-1055

TCM circuit diagram ………………………… AT-1008
TCM inspection table ………………………. AT-1060
Tachometer …………………………………….. EL-1073
Tail lamp ………………………………………… EL-1046
Throttle position switch …………………….. AT-1096
Timing chain ………………………………….. EM-1027
Timing gear ……………………………………. EM-1039
Torque converter clutch solenoid
valve ………………………………………….. AT-1078
Torque converter installation …………….. AT-1128

IDX-1004

ALPHABETICAL INDEX
Tow truck towing …………………….. GI-1009, 1010
Towing point ……………………………………. GI-1010
Trim ………………………………………………. BT-1004
Turbocharger charge air cooler ………… EM-1011
Turbocharger …………………………………. EM-1014
Turn signal lamp ……………………………… EL-1058

VSS — Wiring diagram ………………………
Vacuum hose drawing (Engine
control) ………………………………………..
Valve clearance ………………………………
Valve guide …………………………………….
Valve lifter ………………………………………
Valve seat ………………………………………

EC-1096
EC-1017
EM-1036
EM-1060
EM-1033
EM-1061

Valve spring …………………………………… EM-1062
Vehicle identification number ……. GI-1005, 1007
Vehicle speed sensor (VSS) …………….. EC-1096

WARN — Wiring diagram ……………………
WINDOW — Wiring diagram ……………….
WIPER — Wiring diagram …………………..
Warning chime …………………………………
Warning lamps …………………………………
Washer, front …………………………………..
Water temperature gauge …………………
Wiper, front ……………………………………..

IDX-1005

EL-1080
EL-1117
EL-1098
EL-1091
EL-1078
EL-1098
EL-1073
EL-1098

ENGINE LUBRICATION &
COOLING SYSTEMS

SECTION

MODIFICATION NOTICE:

+The ZD30DDTi engine has been added.

CONTENTS
ZD
ENGINE LUBRICATION SYSTEM…………………. 1002
Lubricating Circuit …………………………………….. 1002
Oil Pressure Check…………………………………… 1003
Oil Pump …………………………………………………. 1004
Oil Jet……………………………………………………… 1006
Oil Cooler ………………………………………………… 1007
ENGINE COOLING SYSTEM………………………… 1008
Cooling Circuit………………………………………….. 1008
System Check………………………………………….. 1009

Water Pump …………………………………………….. 1010
Thermostat ………………………………………………. 1011
Water Outlet…………………………………………….. 1012
Radiator…………………………………………………… 1013
Cooling Fan (Crankshaft driven)…………………. 1014
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1015
Engine Lubrication System ………………………… 1015
Engine Cooling System …………………………….. 1015

ENGINE LUBRICATION SYSTEM

Lubricating Circuit

SLC361B

LC-1002

ENGINE LUBRICATION SYSTEM

Oil Pressure Check
WARNING:
+ Be careful not to burn yourself, as the engine and oil
may be hot.
+ Oil pressure check should be done in “Neutral” gear
position.
1. Check oil level.
2. Remove oil pressure switch.
SLC694A

3. Install pressure gauge.
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
Engine speed
rpm

Approximate discharge pressure
kPa (bar, kg/cm2, psi)

Idle speed
2,000
4,000

More than 147 (1.47, 1.5, 21)
More than 539 (5.39, 5.5, 78)
More than 736 (7.36, 7.5, 107)

JLC362B

If difference is extreme, check oil passage and oil pump.
6. Install oil pressure switch with sealant.
Oil pressure switch:
: 13 — 17 Nzm (1.25 — 1.75 kg-m, 9 — 12 ft-lb)

LC-1003

ENGINE LUBRICATION SYSTEM

Oil Pump
REMOVAL AND INSTALLATION
Refer to “TIMING GEAR” in EM section.

DISASSEMBLY AND ASSEMBLY

JLC363B

+ When installing oil pump, apply new engine oil to gears.

+ When installing the inner and outer gear, face mating
mark toward the oil pump cover as shown (left).

JLC364B

LC-1004

ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
OIL PUMP INSPECTION

Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
0.114 — 0.200
(0.0045 — 0.0079)

1
Body to outer gear radial clearance V
2
Inner gear to outer gear tip clearance V

Less than 0.180 (0.0071)

3
Body to inner gear axial clearance V

0.05 — 0.09
(0.0020 — 0.0035)

4
Body to outer gear axial clearance V

0.050 — 0.105
(0.0020 — 0.0041)

Inner gear to brazed portion of housing
5
clearance V

0.045 — 0.091
(0.0018 — 0.0036)

Regulator valve to oil pump cover
6
clearance V

0.040 — 0.097
(0.0016 — 0.0038)

JLC365B

2 ) exceeds the limit, replace gear
+ If the tip clearance (V
set.
1 , V
3 , V
4 , V
5 ) exceed the
+ If body to gear clearances (V
limit, replace oil pump body assembly.
JLC366B

JLC367B

REGULATOR VALVE INSPECTION
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump cover.

4. Check regulator valve to oil pump cover clearance.
Clearance:
6 : 0.040 — 0.097 mm (0.0016 — 0.0038 in)
V
If it exceeds the limit, replace oil pump cover.

SLC369B

LC-1005

ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)

OIL PRESSURE RELIEF VALVE AND BYPASS VALVE
INSPECTION (For oil cooler)
1. Inspect oil pressure relief valve for movement, cracks and
breaks by pushing the ball. If replacement is necessary,
remove valve by prying it out with suitable tool.
Install a new valve in place by tapping it.

2. Check oil pressure relief valve to oil cooler housing clearance.
Clearance:
C : 0.032 — 0.068 mm (0.0013 — 0.0027 in)
V
If it exceeds the limit, replace oil cooler housing.

SLC371B

Oil Jet
INSPECTION (For timing chain)
Make sure that the holes are not clogged. Clean them with a wire
if necessary.
Drive oil jet into place after positioning alignment mark on.

SLC385B

INSPECTION (For piston)
1. Push cut-off valve of oil jet bolt with a clean resin or brass
rod and make sure that cut-off valve moves smoothly with
proper repulsion.
2. Make sure that the oil jet passage is not clogged. Clean with
a wire if necessary.

FEM124

When installing oil jet, align oil jet’s boss with hole on cylinder block.
Oil jet:
: 30 — 39 Nzm (3.0 — 4.0 kg-m, 22 — 28 ft-lb)

FEM125

LC-1006

ENGINE LUBRICATION SYSTEM
Oil Jet (Cont’d)

OIL FILTER
The oil filter is an element type. Refer to “Changing Oil Filter” in
MA section.

Oil Cooler

SMA for deletion of water feed hole of
turbocharger. Engine serial number
>ZD-104114A

JLC370B

REMOVAL AND INSTALLATION

JLC381B

1. Drain engine oil and coolant.
Remove catalyst and turbocharger. Refer to “CATALYST
AND TURBOCHARGER” in EM section.
2. Remove bolts A to C then remove oil cooler assembly.
+ Do not remove “D” nuts when removing oil cooler
assembly.
Bolt length:
A: 20 mm (0.79 in)
B: 45 mm (1.77 in)
C: 65 mm (2.56 in)
3. Installation is in reverse order of removal.
+ Do not spill coolant on the drive belt.

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

LC-1007

ENGINE COOLING SYSTEM

Cooling Circuit

JLC372B

LC-1008

ENGINE COOLING SYSTEM

CHECKING COOLING SYSTEM HOSES
Check hoses for the following:
+ Improper attachment
+ Leaks
+ Cracks
+ Damage
+ Chafing
+ Deterioration

CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with
a tester.
Testing pressure:
98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
CAUTION:
Higher pressure than specified may cause radiator damage.

SLC134B

CHECKING RADIATOR CAP
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
59 — 98 kPa
(0.59 — 0.98 bar, 0.6 — 1.0 kg/cm2, 9 — 14 psi)

SLC135B

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

SMA967B

LC-1009

ENGINE COOLING SYSTEM

Water Pump
CAUTION:
+ When removing water pump assembly, be careful not to
get coolant on drive belt.
+ Water pump cannot be disassembled and should be
replaced as a unit.
+ Always replace with new gasket.
+ After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
Refer to MA section.

JLC373B

REMOVAL AND INSTALLATION
1. Drain coolant from radiator and cylinder block.
Refer to MA section (“Changing Engine Coolant”, “ENGINE
MAINTENANCE”).
2. Remove radiator upper hose.
3. Remove radiator shroud.
4. Remove cooling fan.
5. Remove drive belt. Refer to MA section, “Checking Drive
Belt”.
6. Remove insulator.
7. Remove vacuum pipe.
8. Remove TDC sensor. Refer to TDC sensor removal and
installation in “TIMING GEAR”.
9. Remove fan coupling with water pump.
10. Install in the reverse order of removal.

LC-1010

ENGINE COOLING SYSTEM
Water Pump (Cont’d)

INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
2. Check for rough operation due to excessive end play.
CAUTION:
Do not disassemble water pump coupling assembly.

SLC374B

Thermostat

JLC380B

REMOVAL AND INSTALLATION

JLC384B

1. Drain engine coolant. Refer to MA section, “Changing Engine
Coolant”.
2. Remove left side battery. (If so equipped)
3. Remove radiator upper hose.
4. Remove radiator shroud.
5. Remove intake air duct, inlet pipe.
6. Remove harness and connectors.
7. Install in reverse order of removal.
+ After installation, run engine for a few minutes and
check for leaks.
+ Be careful not to spill coolant in engine compartment.
Use a rag to absorb coolant.

LC-1011

ENGINE COOLING SYSTEM
Thermostat (Cont’d)
INSPECTION

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

SLC695A

Tropical type and
Gulf standard
model

Standard type
and Australia
model

Frigid type

Valve opening temperature
°C (°F)

76.5 (170)

82 (180)

88 (190)

Maximum valve lift
mm/°C (in/°F)

10/90 (0.39/194)

10/95 (0.39/203)

10/100 (0.39/212)

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

Water Outlet
INSPECTION
Visual inspection for water leaks. If there is leakage, replace
gasket.

SLC377B

LC-1012

ENGINE COOLING SYSTEM

Radiator

JLC378B

REMOVAL AND INSTALLATION
1. Remove under cover.
2. Drain engine coolant. Refer to MA section, “Changing Engine
Coolant”.
3. Remove air cleaner case, air duct and resonator.
4. Remove battery (right side).
5. Move window washer tank.
6. Remove radiator shroud (lower).
7. Remove radiator shroud (front).
8. Disconnect radiator hose (upper and lower).
9. Disconnect reservoir tank hose.
10. Disconnect A/T oil cooler hose (Only A/T models).

LC-1013

ENGINE COOLING SYSTEM
Radiator (Cont’d)

11. Remove radiator.
12. After repairing or replacing radiator, install all removed parts
in reverse order of removal.

Cooling Fan (Crankshaft driven)
DISASSEMBLY AND INSTALLATION

JLC379B

+ Do not release the drive belt tension by removing the fan/
water pump pulley.
+ Fan coupling cannot be disassembled and should be
F is present, install fan so
replaced as a unit. If front mark j
F
that side marked j faces the front.
+ Proper alignment of these components is essential. Improper
alignment will cause them to wobble and may eventually
cause the fan to separate from the water pump causing
extensive damage.

LC-1014

SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Lubrication System
Oil pressure check

Oil pump
Unit: mm (in)

Engine speed
rpm

Approximate discharge pressure
kPa (bar, kg/cm2, psi)

Idle speed

More than 147 (1.47, 1.5, 21)

2,000

More than 539 (5.39, 5.5, 78)

4,000

More than 736 (7.36, 7.5, 107)

1
Body to outer gear radial clearance V
2
Inner gear to outer gear tip clearance V

0.114 — 0.200
(0.0045 — 0.0079)
Less than 0.180 (0.0071)

3
Body to inner gear axial clearance V

0.05 — 0.09
(0.0020 — 0.0035)

4
Body to outer gear axial clearance V

0.050 — 0.105
(0.0020 — 0.0041)

Inner gear to brazed portion of housing
5
clearance V

0.045 — 0.091
(0.0018 — 0.0036)

Regulator valve to oil pump cover clear6
ance V

0.040 — 0.097
(0.0016 — 0.0038)

Engine Cooling System
Radiator

Thermostat
Unit: kPa (bar, kg/cm2, psi)

Cap relief pressure
Leakage test pressure

78 — 98
(0.78 — 0.98, 0.8 — 1.0, 11 — 14)
157 (1.57, 1.6, 23)

Tropical type

Standard type

Valve opening temperature
°C (°F)

76.5 (170)

82 (180)

Valve lift
mm/°C (in/°F)

More than 10/95
(0.39/203)

LC-1015

MAINTENANCE
SECTION

MODIFICATION NOTICE:
+ The ZD30DDTi engine has been replaced with the RD28ETi engine.
+ Descriptions for the engine coolant mixture ratio have been modified.

CONTENTS
PERIODIC MAINTENANCE ………………………….. 1002
Maintenance Schedule for Diesel Engines
(Annual Mileage < 30,000 km/year) ……………. 1002
Chassis and Body Maintenance …………………. 1003
Maintenance Under Severe Driving Conditions
(Annual Driving Distance < 30,000 km/year)… 1004
Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year) ……………. 1005
Chassis and Body Maintenance …………………. 1006
Maintenance Under Severe Driving Conditions
(Annual Driving Distance > 30,000 km/year)… 1007
RECOMMENDED FLUIDS AND
LUBRICANTS ……………………………………………… 1008
Fluids and Lubricants………………………………… 1008
SAE Viscosity Number………………………………. 1009
Engine Coolant Mixture Ratio…………………….. 1010
ZD
ENGINE MAINTENANCE ……………………………… 1011
Checking Tightening Torque………………………. 1011

Adjusting Intake and Exhaust Valve
Clearance………………………………………………… 1011
Checking Drive Belt ………………………………….. 1011
Removal ………………………………………………….. 1012
Installation ……………………………………………….. 1012
Changing Engine Oil…………………………………. 1012
Changing Engine Oil Filter…………………………. 1013
Changing Engine Coolant………………………….. 1014
Checking Cooling System………………………….. 1016
Checking and Replacing Fuel Filter and
Draining Water …………………………………………. 1017
Checking Fuel Lines …………………………………. 1018
Cleaning and Replacing Air Cleaner Filter …… 1019
CHASSIS AND BODY MAINTENANCE …………. 1020
Checking A/T Fluid …………………………………… 1020
Changing A/T Fluid …………………………………… 1021
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1022
Engine Maintenance (ZD)………………………….. 1022

Maintenance Schedule for Diesel Engines
(Annual Mileage < 30,000 km/year)
ZD30DDTi engine
Abbreviations: R = Replace, I = Inspect: Correct or replace if necessary, C = Clean.
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform on a kilometer basis, but on an annual basis
when driving less than 15,000 km (9,000 miles) per
year.

km x 1,000

(miles x 1,000)

(9)

(18)

(27)

(36)

(45)

(54)

Months

72
Reference
pages

Engine compartment and under vehicle
Engine oil (Use recommended oil)★

MA-1012

MA-1013

Drive belts

MA-1011

Cooling system

Engine oil filter (Use Eco filter or equivalent)★

Engine anti-freeze coolant (Use genuine NISSAN Antifreeze Coolant (L2N) or equivalent)

See NOTE (1)

See NOTE (2)

Air cleaner filter★

Fuel lines

MA-1016
MA-1010,
1014

MA-1019
I

MA-1018

Injection nozzles

See NOTE (3)

Intake & exhaust valve clearance

See NOTE (4)

MA-1011

Fuel filter★

MA-1017

NOTE: (1) Oil filter element assembly and O-ring seal are replacement parts.
(2) First replace at 90,000 km (54,000 miles)/60 months, then every 60,000 km (36,000 miles)/48 months. Perform “I”
(Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
(3) If engine power decreases, black exhaust smoke is emitted or engine noise increases, check injection nozzles and,
if necessary, replace injection nozzle assembly.
(4) If valve noise increases, check valve clearance.
★ Maintenance items with “★” should be performed more frequently according to “Maintenance under severe driving conditions”.
*1: “Injection Tube and Injection Nozzle” in EC section

MA-1002

PERIODIC MAINTENANCE
Chassis and Body Maintenance
Abbreviations: R = Replace, I = Inspect: Correct or replace if necessary, L = Lubricate, T = Tighten, [ ] = At the specified mileage only
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform on a kilometer basis, but on an annual basis
when driving less than 15,000 km (9,000 miles) per
year.

km x 1,000

(miles x 1,000)

(9)

(18)

(27)

(36)

(45)

(54)

Months

72
Reference
pages

Underhood and under vehicle
Headlamp aiming

—

When alignment (if necessary, balance & rotate wheels)

—

Brake pads, rotors & other brake components★

—

Foot brake, parking brake & clutch (for free play, stroke & operation)

—

Brake booster vacuum hoses, connections & check valve

Brake & clutch, systems and fluid (for level and leaks)

Brake fluid★

Power steering fluid and lines (for level and leaks)
Supplemental air bag systems

R
I

—

See NOTE (1)

RS-1007

Ventilation air filter★

Manual transmission oil (Inspect for leaks. Replace if leaks are found.)

Automatic transmission fluid (for level and leaks)★

R
I

—

[R]

—

Greasing point of propeller shaft

See NOTE (2)

—

Transfer fluid and limited-slip differential (LSD) gear oil (for
level & leaks or replace)★

See NOTE (3)

—

Drive shafts & steering damper★

—

Front wheel bearing grease★

—

Front axle joint in knuckle flange

—

Free-running hub grease★

—

Body mounting bolts & nuts

—

Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system★

Body corrosion

See NOTE (4)

—
—

NOTE: (1) Inspect after 10 years, then every 2 years.
(2) The propeller shaft should be re-greased after being immersed in water.
(3) Including differential gear with differential lock.
(4) Inspect once per year.
★ Maintenance items with “★” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-1003

PERIODIC MAINTENANCE
Maintenance Under Severe Driving
Conditions (Annual Driving Distance < 30,000
km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be
performed on the following items as shown in the table.
A
B
C
D
E

—
—
—
—
—

Driving under dusty conditions
Driving repeatedly short distances
Towing a trailer or caravan
Extensive idling
Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely
high
F — Driving in high humidity areas or in mountainous areas
Driving condition

Maintenance
operation

Maintenance item

Engine oil & engine oil filter

Air cleaner filter

Fuel filter

Brake pads, rotors & other
brake components

Brake fluid

Ventilation air filter

Automatic transmission fluid

Transfer fluid and limited-slip
differential (LSD) gear oil

Drive shafts & steering
damper

Front wheel bearing grease

Free-running hub grease

Steering gear & linkage, axle
& suspension parts, propeller
shaft & exhaust system

Maintenance interval

Replace

Every 7,500 km (4,500 miles) or 6 months

Replace

Every 30,000 km (18,000 miles) or 24 months

Replace

Every 22,500 km (13,500 miles) or 18 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

Replace

Every 15,000 km (9,000 miles) or 12 months

Replace

Every 15,000 km (9,000 miles) or 12 months

Replace

Every 30,000 km (18,000 miles) or 24 months

Replace

Every 30,000 km (18,000 miles) or 24 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

MA-1004

PERIODIC MAINTENANCE
Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year)
ZD30DDTi engine
Abbreviations: R = Replace, I = Inspect: Correct or replace if necessary.
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform on a kilometer basis only.

km x 1,000

(miles x 1,000)

(9)

(18)

(27)

(36)

(45)

(54)
Reference
pages

Engine compartment and under vehicle
Engine oil (Use recommended oil)★
Engine oil filter (Use Eco filter or equivalent)★

See NOTE (1)

Drive belts
Cooling system
Engine anti-freeze coolant (Use genuine NISSAN Antifreeze Coolant (L2N) or equivalent)

MA-1012

MA-1013

MA-1011

I
See NOTE (2)

I
I

MA-1016

MA-1010,
1014

Air cleaner filter★

MA-1019

Fuel lines

MA-1018

Injection nozzles

See NOTE (3)

Intake & exhaust valve clearance

See NOTE (4)

MA-1011

Fuel filter★

MA-1017

NOTE: (1) Oil filter element assembly and O-ring seal are replacement parts.
(2) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles). Perform “I” (Checking the mixture
ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
(3) If engine power decreases, black exhaust smoke is emitted or engine noise increases, check injection nozzles and,
if necessary, replace injection nozzle assembly.
(4) If valve noise increases, check valve clearance.
★ Maintenance items with “★” should be performed more frequently according to “Maintenance under severe driving conditions”.
*1: “Injection Tube and Injection Nozzle” in EC section

MA-1005

PERIODIC MAINTENANCE
Chassis and Body Maintenance
Abbreviations: R = Replace, I = Inspect: Correct or replace if necessary, L = Lubricate, T = Tighten
MAINTENANCE OPERATION
Perform on a kilometer
basis only

MAINTENANCE INTERVAL
km x 1,000

(miles x 1,000)

(6)

100 110 120

(12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72)
Reference
pages

Underhood and under vehicle
Headlamp aiming

—

When alignment (if necessary, balance & rotate wheels)

—

Brake pads, rotors & other brake components★

—

Foot brake, parking brake & clutch (for free play, stroke & operation)

—

Brake booster vacuum hoses, connections & check valve

Brake & clutch, systems and fluid (for level and leaks)

Brake fluid★

Power steering fluid and lines (for level and leaks)
Supplemental air bag systems

—

See NOTE (1)

—
RS-1007

Ventilation air filter★

Manual transmission oil (Inspect for leaks. Replace if leaks are found.)

—
—

Automatic transmission fluid (for level and leaks)★

—

Greasing point of propeller shaft

See NOTE (2)

—

Transfer fluid and limited-slip differential (LSD) gear oil
(for level & leaks or replace)★

See NOTE (3)

—

Drive shafts & steering damper★

—

Front wheel bearing grease★

—

Front axle joint in knuckle flange

Free-running hub grease★

—

Body mounting bolts & nuts

—

Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system★
Body corrosion

See NOTE (4)

—
—

MA-1006

PERIODIC MAINTENANCE
Maintenance Under Severe Driving
Conditions (Annual Driving Distance > 30,000
km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be
performed on the following items as shown in the table.
A
B
C
D
E

—
—
—
—
—

Driving under dusty conditions
Driving repeatedly short distances
Towing a trailer or caravan
Extensive idling
Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely
high
F — Driving in high humidity areas or in mountainous areas
Driving condition

Maintenance item

Engine oil & engine oil filter

Air cleaner filter

Fuel filter

Brake pads, rotors & other brake components

Brake fluid

Ventilation air filter

Automatic transmission fluid

Transfer fluid and limited-slip differential (LSD)
gear oil

Drive shafts & steering damper

Front wheel bearing grease

Free-running hub grease

Steering gear & linkage, axle & suspension parts,
propeller shaft & exhaust system

MA-1007

Maintenance
operation

Maintenance interval

Replace

Every 7,500 km (4,500 miles)

Replace

Every 30,000 km (18,000 miles)

Replace

Every 30,000 km (18,000 miles)

Inspect

Every 15,000 km (9,000 miles)

Replace

Every 30,000 km (18,000 miles)

Replace

Every 15,000 km (9,000 miles)

Replace

Every 60,000 km (36,000 miles)

Replace

Every 30,000 km (18,000 miles)

Inspect

Every 15,000 km (9,000 miles)

Inspect

Every 15,000 km (9,000 miles)

Inspect

Every 15,000 km (9,000 miles)

Inspect

Every 15,000 km (9,000 miles)

RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants
Capacity (Approximate)
Liter

Imp measure

Recommended Fluids/Lubricants

Engine oil (Refill)
With oil filter

ZD30DDTi

5.7

5 qt

Diesel engine: API CF4 or ACEA
B3-96.98 or ACEA B3/E396.98*3 for ZD30DDTi

Without oil filter

ZD30DDTi

5.2

4-5/8 qt

RHD

12.7

11-1/8 qt

LHD

12.9

11-3/8 qt

RHD

12.0

10-5/8 qt

LHD

12.2

10-3/4 qt

RHD
LHD

13.8
14.0

12-1/8 qt
12-3/8 qt

Manual transmission

—

API GL-4, Viscosity SAE 75W-90 only

Differential carrier gear oil (without limited slip differential)

—

API GL-5*1

—

Genuine Nissan ATF or equivalent*2 or
API GL-4*1

11.8

10-3/8 qt

Cooling system (with reservoir tank)
With front heater

Without front
heater
With rear heater

ZD30DDTi

M/T, A/T

ZD30DDTi

M/T, A/T

ZD30DDTi

M/T, A/T

Transfer fluid
Automatic transmission fluid
Power steering fluid
Brake and clutch fluid
Multi-purpose grease

Refill to the proper oil level
according to the instructions in
“Do-it-yourself operations” section of the owner’s manual.
—

—

Propeller shaft grease
Air conditioning system refrigerant
Air conditioning system lubricants

Genuine Nissan Anti-freeze Coolant
(L250) or equivalent*4

Genuine Nissan ATF or equivalent*2
Type DEXRONTMIII or equivalent
DOT 3 or DOT 4 (U.S. FMVSS No.
116)*5
NLGI No. 2 (Lithium soap base)
NLGI No. 2 (Molybdenum disulphide
lithium soap base)

—

HFC-134a (R-134a)

—

Nissan A/C System Oil Type S or
exact equivalent

*1: For further details, see “SAE viscosity number”.
*2: For more information regarding suitable fluids, contact a Nissan dealer for correct brands of DEXRONTMIII/MERCONTM Automatic Transmission Fluid.
*3: Never use API CG-4.
*4: Use Genuine Nissan Anti-freeze Coolant (L2N) or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling
system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be covered by
the warranty even if such incidents occurred during the warranty period.
*5: Never mix DOT 3 & DOT 4.

MA-1008

RECOMMENDED FLUIDS AND LUBRICANTS
SAE Viscosity Number

TI0006

For cold areas:
10W-30 is preferable.
On turbocharger models, 5W-20 is not
recommended, and 5W-30 should be used
only below 0°C (32°F).
For hot and warm areas:
20W-40 and 20W-50 are suitable.

TI0003

+
+

MA-1009

For cold and warm areas:
75W-90 for transfer and 80W-90 for differential are preferable.
For hot areas:
90 is suitable for ambient temperatures
below 40°C (104°F).

RECOMMENDED FLUIDS AND LUBRICANTS
Engine Coolant Mixture Ratio
The engine cooling system is filled at the factory with a highquality, year-round and extended life engine coolant. The high
quality engine coolant contains the specific solutions effective for
the anti-corrosion and the anti-freeze function. Therefore, additional cooling system additives are not necessary.
CAUTION:
+ When adding or replacing coolant, be sure to use only
Genuine Nissan Anti-freeze Coolant (L2N) or equivalent.
Because L2N is premixed type coolant (Mixture ratio
50%).
The use of other types of engine coolant may damage your
cooling system.
+ When checking the engine coolant mixture ratio by the coolant hydrometer, use the chart below to correct your hydrometer reading (specific gravity) according to coolant temperature.
Mixed coolant specific gravity
Unit: Specific gravity
Coolant temperature °C (°F)

Engine coolant mixture
ratio

15 (59)

25 (77)

35 (95)

45 (113)

30%

1.046 — 1.050

1.042 — 1.046

1.038 — 1.042

1.033 — 1.038

50%

1.076 — 1.080

1.070 — 1.076

1.065 — 1.071

1.059 — 1.065

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping
from the radiator. Wait until the engine and radiator cool
down.

MA-1010

ENGINE MAINTENANCE
Checking Tightening Torque
Checking should be performed while engine is cold.

MANIFOLD BOLTS AND NUTS
Intake and exhaust manifolds:
Intake
: 25 — 28 Nzm (2.5 — 2.9 kg-m, 18 — 20 ft-lb)
Exhaust
: 40 — 49 Nzm (4.0 — 4.5 kg-m, 29 — 36 ft-lb)

Adjusting Intake and Exhaust Valve
Clearance
Refer to EM section.

Checking Drive Belt
+ Because an auto tensioner adjustment mechanism is
provided, it is not necessary to check or adjust the tension of accessory belt.
1. Inspect for cracks, fraying, wear or oil adhesion. Replace if
necessary.
The belts should not touch the bottom of the pulley groove.
2. Check the damper unit of the auto tensioner for oil leaks.

JMA088D

Part
Water pump, alternator, air
conditioner compressor belt

Belt specifications

Tension

Belt deflection

V-ribbed belt (7 ribs)

Automatic adjustment by auto
tensioner

MA-1011

ENGINE MAINTENANCE

Removal
WATER PUMP, ALTERNATOR AND AIR
CONDITIONER BELT
1. Remove radiator shroud.
2. Contract and hold the auto tensioner using the following procedure.
a. Securely hold the 19 mm (0.75 in) hexagonal portion A of
auto tensioner with a closed wrench.
+ Preferably use a tool with a handhold of 500 mm (19.69 in)
or more in length.
+ No bolts or nuts are required to be loosened during the
operation.
b. Turn the hexagonal portion A in the direction shown by the
arrow to contract the damper unit of the auto tensioner.
CAUTION:
+ Because the tensioner has a high tension, it shall be
securely held and turned with a closed wrench.
+ Because the hexagonal portion A of the tensioner is
made of aluminum and may be damaged by sudden
input, turn it slowly according to the contraction of the
damper unit.
3. Remove the belt from the alternator pulley first, and then
remove it from the other pulleys.
+ If the tensioner is not held firmly, your finger may get caught
between the belt and the pulleys. Confirm the holding of the
tensioner, and then hold the belt side in the place away from
the pulleys to attach or remove the belt, paying attention to
prevent your finger from being caught.
CAUTION:
+ When handling the belt, pay attention to prevent the oil
or coolant from adhering to the belt.
+ Do not distort or bend the belt intensively.

Installation
+ Install the belt in the reverse order of removal.
+ After installation of the belt, confirm that the belt engages the
pulleys securely.
+ Depending on the engagement between the belt and the idler
pulley, noise (belt noise) may be heard when the engine is
started just after installation. This noise will stop with time.

Changing Engine Oil
WARNING:
+ Be careful not to burn yourself, as engine oil is hot.
+ Prolonged and repeated contact with used engine oil
may cause skin cancer; try to avoid direct skin contact
with used oil. If skin contact is made, wash thoroughly
with soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine components.
2. Remove drain plug and oil filler cap.
SMA101D

MA-1012

ENGINE MAINTENANCE
Changing Engine Oil (Cont’d)

3. Drain oil and fill with new engine oil.
Oil grade: API CF4 or ACEA B3-96.98 or ACEA B3/E396.98
Viscosity:
See “RECOMMENDED FLUIDS AND
LUBRICANTS”, MA-1009.
Refill oil capacity (approximate):
Without oil filter change
5.2! (4-5/8 Imp qt)
With oil filter change
5.7! (5 Imp qt)
CAUTION:
+ Be sure to clean and install oil pan drain plug with
washer.
Drain plug:
: 54 — 58 Nzm (5.5 — 6.0 kg-m, 40 — 43 ft-lb)
+ The refill capacity changes depending on the oil temperature and drain time; use these valves as a reference
and be certain to check with the dipstick when changing
the oil.

4. Check oil level.
5. Start engine. Check area around drain plug and oil filter for
any sign of oil leakage.
6. Run engine for a few minutes, then turn it off. After 10 minutes check oil level.

SMA102D

JMA103D

Changing Engine Oil Filter
REMOVAL
1. Insert a suitable tool with a 12.7 mm square (1/2 inch square)
such as an extension bar and ratchet handle into the filter
body, and loosen the body by approximately 4 turns.
WARNING:
Be careful not to burn yourself, as the engine and engine oil
are hot.
JMA104D

MA-1013

ENGINE MAINTENANCE
Changing Engine Oil Filter (Cont’d)

JMA105D

2. Set the m mark of the filter body to the top position and discharge the oil.
+ Receive the oil discharged from the drain hose in a tray.
+ About 500 cc (17.6 Imp fl oz) of oil will be discharged in about
3 minutes.
+ The oil is discharged from the oil catcher to under the vehicle
through the drain hose.
3. Remove the filter body, and then remove the oil filter element.
CAUTION:
+ If the engine oil gets on the engine or vehicle, thoroughly
wipe it off.
+ Thoroughly wipe off the oil remaining in the oil catcher.
(This is to prevent misidentifying oil leaking from the oil
catcher as oil leaking from the engine.)
4. Remove the O-ring from the filter body.
+ Press the O-ring in any direction with your finger, and pull on
the portion of the O-ring separated from the filter body to
remove it.
CAUTION:
Because wire and screwdrivers may cause damage to the
filter body, do not use such tools.

JMA106D

INSTALLATION
1. Thoroughly remove foreign matter adhering to the inside of
filter body and O-ring mounting areas (of the body and oil
cooler).
2. Install the oil filter element and O-ring to the filter body.
+ Securely press the oil filter element into the filter body.
3. Install the filter body.
: 20 — 24 Nzm (2.0 — 2.5 kg-m, 15 — 18 ft-lb)
4. After warming up the engine, check that no engine oil leaks.

Changing Engine Coolant
WARNING:
To avoid the danger of being scalded, never change the
coolant when the engine is hot.

—DRAINING ENGINE COOLANT—
1. Move heater TEMP control knob all the way to HOT.
2. Remove undercover and open radiator drain plug at the bottom of radiator.
SMA972C

3. Remove radiator filler cap (side with pressure valve).

SMA117D

MA-1014

ENGINE MAINTENANCE
Changing Engine Coolant (Cont’d)

4. Remove water inlet and cylinder block drain plug located at
left center of cylinder block.
5. Remove reservoir tank (sides with pressure valve and without pressure valve) and drain coolant.

JMA107D

SMA108D

—REFILLING ENGINE COOLANT—

SMA182B

6. Install reservoir tank, radiator drain plug, and cylinder block
drain plugs.
+ Apply sealant to the thread of cylinder block drain plug.
Cylinder block drain plug:
: 24 — 26 Nzm (2.4 — 2.7 kg-m, 18 — 19 ft-lb)
Water inlet drain plug:
Height (H) mm (in): 5.0 — 7.8 (0.197 — 0.307)
7. Move heater TEMP control knob all the way to HOT.
8. Fill radiator with coolant up to the filler neck and install radiator cap.
For coolant mixture ratio, refer to MA-1010.
9. Fill reservoir tank (with pressure valve) with coolant up to the
filler neck.
10. Fill reservoir tank with coolant up to the MAX level.

MA-1015

ENGINE MAINTENANCE
Changing Engine Coolant (Cont’d)

SMA412B

JMA109D

Coolant capacity (With reservoir tank): ! (Imp qt)
RHD models
Without rear heater 11.8 (10-3/8)
With rear heater 12.9 (11-3/8)
LHD models
Without rear heater 11.6 (10-1/4)
With rear heater 12.7 (11-1/8)
Reservoir tank capacity (for MAX level):
1.2 ! (1-1/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air
in system to escape.
11. Install radiator cap (side with pressure valve).
12. Warm up engine to normal operating temperature.
13. Run engine at 2,000 rpm for 10 seconds and return to idle
speed.
+ Repeat 2 or 3 times.
Watch coolant temperature gauge so as not to overheat the
engine.
14. Stop engine and cool it down.
+ Cool down using a fan to reduce the time.
15. Remove the reservoir tank filler cap (side with pressure
valve) and check coolant level.
+ If necessary, refill reservoir tank (side with pressure valve) up
to filler neck with coolant.
16. Refill reservoir tank to Max line with coolant.
17. Repeat step 10 through step 16 two or more times.
18. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 2,000 rpm with heater temperature control set at several positions between COOL and
HOT.
+ Sound may be noticeable at heater water cock.
19. If sound is heard, bleed air from cooling system by repeating steps 12 through 18 until coolant level no longer drops.
+ Clean excess coolant from engine.

Checking Cooling System
CHECKING HOSES AND CLAMPS
Check hoses and clamps for proper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.

CHECKING RADIATOR CAP
Apply pressure to radiator cap (side with pressure valve) with
cap tester to see if it is satisfactory.
Radiator cap relief pressure:
59 — 98 kPa
(0.59 — 0.98 bar, 0.6 — 1.0 kg/cm2, 9 — 14 psi)

SLC613

MA-1016

ENGINE MAINTENANCE
Checking Cooling System (Cont’d)

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

SMA871B

JMA109D

JMA110D

Checking and Replacing Fuel Filter and
Draining Water
Be careful not to spill fuel in engine compartment. Place a
rag to absorb fuel.

CHECKING FUEL FILTER
Check fuel filter for fuel leakage, damage and other abnormal
signs.
DMA011

REPLACING FUEL FILTER
1. Disconnect harness connector and drain fuel.
2. Remove fuel filter using band-type filter wrench.
3. Remove fuel filter and fuel filter sensor.
CAUTION:
Remove fuel filter without spilling fuel. If spilt, wipe off
immediately. Be specially careful not to spill fuel on engine
mount insulator.

SMA111D

MA-1017

ENGINE MAINTENANCE
Checking and Replacing Fuel Filter and
Draining Water (Cont’d)

4. Wipe clean fuel filter mounting surface on fuel filter bracket
and smear a little fuel on rubber seal of fuel filter.
5. Screw fuel filter on until a slight resistance is felt, then tighten
an additional more than 2/3 of a turn.
6. Install fuel filter sensor to new fuel filter. (Type A)
7. Bleed air from fuel filter.
Refer to “Air Bleeding” in EC section.
8. Start engine and check for leaks.
SMA010

DRAINING WATER
1. Drain water as follows.
Type A
Loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it excessively.
If water does not drain properly, move the priming pump up and
down.
SMA825B

Type B
Loosen air bleeder screw from the sedimentor cover and then
loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it excessively.

SMA281C

2. Bleed air.
Refer to “Air Bleeding” in EC section.

SMA803A

MA-1018

ENGINE MAINTENANCE

Cleaning and Replacing Air Cleaner Filter

SMA114D

VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any
cleaning operation between renewal.

MA-1019

CHASSIS AND BODY MAINTENANCE
Checking A/T Fluid

SMA515C

1. Warm up engine.
2. Check for fluid leakage.
3. Before driving, fluid level can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on
dipstick.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear position. Leave selector lever in “P” position.
c. Check fluid level with engine idling.
d. Remove dipstick and note reading. If level is at low side of
either range, and fluid to the charging pipe.
e. Re-insert dipstick into charging pipe as far as it will go.
f. Remove dipstick and note reading. If reading is at low side
of range, add fluid to the charging pipe.
Do not overfill.
4. Drive vehicle for approximately 5 minutes in urban areas.
5. Re-check fluid level at fluid temperatures of 50 to 80°C (122
to 176°F) using “HOT” range on dipstick.
CAUTION:
Securely install A/T fluid level gauge.

SMA070D

6. Check fluid condition.
+ If fluid is very dark or smells burned, refer to AT section for
checking operation of A/T. Flush cooling system after repair
of A/T.
+ If A/T fluid contains frictional material (clutches, bands, etc.),
replace radiator and flush cooler line using cleaning solvent
and compressed air after repair of A/T. Refer to LC section
(“Radiator”, “ENGINE COOLING SYSTEM”).

SMA107

MA-1020

CHASSIS AND BODY MAINTENANCE
Changing A/T Fluid

SMA515C

1. Warm up A/T fluid.
2. Stop engine.
3. Drain A/T fluid from drain plug and refill with new A/T fluid.
Always refill same volume with drained fluid.
Fluid grade:
Genuine Nissan ATF or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”,
MA-1008.
Fluid capacity (With torque converter):
11.8 ! (10-3/8 Imp qt)
Drain plug:
: 29 — 39 Nzm (3.0 — 4.0 kg-m, 22 — 29 ft-lb)
4. Run engine at idle speed for five minutes.
5. Check fluid level and condition. Refer to “Checking A/T
Fluid”. If fluid is still dirty, repeat steps 2 through 5.

MA-1021

SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Maintenance (ZD)
INSPECTION AND ADJUSTMENT

Cooling system check
Unit: kPa (bar, kg/cm2, psi)

Oil capacity (Refill capacity)
Unit: ! (Imp qt)

With oil filter change
Without oil filter change

5.7 (5)

Cooling system testing pressure
Radiator cap relief pressure

5.2 (4-5/8)

MA-1022

98 (0.98, 1.0, 14)
59 — 98
(0.59 — 0.98, 0.6 — 1.0, 9 — 14)

MANUAL TRANSAXLE
SECTION

CONTENTS
PREPARATION …………………………………………… 1002
Special Service Tools ……………………………….. 1002
Commercial Service Tools…………………………. 1004
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………….. 1005
NVH Troubleshooting Chart……………………….. 1005
ON-VEHICLE SERVICE ……………………………….. 1006
Replacing Rear Oil Seal ……………………………. 1006
Position Switch Check ………………………………. 1006
REMOVAL AND INSTALLATION ………………….. 1007
Removal ………………………………………………….. 1007
Installation ……………………………………………….. 1008
DESCRIPTION …………………………………………….. 1009
Cross-sectional View ………………………………… 1009
AIR BREATHER ………………………………………….. 1010
Air Breather Piping……………………………………. 1010
MAJOR OVERHAUL ……………………………………. 1011
Case Components ……………………………………. 1011

Gear Components…………………………………….. 1012
Shift Control Components………………………….. 1014
DISASSEMBLY……………………………………………. 1015
Case Components ……………………………………. 1015
Shift Control Components………………………….. 1015
Gear Components…………………………………….. 1018
INSPECTION……………………………………………….. 1024
Shift Control Components………………………….. 1024
Gear Components…………………………………….. 1024
ASSEMBLY…………………………………………………. 1026
Shift Control Components………………………….. 1026
Gear Components…………………………………….. 1028
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1037
General Specifications ………………………………. 1037
Inspection and Adjustment ………………………… 1038

FS5R50B

PREPARATION
Special Service Tools
Tool number
Tool name

Description

KV321022S1
Bushing hook set
1 KV32102211
V
Bushing hook
2
V KV32102221
Spacer
3
V KV32102240
Spacer
4
V KV32102231
Bolt (M12)
5
V KV32102250
Bolt (M8)

Removing OD gear bushing
Removing 3rd gear bushing

a: 75 (2.95) dia.
b: 59 (2.32) dia.
c: 15 (0.59)
d: 55 (2.17) dia.
e: 42.2 (1.661) dia.
f: 55 (2.17) dia.
g: 40.2 (1.583) dia.
Unit: mm (in)

NT730

KV32102400
Counter gear stopper

Installing OD gear bushing

a: 48 (1.89)
b: 48 (1.89)
c: 12 (0.47)
d: 15 (0.59)
e: 49 (1.93)
f: 40 (1.57)
g: 5 (0.20)
Unit: mm (in)

NT731

KV32102501
Mainshaft stopper

Installing mainshaft bearing
Installing OD main gear
Installing mainshaft rear end bearing
a: 2 (0.08)
b: 212 (8.35)
c: 2 (0.08)
d: 85 (3.35)
e: 75 (2.95)
f: 16 (0.63)
g: 38 (1.50)
h: 115 (4.53)
i: 140 (5.51)
j: 110 (4.33)
Unit: mm (in)

NT732

KV31100300
Pin punch

Removing and installing retaining pin for
reverse check assembly, reverse shift
fork, reverse fork rod bracket, striking
lever, and shift lever bracket
a: 4.5 (0.177) dia.
b: 12 (0.47) dia.
Unit: mm (in)

NT442

MT-1002

PREPARATION
Special Service Tools (Cont’d)
Tool number
Tool name

FS5R50B

Description

ST25420001
Clutch spring compressor

Installing sub-gear components

a: 157 mm (6.18 in)

NT443

ST30031000
Puller

Removing OD main gear
Removing main drive gear bearing
a: 90 (3.54) dia.
b: 50 (1.97) dia.
Unit: mm (in)

NT411

ST30613000
Drift

Installing main drive gear bearing
Installing OD synchronizer cone
a: 71.5 (2.815) dia.
b: 47.5 (1.870) dia.
Unit: mm (in)

NT073

ST33200000
Drift

Installing 3rd gear bushing
Installing 3rd & 4th synchronizer assembly
Installing counter gear front bearing
Installing counter gear rear bearing
(Use with KV40100630)
a: 60 (2.36) dia.
b: 44.5 (1.752) dia.
Unit: mm (in)

NT091

KV40100630
Drift

Installing counter gear rear bearing
(Use with ST33200000)
a: 67.5 (2.657) dia.
b: 44 (1.73) dia.
c: 38.5 (1.516) dia.
Unit: mm (in)

NT107

KV38102100
Drift

Installing front cover oil seal

a: 44 (1.73) dia.
b: 24.5 (0.965) dia.
Unit: mm (in)

NT084

ST22452000
Drift

Installing OD gear bushing
Installing OD main gear
Installing mainshaft rear end bearing
a: 45 (1.77) dia.
b: 36 (1.42) dia.
Unit: mm (in)

NT065

ST30720000
Drift

Installing rear oil seal
a: 77 (3.03) dia.
b: 55.5 (2.185) dia.
Unit: mm (in)

NT086

MT-1003

FS5R50B

PREPARATION
Commercial Service Tools
Tool name

Description
Removing
Removing
Removing
Removing
Removing
Removing
Removing
Removing
Removing

Puller

companion flange
mainshaft rear end bearing
OD synchronizer assembly
OD gear bushing
OD main gear
mainshaft bearing
reverse synchronizer hub
3rd & 4th synchronizer hub
3rd gear bushing

NT077

Puller

Removing mainshaft low gear bearing
Removing counter low & high gear front
bearing
Removing counter gear front and rear
bearing
NT726

Puller

Installing reverse synchronizer hub
Installing 1st & 2nd synchronizer hub
Installing mainshaft bearing
a: 48.6 (1.913) dia.
b: 41.6 (1.638) dia.
c: 410 (16.14)
Unit: mm (in)

NT733

Drift

Removing slide ball bearing
Installing slide ball bearing
a: 16 (0.63) dia.
b: 18 (0.71) dia.
c: 30 (1.18)
d: 300 (11.81)
Unit: mm (in)

NT734

MT-1004

Symptom

SUSPECTED PARTS
(Possible cause)

1
2

Jumps out of gear

MT-1005

MT-1014
MT-1012
MT-1012
MT-1012
MT-1012

GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
INSERT SPRING (Damaged)

Refer to MA section (‘‘Checking M/T Oil’’,
‘‘CHASSIS AND BODY MAINTENANCE’’).

SHIFT FORK (Worn)

MT-1014

CHECK PLUG RETURN SPRING AND
CHECK BALL (Worn or damaged)

Hard to shift or will not shift
MT-1011

1
OIL SEAL (Worn or damaged)

MT-1011

Oil leakage
LIQUID GASKET (Damaged)

OIL (Level too high)

OIL (Wrong)

Noise
OIL (Level low)

FS5R50B

Reference page

Transmission model

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING

3
3

2
2

1
2

FS5R50B

NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the
inspection. If necessary, repair or replace these parts.

FS5R50B

ON-VEHICLE SERVICE
Replacing Rear Oil Seal
REMOVAL

1. Remove transfer assembly. — Refer to TF section.
2. Pull out rear oil seal.

SMT321B

INSTALLATION
1. Install rear oil seal.
● Before installing apply multi-purpose grease to seal lip.
2. Install transfer assembly. — Refer to TF section.

SMT322B

Position Switch Check
Switch
Reverse position switch

Neutral position switch
Reverse position
switch
Neutral position switch
SMT274D

MT-1006

Gear position

Continuity

Reverse

Yes

Except reverse

Neutral

Yes

Except neutral

REMOVAL AND INSTALLATION

FS5R50B

Removal

Exhaust front tube
Front

Exhaust rear tube

Clutch operating cylinder

Rear propeller tube

Front propeller tube

SMT321D

1. Remove front and rear propeller shafts. Refer to PD section
(‘‘Removal and Installation’’, ‘‘PROPELLER SHAFT’’).
2. Remove clutch operating cylinder.
3. Remove exhaust front and rear tubes. Refer to FE section
(‘‘EXHAUST SYSTEM’’).
4. Disconnect vehicle speed sensor, back-up lamp switch, 4WD
switch and neutral position switch harness connector.
5. Remove center brake cable. Refer to BR section.
6. Remove shift lever of transmission. Refer to MT-1014
(FS5R50B).
7. Remove transfer control lever. Refer to TF section
(‘‘Removal’’, ‘‘REMOVAL AND INSTALLATION’’).
8. Support engine by placing a jack under oil pan.
● Do not place jack under the oil pan drain plug.
9. Remove transmission with transfer from engine.
WARNING:
Support Manual Transmission with transfer, while removing
it.

MT-1007

FS5R50B

REMOVAL AND INSTALLATION
Installation
●

Engine rear plate

Apply sealant as below:

Transmission case

Engine block

23.6 (0.929)
23.6 (0.929)

1) Place
: Sticked out portion for engine rear plate
from transmission case.
Do not apply sealant
in this range.
Sealant

: Mating surface of transmission case and
rear plate.
2) Sealant

Rear plate

: Apply genuine anaerobic liquid gasket,
Three Bond TB1207B or TB1207D.
: Apply genuine anaerobic liquid gasket,
Three Bond TB1215 or TB1207D.
Transmission case
Grommet
Engine rear plate

Starter
Unit: mm (in)

SMT280D

●

ZD30DDTi engine

Tighten bolts securing transmission.

Dowel hole
For starter

Engine

Dowel hole

ZD30DDTi

M/T to engine
Engine to M/T

(Not used)

Bolts

Tightening torque
N·m (kg-m, ft-lb)

! mm (in)

1
V

M/T to engine block

83 — 113
(8.5 — 11.5, 61 — 83)

100 (3.94)

2
V

M/T to engine oil pan

29 — 39
(3.0 — 4.0, 22 — 29)

100 (3.94)

3
V

Engine oil pan to M/T

29 — 39
(3.0 — 4.0, 22 — 29)

70 (2.76)

SMT324DB

MT-1008

MT-1009

Mainshaft

Release sleeve

Front

Main drive gear ball bearing

Clutch housing

Filler plug

Drain plug

Reverse idler gear shaft

Reverse idler gear

Reverse coupling sleeve

Reverse main gear

Slide ball bearing

1st main gear

1st & 2nd coupling sleeve

Transmission case

Counter gear

Sub-gear

Counter gear front bearing

Front cover

Main drive gear

3rd & 4th coupling sleeve

Gear shift housing

3rd main gear

2nd main gear

Mainshaft rear end
bearing

OD main gear

Slide ball bearing

Mainshaft bearing

Shift lever

Counter gear rear end bearing

OD counter gear

OD gear case

OD coupling sleeve

OD synchronizer cone

Control housing

Striking rod

DESCRIPTION
FS5R50B

Cross-sectional View

SMT269D

FS5R50B

AIR BREATHER
Air Breather Piping
Remarks:
1. Route rubber hoses so that they are not bent pinched.
2. Hose insertion
• Insert the tube bulge spool into the spool.
• Insert the tube bulge into the right-angle bend section of the tube.
• Insert unit bulge until the hose connot go in any further.

Front

Place hose clamp at the hose joint
(made of resin) as illustrated so as
not to pinch the rubber hose.

Breather hose

Breather tube

White paint mark

Details at A

Make two paint marks on the breather hose
facing up.

White paint mark

Transmission case

10.8 — 14.7
(1.1 — 1.5, 8 — 11)

OD case
Install so that the white paint marks
are facing to the left hand side of
the vehicle.

Yellow paint
mark

Yellow paint mark
Transfer
(front case)
Transfer
(center case)

Transfer
(rear case)

Breather hose
Pink paint mark

Hose clamp (4 places marked with .)

Tube to side member
Clamp-hose tab here must be placed facing up.

: N·m (kg-m, ft-lb)

SMT547D

MT-1010

FS5R50B

MAJOR OVERHAUL
Case Components
16 — 21 (1.6 — 2.1, 12 — 15)
16 — 21 (1.6 — 2.1, 12 — 15)

Gear shift housing
Control housing
Mating surfaces to gear shift
housing cover

Liquid gasket

16 — 21 (1.6 — 2.1, 12 — 15)
57 — 75 (5.8 — 7.6, 42 — 55)
)
(Self-sealing bolt

Mating
surface D

)

(Self-sealing bolt

2 — 6 (0.08 — 0.24)
19 — 24
(1.9 — 2.4, 14 — 17)

Gear shift housing

Mating surface D
Rear oil seal

Seal lip

OD gear case
16 — 21
(1.6 — 2.1, 12 — 15)

Transmission case
Filler plug
25 — 34
(2.5 — 3.5, 18 — 25)
Thread of bolt

Liquid gasket

Mating
surface B
2 — 6 (0.08 — 0.24)

Mating
surface C

OD gear case

Mating surface C

54 — 72
(5.5 — 7.3, 40 — 53)

Transmission case

16 — 21 (1.6 — 2.1, 12 — 15)
2-6
(0.08 — 0.24)

Bearing retainer
Drain plug
25 — 34 (2.5 — 3.5, 18 — 25)

54 — 72
(5.5 — 7.3, 40 — 53)

Thread of bolt
Front

Front cover oil seal
Seal lip
Liquid gasket
Mating surface B
Mating
surface A

Clutch housing

Front cover
To cylinder block

Front
cover

Liquid gasket

Gusset RH

2 — 6 (0.08 — 0.24)
To cylinder block
Mating surface A

Sealing grommet
54 — 72 (5.5 — 7.3, 40 — 53)

Gusset LH
To clutch housing

32 — 42 (3.3 — 4.3, 24 — 31)
19 — 24 (1.9 — 2.4, 14 — 17)
(Self-sealing bolt

)

Illustration for TB42S engine
model

29 — 39 (3.0 — 4.0, 22 — 29)
Unit: mm (in)
: N·m (kg-m, ft-lb)
29 — 39 (3.0 — 4.0, 22 — 29)

: Apply genuine anaerobic liquid gasket,
Three Bond TB1215, Loctite Part No.
51813 or equivalent.

SMT270D

MT-1011

FS5R50B

MAJOR OVERHAUL
Gear Components

3rd gear bushing
3rd gear needle bearing
3rd main gear
3rd inner baulk ring
Synchronizer cone
3rd outer baulk ring
3rd & 4th coupling sleeve
Shifting insert
Shifting insert spring >
4th baulk ring
Main drive gear
Shifting insert spring >
Main drive bearing
snap ring

3rd & 4th synchronizer hub >
3rd & 4th hub snap ring .
Pilot bearing
1st gear needle bearing
1st main gear
Main drive bearing >

1st inner baulk ring

Main drive gear snap
ring .

Synchronizer cone
1st outer baulk ring
Mainshaft

Shifting insert

2nd main gear
2nd gear
needle
bearing

1st & 2nd coupling sleeve
Shifting insert spring
1st & 2nd synchronizer hub >
Shifting insert spring
1st & 2nd hub snap ring .
2nd outer baulk ring
Synchronizer cone

Counter gear

2nd inner baulk ring
Sub-gear washer
16 — 21 N·m
(1.6 — 2.1 kg-m, 12 — 15 ft-lb)

Sub-gear snap ring

Lock plate

(Inner race)
(Outer race)

Sub-gear
Sub-gear spring >

Counter gear front bearing >

Reverse idler shaft
Reverse idler needle bearing
Reverse idler gear >

SMT271D

MT-1012

FS5R50B

MAJOR OVERHAUL
Gear Components (Cont’d)

OD main gear >
Mainshaft bearing snap ring
Mainshaft bearing >
Reverse coupling sleeve >
Mainshaft spacer
Shifting insert >
Mainshaft rear end bearing
Shifting insert spring
Mainshaft rear snap ring

Shifting insert spring
Reverse synchronizer hub >
Reverse baulk ring
Reverse gear needle bearing
Reverse main gear
Counter gear rear snap ring
OD synchronizer cone

Shifting insert spring >
OD gear needle bearing
OD counter gear bushing

OD baulk ring

Thrust washer

OD coupling sleeve >
Shifting insert >

OD counter gear
Snap ring
(Inner race)

(Outer race)

Counter gear rear
bearing >

Transmission case

Apply gear oil to gears, shafts, synchronizers and
bearings when assembling.
. : Select with proper thickness.
> : Pay attention to its direction.

SMT272D

MT-1013

FS5R50B

MAJOR OVERHAUL
Shift Control Components
Bushing
Boot band

Shift knob

Select check plunger
Contact surface to shift lever bracket
Boot

Select check spring (Color: white)

Shift lever

Boot band
Resin seat
Select check plug
Snap ring

20 — 29
(2.0 — 3.0, 14 — 22)

Snap ring
Socket
Spring
Plug

16 — 21 (1.6 — 2.1, 12 — 15)
Cam pin

16 — 21
(1.6 — 2.1, 12 — 15)

Bracket
Control housing
Contact surface to shift lever bracket

Select check plunger

Select check spring (Color: black)

16 — 21
(1.6 — 2.1, 12 — 15)

Air breather

Select check plug

Neutral position switch
Check plunger
Spacer
Reverse check spring

20 — 29 (2.0 — 3.0, 14 — 22)
Plunger

Reverse position switch

20 — 29 (2.0 — 3.0, 14 — 22)

Thrust washer

20 — 29 (2.0 — 3.0, 14 — 22)

Fork rod cap

E-ring
Slide ball bearing

Striking rod cap

Striking rod cap
Plug

Fork rod cap

Check ball
20 — 29
(2.0 — 3.0, 14 — 22)
Interlock plunger
Interlock pin
Check ball

Reverse fork rod
Check ball spring

Retaining pin

Check ball
Reverse shift fork
Retaining pin

Gear shift housing
16 — 21 (1.6 — 2.1, 12 — 15)

Clip

Shift lever bracket
Striking rod

Fork rod cap
Retaining pin

16 — 21 (1.6 — 2.1, 12 — 15)

Retaining pin
3rd & 4th rod bracket
1st & 2nd rod bracket

Striking lever
Retaining pin

Interlock pin

Retaining pin

3rd & 4th fork rod
OD fork rod
OD shift fork
1st & 2nd fork rod
Retaining pin
3rd & 4th shift fork
: N·m (kg-m, ft-lb)

1st & 2nd shift fork
Retaining pin

: Apply genuine anaerobic liquid gasket, Three
Bond TB1215, Loctite Part No. 51813 or
equivalent.

SMT273D

MT-1014

DISASSEMBLY

FS5R50B

Case Components
Control housing

Gear shift housing

1. Remove transmission case outer parts.
● Control housing
● Gear shift housing
● Clutch housing
● OD gear case
● Front cover

OD gear case
Transmission case
Clutch housing
Front cover

SMT276D

2. Remove front cover oil seal.
Front cover

SMT305D

3. Remove rear oil seal.

SMT551D

Shift Control Components

Control housing

●

Remove and disassemble gear shift housing and control
housing parts.

Gear shift housing

SMT290D

MT-1015

DISASSEMBLY
Shift Control Components (Cont’d)
Select check spring
(Color: white)
Plug
Select check
plug
Select check
plunger

FS5R50B

CONTROL HOUSING
Cam pin
Control housing
Select check plunger

1. Remove select check plugs, springs and select check plungers.

Select check
plug

Air breather

Select check spring
(Color: black)
Spacer
Reverse check spring
Thrust washer
E-ring
SMT548D
Check plunger

Reverse check assembly

2. Remove E-ring, thrust washer, reverse check spring, spacer,
check plunger and cam pin.
3. Remove plug.

Cam pin

E-ring

SMT298D

GEAR SHIFT HOUSING

Reverse position switch
Interlock plunger

Neutral position switch

Plug

1. Remove reverse and neutral position switch.
● Do not lose check balls and plungers.
2. Remove plug, check balls, interlock pin and interlock plunger.
● Do not lose check balls.

Interlock pin
Check ball

SMT295D
Shift lever bracket

3. Drive out retaining pin from shift lever bracket.

SMT292D

Gear shift housing
Striking lever

4. Remove retaining pin and plug.
a. Drive out retaining pin from striking lever through plug on
gear shift housing.

SMT293D

MT-1016

DISASSEMBLY
Shift Control Components (Cont’d)

FS5R50B

Mating surface
Striking lever

Gear shift housing

Striking rod
Retaining pin

Striking rod cap
SMT549D
3rd & 4th rod bracket

1st & 2nd shift fork
1st & 2nd rod bracket
Alignment portion

1st & 2nd fork rod

b. Drive out retaining pin from reverse shift fork, then drive out
reverse fork rod and fork rod cap with brass bar.
c. Remove interlocking parts.
d. Drive out retaining pins from 3rd & 4th shift fork and 3rd &
4th rod bracket, then drive out 3rd & 4th fork rod and fork rod
cap with brass bar.
e. Drive out retaining pins from 1st & 2nd shift fork and 1st &
2nd rod bracket, then drive out 1st & 2nd fork rod and fork
rod cap with brass bar.

Front

Gear shift housing

Reverse shift fork
3rd & 4th fork
rod

Striking lever

3rd & 4th shift fork

Striking rod
Reverse fork rod
SMT296D

Check ball

Check ball spring

Plug

Interlock plunger
Interlock pin
SMT545D

5. Drive out striking rod with brass bar through control rod plug
on gear shift housing.

SMT294D

MT-1017

DISASSEMBLY
Shift Control Components (Cont’d)

FS5R50B

6. Drive out slide ball bearing using SST.

Slide ball bearing

Tool
Gear shift housing
SMT328D

7. Remove caps.

SMT291D

Gear Components
Mainshaft rear end bearing

TRANSMISSION CASE

Snap ring

1. Remove snap ring for mainshaft rear end bearing.

Rear
SMT277D

2. Pull out mainshaft rear end bearing, then remove mainshaft
spacer.

Mainshaft spacer
Puller

SMT278D

3. Check OD counter gear end play.
Gear end play
Gear
OD counter gear
●

Feeler gauge

End play

mm (in)

0.20 — 0.47 (0.0079 — 0.0185)

If not within specification, disassemble and check contact
surface of gear to hub, washer, bushing, needle bearing and
shaft.

SMT264B

MT-1018

DISASSEMBLY
Gear Components (Cont’d)

FS5R50B

4. Remove counter gear rear snap ring.

SMT265B

5. Remove lock plate of reverse idler shaft and then remove
reverse idler gear, washers, reverse idler needle bearings
and reverse idler shaft.

SMT863A

6. Pull out the following parts.
● OD counter gear
● OD synchronizer assembly with OD shift fork and OD fork
rod

Puller
SMT266B

7. Pull out OD gear bushing and thrust washer.
8. Remove bolts securing bearing retainer and then remove
bearing retainer.

Mainshaft

OD gear bushing
Bearing retainer
Rear
SMT279D

9. Pull out OD main gear.
Puller

SMT268B

MT-1019

DISASSEMBLY
Gear Components (Cont’d)

FS5R50B

10. Remove mainshaft bearing snap ring.
11. Pull out mainshaft bearing.

Mainshaft bearing

Rear

Puller
SMT281D

12. Support mainshaft with hoist.
13. Remove bolts securing front cover and then remove front
cover.
Rear

SMT319D

14. Remove counter gear front bearing outer race.
● Tap rear end of counter gear lightly before removing
bearing.

SMT282D

15. Remove counter gear rear bearing outer race.
● Tap front end of counter gear lightly before removing
bearing.
16. Settle counter gear assembly down on bottom of transmission case.
(Outer race)

Counter gear rear bearing
(Inner race)
SMT283D

17. Remove main drive gear assembly.
● Set cutting portion of clutch gear on main drive gear to
upper side.

Upper

Rear view

Front
SMT284D

MT-1020

FS5R50B

DISASSEMBLY
Gear Components (Cont’d)
18. Remove mainshaft assembly.

Mainshaft
assembly

Rear
SMT285D

19. Remove counter gear assembly.
Counter gear

Rear
SMT286D

MAIN DRIVE GEAR
1. Remove main drive gear snap ring and main drive bearing
snap ring.
2. Press out main drive gear bearing.

SMT420AA

MAINSHAFT AND GEARS
2nd main gear

1. Before disassembly, check 1st, 2nd, 3rd and reverse main
gear end play.
Gear end play:

3rd main gear

Front

Unit: mm (in)

Gears
Reverse main gear
1st main gear
Feeler gauge
Main drive gear

3rd main gear

SMT287D
Dial indicator

End play

1st main gear

0.20 — 0.48 (0.0079 — 0.0189)

2nd main gear

0.20 — 0.60 (0.0079 — 0.0236)

3rd main gear

0.20 — 0.45 (0.0079 — 0.0177)

OD counter gear

0.20 — 0.47 (0.0079 — 0.0185)

Reverse main gear

0.20 — 0.44 (0.0079 — 0.0173)

●

If not within specification, disassemble and check contact
surface of gears to hub, washer, bushing, needle bearing and
shaft.

Puller
SMT907A

MT-1021

DISASSEMBLY
Gear Components (Cont’d)

FS5R50B

2. Remove 3rd & 4th hub snap ring.
3. Pull out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.

Puller

SMT908A

4. Pull out 3rd gear bushing.
5. Remove 2nd main gear and 2nd gear needle bearing.
Puller

SMT839A

6. Pull out reverse synchronizer assembly.
7. Remove reverse main gear and reverse gear needle bearing.
8. Remove 1st & 2nd hub snap ring.

Puller

SMT274B

9. Press out 1st main gear together with 1st & 2nd synchronizer
assembly.

SMT911A

COUNTER GEAR
1. Remove sub-gear components.
a. Remove sub-gear snap ring.
b. Remove sub-gear, sub-gear washer and sub-gear spring.

SMT333D

MT-1022

DISASSEMBLY
Gear Components (Cont’d)
Counter gear rear
bearing outer race

Counter gear front
bearing inner race

Puller

FS5R50B

2. Pull out counter gear front and rear bearing inner race.

Puller

SMT924A

MT-1023

INSPECTION

FS5R50B

Shift Control Components
●

Check contact surface and sliding surface for wear,
scratches, projections or other damage.

SMT301D

Gear Components
GEAR AND SHAFT
●
●

Check for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.

SMT276B

SMT946A

SMT925A

shifting insert

SYNCHRONIZER
Spline
portion

●
●
●

Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.

SMT387A

MT-1024

INSPECTION
Gear Components (Cont’d)

FS5R50B

● Measure clearance between baulk ring and gear.
Clearance between baulk rings and main gears:

Baulk ring to gear
clearance

Unit: mm (in)

Gears

Standard

Main drive gear

1.00 — 1.45 (0.0394 — 0.0571)

OD counter gear

1.00 — 1.45 (0.0394 — 0.0571)

Reverse main gear

1.00 — 1.45 (0.0394 — 0.0571)

Wear limit

0.7 (0.028)

SMT140
Inner baulk ring
Inner baulk ring
Synchronizer cone

Dial indicator
SMT041BA
Outer baulk ring

Outer baulk ring

● Measure wear of 1st, 2nd and 3rd baulk rings.
a. Place inner baulk ring in position on synchronizer cone.
b. Hold baulk ring evenly against synchronizer cone and measure distance ‘‘A’’.
c. Place outer baulk ring in position on synchronizer cone.
d. Hold baulk ring evenly against synchronizer cone and measure distance ‘‘B’’.
Standard:
Inner-A 0.7 — 0.9 mm (0.028 — 0.035 in)
Outer-B 1.4 — 1.6 mm (0.055 — 0.063 in)
Wear Limit:
0.2 mm (0.008 in)
e. If distance ‘‘A’’ or ‘‘B’’ is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as
a set.

Synchronizer cone

SMT330D

BEARING
●

Make sure bearings roll freely and are free from noise,
cracks, pitting or wear.

SMT552D

MT-1025

ASSEMBLY
Select check spring
(Color: white)
Plug
Select check
plug
Select check
plunger

FS5R50B

Shift Control Components
Cam pin
Control housing
Select check plunger
Select check
plug

Air breather

Select check spring
(Color: black)
Spacer
Reverse check spring
Thrust washer
E-ring
SMT548D

CONTROL HOUSING
1. Install
check
2. Install
a. Install

select check plunger, select check spring and select
plug.
reverse check parts.
cam pin.

Check plunger

b. Install check plunger, spacer, reverse check spring and
thrust washer.

Reverse check assembly

SMT299D

c. Install E-ring.
Reverse check assembly

E-ring

SMT300D

3. Assemble control housing parts as shown on left.

SMT304D

GEAR SHIFT HOUSING

Slide ball bearing

1. Assemble gear shift housing.
2. Install slide ball bearing into gear shift housing using SST.
Press in 4 mm (0.16 in)

Press in 35 mm (1.38 in)

SMT329D

MT-1026

ASSEMBLY
Shift Control Components (Cont’d)
3rd & 4th rod bracket
1st & 2nd shift fork
1st & 2nd rod bracket
Alignment portion

1st & 2nd fork rod

Front

FS5R50B

3. Install striking rod through striking lever and shift lever
bracket.
● Pay attention to direction of each part.
● Pay attention to direction of each part.
● Align cutout portion of striking lever, 1st & 2nd rod
bracket, 3rd & 4th rod bracket and reverse shift fork.
4. Install 1st & 2nd shift fork, 1st & 2nd rod bracket and 1st &
2nd fork rod.
5. Install 3rd & 4th rod bracket, 1st & 2nd and 3rd & 4th shift
forks and 3rd & 4th fork rod.
6. Insert interlock plunger and check ball for interlock part, then
install reverse shift fork and reverse fork rod.

Gear shift housing

Reverse shift fork
3rd & 4th fork
rod

Striking lever

3rd & 4th shift fork

Striking rod
Reverse fork rod
SMT296D

Check ball

Check ball spring

Plug

Interlock plunger
Interlock pin
SMT545D

7. Drive in retaining pins into striking lever, each shift fork and
bracket.

Reverse fork
rod
Striking lever

SMT302D
Shift lever bracket

8. Install retaining pin into shift lever bracket.

SMT292D

MT-1027

ASSEMBLY
Shift Control Components (Cont’d)

FS5R50B

9. Install fork rod caps by tapping lightly.

Striking rod cap
Fork rod cap
Striking
lever cap

Fork rod cap

Gear shift housing
Shift rod cap
SMT303D

10. Install reverse and neutral position switches.

Reverse position switch
Interlock plunger

Neutral position switch

Plug
Interlock pin
Check ball

SMT295D

Gear Components
MAIN DRIVE GEAR
1. Press main drive gear bearing.

SMT425AA

2. Select proper main drive gear snap ring to minimize clearance of groove, then install it.
Allowable clearance of groove:
0 — 0.15 mm (0 — 0.0059 in)
Main drive gear snap ring:
Refer to SDS, MT-1038.

SMT426A

MAIN SHAFT

Coupling sleeve

1. Assemble synchronizers.

Synchronizer
hub

1st & 2nd synchronizer
●

Opening of shifting insert springs must not be aligned
with each other.

Shifting insert

Shifting insert
Shifting insert spring
SMT914A

MT-1028

ASSEMBLY
Gear Components (Cont’d)

FS5R50B

3rd & 4th synchronizer

Shifting insert spring
Shifting insert
spring

Coupling
sleeve

Shifting insert
SMT288D
Synchronizer hub
Stopper
Shifting insert

Reverse synchronizer
●

Coupling sleeve

●

Pay attention to direction of synchronizer hub, shifting
inserts and coupling sleeve.
Openings of shift insert springs must not be aligned with
each other.

Front
SMT331D

2. Press reverse synchronizer assembly together with reverse
main gear and reverse gear needle bearing.
● Pay attention to direction of reverse synchronizer hub
assembly.
3. Install 1st main gear and 1st gear needle bearing.

Drift

SMT278B

MT-1029

ASSEMBLY
Gear Components (Cont’d)

FS5R50B

4. Press 1st & 2nd synchronizer assembly.
● 1st baulk ring and 2nd baulk ring are different.
Drift

This groove is only
on front side.

SMT289D

1st & 2nd hub snap
ring

5. Select proper 1st & 2nd hub snap ring to minimize clearance
of groove, then install it.
Allowable clearance of groove:
0 — 0.13 mm (0 — 0.0051 in)
1st & 2nd hub snap ring:
Refer to SDS, MT-1038.

SMT280B

6. Install 2nd main gear and 2nd gear needle bearing.
7. Press 3rd gear bushing.
8. Install 3rd main gear and 3rd gear needle bearing.

SMT281B

9. Press 3rd & 4th synchronizer assembly.
● Pay attention to direction of synchronizer assembly.
Front

SMT282B

MT-1030

ASSEMBLY
Gear Components (Cont’d)

FS5R50B

10. Select proper 3rd & 4th hub snap ring to minimize clearance
of groove, then install it.
Allowable clearance of groove:
0 — 0.1 mm (0 — 0.004 in)
3rd & 4th hub snap ring:
Refer to SDS, MT-1038.
11. Measure 1st, 2nd, 3rd and reverse main gear end plays as
the final check. — Refer to ‘‘Disassembly’’.

SMT332D
Counter gear front
bearing inner race

Counter gear rear
bearing outer race

COUNTER GEAR
1. Press on counter gear front and rear bearing inner race.

SMT924A

2. Install sub-gear, sub-gear spring, sub-gear washer, and snap
ring, while compressing sub-gear spring.
● Pay attention to direction of sub-gear spring.

Front

Sub-gear
spring

SMT334D

TRANSMISSION CASE

Reverse idler gear

1. Install reverse idler shaft, thrust washers, needle bearings
and gear.
● Pay attention to direction of reverse idler gear and washers.
2. Install lock plate of reverse idler shaft.
Front

Transmission
case

SMT306D

3. Settle counter gear assembly on bottom of transmission
case.

Counter gear

Front

SMT307D

MT-1031

ASSEMBLY
Gear Components (Cont’d)

FS5R50B

4. Place mainshaft assembly on top of counter gear assembly
and then support it with hoist.

Mainshaft
assembly

Front
SMT308D

●

Align matching portion of counter gear and sub-gear
tooth to upper side.

SMT309D

5. Install main drive gear assembly by tapping front end of it
lightly.
● Set cutting portion of clutch gear on main drive gear to
the upper side.

Upper

Rear view

Soft hammer
SMT310D

6. Install counter gear front bearing outer race by tapping it
lightly while holding counter gear assembly.
● Pay attention to direction.

Front
Soft hammer
SMT311D

7. Install counter gear rear bearing outer race by tapping it
lightly while holding counter gear assembly.
● Pay attention to direction.
8. Take off hoist from mainshaft.

Front

Tool
SMT312D

MT-1032

ASSEMBLY
Gear Components (Cont’d)

FS5R50B

9. Install Tool onto transmission case.

SMT313D

10. Install OD gear bushing.
11. Remove KV32102400 (Counter gear stopper).

SMT308B

12. Install front cover oil seal.
● Apply multi-purpose grease to lip of oil seal before
installing.

SMT942AA

13. Install front cover.
● Always use new bolts at portion V
A as they are selfsealing bolts.
Tightening torque:
Refer to Case Components, MT-1011.

SMT295B

14. Install clutch housing.
Tightening torque:
Refer to Case Components, MT-1011.

SMT319B

MT-1033

ASSEMBLY
Gear Components (Cont’d)

FS5R50B

15. Install Tool onto transmission case.

SMA for FS5R50B with serial number
>3081Z00340 (December 2001)

Adjusting bolt

SMT314D

16. Stand transmission case assembly on two wooden blocks
placed under clutch housing.
17. Install mainshaft bearing without snap ring to prevent it from
damaging transmission case.
● Pay attention to direction.
18. Put snap ring back in place.

Drift

Front

SMT309B

19. Install OD main gear.
● Pay attention to direction.
20. Remove KV32102500 (Mainshaft stopper).

Front
SMT872A

21. Install bearing retainer and then stake 4 torx bolts at two
points.
● Install thrust washer and OD counter gear bushing.

SMT310B

MT-1034

ASSEMBLY
Gear Components (Cont’d)

FS5R50B

22. Install the following parts.
a. Assemble OD synchronizer onto OD counter gear.
● Pay attention to direction of shifting inserts and OD coupling sleeve.

Rear side
OD coupling sleeve

OD shifting insert

Front

OD synchronizer assembly
(with OD counter gear)
SMT315D

b. Install OD counter gear with OD synchronizer assembly, OD
shift fork and rod.

SMT311B

23. Install OD synchronizer cone.
24. Install OD synchronizer cone washer.

SMT312B

25. Select proper counter gear rear snap ring to minimize clearance of groove, then install it.
Allowable clearance of groove:
0 — 0.15 mm (0 — 0.0059 in)
Counter gear rear snap ring:
Refer to SDS, MT-1038.
● Measure OD counter gear end play as the final check —
Refer to ‘‘SDS’’, MT-1038.

SMT313B

MT-1035

ASSEMBLY
Gear Components (Cont’d)

FS5R50B

26. Install mainshaft spacer and mainshaft rear end bearing.

SMT985A

27. Select proper set of mainshaft rear end bearing snap ring to
minimize clearance of groove, then install it.
Allowable clearance of groove:
0 — 0.15 mm (0 — 0.0059 in)
Mainshaft rear end bearing snap ring:
Refer to SDS, MT-1038.

Mainshaft rear
end bearing

Snap ring
SMT318D

28. Install rear oil seal.
● Apply multi-purpose grease to lip of oil seal on OD gear
case before installing.

SMT304B

29. Install OD gear case and then tighten fixing bolts.
● Always use new bolts at portion V
A as they are selfsealing bolts.
Tightening torque:
Refer to Case Components, MT-1011.

OD gear case

SMT316D

30. Install gear shift housing and control housing onto transmission case.
● Always use new bolts at portion V
A as they are selfsealing bolts.

Gear shift housing

Front

Control housing
SMT317D

MT-1036

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
ZD30DDTi
Applied model

Hardtop & Wagon

Transmission

FS5R50B

4WD

Number of speed

Transmission control

Floor direct

Shift pattern

Synchromesh type

Warner

Gear ratio
1st

4.262

2nd

2.456

3rd

1.488

4th

1.000

0.851

Reverse

3.972

Number of teeth
Mainshaft
Drive

1st

2nd

3rd

Reverse

Countershaft
Drive

1st

2nd

3rd

Reverse

Reverse idler gear
Oil capacity

27
! (Imp pt)

3.8 (6-3/4)
1st, 2nd and 3rd double baulk ring type synchronizer

Remarks
Reverse synchronizer type

MT-1037

FS5R50B

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment
GEAR END PLAY

1st & 2nd hub snap ring
Unit: mm (in)

Gear

End play

1st main gear
2nd main gear
3rd main gear
OD counter gear
Reverse main gear

0.20
0.20
0.20
0.20
0.20

—

0.48
0.60
0.45
0.47
0.44

Unit: mm (in)

Allowable clearance

(0.0079
(0.0079
(0.0079
(0.0079
(0.0079

—

0.0189)
0.0236)
0.0177)
0.0185)
0.0173)

0 — 0.13 (0 — 0.0051)

Thickness

Part number

2.05 (0.0807)

32348-0T200

2.15 (0.0846)

32348-0T201

3rd & 4th hub snap ring
Unit: mm (in)

CLEARANCE BETWEEN BAULK RING
AND GEAR

Allowable clearance

Main drive, OD and reverse baulk ring

1.95
2.00
2.05
2.10
2.15
2.20

Unit: mm (in)

Gear

Standard

Main drive gear
OD counter gear
Reverse gear

1.00
(0.0394
1.00
(0.0394
1.00
(0.0394

—

Wear limit

1.45
0.0571)
1.45
0.0571)
1.45
0.0571)

0 — 0.10 (0 — 0.0039)

Thickness

0.7 (0.028)

(0.0768)
(0.0787)
(0.0807)
(0.0827)
(0.0846)
(0.0866)

Part number
32348-0T210
32348-0T211
32348-0T212
32348-0T213
32348-0T214
32348-0T215

Counter gear rear snap ring
Unit: mm (in)

1st, 2nd and 3rd baulk ring (double baulk
ring)

Allowable clearance
Thickness
1.35
1.45
1.55
1.65
1.75
1.85

Outer baulk ring

(0.0531)
(0.0571)
(0.0610)
(0.0650)
(0.0689)
(0.0728)

0 — 0.15 (0 — 0.0059)
Part number
32204-VB000
32204-VB001
32204-VB002
32204-VB003
32204-VB004
32204-VB005

Mainshaft rear end bearing snap ring
Unit: mm (in)

Inner baulk ring

Allowable clearance
Synchronizer cone

SMT327D

Unit: mm (in)
Dimension

Standard

Wear limit

0.7 — 0.9
(0.028 — 0.035)

0.2 (0.008)

1.4 — 1.6
(0.055 — 0.063)

0.2 (0.008)

AVAILABLE SNAP RING
Main drive gear snap ring
Unit: mm (in)

Allowable clearance

0 — 0.15 (0 — 0.0059)

Thickness

Part number

2.05 (0.0807)

32348-0T200

2.15 (0.0846)

32348-0T201

2.25 (0.0886)

32348-0T202

MT-1038

0 — 0.15 (0 — 0.0059)

Thickness

Part number

1.8
1.9
2.0
2.1
2.2
2.3
2.4

32204-VB010
32204-VB011
32204-VB012
32204-VB013
32204-VB014
32204-VB015
32204-VB016

(0.071)
(0.075)
(0.079)
(0.083)
(0.087)
(0.091)
(0.094)

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

SECTION

MODIFICATION NOTICE:
+ ZD30ETi engine has been adopted.

CONTENTS
PROPELLER SHAFT …………………………………… 1002
On-vehicle Service……………………………………. 1003
FRONT FINAL DRIVE ………………………………….. 1004
REAR FINAL DRIVE ……………………………………. 1005
DIFFERENTIAL LOCK …………………………………. 1006
Wiring Diagram — DIFF/L —/LHD Models ….. 1006

Wiring Diagram — DIFF/L —/RHD Models….. 1008
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1010
Propeller Shaft …………………………………………. 1010
Final Drive……………………………………………….. 1011

PROPELLER SHAFT

JPD521D

PD-1002

PROPELLER SHAFT
On-vehicle Service
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft
runout first.
1. Raise front and rear wheels.
2. Measure propeller shaft runout at several points by rotating
final drive companion flange with hands.
Runout limit: 0.6 mm (0.024 in)
SPD728

Unit: mm (in)

Distance
Applied model
A
Front
propeller shaft

ZD30ETi

M/T

273 (10.75)

ZD30ETi

A/T

257.5 (10.14)

ZD30ETi (Hardtop)

A/T

160
(6.30)

410
(16.14)

—

ZD30ETi (Wagon)

M/T

190
(7.48)

445
(17.52)

606
(23.86)

ZD30ETi (Wagon)

A/T

190
(7.48)

445
(17.52)

649.5
(25.57)

ZD30ETi (Hardtop)

M/T

—

II
Rear
propeller shaft

III

SPD520D

3. If runout exceeds specifications, disconnect propeller shaft at
final drive companion flange; then rotate companion flange
180 degrees and reconnect propeller shaft.
4. Check runout again. If runout still exceeds specifications,
replace propeller shaft assembly.
5. Perform road tests.

APPEARANCE CHECKING
+ Inspect propeller shaft tube surface for dents or cracks. If
damaged, replace propeller shaft assembly.
SPD102

PD-1003

FRONT FINAL DRIVE

SPD436AA

PD-1004

REAR FINAL DRIVE

SPD437AA

PD-1005

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/LHD Models

TPD013

PD-1006

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/LHD Models
(Cont’d)

TPD018

PD-1007

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/RHD Models

TPD016

PD-1008

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/RHD Models
(Cont’d)

TPD001M

PD-1009

SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft
GENERAL SPECIFICATIONS
Front propeller shaft
ZD30ETi engine
Applied model
M/T

A/T

Propeller shaft model

2F80B

Number of joints

Type of journal bearing

Solid (Disassembly type)

Coupling type with transmission

Flange type

Distance between yokes
mm (in)

73 (2.87)

Shaft length (Spider-tospider)
mm (in)

832 (32.76)

Shaft outer diameter
mm (in)

796 (31.34)

50.8 (2.000)

Rear propeller shaft
Applied model
Engine

ZD30ETi

Transmission
Body

M/T

A/T

Hardtop

Wagon

Propeller shaft model

A/T

M/T

Hardtop

Wagon

2F100H

Number of joints

Type of journal bearing

Solid (Disassembly type)

Coupling type with transmission

Flange type

Distance between yokes
mm (in)

94 (3.70)

Shaft length (Spider-tospider)
mm (in)

440 (17.32)

1,044 (41.10)

480 (18.90)

957 (37.68)

Shaft outer diameter
mm (in)

57 (2.24)

89.6 (3.528)

75.2 (2.961)

89.6 (3.528)

Available snap rings

2F100H

2F80B

Thickness mm (in)

Color

Part number

Thickness mm (in)

Color

Part number

1.95 (0.0768)

White

37146-61502

1.99 (0.0783)

White

37146-C9400

1.98 (0.0780)

Yellow

37147-61502

Red

37148-61502

2.02 (0.0795)

Yellow

37147-C9400

2.01 (0.0791)

2.05 (0.0807)

Red

37148-C9400

2.04 (0.0803)

Green

37149-61502

2.08 (0.0819)

Green

37149-C9400

2.07 (0.0815)

Blue

37150-61502

2.11 (0.0831)

Blue

37150-C9400

2.10 (0.0827)

Light brown

37151-61502

Pink

37146-61503

2.14 (0.0843)

Light brown

37151-C9400

2.13 (0.0839)

2.17 (0.0854)

Black

37152-C9400

2.16 (0.0850)

Gold

37147-61503

2.20 (0.0866)

Colorless

37153-C9400

2.19 (0.0862)

Black

37148-61503

2.22 (0.0874)

Colorless

37149-61503

PD-1010

SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive
GENERAL SPECIFICATIONS
Body type

Wagon

Transmission

Hardtop

M/T

A/T

M/T

A/T

2-pinion

4-pinion

Optional

Standard

Diff. lock

LSD

Standard
Front final drive

H233B
2-pinion

4-pinion

Gear ratio

4.375

Number of teeth (Ring gear/drive
pinion)

35/8

Oil capacity (Approx.)

5.4 (9-1/2)

! (Imp pt)
Optional

Standard

Rear final drive
[Grade]

Optional

Standard

H260
Diff. lock

H233B
LSD

Diff. lock

LSD

Gear ratio

4.375

Number of teeth (Ring gear/drive
pinion)

35/8

Oil capacity
Without diff. lock
(Approx.)
With diff. lock
! (Imp pt)

4.7 (8-1/4)

2.4 (4-1/4)

3.7 (6-1/2)

3.0 (5-1/4)

INSPECTION AND ADJUSTMENT (H233B)
Drive pinion preload adjustment
Drive pinion bearing preload adjusting method

Adjusting shim and spacer

Total preload adjustment
Total preload
Nzm (kg-cm, in-lb) Drive pinion bearing
With front oil seal
Ring gear backlash

Drive pinion preload [P1]
Nzm (kg-cm, in-lb)

Side bearing adjusting method

With front oil seal

1.4 — 2.2
(14 — 22, 12 — 19)

Without front oil seal

1.2 — 2.0
(12 — 20, 10 — 17)

P1: Drive pinion preload

Available drive pinion preload adjusting washer
Thickness
2.31
2.33
2.35
2.37
2.39
2.41
2.43
2.45
2.47
2.49
2.51
2.53
2.55
2.57
2.59

mm (in)
(0.0909)
(0.0917)
(0.0925)
(0.0933)
(0.0941)
(0.0949)
(0.0957)
(0.0965)
(0.0972)
(0.0980)
(0.0988)
(0.0996)
(0.1004)
(0.1012)
(0.1020)

Part number*
38125-82100
38126-82100
38127-82100
38128-82100
38129-82100
38130-82100
38131-82100
38132-82100
38133-82100
38134-82100
38135-82100
38136-82100
38137-82100
38138-82100
38139-82100

Available drive pinion preload adjusting spacers
Length

mm (in)
4.50
4.75
5.00
5.25
5.50

(0.1772)
(0.1870)
(0.1969)
(0.2067)
(0.2165)

Part number
38165-76000
38166-76000
38167-76000
38166-01J00
38166-01J10

* Always check with the Parts Department for the latest parts information.

PD-1011

mm (in)

P1 + [0.3 to 0.4
(3 to 4, 2.6 to 3.5)]
0.15 — 0.20
(0.0059 — 0.0079)
Side adjuster

REAR AXLE &
REAR SUSPENSION

SECTION

MODIFICATION NOTICE:
+ Wiring diagram connector colors have been changed.

CONTENTS
STABILIZER RELEASE DEVICE…………………… 1002
Wiring Diagram ………………………………………… 1002

STABILIZER RELEASE DEVICE
Wiring Diagram

TRA001

RA-1002

STABILIZER RELEASE DEVICE
Wiring Diagram (Cont’d)

TRA001M

RA-1003

RESTRAINT SYSTEM
SECTION

MODIFICATION NOTICE:
+ Side air bag has been adopted as optional equipment.
+ Diagnosis sensor unit has been changed.
+ Seat belt pre-tensioner with load limiter has been added.
+ Deployment procedure of seat belt pre-tensioner has been changed.

CONTENTS
PRECAUTION……………………………………………… 1002
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 1002
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)1003
Precautions for SRS “AIR BAG” and “SEAT
BELT PRE-TENSIONER” Service ………………. 1003
Special Service Tools ……………………………….. 1003
Description ………………………………………………. 1004
Built-in Type Side Air Bag …………………………. 1004
Seat Belt Pre-tensioner with Load Limiter……. 1005
SRS Component Parts Location…………………. 1005
Maintenance Items……………………………………. 1006
Removal and Installation — Diagnosis Sensor
Unit, Seat Belt Pre-tensioner with Load Limiter
and Satellite Sensor………………………………….. 1008
Removal — Driver Air Bag Module and Spiral
Cable………………………………………………………. 1009

Installation — Driver Air Bag Module and
Spiral Cable …………………………………………….. 1011
Removal — Side Air Bag Module……………….. 1012
Installation — Side Air Bag Module…………….. 1013
Disposal of Air Bag Module and Seat Belt
Pre-tensioner……………………………………………. 1015
TROUBLE DIAGNOSES — Supplemental
Restraint System (SRS) ………………………………. 1019
Trouble Diagnoses Introduction………………….. 1019
How to Perform Trouble Diagnoses for Quick
and Accurate Repair …………………………………. 1021
Schematic ……………………………………………….. 1023
Wiring Diagram — SRS —/LHD Models ……… 1024
Wiring Diagram — SRS —/RHD Models …….. 1028
Self-diagnosis…………………………………………… 1032
Trouble Diagnoses for Air Bag Warning Lamp1050
COLLISION DIAGNOSIS………………………………. 1052

PRECAUTION
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS composition which is available to NISSAN MODEL Y61 is as follows (The composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.

RS-1002

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Precautions for SRS “AIR BAG” and “SEAT
BELT PRE-TENSIONER” Service
+Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual.
+Before servicing the SRS, turn ignition switch “OFF”, disconnect both battery cables and wait at least 3
minutes.
For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt pretensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed.
+ Diagnosis sensor unit must always be installed with their arrow marks “S” pointing towards the front of
the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before
installation and replace as required.
+ The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt
to turn steering wheel or column after removal of steering gear.
+ Handle air bag module carefully. Always place driver and passenger air bag modules with the pad side
facing upward and front side air bag modules (built-in type) with the stud bolt side facing down.
+ Conduct self-diagnosis to check entire SRS for proper function after replacing any components.
+ After air bag inflates, the front instrument panel assembly should be replaced if damaged.

Special Service Tools
Tool number
Tool name

Description

KV99106400
Deployment tool

Disposing of air bag module

NT357

KV99105300
Air bag module bracket

Anchoring air bag module

NT354

HT61961000 and
HT62152000 combined
*Special torx bit

Use for special bolts
[TAMPER RESISTANT TORX (Size T50)]

a: 3.5 (0.138) dia.
b: 8.5 — 8.6 (0.335 — 0.339) dia.
c: approx. 10 (0.39) sq.

Unit: mm (in)

NT361

KV99108300
Deployment tool adapters for
built-in type side air bag and
passenger air bag modules

NT780

KV99108200 (KV999R0020)
Deployment tool adapters for
seat belt pre-tensioner

NT721

*: Special tool or commercial equivalent

RS-1003

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Description
The air bag deploys if the diagnosis sensor unit activates while the ignition switch is in the “ON” or “START”
position.

SRS585-A

The collision modes for which supplemental restraint systems are activated are different among the SRS
systems. For example, the driver air bag module and passenger air bag module are activated in a frontal
collision but not in a side collision.
SRS configurations which are activated for some collision modes are as follows;
SRS configuration

Frontal collision

Left side collision

Right side collision

Driver air bag module

—

Passenger air bag module

—

Seat belt pre-tensioner (Driver side)

—

Seat belt pre-tensioner (Passenger side)

—

Side air bag module (LH)

—

Side air bag module (RH)

—

Built-in Type Side Air Bag
Front side air bag is built-in type.
The front seat backs with built-in type side air bag have the labels
shown in figures at left.

SRS755

RS-1004

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Seat Belt Pre-tensioner with Load Limiter
The seat belt pre-tensioner system with load limiter is installed
to both the driver’s seat and the front passenger’s seat. It operates simultaneously with the SRS air bag system in the event of
a frontal collision with an impact exceeding a specified level.
When a frontal collision with an impact exceeding a specified
level occurs, seat belt slack resulting from clothing or other factors is immediately taken up by the pre-tensioner. Vehicle passengers are securely restrained.
When passengers in a vehicle are thrown forward in a collision
and the restraining force of the seat belt exceeds a specified
level, the stopper-A pin will break, allowing the ring gear to
rotate. At this point, resistance force from the belt housing is
applied to the wire attached to the ring gear so that the wire
keeps a constant level of tension (resistance against further rotation of the ring gear in the normal direction). As the ring gear
stopper-A rotates and reaches the stopper-B position, it will
cease its rotation, causing the seat belt webbing to stop extending. By the mechanism previously described, the load limiter
permits the specified extension of the seat belt and a relaxation
of the chest-area seat belt web tension while maintaining force.
SRS501

SRS Component Parts Location

SRS756

RS-1005

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Maintenance Items

SRS222-B

CAUTION:
Do not use electrical test equipment to check SRS circuit.
1. Check operation of “AIR BAG” and “SEAT BELT” warning
lamps (“SEAT BELT” warning lamp can be used for checking seat belt pre-tensioner on models except for Europe.).
After turning ignition key to “ON” position, both warning
lamps illuminate. The “AIR BAG” warning lamp will go off
after about 7 seconds if no malfunction is detected. The
“SEAT BELT” warning lamp will also go off after about 7
seconds after seat belt has been fastened and no malfunction is detected. (When seat belt has not been fastened, the
warning lamp continues to illuminate until seat belt is fastened.)
If any of the following warning lamp conditions occur, immediately check the air bag or seat belt pre-tensioner system.
Refer to RS-1032 for details.
+ The “AIR BAG” or “SEAT BELT” warning lamp does not illuminate when the ignition switch is turned “ON”.
+ The “AIR BAG” or “SEAT BELT” (with seat belt fastened)
warning lamp does not go off about 7 seconds after the ignition switch is turned “ON”.
+ The “AIR BAG” or “SEAT BELT” (with seat belt fastened)
warning lamp blinks after about 7 seconds after the ignition
switch is turned “ON”.
2. Visually check SRS components
(1) Diagnosis sensor unit
+ Check diagnosis sensor unit and bracket for dents, cracks or
deformities.
+ Check connectors for damage, and terminals for deformities.
(2) Air bag module and steering wheel
+ Remove air bag module from steering wheel, instrument
panel or seat back. Check harness cover and connectors for
damage, terminals for deformities, and harness for binding.
+ Install driver air bag module to steering wheel to check fit or
alignment with the wheel.
+ Check steering wheel for excessive free play.
+ Install passenger air bag module to instrument panel to
check fit or alignment with the instrument panel.
+ Install side air bag module to seat back to check fit and
alignment with the seat.
(3)
+
+
+

Spiral cable
Check spiral cable for dents, cracks, or deformities.
Check connectors and protective tape for damage.
Check steering wheel for noise, binding or heavy operation.

(4) Main harness and body harness
+ Check connectors for poor connections, damage, and terminals for deformities.
+ Check harnesses for binding, chafing or cut.
(5) Seat belt pre-tensioner
+ Check harness cover and connectors for damage, terminals
for deformities, and harness for binding.
+ Check belts for damage and anchors for loose mounting.
+ Check retractor for smooth operation.

RS-1006

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Maintenance Items (Cont’d)
+ Perform self-diagnosis for seat belt pre-tensioner using seat
belt warning lamp or CONSULT-II. Refer to “Self-diagnosis”
for details.
(6) Satellite sensor
+ Check satellite sensor (including bracket portion) for dents,
cracks or deformities.
+ Check connectors for damage, and terminals for deformities.
CAUTION:
Replace previously used special bolts, ground bolt and nuts
coated with bonding agent.

RS-1007

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal and Installation — Diagnosis
Sensor Unit, Seat Belt Pre-tensioner with
Load Limiter and Satellite Sensor
CAUTION:
+ Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait at least
3 minutes.
+ Do not use old bolts and nuts coated with bonding agent after removal; replace with new ones.
+ Check diagnosis sensor unit, seat belt pre-tensioner with load limiter and satellite sensor for
proper installation.
+ Check diagnosis sensor unit and satellite sensor to ensure they are free of deformities, dents,
cracks or rust. If they show any visible signs of damage, replace them with new ones.
+ Check diagnosis sensor unit brackets to ensure they are free of deformities and rust.
+ After replacement of diagnosis sensor unit, seat belt pre-tensioner and satellite sensor, check
SRS function and perform self-diagnosis for SRS. Refer to “Self-diagnosis” for details. (RS-1032)
+ Do not attempt to disassemble diagnosis sensor unit, seat belt pre-tensioner with load limiter and
satellite sensor.
+ Replace diagnosis sensor unit, seat belt pre-tensioner and satellite sensor if it has been dropped
or sustained an impact.
+ Do not expose seat belt pre-tensioner to temperatures exceeding 80°C (176°F).

REMOVAL OF DIAGNOSIS SENSOR UNIT

SRS757

1. Disconnect driver, passenger and side air bag module connectors. Also, disconnect seat belt pre-tensioner connector.
2. Remove console finisher, console box assembly and instrument panel stay cover. Refer to “INSTRUMENT PANEL” in
BT section.
3. Disconnect diagnosis sensor unit connector.
4. Remove bolt and also remove special bolts using the
TAMPER RESISTANT TORX (Size T50), from diagnosis
sensor unit.
Then remove the diagnosis sensor unit.
NOTE:
+ To install, reverse the removal procedure sequence.
+ After replacement, perform self-diagnosis for SRS. Refer
to “Self-diagnosis” for details (RS-1032).
CAUTION:
+ Do not use old special bolts coated with bonding agent;
replace with new coated special bolts.

RS-1008

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal and Installation — Diagnosis
Sensor Unit, Seat Belt Pre-tensioner with
Load Limiter and Satellite Sensor (Cont’d)
REMOVAL OF SATELLITE SENSOR
1. Remove seat belt pre-tensioner with load limiter or seat belt
retractor. Refer to “REMOVAL OF SEAT BELT PRE-TENSIONER WITH LOAD LIMITER” or “Front seat belt” in RS
section of Service Manual (Pub. No. SM7E-2Y61G0 or
SM7E-2Y61G1) for details.
2. Disconnect satellite sensor connector.
3. Remove bolt and nuts coated with bonding agent from satellite sensor unit.
Then remove the satellite sensor.
NOTE:
+ To install, reverse the removal procedure sequence.
CAUTION:
+ Do not use old nuts coated with bonding agent after
removal; replace with new coated nuts.

SRS758

Removal — Driver Air Bag Module and Spiral
Cable

SRS759-A

RS-1009

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal — Driver Air Bag Module and
Spiral Cable (Cont’d)
CAUTION:
+ Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes.
+ Always work from the side of air bag module.
1. Remove lower lid from steering wheel, and disconnect air
bag module connector.

SBF811E

2. Remove side lid, ASCD steering switch and audio steering
switch (only on models for the Middle East). Using the
TAMPER RESISTANT TORX (Size T50), remove left and
right special bolts. Air bag module can then be removed.

SBF812E

CAUTION:
+ Always place air bag module with pad side facing
upward.
+ Do not attempt to disassemble air bag module.
+ The special bolts are coated with bonding agent. Do not
use old bolts after removal; replace with new ones.
+ Do not insert any foreign objects (screwdriver, etc.) into
air bag module connector.

SRS161

SBF814E

3. Set steering wheel in the neutral position.
4. Disconnect horn connector and remove nuts.
5. Remove dynamic damper. Then using steering wheel puller,
remove steering wheel. Be careful not to over-tighten puller
bolt on steering wheel.
CAUTION:
+ Do not tap or bump the steering wheel.
6. Remove steering column cover.

SBF239F

RS-1010

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal — Driver Air Bag Module and
Spiral Cable (Cont’d)
7. Remove the four screws. Then unlock the spiral cable connector and disconnect connector. The spiral cable can then
be removed.
CAUTION:
+ Do not attempt to disassemble spiral cable.
+ Do not apply lubricant to the spiral cable.

SRS384

Installation — Driver Air Bag Module and
Spiral Cable
1. Set the front wheels in the straight-ahead position.
2. Connect spiral cable connector. Then, lock the connector
and tighten with screws. Install steering column cover.

SRS384

3. Make sure that the spiral cable is in the neutral position.
The neutral position is detected by turning left about 2.5
revolutions from the right end position. Align the two marks
, ).
(m
CAUTION:
+ The spiral cable may snap due to steering operation if
the cable is installed in an improper position.
Also, with the steering linkage disconnected, the cable
may snap by turning the steering wheel beyond the limited number of turns.
The spiral cable can be turned up to about 2.5 turns from
the neutral position to both the right and left.
4. Connect spiral cable connector and tighten with screws.
Install steering column cover.

SRS165

5. Install steering wheel, setting spiral cable pin guide, and pull
spiral cable through.
6. Connect horn connector and engage spiral cable with pawls
in steering wheel. Move air bag module connector away from
steering wheel lower lid opening.
7. Tighten nut.
: 29 — 39 Nzm (3.0 — 4.0 kg-m, 22 — 29 ft-lb)
8. Install dynamic damper.

SRS231

RS-1011

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Installation — Driver Air Bag Module and
Spiral Cable (Cont’d)

SBF812EG

9. Position air bag module and tighten with new special bolts.
+ Always service the air bag module from the side.
10. Connect air bag module connector.
11. Install steering switches and lids.
12. Perform self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or warning lamp check.) Refer to
RS-1032.
Before performing self-diagnosis, connect both battery
cables.
13. Turn steering wheel to the left end and then to the right end
fully to make sure that spiral cable is set in the neutral position.
If air bag warning lamp blinks or stays ON (at the User
mode), it shows the spiral cable may be snapped due to its
improper position. Perform self-diagnosis again (use CONSULT-II or warning lamp). If a malfunction is detected,
replace the spiral cable with a new one.
14. Perform self-diagnosis again to check that no malfunction is
detected.

Removal — Side Air Bag Module
CAUTION:
+ Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes.
+ Always work from the rear of the air bag module.
1. Remove seatback board.
+ When using a clip removal tool to remove the seatback
board, take care not to damage the air bag harness.
2. Disconnect side air bag module connector.

SRS760

3. Remove the nuts securing the inner cloth with seatback
frame. Then pull up the inner cloth.

SRS761-A

RS-1012

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal — Side Air Bag Module (Cont’d)
4. Remove screws securing seatback finisher and pull up the
seatback trim with seatback finisher.

SRS762-A

5. Remove the torx nuts coated with bonding agent from the
side air bag module.
6. Remove side air bag connector. Side air bag module can
then be removed.

SRS763

CAUTION:
+ Always place the air bag module with the stud bolt side
facing down.
+ Do not attempt to disassemble air bag module.
+ The torx nuts are coated with bonding agent. Do not use
old nuts after removal; replace with new coated nuts.
+ Do not insert any foreign objects (screwdriver, etc.) into
air bag module connector.

SRS483

+ Replace air bag module if it has been dropped or sustained an impact.
+ Do not expose the air bag module to temperatures
exceeding 90°C (194°F).
+ Do not allow oil, grease or water to come in contact with
the air bag module.
+ After air bag inflates, all parts of front seatback (including front seatback frame) should be replaced.

SBF814E

Installation — Side Air Bag Module
1. Install side air bag module on seatback frame with new torx
nuts coated with bonding agent.
2. Install side air bag connector.
3. Install seatback trim and seatback finisher with screw.

SRS763

RS-1013

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Installation — Side Air Bag Module (Cont’d)
4. Secure the inner cloth which covers the side air bag module
with nuts.

SRS764-A

5.
6.
7.
8.

Connect side air bag module connector.
Install seatback board with new clips.
Connect both battery cables.
Go to “Self-diagnosis”, RS-1032 and perform self-diagnosis
to
ensure entire SRS operates properly. (Use CONSULT-II or
air bag warning lamp.)

SRS765

RS-1014

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt
Pre-tensioner
+ Before disposing of air bag module and seat belt pre-tensioner, or vehicles equipped with such systems,
deploy the systems. If such systems have already been deployed due to an accident, dispose of them
as indicated in “DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER” (RS-1018).
+ When deploying the air bag module and seat belt pre-tensioner, always use the Special Service Tool;
Deployment tool KV99106400.
+ When deploying the air bag module and seat belt pre-tensioner, stand at least 5 m (16 ft) away from the
deployment component.
+ When deploying air bag module and seat belt pre-tensioner, a fairly loud noise is made, followed by
smoke being released. The smoke is not poisonous, however, be careful not to inhale smoke since it
irritates the throat and can cause choking.
+ Always activate one air bag module at a time.
+ Due to heat, leave air bag module unattended for more than 30 minutes after deployment. Also leave
seat belt pre-tensioner unattended for move than 10 minutes after deployment.
+ Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner.
+ Never apply water to the deployed air bag module and seat belt pre-tensioner.
+ Wash your hands clean after finishing work.
+ Place the vehicle outdoors with an open space of at least 6 m (20 ft) on all sides when deploying air
bag module and seat belt pre-tensioner while mounted in vehicle.
+ Use a voltmeter to make sure the vehicle battery is fully charged.
+ Do not dispose of the air bag module and seat belt pre-tensioner un-deployed.

CHECKING DEPLOYMENT TOOL
Connecting to battery

SRS005-B

CAUTION:
The battery must show voltage of 9.6V or more.
Remove the battery from the vehicle and place it on dry wood
blocks approximately 5 m (16 ft) away from the vehicle.
+ Wait 3 minutes after the vehicle battery is disconnected
before proceeding.
+ Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal.
Make sure the polarity is correct. The right side lamp in the
tool, marked “deployment tool power”, should glow with a
green light. If the right side lamp glows red, reverse the
connections to the battery.

RS-1015

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt
Pre-tensioner (Cont’d)
Deployment tool check
Press the deployment tool switch to the “ON” position. The left
side lamp in the tool, marked “air bag connector voltage” should
illuminate. If it does not illuminate, replace the tool.

Air bag deployment tool lamp illumination chart
(Battery connected)
SBF266H

Switch operation

Left side lamp, green*
“AIR BAG CONNECTOR
VOLTAGE”

Right side lamp, green*
“DEPLOYMENT TOOL
POWER”

OFF

*: If this lamp glows red, the tool is connected to the battery incorrectly.
Reverse the connections and make sure the lamp glows green.

Deployment of side air bag module (outside of
vehicle)
1. Make 6.5 mm (0.256 in) diameter holes in air bag module
bracket [SST: KV99105300] at the position shown in figure
at left.

SRS490

2. Firmly secure air bag module bracket [SST: KV99105300] in
a vise.
3. Insert the stud bolts of side air bag module into the two holes
in air bag module bracket (held in vise) and fix them with two
M6 nuts.
CAUTION:
Side air bag module should be secured to air bag module
bracket [SST: KV99105300] in a vise with metal portion facing down.
SRS491

4. Connect deployment tool adapter [SST: KV99108300] to
deployment tool [SST: KV99106400] connector and connector on air bag module.

SRS492

RS-1016

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt
Pre-tensioner (Cont’d)

SRS020-A

5. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal.
6. The lamp on the right side of the tool, marked “deployment
tool power”, should glow green, not red.
7. Press the button on the deployment tool. The left side lamp
on the tool, marked “air bag connector voltage”, will illuminate
and the air bag module will deploy.
CAUTION:
When deploying the air bag module, stand at least 5 m (16
ft) away from the air bag module.

Deployment of seat belt pre-tensioner (outside of
vehicle)
1. Firmly grip pre-tensioner in a vise and cut the webbing off.

SRS662

2. Connect deployment tool adapter [SST: KV99108200
(KV999R0020)] to deployment tool [SST: KV99106400] connector and seat belt pre-tensioner connector.

SRS663-B

SRS242-A

3. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal.
4. The lamp on the right side of the tool, marked “deployment
tool power”, should glow green, not red.
5. Press the button on the deployment tool. The left side lamp
on the tool, marked “seat belt pre-tensioner connector
voltage”, will illuminate and the seat belt pre-tensioner will
deploy.
CAUTION:
When deploying the seat belt pre-tensioner, stand at least 5
m (16 ft) away from the seat belt pre-tensioner.

RS-1017

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt
Pre-tensioner (Cont’d)
DEPLOYMENT OF AIR BAG MODULE AND SEAT
BELT PRE-TENSIONER WHILE MOUNTED IN
VEHICLE

SRS006

When disposing of a vehicle, deploy air bag modules and seat
belt pre-tensioners while they are mounted in vehicle.
CAUTION:
When deploying air bag module or seat belt pre-tensioner,
ensure vehicle is empty.
1. Disconnect both the vehicle battery cables and wait 3 minutes.
2. Disconnect air bag modules and seat belt pre-tensioners
connector.
3. Connect deployment tool [SST: KV99106400] to air bag
module or seat belt pre-tensioner.
For front passenger air bag module and side air bag module,
attach deployment tool adapter [SST: KV99108300] to the
tool connector. For seat belt pre-tensioner, attach deployment tool adapter [SST: KV99108200 (KV999R0020)] to the
tool connector.
4. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal.
5. The lamp on the right side of the tool, marked “deployment
tool power”, should glow green, not red.
6. Press the button on the deployment tool. The left side lamp
on the tool, marked “air bag connector voltage”, will illuminate
and the air bag module or seat belt pre-tensioner will deploy.
CAUTION:
Activate only one air bag module or seat belt pre-tensioner
at a time.

DISPOSING OF AIR BAG MODULE AND SEAT BELT
PRE-TENSIONER

SBF276H

Deployed air bag modules and seat belt pre-tensioners are very
hot. Before disposing of air bag module, and seat belt pretensioner, wait at least 30 minutes, and 10 minutes, respectively.
Seal them in a plastic bag before disposal.
CAUTION:
+ Never apply water to a deployed air bag module and seat
belt pre-tensioner.
+ Be sure to wear gloves when handling a deployed air
bag module and seat belt pre-tensioner.
+ No poisonous gas is produced upon air bag module
deployment. However, be careful not to inhale gas since
it irritates throat and can cause choking.
+ Do not attempt to disassemble air bag module and seat
belt pre-tensioner.
+ Air bag module and seat belt pre-tensioner can not be
re-used.
+ Wash your hands clean after finishing work.

RS-1018

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction
CAUTION:
+ Do not use electrical test equipment to check SRS harness connectors unless instructed to in
this Service Manual. SRS wiring harnesses can be identified by yellow harness protector or yellow insulation tape before the harness connectors.
+ Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged,
replace it with a new one.
+ Keep ground portion clean.

DIAGNOSIS FUNCTION
The SRS self-diagnosis results can be read by using “AIR BAG” warning lamp, “SEAT BELT” warning lamp
(Models except for Europe) and/or CONSULT-II. The reading of these results is accomplished using one of
two modes — “User mode” and “Diagnosis mode”.
The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a system
malfunction through the operation of the “AIR BAG” warning lamp and/or “SEAT BELT” warning lamp (Models except for Europe).
The Diagnosis mode allows the technician to locate and inspect the malfunctioning part.
The mode applications for the “AIR BAG” warning lamp, “SEAT BELT” warning lamp (Models except for
Europe) and CONSULT-II are as follows:
User mode

Diagnosis mode

Display type

“AIR BAG” warning lamp

ON-OFF operation

“SEAT BELT” warning lamp
(Models except for Europe)

—

ON-OFF operation

CONSULT-II

—

Monitoring

DIAGNOSIS MODE FOR CONSULT-II
+ “SELF-DIAG [CURRENT]”
A current Self-diagnosis result (also indicated by the warning lamp flashes in the Diagnosis mode) is
displayed on the CONSULT-II screen in real time. This refers to a malfunctioning part requiring repairs.
+ “SELF-DIAG [PAST]”
Diagnosis results previously stored in the memory are displayed on the CONSULT-II screen. The stored
results are not erased until memory erasing is executed.
+ “TROUBLE DIAG RECORD”
With TROUBLE DIAG RECORD, diagnosis results previously erased by a reset operation can be displayed on the CONSULT-II screen.
+ “ECU DISCRIMINATED NO.”
The diagnosis sensor unit for each vehicle model is assigned with its own, individual classification number. This number will be displayed on the CONSULT-II screen, as shown at left. When replacing the
diagnosis sensor unit, refer to the part number for the compatibility. After installation, replacement with
a correct unit can be checked by confirming this classification number on the CONSULT-II screen. The
diagnosis sensor unit classification number varies depending on SRS configuration.
For NISSAN MODEL Y61, the diagnosis sensor unit classification numbers are as follows.

Wagon

Hardtop

MODEL

ECU DISCRIMINATED NO.

Model with dual air bags and side air bag

5A0F

Model with dual air bags

5A11

Model with single air bag

5A13

Model with side air bag

5A15

Model with dual air bags

5A17

Model with single air bag

5A19

RS-1019

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction (Cont’d)
HOW TO CHANGE SELF-DIAGNOSIS MODE
With CONSULT-II
From User mode to Diagnosis mode
After selecting AIR BAG on the “SELECT SYSTEM” screen, User mode automatically changes to Diagnosis mode.

SRS769

From Diagnosis mode to User mode
To return to User mode from Diagnosis mode, touch “BACK” key of CONSULT-II until “SELECT SYSTEM”
appears, Diagnosis mode automatically changes to User mode.

SRS770

Without CONSULT-II
From User mode to Diagnosis mode
Diagnosis mode activates only when a malfunction is detected,
by pressing the driver’s door switch at least 5 times within 7
seconds after turning the ignition “ON”. SRS will not enter Diagnosis mode if no malfunction is detected.

SRS168

From Diagnosis mode to User mode
After a malfunction is repaired, switch the ignition “OFF” for at least 1 second, then back “ON”. Diagnosis
mode returns to User mode. If switching from Diagnosis mode to User mode is required while malfunction
is being detected, switch the ignition “OFF”, then back “ON” and press the driver’s door switch at least 5
times within 7 seconds.

RS-1020

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction (Cont’d)
HOW TO ERASE SELF-DIAGNOSIS RESULTS
With CONSULT-II
+ “SELF-DIAG [CURRENT]”
A current Self-diagnosis result is displayed on the CONSULT-II screen in real time. After the malfunction is repaired completely, no malfunction is detected on “SELF-DIAG [CURRENT]”.

+ “SELF-DIAG [PAST]”
Return to the “SELF-DIAG [CURRENT]” CONSULT-II screen
by pushing “BACK” key of CONSULT-II and select “SELFDIAG [CURRENT]” in “SELECT DIAG MODE”. Touch
“ERASE” in “SELF-DIAG [CURRENT]” mode.
NOTE:
If the memory of the malfunction in “SELF-DIAG [PAST]” is
not erased, the User mode shows the system malfunction by
the operation of the warning lamp even if the malfunction is
repaired completely.
SRS701

+ “TROUBLE DIAG RECORD”
The memory of “TROUBLE DIAG RECORD” cannot be erased.

Without CONSULT-II
After a malfunction is repaired, return Diagnosis mode to User mode by switching the ignition “OFF” for at
least 1 second, then back “ON”. At that time, the self-diagnostic result is cleared.

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a malfunction. It is important to fully understand the symptoms or conditions for a customer complaint.

INFORMATION FROM CUSTOMER
WHAT ……..

Vehicle model

WHEN …….
WHERE …..

Date, Frequencies
Road conditions

HOW ……….

Operating conditions, Symptoms

PRELIMINARY CHECK
Check that the following parts are in good order.
+ Battery [Refer to EL section (“BATTERY”) of Service Manual.]
+ Fuse [Refer to EL section (“Fuse”, “POWER SUPPLY ROUTING”) of Service Manual.]
+ System component-to-harness connections

RS-1021

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
How to Perform Trouble Diagnoses for
Quick and Accurate Repair (Cont’d)
WORK FLOW
ACTION ITEM

REFERENCE ITEM

Check in

Listen to customer complaints and requests.

Perform preliminary check.

Preliminary check (RS-1021)

DIAGNOSTIC PROCEDURE 1
(RS-1032)

Check for any Service Bulletin.

Check air bag system operation by using “AIR BAG” warning lamp.
Check seat belt pre-tensioner system operation by using a bulb.

.
c

Inspect malfunctioning part. — Diagnosis mode

Perform self-diagnosis using CONSULT-II.
—————————————————————————————————————— OR —————————————————————————————————————-Perform self-diagnosis using “AIR BAG” warning lamp.

DIAGNOSTIC PROCEDURE 2:
Using CONSULT-II (RS-1034)
DIAGNOSTIC PROCEDURE 6:
Using “AIR BAG” warning lamp
(RS-1044)

Repair/Replace

Final check — Diagnosis mode and User mode
OK

Check out

RS-1022

DIAGNOSTIC PROCEDURE 3:
Using CONSULT-II (RS-1038)
DIAGNOSTIC PROCEDURE 7:
Using “AIR BAG” warning lamp
(RS-1048)

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Schematic

TRS005M

RS-1023

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models

TRS006M

RS-1024

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models (Cont’d)

TRS007M

RS-1025

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models (Cont’d)
WITH CONSULT-II (Except for China and for the Middle East with TB and TD engines)

TRS009M

RS-1026

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models (Cont’d)

TRS010M

RS-1027

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models

TRS011M

RS-1028

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models (Cont’d)

TRS012M

RS-1029

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models (Cont’d)
WITH CONSULT-II (Except for Australia with TD engine)

TRS014M

RS-1030

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models (Cont’d)

TRS015M

RS-1031

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis
DIAGNOSTIC PROCEDURE 1 (
CONSULT-II)

without

Checking SRS operation by using “AIR BAG” warning lamp
— User mode
1. After turning ignition switch from “OFF” to “ON”, “AIR BAG”
warning lamp operates.
2. Compare “AIR BAG” warning lamp operation to the chart
below.
SRS465

“AIR BAG” warning lamp operation — User mode —

SRS condition

Reference item

No malfunction is
detected.
No further action is necessary.
—

MRS095A

The system is malfunction- Go to DIAGNOSTIC PROCEDURE 2, or 6 (RS-1034
ing and needs to be
or 1044).
repaired as indicated.

MRS096A

Air bag is deployed.

Go to COLLISION DIAGNOSIS (RS-1052).

Air bag fuse, diagnosis
sensor unit or harness is
malfunctioning and needs
to be repaired.

Go to DIAGNOSTIC PROCEDURE 9 (RS-1050).

MRS097A

Go to DIAGNOSTIC PROOne of the following has
occurred and needs to be CEDURE 10 (RS-1051).
repaired.
+ Meter fuse is blown.
+ “AIR BAG” warning lamp
circuit has open or
short.
+ Diagnosis sensor unit is
malfunctioning.

MRS098A

NOTE:
If “AIR BAG” warning lamp operates differently from the
operations shown above, refer to “AIR BAG” warning lamp
operation — Diagnosis mode —, DIAGNOSTIC PROCEDURE
6 (step 4), RS-1044.

RS-1032

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
Checking seat belt pre-tensioner system operation
Check seat belt pre-tensioner system operation using a bulb as
follows:
1. Connect a bulb of less than 3.4W between data link connec3 and V
8 .
tor terminals V
2.After turning ignition switch from “OFF” to “ON”, the bulb operates.
3.Compare the bulb operation to the chart below.

SRS848

Lighting condition of the bulb

SRS condition

Reference item

No malfunction is detected.
No further action is necessary.

—

MRS095A

+ Seat belt pre-tensioner circuit is opened, or
+ Seat belt pre-tensioner
power supply or ground circuit is shorted.

+ If CONSULT-II is available,
go to DIAGNOSTIC PROCEDURE 2 (RS-1034).
+ If CONSULT-II is not
available, repair the system
as follows.*
1. Visually check the wiring
harness connections.
2. Replace the harness if it
has visible damage.
3. Replace driver’s and front
passenger seat belt assemblies.
(Before disposing, they
must be deactivated.)
4. Replace diagnosis sensor
unit.

Seat belt pre-tensioner (and
air bag) is deployed.

Go to COLLISION DIAGNOSIS (RS-1052).

MRS096A

MRS097A

* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated
using a bulb or CONSULT-II each time repair is finished. If malfunction is still observed, proceed to the next step. When
malfunction is eliminated, further repair work is not required.

RS-1033

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 2 (

with CONSULT-II)

Inspecting SRS malfunctioning parts by using CONSULT-II
— Diagnosis mode
1. Turn ignition switch “OFF”.
2. Connect CONSULT-II to data link connector.

SRS468-A

3. Turn ignition switch “ON”.
4. Touch “START”.

SRS695

5. Touch “AIR BAG”.

SRS771

6. Touch “SELF-DIAG [CURRENT]”.

SRS697

7. Diagnostic codes are displayed on “SELF-DIAG [CURRENT]”.

SRS772

RS-1034

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
If no malfunction is detected on “SELF-DIAG [CURRENT]” even
though malfunction is detected by the “AIR BAG” warning lamp,
go to DIAGNOSTIC PROCEDURE 4, page RS-1040 to diagnose
the following cases:
+ Self-diagnostic result “SELF-DIAG [PAST] (previously stored
in the memory) might not be erased after repair.
+ The SRS system malfunctions intermittently.

SRS701

8. Touch “PRINT”.
9. Compare diagnostic codes to the CONSULT-II DIAGNOSTIC CODE CHART, page RS-1036.
10. Touch “BACK” key of CONSULT-II until SELECT SYSTEM
appears in order to return to User mode from Diagnosis
mode.
11. Turn ignition switch “OFF”, then turn of and disconnect CONSULT-II and both battery cables.
12. Repair the system as outlined by the “Repair order” in CONSULT-II DIAGNOSTIC CODE CHART, that corresponds to
the self-diagnostic result. For replacement procedure of component parts, refer to RS-1008 and “Removal and Installation” in RS section of Service Manual (Pub. No. SM7E2Y61G0 or SM7E-2Y61G1).
13. After repairing the system, go to DIAGNOSTIC PROCEDURE 3 for final checking, page RS-1038.

RS-1035

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
CONSULT-II DIAGNOSTIC CODE CHART (“SELF-DIAG [CURRENT]”)
Diagnostic item
NO DTC IS DETECTED

Explanation
When malfunction is indicated
by the “AIR BAG” warning lamp
in User mode

+ Self-diagnostic result “SELFDIAG [PAST]” (previously
stored in the memory) might
not be erased after repair.
+ Intemittent malfunction has
been detected in the past.

Repair order
Recheck SRS at each
replacement.
+ Go to DIAGNOSTIC PROCEDURE 4 (RS-1040).

+ No malfunction is detected.

+ Go to DIAGNOSTIC PROCEDURE 3 (RS-1038).

AIRBAG MODULE
[OPEN]

+ Driver’s air bag module circuit is open. (including the spiral cable)

AIRBAG MODULE
[VB-SHORT]

+ Driver’s air bag module circuit is shorted to some power supply
circuit. (including the spiral cable)

AIRBAG MODULE
[GND-SHORT]

+ Driver’s air bag module circuit is shorted to ground. (including the
spiral cable)

AIRBAG MODULE
[SHORT]

+ Driver’s air bag module circuits are shorted to each other.

1. Visually check the wiring harness connection.
2. Replace the harness if it has
visible damage.
3. Replace the spiral cable.
4. Replace driver’s air bag module.
(Before disposal of it, it must
be deployed.)
5. Replace the diagnosis sensor
unit.
6. Replace the related harness.

ASSIST A/B MODULE
[VB-SHORT]

+ Front passenger air bag module circuit is shorted to some power
supply circuit.

ASSIST A/B MODULE
[OPEN]

+ Front passenger air bag module circuit is open.

ASSIST A/B MODULE
[GND-SHORT]

+ Front passenger air bag module circuit is shorted to ground.

ASSIST A/B MODULE
[SHORT]

+ Front passenger air bag module circuits are shorted to each
other.

SIDE MODULE LH
[OPEN]

+ Side air bag module (LH) circuit is open.

SIDE MODULE LH
[VB-SHORT]

+ Side air bag module (LH) circuit is shorted to some power supply
circuits.

SIDE MODULE LH
[GND-SHORT]

+ Side air bag module (LH) circuit is shorted to ground.

SIDE MODULE LH
[SHORT]

+ Side air bag module (LH) circuits are shorted to each other.

SIDE MODULE RH
[OPEN]

+ Side air bag module (RH) circuit is open.

SIDE MODULE RH
[VB-SHORT]

+ Side air bag module (RH) circuit is shorted to some power supply
circuits.

SIDE MODULE RH
[GND-SHORT]

+ Side air bag module (RH) circuit is shorted to ground.

SIDE MODULE RH
[SHORT]

+ Side air bag module (RH) circuits are shorted to each other.

RS-1036

1. Visually check the wiring harness connection.
2. Replace the harness if it has
visible damage.
3. Replace front passenger air
bag module.
(Before disposal of it, it must
be deployed.)
4. Replace the diagnosis sensor
unit.
5. Replace the related harness.
1. Visually check the wiring harness connection.
2. Replace the harness if it has
visible damage.
3. Replace side air bag module
(LH).
(Before disposal, it must be
deployed.)
4. Replace the diagnosis sensor
unit.
5. Replace the related harness.
1. Visually check the wiring harness connection.
2. Replace the harness if it has
visible damage.
3. Replace side air bag module
(RH).
(Before disposal, it must be
deployed.)
4. Replace the diagnosis sensor
unit.
5. Replace the related harness.

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
Diagnostic item

Explanation

Repair order
Recheck SRS at each
replacement.

SATELLITE SENS LH
[UNIT FAIL]
SATELLITE SENS LH
[COMM FAIL]

+ Satellite sensor (LH)

1. Visually check the wiring harness connection.
2. Replace the harness if it has
visible damage.
3. Replace the satellite sensor
(LH).
4. Replace the diagnosis sensor
unit.
5. Replace the related harness.

SATELLITE SENS RH
[UNIT FAIL]
SATELLITE SENS RH
[COMM FAIL]

+ Satellite sensor (RH)

1. Visually check the wiring harness connection.
2. Replace the harness if it has
visible damage.
3. Replace the satellite sensor
(RH).
4. Replace the diagnosis sensor
unit.
5. Replace the related harness.

PRE-TEN FRONT LH
[OPEN/VB-SHORT]

+ The circuit for front LH pre-tensioner is open or shorted to some
power supply circuit.

PRE-TEN FRONT LH
[GND-SHORT]

+ The circuit for front LH pre-tensioner is shorted to ground.

1. Visually check the wiring harness connections.
2. Replace the harness if it has
visible damage.
3. Replace front LH seat belt.
(Before disposing, it must be
deactivated.)
4. Replace the diagnosis sensor
unit.
5. Replace the related harness.

PRE-TEN FRONT RH
[OPEN/VB-SHORT]

+ The circuit for front RH pre-tensioner is open or shorted to some
power supply circuit.

PRE-TEN FRONT RH
[GND-SHORT]

+ The circuit for front RH pre-tensioner is shorted to ground.

CONTROL UNIT

+ Low battery voltage (Less than 9V)

+ Go to DIAGNOSTIC PROCEDURE 3 (RS-1038) after
charging battery.

+ Diagnosis sensor unit is malfunctioning.

1. Visually check the wiring harness connections.
2. Replace the harness if it has
visible damage.
3. Replace the diagnosis sensor
unit.
4. Replace the air bag harness.

1. Visually check the wiring harness connections.
2. Replace the harness if it has
visible damage.
3. Replace front RH seat belt.
(Before disposing, it must be
deactivated.)
4. Replace the diagnosis sensor
unit.
5. Replace the related harness.

* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated
using the air bag warning lamp or CONSULT-II each time repair is finished. If malfunction is still observed, proceed to the
next step. When malfunction is eliminated, further repair work is not required.

RS-1037

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 3 (

with CONSULT-II)

Final checking after repairing SRS by using CONSULT-II —
Diagnosis mode
1. After repairing SRS, connect both battery cables.
2. Connect CONSULT-II to data link connector.
3. Turn ignition switch from “OFF” to “ON”.

SRS468-A

4. Touch “START”.

SRS695

5. Touch “AIR BAG”.

SRS771

6. Touch “SELF-DIAG [CURRENT]”.

SRS697

7. If no malfunction is detected on “SELF-DIAG [CURRENT]”,
repair of SRS is completed. Go to step 8.
(When the malfunction was only in seat belt pre-tensioner
system, go to step 11.)
If any malfunction is detected on “SELF-DIAG [CURRENT]”,
the malfunctioning part is not repaired completely or another
malfunctioning part is detected. Go to DIAGNOSTIC PROCEDURE 2, page RS-1034, and repair malfunctioning part
completely.
SRS701

RS-1038

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
8. Touch “ERASE”.
NOTE:
Touch “ERASE” to clear the memory of the malfunction
(“SELF-DIAG [PAST]”).
If the memory of the malfunction is “SELF-DIAG [PAST]” is
not erased, the User mode shows the system malfunction by
the operation of the warning lamp even if the malfunction is
repaired completely.

SRS773

9. Touch “BACK” key of CONSULT-II to select “SELF-DIAG
[PAST]” in the “SELECT DIAG MODE” screen. Touch “SELFDIAG [PAST]”.

SRS697

10. Check that no malfunction is detected on “SELF-DIAG
[PAST]”.
NOTE:
Past malfunction for seat belt pre-tensioner system will not
be displayed on “SELF-DIAG [PAST]”.

SRS702

11. Touch “BACK” key of CONSULT-II until SELECT SYSTEM
appears.
12. Turn ignition switch “OFF”, then turn off and disconnect
CONSULT-II.
13. Go to DIAGNOSTIC PROCEDURE 1, page RS-1032 to
checkSRS operation by using “AIR BAG” warning lamp with
User mode.

RS-1039

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 4 (Continued from
DIAGNOSTIC PROCEDURE 2)
Inspecting SRS malfunctioning record
Is it the first time for maintenance of
SRS?

Yes

“SELF-DIAG [PAST]”
(which was previously
entered) is still retained in
memory.
Go to DIAGNOSTIC PROCEDURE 3 (RS-1038).

Go to DIAGNOSTIC PROCEDURE 5
(RS-1040).

DIAGNOSTIC PROCEDURE 5 (

with CONSULT-II)

Inspecting SRS intermittent malfunction by using CONSULT-II — Diagnosis mode
1. Turn ignition switch “OFF”.
2. Connect CONSULT-II to data link connector.

SRS468-A

3. Turn ignition switch “ON”.
4. Touch “START”.

SRS695

5. Touch “AIR BAG”.

SRS771

RS-1040

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
6. Touch “SELF-DIAG [PAST]”.

SRS697

7. If diagnostic codes are displayed on “SELF-DIAG [PAST]”,
go to step 10.

SRS700

If no malfunction is detected on “SELF-DIAG [PAST]”, touch
“BACK” and go back to “SELECT DIAG MODE”.
NOTE:
Past malfunction for seat belt pre-tensioner system will not
be displayed on “SELF-DIAG [PAST]”.

SRS702

8. Touch “TROUBLE DIAG RECORD”.
NOTE:
With “TROUBLE DIAG RECORD”, diagnosis results previously erased by a reset operation can be displayed.

SRS697

9. Diagnostic code
RECORD”.

SRS704

RS-1041

displayed

“TROUBLE

DIAG

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
10. Touch “PRINT”.
11. Compare diagnostic codes to the INTERMITTENT MALFUNCTION DIAGNOSTIC CODE CHART, page RS-1043.
12. Touch “BACK” key of CONSULT-II until SELECT SYSTEM
appears.
13. Turn ignition switch “OFF”, then turn off and disconnect
CONSULT-II and both battery cables.
14. Repair the system as outlined by the “Repair order” in
INTERMITTENT MALFUNCTION DIAGNOSTIC CODE
CHART, that corresponds to the self-diagnosis result. For
replacement procedure of component parts, refer to RS-1008
and “Removal and Installation” in RS section of Service
Manual (Pub. No. SM7E-2Y61G0 or SM7E-2Y61G1).
15. Go to DIAGNOSTIC PROCEDURE 3, page RS-1038.

RS-1042

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
INTERMITTENT MALFUNCTION DIAGNOSTIC CODE CHART (“SELF-DIAG [PAST]” or
“TROUBLE DIAG RECORD”)
Diagnostic item

Explanation

Repair order

NO DTC IS DETECTED

+ No malfunction is detected.

+ Go to DIAGNOSTIC PROCEDURE 3 (RS1038).

AIRBAG MODULE
[OPEN]

+ Driver’s air bag module circuit is open.
(including the spiral cable)

AIRBAG MODULE
[VB-SHORT]

+ Driver’s air bag module circuit is shorted to
some power supply circuit. (including the spiral cable)

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check is OK, replace the spiral
cable, diagnosis sensor unit and driver air
bag module. (Before disposing the driver air
bag module, it must be deployed.)

AIRBAG MODULE
[GND-SHORT]

+ Driver’s air bag module circuit is shorted to
ground. (including the spiral cable)

AIRBAG MODULE
[SHORT]

+ Driver’s air bag module circuits are shorted to
each other.

ASSIST A/B MODULE
[VB-SHORT]

+ Front passenger air bag module circuit is
shorted to some power supply circuit.

ASSIST A/B MODULE
[OPEN]

+ Front passenger air bag module circuit is
open.

ASSIST A/B MODULE
[GND-SHORT]

+ Front passenger air bag module circuit is
shorted to ground.

ASSIST A/B MODULE
[SHORT]

+ Front passenger air bag module circuits are
shorted to each other.

SIDE MODULE LH
[OPEN]

+ Side air bag module (LH) circuit is open.

SIDE MODULE LH
[VB-SHORT]

+ Side air bag module (LH) circuit is shorted to
some power supply circuits.

SIDE MODULE LH
[GND-SHORT]

+ Side air bag module (LH) circuit is shorted to
ground.

SIDE MODULE LH
[SHORT]

+ Side air bag module (LH) circuits are shorted
to each other.

SIDE MODULE RH
[OPEN]

+ Side air bag module (RH) circuit is open.

SIDE MODULE RH
[VB-SHORT]

+ Side air bag module (RH) circuit is shorted to
some power supply circuits.

SIDE MODULE RH
[GND-SHORT]

+ Side air bag module (RH) circuit is shorted to
ground.

SIDE MODULE RH
[SHORT]

+ Side air bag module (RH) circuits are shorted
to each other.

SATELLITE SENS LH
[UNIT FAIL]
SATELLITE SENS LH
[COMM FAIL]

+ Satellite sensor (LH)

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check is OK, replace the diagnosis sensor unit and satellite sensor (LH).

SATELLITE SENS RH
[UNIT FAIL]
SATELLITE SENS RH
[COMM FAIL]

+ Satellite sensor (RH)

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check is OK, replace the diagnosis sensor unit and satellite sensor (RH).

CONTROL UNIT

+ Diagnosis sensor unit is malfunctioning.

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check is OK, replace the diagnosis sensor unit.

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check is OK, replace the diagnosis sensor unit and passenger air bag
module. (Before disposing the passenger air
bag module, it must be deployed.)

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check is OK, replace the diagnosis sensor unit and front side air bag module (LH). (Before disposing the front side air
bag module (LH), it must be deployed.)

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. If the harness check is OK, replace the diagnosis sensor unit and front side air bag module (RH). (Before disposing the front side air
bag module (RH), it must be deployed.)

* Follow the procedures in numerical order when repairing malfunctioning parts, then make the final system check.

RS-1043

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 6 (
CONSULT-II)

SRS465

No.

without

Inspecting SRS malfunctioning parts by using “AIR BAG”
warning lamp — Diagnosis mode
NOTE:
SRS will not enter Diagnosis mode if no malfunction is
detected in User mode.
1. Open driver’s door.
2. Turn ignition switch from “OFF” to “ON”.
3. Press driver’s door switch at least 5 times within 7 seconds
after turning ignition switch “ON”.
SRS is now in Diagnosis mode.
4. “AIR BAG” warning lamp operates in Diagnosis mode as follows:
NOTE:
If SRS does not enter Diagnosis mode even though malfunction is detected in User mode, go to DIAGNOSTIC PROCEDURE 11, page RS-1051.

“AIR BAG” warning lamp flash pattern — Diagnosis mode —
a through V
b are repeated.
V

+ Diagnosis
results (previously stored
in the
memory)
might not be
erased after
repair.
+ Intermittent
malfunction
has been
detected in
the past.
Go to DIAGNOSTIC PROCEDURE 8 (RS1050).

a through V
d are repeated.
V
b — Driver and passenger air bag
V

The system is
malfunctioning
and needs to be
repaired.

SRS333

marker (For identifying driver
and/or passenger air bag malfunctioning)
d — Indicates malfunctioning part.
V
The number of flash varies with
malfunctioning part (0.5 sec.
ON and 0.5 sec. OFF is
counted as one flash.)

SRS341
a through V
f are repeated.
V
b ,V
c ,V
d — Side air bag marker
V

f
V

SRS342-A

RS-1044

SRS condition

(For identifying side
air bag malfunctioning)
— Indicates malfunctioning part.
The number of flash varies with
malfunctioning part (0.5 sec.
ON and 0.5 sec. OFF is
counted as one flash.)

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
5. Malfunctioning part is indicated by the number of flashes
(part V
d or V
f ). Compare the number of flashes to AIR BAG
WARNING LAMP FLASH CODE CHART, page RS-1045,
and locate malfunctioning part.
6.Turn ignition switch “OFF”, and disconnect both battery cables.
7. Repair the system as outlined by the “Repair order” in AIR
BAG WARNING LAMP FLASH CODE CHART that corresponds to the flash code. For replacement procedure of component parts, refer to RS-1008 and “Removal and Installation” in RS section of Service Manual (Pub. No. SM7E2Y61G0).
8. After repairing the system, go to DIAGNOSTIC PROCEDURE 7, page RS-1048.

AIR BAG WARNING LAMP FLASH CODE CHART (DIAGNOSIS MODE)
Flash pattern
a through V
b are repeated.
V

+ Diagnosis results
(previously stored in
the memory) might
not be erased after
repair.
+ Intermittent malfunction has been
detected in the past.

SRS333

Repair order
+ Go to DIAGNOSTIC PROCEDURE 8 (RS-1050).
Flash pattern
a through V
d are repeated.
V
d
—
Two
flashes
indicate
V

malfunctioning driver’s
air bag module circuit.

The driver’s air bag
module circuit is malfunctioning.
(V
d : 2 flashes)

SRS334

Repair order (“Recheck SRS at each replacement.”)
1.
2.
3.
4.

Visually check the wiring harness connection.
Replace the harness if it has visible damage.
Replace the spiral cable.
Replace driver’s air bag module.
(Before disposal, it must be deployed.)
5. Replace the diagnosis sensor unit.
6. Replace the related harness.

RS-1045

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
Flash pattern
a through V
d are repeated.
V
d — Seven flashes indicate
V

malfunctioning diagnosis sensor unit.

The diagnosis sensor
unit is malfunctioning.
(V
d : 7 flashes)
SRS335

Repair order (“Recheck SRS at each replacement.”)
1.
2.
3.
4.

Visually check the wiring harness connections.
Replace the harness if it has visible damage.
Replace the diagnosis sensor unit.
Replace the related harness.
Flash pattern
a through V
d are repeated.
V
d — Eight flashes indicate
V

malfunctioning front
passenger air bag
module circuit.
The front passenger air
bag module circuit is
malfunctioning.
(V
d : 8 flashes)

SRS336

Repair order (“Recheck SRS at each replacement.”)
1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. Replace front passenger air bag module.
(Before disposal, it must be deployed.)
4. Replace the diagnosis sensor unit.
5. Replace the related harness.
Flash pattern
a through V
f are repeated.
V
f — One flash indicates
V

malfunctioning side air
bag module (RH) circuit.
The front side air bag
module (RH) circuit is
malfunctioning.
(V
f : 1 flash)

SRS338

Repair order (“Recheck SRS at each replacement.”)
1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. Replace side air bag module (RH).
(Before disposal, it must be deployed.)
4. Replace the diagnosis sensor unit.
5. Replace the related harness.

RS-1046

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
Flash pattern
a through V
f are repeated.
V
f — Two flashes indicate
V

malfunctioning side air
bag module (LH) circuit.
The front side air bag
module (LH) circuit is
malfunctioning.
(V
f : 2 flashes)

SRS337

Repair order (“Recheck SRS at each replacement.”)
1. Visually check the wiring harness connection.
2. Replace the harness if it has visible damage.
3. Replace side air bag module (LH).
(Before disposal, it must be deployed.)
4. Replace the diagnosis sensor unit.
5. Replace the related harness.
Flash pattern
a through V
f are repeated.
V
f
—
Three
flashes indicate
V

malfunctioning satellite
sensor (RH) circuit.

The satellite sensor
(RH) is malfunctioning.
(V
f : 3 flashes)

SRS340

Repair order (“Recheck SRS at each replacement.”)
1.
2.
3.
4.
5.

Visually check the wiring harness connection.
Replace the harness if it has visible damage.
Replace the satellite sensor (RH).
Replace the diagnosis sensor unit.
Replace the related harness.
Flash pattern
a through V
f are repeated.
V
f — Four flashes indicate
V

malfunctioning satellite
sensor (LH) circuit.

The satellite sensor
(LH) is malfunctioning.
(V
f : 4 flashes)
SRS339-A

Repair order (“Recheck SRS at each replacement.”)
1.
2.
3.
4.
5.

Visually check the wiring harness connection.
Replace the harness if it has visible damage.
Replace the satellite sensor (LH).
Replace the diagnosis sensor unit.
Replace the related harness.

* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated
using the air bag warning lamp (in User mode) or CONSULT-II each time repair is finished. If malfunction is still observed,
proceed to the next step. When malfunction is eliminated, further repair work is not required.

RS-1047

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 7 (
CONSULT-II)

without

Final checking after repairing SRS by using “AIR BAG”
warning lamp — Diagnosis mode and User mode
1. After repairing SRS connect both battery cables.
2. Open driver’s door.
3. Turn ignition switch from “OFF” to “ON”.
4. “AIR BAG” warning lamp operates in Diagnosis mode as follows:
SRS465

No.

“AIR BAG” warning lamp flash pattern — Diagnosis mode —
a through V
b are repeated.
V

SRS condition
No malfunction is
detected or
repair is completed.
No further
action is necessary.

SRS333

a through V
d are repeated.
V
b — Driver and passenger air
V

The system is
malfunctioning
bag marker (For identifying and needs to
driver and/or passenger air be repaired.
bag malfunctioning)
d — Indicates malfunctioning
V
part. The number of
flashes varies with malfunctioning part (0.5 sec.
ON and 0.5 sec. OFF is
counted as one flash.)

SRS341

a through V
f are repeated.
V
c ,V
b ,j
d — Side air bag
V

marker (For
identifying side
air bag malfunctioning)
f — Indicates malfunctioning
V
part. The number of
flashes varies with malfunctioning part (0.5 sec.
ON and 0.5 sec. OFF is
counted as one flash.)

SRS342-A

NOTE:
When diagnosis sensor unit is replaced with new one, “AIR
BAG” warning lamp will operate in User mode. Checking
“AIR BAG” warning lamp operation in Diagnosis mode is
not required. Go to step 6.
5. If “AIR BAG” warning lamp operates as shown in No. 1 in
chart above, turn ignition switch “OFF” to reset from Diagnosis mode to User mode and to erase the memory of the malfunction. Then go to step 6.
If “AIR BAG” warning lamp operates as shown in No. 2 or No.
3 in chart above, the malfunctioning part is not repaired

RS-1048

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
completely, or another malfunctioning part is detected. Go to
DIAGNOSTIC PROCEDURE 6, page RS-1044, and repair
malfunctioning part completely.
6. Turn ignition switch “ON”. “AIR BAG” warning lamp operates
in User mode. Compare “AIR BAG” warning lamp operation
to the chart below.
NOTE:
If switching Diagnosis mode to User mode is required while
malfunction is being detected, turn ignition switch from
“OFF” to “ON”. Then press driver’s door switch at least 5
times within 7 seconds after turning ignition switch “ON”.
SRS is now in User mode.
“AIR BAG” warning lamp operation — User mode —

SRS condition
No malfunction is
detected.
No further action is necessary.

Reference item

—

MRS095A

The system is malfunction- Go to DIAGNOSTIC PROCEDURE 2 or 6 (RS-1034
ing and needs to be
or 1044).
repaired as indicated.

MRS096A

Air bag is deployed.

Go to COLLISION DIAGNOSIS (RS-1052).

Air bag fuse diagnosis
sensor unit or harness is
malfunctioning and needs
to be repaired.

Go to DIAGNOSTIC PROCEDURE 9 (RS-1050).

MRS097A

MRS098A

RS-1049

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Self-diagnosis (Cont’d)
DIAGNOSTIC PROCEDURE 8 (Continued from
DIAGNOSTIC PROCEDURE 3) (
without
CONSULT-II)
Inspecting SRS malfunctioning record
Is it the first time for maintenance of
SRS?

No
c

Yes

Diagnosis results (previously stored in the
memory) might not be
erased after repair.
Go to DIAGNOSTIC PROCEDURE 7, step 5 (RS1048).

GO TO DIAGNOSTIC PROCEDURE 5
(RS-1040). Further inspection cannot be
performed without CONSULT-II.

Trouble Diagnoses for Air Bag Warning
Lamp
DIAGNOSTIC PROCEDURE 9
SYMPTOM:“AIR BAG” warning lamp does not turn off.
Is air bag module deployed?

Yes
c

No
.
SRS307

Is SRS “AIR BAG” fuse OK?

No
c

Yes
.

Connect CONSULT-II and touch
“START”.
+ Is “AIRBAG” displayed on
CONSULT-II?

No
c

Replace air bag module
and diagnosis sensor unit.
Refer to COLLISION
DIAGNOSIS, (RS-1052).
Replace fuse and turn ignition switch ON. If SRS “AIR
BAG” fuse is blown again,
repair related harness.
Replace diagnosis sensor
unit.

Yes
.

Is harness connection between warning
lamp and diagnosis sensor unit OK?
SRS771

Yes
.

Replace diagnosis sensor unit.

RS-1050

No
c

Connect warning lamp and
diagnosis sensor unit connector properly. If warning
lamp still does not go off,
replace harness.

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses for Air Bag Warning
Lamp (Cont’d)
DIAGNOSTIC PROCEDURE 10
SYMPTOM: “AIR BAG” warning lamp does not turn on.
No

Is warning lamp fuse OK?

Yes

Replace fuse and turn ignition switch ON. If meter
fuse is blown again, repair
related harness.

Is warning lamp LED OK?

c
SRS469

Yes

Replace warning lamp
LED.

1. Disconnect diagnosis sensor unit connector.
2. Turn the ignition key to ON position.
+ Does warning lamp turn on?

No
c

Yes

Connect warning lamp and
diagnosis sensor unit connector properly. If warning
lamp still does not come
on, replace harness.

Replace diagnosis sensor unit.

DIAGNOSTIC PROCEDURE 11
SYMPTOM: SRS does not enter Diagnostic mode.
Disconnect both battery cables and check
battery voltage using circuit tester.
+ Is battery voltage more than 9V?

Charge battery.
c

Yes
.
SRS058

Remove driver’s door switch and check
continuity between driver’s door switch
1 and V
3 under the
connector terminals V
following conditions.
Condition

No
c

Replace driver’s door
switch.

Continuity

Door switch is depressed
(Door is closed).

Door switch is released (Door
is open).

YES

Yes
SRS470

Check harness continuity between driver’s
3 and
door switch connector terminal V
body ground.
+ Does continuity exist?
Yes
.

Replace diagnosis sensor unit.
.

Go to DIAGNOSTIC PROCEDURE 1 (RS1032).
SRS265-D

RS-1051

Replace or repair harness.
c

COLLISION DIAGNOSIS
FOR FRONTAL COLLISION
To repair the SRS for a frontal collision, perform the following steps.
When SRS (except the side air bag) is activated in a collision:
1 Replace the diagnosis sensor unit.
V
2 Remove the air bag modules (except the side air bag module) and seat belt pre-tensioner assemblies.
V
3 Check the SRS components using the table shown below:
V
+ Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
4 Install new air bag modules (except the side air bag module) and seat belt pre-tensioner assemblies.
V
5 Conduct self-diagnosis using CONSULT-II, and “AIR BAG” and “SEAT BELT” warning lamps (Models
V
except for Europe). Refer to “Self-diagnosis” for details (RS-1032). Ensure entire SRS operates properly.
When SRS is not activated in a collision:
1 Check the SRS components using the table shown below:
V
+ Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
2 Conduct self-diagnosis using CONSULT-II, and “AIR BAG” and “SEAT BELT” warning lamps (Models
V
except for Europe). Refer to “Self-diagnosis” for details (RS-1032). Ensure entire SRS operates properly.

SRS inspection
Part

SRS is NOT activated

SRS (except the
side air bag) is activated

Air bag module
(driver and passenger side)

REPLACE
Install air bag module with new bolts.

Seat belt pre-tensioner assembly

REPLACE
Install seat belt pretensioner with new
bolts.

Diagnosis sensor
unit

REPLACE
Install diagnosis sensor unit with new
bolts.

1.
2.
3.
4.

Steering wheel

1.
2.
3.
4.
5.
6.

Spiral cable

1.
2.
3.
4.
5.

Harness and Connectors

1.
2.
3.
4.

Instrument panel

Refer to the table on next page.

Check case and bracket for dents, cracks or deformities.
Check connectors for damage, and terminals for deformities.
If no damage is found, reinstall with new bolts.
If damaged—REPLACE. Install diagnosis sensor unit with new bolts coated with
bonding agent.

RS-1052

COLLISION DIAGNOSIS
Part

Instrument panel

SRS is NOT activated

SRS (except the
side air bag) is activated

1. When passenger air bag inflates, check the following points for bending, deformities or cracks.
+ Opening portion for passenger air bag

SRS472

+ Passenger air bag module brackets

SRS473

+ The portions securing the instrument panel

SRS474

2. If no damage is found, reinstall the instrument panel.
3. If damaged—REPLACE the instrument panel with bolts.

RS-1053

COLLISION DIAGNOSIS
FOR SIDE COLLISION
To repair the SRS for a side collision, perform the following steps.
When the built-in type front side air bag is activated in the side collision:
1 Replace the following components:
V
— All parts of front seat back with side air bag modules (on the side on which side air bag is activated)
— Diagnosis sensor unit
— Satellite sensor (on the side on which side air bag is activated)
2 Check the SRS components and the related parts using the table shown below.
V
+ Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
3 Conduct self-diagnosis using CONSULT-II, and “AIR BAG” warning lamp and “SEAT BELT” warning
V
lamp (Models except for Europe). Refer to “Self-diagnosis” for details (RS-1032). Ensure entire SRS
operates properly.
When SRS is not activated in the side collision:
1 Check the SRS components and the related parts using the table shown below.
V
+ Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
2 Conduct self-diagnosis using CONSULT-II, “AIR BAG” warning lamp and “SEAT BELT” warning lamp
V
(Models except for Europe). Refer to “Self-diagnosis” for details (RS-1032). Ensure entire SRS operates
properly.

In the case of the side collision
Part

Side air bag is activated

SRS is NOT activated

Built-in side air bags
module (LH or RH)

REPLACE all parts
of front seatback
with deployed side
air bag module.

1. Check for visible signs of damage (dents, tears, deformation) of the seatback on
the collision side.
2. If damaged—REPLACE the damaged seat parts with new bolts and remove the
side air bag module.
3. Check for visible signs of damage (tears etc.) of the side air bag module.
4. Check harness and connectors for damage, and terminals for deformities.
5. If no damage is found, reinstall the side air bag module with new torx nuts coated
with bonding agent.
6. If damaged—REPLACE the side air bag module with new torx nuts coated with
bonding agent. Air bag must be deployed before disposing of it.

Satellite sensor (LH
or RH)

REPLACE the satellite sensor on the
collision side with
new nuts.
(Repair the center
pillar inner, etc.
before installing new
one if damaged.)

1. Remove the satellite sensor on the collision side. Check harness connectors for
damage, terminals for deformities, and harness for binding.
2. Check for visible signs of damage (dents, cracks, deformation) of the satellite
sensor.
3. Install the satellite sensor to check fit.
4. If no damage is found, reinstall the satellite sensor with new nuts coated with
bonding agent.
5. If damaged—REPLACE the satellite sensor with new nuts coated with bonding
agent.

Diagnosis sensor
unit

REPLACE the diagnosis sensor unit
with the new bolts.

1. Check case and bracket for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall the diagnosis sensor unit with new special bolts
and ground bolt coated with bonding agent.
4. If damaged—REPLACE the diagnosis sensor unit with new special bolts and
ground bolt coated with bonding agent.

Seat belt pre-tensioner assembly

1. Check if the seat belt can be extended smoothly.
If the seat belt cannot be extended smoothly.
— Check for deformities of the center pillar inner.
— If the center pillar inner has no damage, REPLACE the seat belt pre-tensioner assembly.
2. Remove the seat belt pre-tensioner assembly on the collision side. Check harness cover and connectors
for damage, terminals for deformities, and harness for binding.
3. Check for visible signs of damage (dents, cracks, deformation) of the seat belt pre-tensioner assembly.
4. If no damage is found, reinstall the seat belt pre-tensioner assembly with new bolts coated with bonding
agent.
5. If damaged—REPLACE the seat belt pre-tensioner assembly with new bolts coated with bonding agent.
The seat belt pre-tensioner assembly must be deployed before disposing of it.

RS-1054

COLLISION DIAGNOSIS
Part

Side air bag is activated

SRS is NOT activated

Seat with built-in
side air bag

REPLACE all parts
of front seatback
(including front seatback frame)

1. Visually check the seat on the collision side.
2. Remove the seat on the collision side and check the following for damage and
deformities.
+ Harness, connectors and terminals
+ Frame and recliner (for front seat), and also adjuster and slides (for front seat)
3. If no damage is found, reinstall the seat.
4. If damaged—REPLACE the damaged seat parts with new bolts.

Center pillar inner

1. Check the center pillar inner on the collision side for damage (dents, cracks, deformation).
2. If damaged—REPAIR the center pillar inner.

Trim

1. Check for visible signs of damage (dents, cracks, deformation) of the interior trim on the collision side.
2. If damaged—REPLACE the damaged trim parts.

RS-1055

STEERING SYSTEM
SECTION

MODIFICATION NOTICE:
+ Power steering oil pump for ZD30ETi engine has been adopted.

CONTENTS
POWER STEERING OIL PUMP…………………….. 1002
Removal and Installation …………………………… 1002
Disassembly and Assembly……………………….. 1003

SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1004
Inspection and Adjustment ………………………… 1004

POWER STEERING OIL PUMP
Removal and Installation

SST921C

ST-1002

POWER STEERING OIL PUMP
Disassembly and Assembly

SST922C

1
V
2
V
3
V
4
V
5
V
6
V
7
V

Rear body
Pin
Gasket
Cam ring
Vane
Rotor
Front side plate

8
V
9
V
10
V
11
V
12
V
13
V

O-ring (Outer)
O-ring (Inner)
Blacket
Suction pipe
O-ring
O-ring

ST-1003

14
V
15
V
16
V
17
V
18
V
19
V

Connector bolt
O-ring
Spool valve
Spring
Snap ring
Plug

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment
POWER STEERING SYSTEM
(Model: PB69K)
Steering wheel turning force
(at 360° from neutral position and circumference of
steering wheel)
N (kg, lb)
Oil pump pressure
kPa (bar, kg/cm2, psi)

39 (4, 9) or less

8,140 — 8,728
(81.4 — 87.3, 83 — 89, 1,180 — 1,266)
at idling

Fluid capacity liter
m (Imp fl oz)

Approximately 1,000 (35.2)

Normal operating temperature
°C (°F)

60 — 80 (140 — 176)

Steering gear turning torque
Nzm (kg-cm, in-lb)
360° position from
straight-ahead position

0.15 — 0.69 (1.5 — 7.0, 1.3 — 6.1)

Straight-ahead position
(As compared with steering wheel turned 360°)

0.2 (2, 1.7) higher

Maximum turning torque

0.7 — 1.0 (7 — 10, 6.1 — 8.7)

Backlash at pitman arm top
end (in a straightahead position)
mm (in)

0 — 0.1 (0 — 0.004)

End play (at sector shaft
end in neutral position)
mm (in)

0.1 (0.004) or less

ST-1004

TRANSFER
SECTION

MODIFICATION NOTICE:
Mainshaft front bearing snap rings have been changed.

CONTENTS
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 1002
Inspection and Adjustment ………………………… 1002

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment
AVAILABLE SNAP RING
Mainshaft front bearing
Unit: mm (in)
Allowable clearance

0 — 0.15 (0 — 0.0059)

Thickness

Part number

3.10 (0.1220)
3.19 (0.1256)
3.28 (0.1291)

33138-73P10
33138-73P11
33138-73P12

TF-1002

AUTOMATIC TRANSMISSION
SECTION

MODIFICATION NOTICE:
+ Wiring diagrams have been changed.
+ Service Data and Specifications (SDS) have been changed.

CONTENTS
OVERALL SYSTEM …………………………………….. 2002
Circuit Diagram ………………………………………… 2002
Wiring Diagram — A/T —………………………….. 2003
TROUBLE DIAGNOSES — A/T Shift Lock
System……………………………………………………….. 2013

Wiring Diagram — SHIFT — ……………………… 2013
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 2014
General Specifications ………………………………. 2014
Specifications and Adjustment……………………. 2014

OVERALL SYSTEM
Circuit Diagram

TAT012M

AT-2002

OVERALL SYSTEM
Wiring Diagram — A/T —

TAT036M

AT-2003

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT037M

AT-2004

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT038M

AT-2005

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT039M

AT-2006

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT040M

AT-2007

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT042M

AT-2008

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT043M

AT-2009

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT044M

AT-2010

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT045M

AT-2011

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

TAT046M

AT-2012

TROUBLE DIAGNOSES — A/T Shift Lock System
Wiring Diagram — SHIFT —

TAT047M

AT-2013

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Automatic transmission model

RE4R03A

Transmission model
code number

57X17

Stall torque ratio

2.0 : 1

Transmission gear
ratio
1st

2.784

2nd

1.544

Top

1.000

0.694

Reverse

2.275

Recommended fluid

Genuine Nissan ATF or equivalent

Fluid capacity
! (Imp qt)

11.8 (10-3/8)

Specifications and Adjustment
SHIFT SCHEDULE
Vehicle speed when shifting gears
Throttle position

Vehicle speed km/h (MPH)
Shift pattern

D 1 → D2

D2 → D 3

D3 → D 4

D4 → D 3

D3 → D 2

D2 → D 1

12 → 1 1

Standard

36 — 40
(22 — 25)

72 — 80
(45 — 50)

117 — 127
(73 — 79)

113 — 123
(70 — 76)

59 — 67
(37 — 42)

29 — 33
(18 — 21)

Power

36 — 40
(22 — 25)

72 — 80
(45 — 50)

117 — 127
(73 — 79)

113 — 123
(70 — 76)

59 — 67
(37 — 42)

29 — 33
(18 — 21)

Standard

32 — 36
(20 — 22)

63 — 69
(39 — 43)

101 — 109
(63 — 68)

49 — 59
(30 — 37)

28 — 34
(17 — 21)

7 — 11
(4 — 7)

Power

32 — 36
(20 — 22)

63 — 69
(39 — 43)

101 — 109
(63 — 68)

78 — 86
(48 — 53)

48 — 54
(30 — 34)

7 — 11
(4 — 7)

Full throttle

Half throttle

AT-2014

BRAKE SYSTEM
SECTION

MODIFICATION NOTICE:
+ Wiring Diagrams have been changed.

CONTENTS
TROUBLE DIAGNOSES ………………………………. 2002
Schematic ……………………………………………….. 2002

Wiring Diagram — ABS — ………………………… 2003

TROUBLE DIAGNOSES
Schematic

TBR021M

BR-2002

TROUBLE DIAGNOSES
Wiring Diagram — ABS —

TBR022M

BR-2003

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR023M

BR-2004

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR024M

BR-2005

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR025M

BR-2006

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR026M

BR-2007

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR027M

BR-2008

BODY & TRIM
SECTION

MODIFICATION NOTICE:
+ Front grille and bumper assembly have been changed.
+ Front grille guard has been added.

CONTENTS
PRECAUTIONS …………………………………………… 2002
Service Notice………………………………………….. 2002
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 2002

BODY END …………………………………………………. 2003
Body Front End………………………………………… 2003
EXTERIOR ………………………………………………….. 2006

★ For seat belt, refer to MA and RS section.
★ For wiring diagrams of body electrical systems, refer to EL section.

PRECAUTIONS
Service Notice
+
+
+
+
+

Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and
Air Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified with yellow harness connector.

BT-2002

BODY END
Body Front End
+
+
+
+
+

When removing or installing hood, place a cloth or other padding on front fender panel and cowl top.
This prevents vehicle body from being scratched.
Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
Hood adjustment: Adjust at hinge portion.
Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood
locks engaging mechanism.
Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.

REMOVAL — Front bumper assembly
1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V

Remove front guard bar. Refer to “EXTERIOR” for details, BT-2005.
Remove left and right headlamp wipers (on models with headlamp wipers).
Remove clips securing front grille and remove the front grille.
Remove screws and bolts securing left and right front bumper side bracket.
Remove bolts securing bumper lower to engine under cover.
Remove bolts securing left and right front bumper stay upper (without winch).
Remove bolts securing left and right front bumper stay side.
Extract bumper assembly.

SBT243A

BT-2003

BODY END
Body Front End (Cont’d)

SBT244A

BT-2004

BODY END
Body Front End (Cont’d)

SBT245A

BT-2005

EXTERIOR
Front grille guard

SBT246A

BT-2006

CLUTCH
SECTION

MODIFICATION NOTICE:
+ Service Data and Specifications (SDS) have been changed.

CONTENTS
CLUTCH SYSTEM……………………………………….. 2002
HYDRAULIC CLUTCH CONTROL ………………… 2003
Clutch Operating Cylinder………………………….. 2003
Clutch Master Cylinder ……………………………… 2004
CLUTCH DISC AND CLUTCH COVER ………….. 2005

Clutch Cover ……………………………………………. 2005
SERVICE DATA AND SPECIFICATIONS
(SDS)………………………………………………………….. 2006
General Specifications ………………………………. 2006
Inspection and Adjustment ………………………… 2006

CLUTCH SYSTEM

SCL906

CL-2002

HYDRAULIC CLUTCH CONTROL
Clutch Operating Cylinder

SCL907

CL-2003

HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder

SCL908

CL-2004

CLUTCH DISC AND CLUTCH COVER
Clutch Cover
INSTALLATION
Model 300
+ Apply recommended grease to contact surface of splines.
+ Too much lubricant may damage clutch disc facing.
+ Insert Tool into clutch disc hub when installing clutch cover
and disc.
+ Be careful not to allow grease to contaminate clutch facing.
+ Tighten bolts in numerical order, in two steps.
First step:
: 10 — 20 Nzm (1.0 — 2.0 kg-m, 7 — 14 ft-lb)
Final step:
: 29 — 39 Nzm (2.9 — 4.0 kg-m, 21 — 28 ft-lb)

SCL909

CL-2005

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch control

CLUTCH DISC
ZD30DDTi

Hydraulic
Applied model

CLUTCH MASTER CYLINDER
(with clutch damper)

H/T and Wagon
Unit: mm (in)

Inner diameter

275

17.46 (11/16)

CLUTCH OPERATING CYLINDER

Facing size
(Outer dia. x inner dia. x thickness)
mm (in)

275 x 180 x 3.5
(10.83 x 7.09 x 0.14)

Thickness of disc assembly with
load
mm (in)/N (kg, lb)

7.8 — 8.4
(0.31 — 0.33)
/7,846 (800, 1,764)

Unit: mm (in)

Inner diameter

CLUTCH COVER

20.64 (13/16)

ZD30DDTi

CLUTCH BOOSTER

Applied model

Unit: mm (in)

Type

H/T

Wagon

6,473 — 7,257
(660 — 740,
1,455 — 1,632)

7,355 — 8,366
(750 — 850,
1.654 — 1,874)

M45

Diaphragm diameter
Check valve type

275

Full load

114.3 (4.50)

N (kg, lb)

Built-in hose type

Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)

ZD30DDTi
Applied model

Pedal height “H*”

H/T

Wagon

195 — 205
(7.68 — 8.07)

200 — 210
(7.87 — 8.27)

Pedal free play “A” (at pedal pad)

1.0 — 3.0 (0.039 — 0.118)

*: Measured from surface of melt sheet to pedal pad

CLUTCH BOOSTER
Unit: mm (in)

Output rod length “A”

1.30 — 1.55 (0.0512 — 0.0610)

Input rod length “B”

130 (5.12)

CLUTCH DISC
Unit: mm (in)

ZD30DDTi
Applied model

275
H/T and Wagon

Wear limit of facing surface to rivet head

0.3 (0.012)

Runout limit of facing

1.3 (0.051)

Distance of runout check point (from the hub center)

132.5 (5.22)

Maximum backlash of spline (at outer edge of disc)

1.0 (0.039)

CL-2006

SERVICE DATA AND SPECIFICATIONS (SDS)
CLUTCH COVER
Unit: mm (in)

ZD30DDTi
Applied model

275
H/T and Wagon

Diaphragm spring height “A”

44 — 46 (1.732 — 1.811)

Uneven limit of diaphragm spring toe height

0.7 (0.028)

CL-2007

ENGINE CONTROL SYSTEM
SECTION

EC
EC

CONTENTS
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM……………………………………………………… 2003
Circuit Diagram ………………………………………… 2003
TROUBLE DIAGNOSIS FOR POWER
SUPPLY ……………………………………………………… 2004
Main Power Supply and Ground Circuit ………. 2004
DTC 0102 MASS AIR FLOW SEN…………………. 2006
Wiring Diagram ………………………………………… 2006
DTC 0103 COOLANT TEMP SEN …………………. 2007
Wiring Diagram ………………………………………… 2007
DTC 0104 VEHICLE SPEED SEN …………………. 2008
Wiring Diagram ………………………………………… 2008
DTC 0203 ACCEL POS SW (F/C) …………………. 2009
Wiring Diagram ………………………………………… 2009
DTC 0208 OVER HEAT………………………………… 2010
Wiring Diagram ………………………………………… 2010
Diagnostic Procedure………………………………… 2011
Component Inspection ………………………………. 2016
Main 12 Causes of Overheating…………………. 2017
DTC 0402 P9zFUEL TEMP SEN ……………………. 2018
Wiring Diagram ………………………………………… 2018
DTC 0403 ACCEL POS SENSOR …………………. 2019
Wiring Diagram ………………………………………… 2019
DTC 0504 A/T COMM LINE ………………………….. 2021
Wiring Diagram ………………………………………… 2021
DTC 0701 P1zCAM POS SEN ……………………….. 2022
Wiring Diagram ………………………………………… 2022
DTC 0702 P2zTDC PULSE SIG……………………… 2023
Wiring Diagram ………………………………………… 2023
DTC 0703 P3zPUMP COMM LINE …………………. 2024
Wiring Diagram ………………………………………… 2024
DTC 0704 P4zSPILL/V CIRC, DTC 0706
P6zSPILL VALVE …………………………………………. 2025

Wiring Diagram ………………………………………… 2025
DTC 0707 P7zF/INJ TIMG FB………………………… 2026
Wiring Diagram ………………………………………… 2026
DTC 0807 ECM 14……………………………………….. 2027
Wiring Diagram ………………………………………… 2027
DTC 0902 ECM RLY ……………………………………. 2028
Wiring Diagram ………………………………………… 2028
DTC 0905 TURBO PRESSURE …………………….. 2029
Wiring Diagram ………………………………………… 2029
DTC 1003 EGR VOLUME CONT/V………………… 2030
Wiring Diagram ………………………………………… 2030
DTC 1004 FUEL CUT SYSTEM1…………………… 2031
Wiring Diagram ………………………………………… 2031
GLOW CONTROL SYSTEM …………………………. 2032
Wiring Diagram ………………………………………… 2032
START SIGNAL…………………………………………… 2033
Wiring Diagram ………………………………………… 2033
PARK/NEUTRAL POSITION (PNP) SWITCH …. 2034
Wiring Diagram ………………………………………… 2034
HEAT UP SWITCH ………………………………………. 2035
Wiring Diagram ………………………………………… 2035
SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE………………………………………. 2036
Wiring Diagram ………………………………………… 2036
INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE………………………………………. 2037
Wiring Diagram ………………………………………… 2037
AIR CONDITIONER CONTROL …………………….. 2038
Wiring Diagram ………………………………………… 2038
MI (MIL) & DATA LINK CONNECTORS ………… 2039
Wiring Diagram ………………………………………… 2039

EC-2002

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram
SMA for models without fuel filter switch

TEC095M

EC-2003

TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
WIRING DIAGRAM

TEC181M

EC-2004

TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont’d)

TEC097M

EC-2005

DTC 0102 MASS AIR FLOW SEN
Wiring Diagram

TEC182M

EC-2006

DTC 0103 COOLANT TEMP SEN
Wiring Diagram

TEC183M

EC-2007

DTC 0104 VEHICLE SPEED SEN
Wiring Diagram

TEC184M

EC-2008

DTC 0203 ACCEL POS SW (F/C)
Wiring Diagram

TEC185M

EC-2009

DTC 0208 OVER HEAT
Wiring Diagram

TEC186M

EC-2010

DTC 0208 OVER HEAT
Diagnostic Procedure
1

INSPECTION START

Do you have CONSULT-II?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

CHECK COOLING FAN OPERATION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II.

SEF646X

3. Make sure that cooling fan-1 operates.
OK or NG
OK

c GO TO 12.

c GO TO 4.

CHECK COOLING FAN OPERATION

MEC475B

OK or NG
OK

c GO TO 12.

c GO TO 4.

EC-2011

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
4

CHECK COOLING FAN POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect cooling fan relay-1.

SEF690V

3. Turn ignition switch “ON”.
4. Check voltage between cooling fan relay-1 terminals 1, 5 and ground with CONSULT-II or tester.

SEF607X

OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

EC-2012

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
6

CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect cooling fan motor-1 harness connector.

SEF691V

c GO TO 7.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK COOLING FAN OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

c GO TO 9.

c GO TO 8.

DETECT MALFUNCTIONING PART

CHECK COOLING FAN RELAY-1

Refer to “Component Inspection”, EC-2016.
OK or NG
OK

c GO TO 10.

c Replace cooling fan relay.

EC-2013

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
10

CHECK COOLING FAN MOTOR-1

Supply battery voltage between the following terminals and check operation.

SEF292Z

OK or NG
OK

c GO TO 11.

c Replace cooling fan motor.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END
12

CHECK COOLING SYSTEM FOR LEAK

SLC754A

Pressure should not drop.
OK or NG
OK

c GO TO 14.

c GO TO 13.

DETECT MALFUNCTIONING PART

Check the following for leak.
+ Hose
+ Radiator
+ Water pump (Refer to LC section, “Water Pump”.)
c Repair or replace.

EC-2014

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
14

CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief pressure.

SLC755A

Radiator cap relief pressure:
79 — 98 kPa (0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2, 11 — 14 psi)
OK or NG
OK

c GO TO 15.

c Replace radiator cap.

CHECK THERMOSTAT

1. Remove thermostat.
2. Check valve seating condition at normal room temperatures.
It should seat tightly.
3. Check valve opening temperature and valve lift.

SLC343

c GO TO 16.

c Replace thermostat.

EC-2015

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
16

CHECK ENGINE COOLANT TEMPERATURE SENSOR

1. Remove engine coolant temperature sensor.
2. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure.

SEF304X

OK or NG
OK

c GO TO 17.

c Replace engine coolant temperature sensor.

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-2017.
c INSPECTION END

Component Inspection
FUEL PUMP RELAY
Check continuity between terminals 3 and 5.
Conditions

SEF145X

Continuity

12V direct current supply between
terminals 1 and 2

Yes

No current supply

If NG, replace relay.

EC-2016

DTC 0208 OVER HEAT
Main 12 Causes of Overheating
Engine

Step

Inspection item

OFF

+
+
+
+

Equipment

Standard

Reference page

+ Visual

No blocking

+ Coolant mixture

+ Coolant tester

30 — 50% coolant mixture

See “RECOMMENDED
FLUIDS AND LUBRICANTS” in MA section.

+ Coolant level

+ Visual

Coolant up to MAX level
in reservoir tank and
radiator filler neck

See “Changing Engine
Coolant”, “ENGINE MAINTENANCE” in MA section.

+ Radiator cap

+ Pressure tester

78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0
kg/cm2, 11 — 14 psi)
59 — 98 kPa (0.59 — 0.98
bar, 0.6 — 1.0 kg/cm2,
9 — 14 psi) (Limit)

See “System Check”,
“ENGINE COOLING SYSTEM” in LC section.

ON*2

+ Coolant leaks

+ Visual

No leaks

See “System Check”,
“ENGINE COOLING SYSTEM” in LC section.

ON*2

+ Thermostat

+ Touch the upper and
lower radiator hoses

Both hoses should be hot. See “Thermostat” and
“Radiator”, “ENGINE
COOLING SYSTEM” in
LC section.

ON*1

+ Cooling fan

+ Visual

Operating

OFF

+ Combustion gas leak

+ Color checker chemical Negative
tester 4 gas analyzer

—

ON*3

+ Coolant temperature
gauge

+ Visual

—

Blocked
Blocked
Blocked
Blocked

radiator
condenser
radiator grille
bumper

Gauge less than 3/4
when driving

—

See “DTC 0208 OVER
HEAT”.

+ Coolant overflow to res- + Visual
ervoir tank

No overflow during driving See “Changing Engine
and idling
Coolant”, “ENGINE MAINTENANCE” in MA section.

OFF*4

+ Coolant return from res- + Visual
ervoir tank to radiator

Should be initial level in
reservoir tank

See “ENGINE MAINTENANCE” in MA section.

OFF

+ Cylinder head

+ Straight gauge feeler
gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD” in EM section.

+ Cylinder block and pistons

+ Visual

No scuffing on cylinder
walls or piston

See “Inspection”, “CYLINDER BLOCK” in EM section.

EC-2017

DTC 0402 P9zFUEL TEMP SEN
Wiring Diagram

TEC187M

EC-2018

DTC 0403 ACCEL POS SENSOR
Wiring Diagram

TEC188M

EC-2019

DTC 0403 ACCEL POS SENSOR
Wiring Diagram (Cont’d)

TEC189M

EC-2020

DTC 0504 A/T COMM LINE
Wiring Diagram

TEC190M

EC-2021

DTC 0701 P1zCAM POS SEN
Wiring Diagram

TEC187M

EC-2022

DTC 0702 P2zTDC PULSE SIG
Wiring Diagram

TEC187M

EC-2023

DTC 0703 P3zPUMP COMM LINE
Wiring Diagram

TEC187M

EC-2024

DTC 0704 P4zSPILL/V CIRC, DTC 0706 P6zSPILL VALVE
Wiring Diagram

TEC187M

EC-2025

DTC 0707 P7zF/INJ TIMG FB
Wiring Diagram

TEC187M

EC-2026

DTC 0807 ECM 14
Wiring Diagram

TEC191M

EC-2027

DTC 0902 ECM RLY
Wiring Diagram

TEC451

EC-2028

DTC 0905 TURBO PRESSURE
Wiring Diagram

TEC193M

EC-2029

DTC 1003 EGR VOLUME CONT/V
Wiring Diagram

TEC194M

EC-2030

DTC 1004 FUEL CUT SYSTEM1
Wiring Diagram

TEC187M

EC-2031

GLOW CONTROL SYSTEM
Wiring Diagram

TEC195M

EC-2032

START SIGNAL
Wiring Diagram

TEC196M

EC-2033

PARK/NEUTRAL POSITION (PNP) SWITCH
Wiring Diagram

TEC197M

EC-2034

HEAT UP SWITCH
Wiring Diagram

TEC198M

EC-2035

SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
Wiring Diagram

TEC199M

EC-2036

INTAKE AIR CONTROL VALVE CONTROL SOLENOID VALVE
Wiring Diagram

TEC200M

EC-2037

AIR CONDITIONER CONTROL
Wiring Diagram

TEC201M

EC-2038

MI (MIL) & DATA LINK CONNECTORS
Wiring Diagram

SMA for models without
fuel filter switch

TEC202M

EC-2039

MI (MIL) & DATA LINK CONNECTORS

EC-2040

ELECTRICAL SYSTEM
SECTION

MODIFICATION NOTICE:
+

Wiring Diagram has been changed.

CONTENTS
PRECAUTIONS AND PREPARATION …………… 2003
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 2003
POWER SUPPLY ROUTING…………………………. 2004
Schematic ……………………………………………….. 2004
POWER SUPPLY ROUTING/WAGON AND
HARDTOP MODELS ……………………………………. 2005
Wiring Diagram — POWER —…………………… 2005
GROUND DISTRIBUTION/WAGON AND
HARDTOP MODELS ……………………………………. 2014
Engine Room Harness/LHD Models……………. 2014
Engine Control Harness/LHD Models………….. 2017
Main Harness/LHD Models………………………… 2018
Body Harness/LHD Models ……………………….. 2021
Body No. 2 Harness/LHD Models ………………. 2023
Back Door and Rear Window Defogger
Harness/LHD Models………………………………… 2024
Engine Room Harness/RHD Models …………… 2025
Main Harness/RHD Models ……………………….. 2026
STARTING SYSTEM ……………………………………. 2029
Wiring Diagram — START —/M/T Models…… 2029
Wiring Diagram — START —/A/T Models …… 2030
Construction …………………………………………….. 2031
Service Data and Specifications (SDS)……….. 2032
CHARGING SYSTEM …………………………………… 2033
Wiring Diagram — CHARGE — …………………. 2033
HEADLAMP/WAGON AND HARDTOP
MODELS — Conventional Type — ………………. 2034
Wiring Diagram — H/LAMP — …………………… 2034

Bulb Replacement…………………………………….. 2035
Aiming Adjustment ……………………………………. 2035
HEADLAMP/WAGON AND HARDTOP
MODELS — Headlamp Aiming Control —……. 2037
Wiring Diagram — H/AIM — ……………………… 2037
HEADLAMP/WAGON AND HARDTOP
MODELS — Daytime Light System — …………. 2039
Wiring Diagram — DTRL — ………………………. 2039
PARKING, LICENSE AND TAIL
LAMPS/WAGON AND HARDTOP MODELS ….. 2041
Wiring Diagram — TAIL/L —/Type A ………….. 2041
Wiring Diagram — TAIL/L —/Type B ………….. 2043
Wiring Diagram — TAIL/L —/Type C ………….. 2045
BACK-UP LAMP/WAGON AND HARDTOP
MODELS …………………………………………………….. 2047
Wiring Diagram — BACK/L —/LHD Models…. 2047
FRONT FOG LAMP/WAGON AND HARDTOP
MODELS …………………………………………………….. 2048
Wiring Diagram — F/FOG — …………………….. 2048
REAR FOG LAMP/WAGON AND HARDTOP
MODELS …………………………………………………….. 2049
Wiring Diagram —R/FOG— ………………………. 2049
TURN SIGNAL AND HAZARD WARNING
LAMPS/WAGON AND HARDTOP MODELS ….. 2050
Wiring Diagram — TURN —/Type A…………… 2050
Wiring Diagram — TURN —/Type C…………… 2052
ILLUMINATION/WAGON AND HARDTOP
MODELS …………………………………………………….. 2054
Schematic ……………………………………………….. 2054

Wiring Diagram — ILL — ………………………….. 2055
METER AND GAUGES/WAGON AND
HARDTOP MODELS ……………………………………. 2062
Combination Meter……………………………………. 2062
Schematic ……………………………………………….. 2063
Wiring Diagram — METER —……………………. 2064
COMPASS AND THERMOMETER ………………… 2066
Wiring Diagram — COMPAS —…………………. 2066
WARNING LAMPS/WAGON AND HARDTOP
MODELS …………………………………………………….. 2067
Schematic ……………………………………………….. 2067
Wiring Diagram/— WARN —……………………… 2069
WARNING CHIME/WAGON AND HARDTOP
MODELS …………………………………………………….. 2077
Electrical Components Inspection ………………. 2077
REAR WIPER AND WASHER/WAGON AND
HARDTOP MODELS ……………………………………. 2078
System Description …………………………………… 2078
Wiring Diagram — WIP/R —/LHD Models …… 2079
Wiring Diagram — WIP/R —/RHD Models ….. 2081
HEADLAMP WIPER AND WASHER ……………… 2083
Wiring Diagram — HLC — ………………………… 2083
HORN …………………………………………………………. 2084
Wiring Diagram — HORN —……………………… 2084
CIGARETTE LIGHTER/WAGON AND
HARDTOP MODELS ……………………………………. 2085
Wiring Diagram — CIGAR — …………………….. 2085
WIPER DEICER/WAGON AND HARDTOP
MODELS …………………………………………………….. 2086
Wiring Diagram — DEICER —…………………… 2086
REAR WINDOW DEFOGGER/WAGON AND
HARDTOP MODELS ……………………………………. 2087
Electrical Components Inspection ………………. 2087
AUDIO/WAGON AND HARDTOP MODELS …… 2088
Wiring Diagram — AUDIO —/LHD Models ….. 2088
Wiring Diagram — AUDIO —/RHD Models …. 2090
Wiring Diagram — CD/CHG —/LHD Wagon .. 2092
Wiring Diagram — CD/CHG —/LHD
Hardtop …………………………………………………… 2093

Wiring Diagram — CD/CHG —/RHD
Hardtop …………………………………………………… 2094
Wiring Diagram — REMOTE — …………………. 2095
Wiring Diagram — P/ANT —/LHD Models…… 2096
Wiring Diagram — P/ANT —/RHD Models ….. 2097
POWER DOOR MIRROR/WAGON AND
HARDTOP MODELS ……………………………………. 2098
Wiring Diagram — MIRROR —/LHD Models.. 2098
Wiring Diagram — MIRROR —/RHD Models . 2099
NATS (Nissan Anti-Theft System)/ZD ENGINE
MODELS …………………………………………………….. 2100
Wiring Diagram — NATS —………………………. 2100
Wiring Diagram — NATS —/LHD Models……. 2101
Wiring Diagram — NATS —/RHD Models …… 2102
LOCATION OF ELECTRICAL UNITS/WAGON
AND HARDTOP MODELS ……………………………. 2103
Engine Compartment ………………………………… 2103
Passenger Compartment — LHD Models ……. 2104
HARNESS LAYOUT …………………………………….. 2106
How to Read Harness Layout ……………………. 2106
HARNESS LAYOUT/WAGON AND HARDTOP
MODELS …………………………………………………….. 2108
Main Harness/LHD Models………………………… 2108
Main Harness/RHD Models ……………………….. 2112
Engine Room Harness/LHD Models……………. 2116
Body Harness/LHD Models ……………………….. 2120
Body Harness/RHD Models……………………….. 2124
Body No. 2 Harness/LHD Models ………………. 2128
Body No. 2 Harness/RHD Models………………. 2130
WIRING DIAGRAM CODES (CELL CODES)….. 2132
Wiring Diagram Codes (Cell Codes) …………… 2132

EL-2002

PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by intentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.

EL-2003

POWER SUPPLY ROUTING
Schematic

TEL371M

EL-2004

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER —
BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

TEL373M

EL-2005

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL374M

EL-2006

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL375M

EL-2007

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL376M

EL-2008

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON”

TEL377M

EL-2009

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START”

TEL378M

EL-2010

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL379M

EL-2011

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL380M

EL-2012

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL381M

EL-2013

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models

CEL210M

EL-2014

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)

CEL211M

EL-2015

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)

CEL212M

EL-2016

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Control Harness/LHD Models
ZD ENGINE

CEL214M

EL-2017

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models

CEL216M

EL-2018

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

CEL217M

EL-2019

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

CEL218M

EL-2020

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/LHD Models

CEL219M

EL-2021

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)

CEL220M

EL-2022

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models

CEL221M

EL-2023

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Back Door and Rear Window Defogger
Harness/LHD Models

CEL222M

EL-2024

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models

CEL223M

EL-2025

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/RHD Models

CEL224M

EL-2026

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

CEL225M

EL-2027

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

CEL226M

EL-2028

STARTING SYSTEM
Wiring Diagram — START —/M/T Models

TEL383M

EL-2029

STARTING SYSTEM
Wiring Diagram — START —/A/T Models

TEL384M

EL-2030

STARTING SYSTEM
Construction

MEL744IA

MEL656KA

EL-2031

STARTING SYSTEM
Service Data and Specifications (SDS)
STARTER
S13-551A
Type

S14-607
HITACHI make

Reduction gear type
Applied model
System voltage

ZD30 Standard
V

ZD30 Option
12

No-load
Terminal voltage

Current

Revolution

rpm

11
Less than 160
3,300

Minimum diameter of commutator
mm (in)
Minimum length of brush mm (in)

3,400
35.5 (1.398)

11 (0.43)

10.5 (0.413)

28.4 — 34.3
(2.9 — 3.5,
6.4 — 7.7)

24.5 — 34.3
(2.5 — 3.5,
5.5 — 7.7)

Clearance between bearing metal
and armature shaft
mm (in)

—

Clearance “!” between pinion
front edge and pinion stopper
mm (in)

—

Brush spring tension
N (kg, lb)

Movement “!” in height of pinion
assembly
mm (in)

EL-2032

0.3 — 2.0
(0.012 — 0.079)

CHARGING SYSTEM
Wiring Diagram — CHARGE —

TEL483M

EL-2033

HEADLAMP/WAGON AND HARDTOP MODELS — Conventional Type —
Wiring Diagram — H/LAMP —

TEL387M

EL-2034

HEADLAMP/WAGON AND HARDTOP MODELS — Conventional Type —
Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replaceable halogen bulb. The bulb can be replaced from the engine
compartment side without removing the headlamp body.
+ Grasp only the plastic base when handling the bulb.
Never touch the glass envelope.
1. Disconnect the battery cable.
2. Turn the bulb retaining ring counterclockwise until it is free
from the headlamp reflector, and then remove it.
3. Disconnect the harness connector from the back side of the
bulb.
4. Remove the headlamp bulb carefully. Do not shake or rotate
the bulb when removing it.
5. Install in the reverse order of removal.
CAUTION:
Do not leave headlamp reflector without bulb for a long
period of time. Dust, moisture, smoke, etc. entering headlamp body may affect the performance of the headlamp.
Remove headlamp bulb from the headlamp reflector just
before a replacement bulb is installed.
SEL995K

Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers should
be in good repair, calibrated and operated in accordance with
respective operation manuals.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is no-load in vehicle (coolant, engine oil
filled up to correct level and full fuel tank) other than the
driver (or equivalent weight placed in driver’s position).

CAUTION:
Be sure aiming switch is set to “0” when performing aiming
adjustment on vehicles equipped with headlamp aiming
control.

SEL466V

EL-2035

HEADLAMP/WAGON AND HARDTOP MODELS — Conventional Type —
Aiming Adjustment (Cont’d)
LOW BEAM
1. Turn headlamp low beam on.
2. Use adjusting screws to perform aiming adjustment.
+ First tighten the adjusting screw all the way and then
make adjustment by loosening the screw.

CEL735

+ Adjust headlamps so that main axis of light is parallel to
center line of body and is aligned with point P shown in
illustration.
+ Figure to the left shows headlamp aiming pattern for
driving on right side of road; for driving on left side of
road, aiming pattern is reversed.
+ Dotted lines in illustration show center of headlamp.
“H”:
Horizontal center line of headlamps
“WL”: Distance between each headlamp center
“L”:
5,000 mm (196.85 in)
“C”:
63 mm (2.48 in)

SEL254I

EL-2036

HEADLAMP/WAGON AND HARDTOP MODELS
— Headlamp Aiming Control —
Wiring Diagram — H/AIM —

TEL389M

EL-2037

HEADLAMP/WAGON AND HARDTOP MODELS
— Headlamp Aiming Control —
Wiring Diagram — H/AIM — (Cont’d)

TEL390M

EL-2038

HEADLAMP/WAGON AND HARDTOP MODELS
— Daytime Light System —
Wiring Diagram — DTRL —

TEL675B

EL-2039

HEADLAMP/WAGON AND HARDTOP MODELS
— Daytime Light System —
Wiring Diagram — DTRL — (Cont’d)

TEL484M

EL-2040

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type A
Rear combination lamps are not located on rear bumper.

TEL391M

EL-2041

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type A (Cont’d)

TEL212M

EL-2042

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type B
LHD MODELS

Rear combination lamps are located on rear bumper.

TEL392M

EL-2043

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type B (Cont’d)

TEL213M

EL-2044

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type C
RHD MODELS

Rear combination lamps are located on rear bumper.

TEL393M

EL-2045

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type C (Cont’d)

TEL394M

EL-2046

BACK-UP LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — BACK/L —/LHD Models

TEL395M

EL-2047

FRONT FOG LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — F/FOG —

TEL397M

EL-2048

REAR FOG LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram —R/FOG—

TEL485M

EL-2049

TURN SIGNAL AND HAZARD WARNING LAMPS/
WAGON AND HARDTOP MODELS
Wiring Diagram — TURN —/Type A
Rear combination lamps are not located on rear bumper.

TEL399M

EL-2050

TURN SIGNAL AND HAZARD WARNING LAMPS/
WAGON AND HARDTOP MODELS
Wiring Diagram — TURN —/Type A (Cont’d)

TEL400M

EL-2051

TURN SIGNAL AND HAZARD WARNING LAMPS/
WAGON AND HARDTOP MODELS
Wiring Diagram — TURN —/Type C
Rear combination lamps are located on rear bumper.

TEL401M

EL-2052

TURN SIGNAL AND HAZARD WARNING LAMPS/
WAGON AND HARDTOP MODELS
Wiring Diagram — TURN —/Type C (Cont’d)

TEL402M

EL-2053

ILLUMINATION/WAGON AND HARDTOP MODELS
Schematic

TEL403M

EL-2054

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL —

TEL404M

EL-2055

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL405M

EL-2056

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL406M

EL-2057

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL407M

EL-2058

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL408M

EL-2059

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL409M

EL-2060

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL410M

EL-2061

METER AND GAUGES/WAGON AND HARDTOP MODELS
Combination Meter

CEL231M

EL-2062

METER AND GAUGES/WAGON AND HARDTOP MODELS
Schematic

TEL481M

EL-2063

METER AND GAUGES/WAGON AND HARDTOP MODELS
Wiring Diagram — METER —

TEL415M

EL-2064

METER AND GAUGES/WAGON AND HARDTOP MODELS
Wiring Diagram — METER — (Cont’d)

TEL416M

EL-2065

COMPASS AND THERMOMETER
Wiring Diagram — COMPAS —

TEL486M

EL-2066

WARNING LAMPS/WAGON AND HARDTOP MODELS
Schematic

TEL421M

EL-2067

WARNING LAMPS/WAGON AND HARDTOP MODELS
Schematic (Cont’d)

SMA for models without fuel filter switch

TEL422M

EL-2068

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN —

TEL425M

EL-2069

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL426M

EL-2070

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL427M

EL-2071

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL428M

EL-2072

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
SMA for models without fuel filter switch

TEL429M

EL-2073

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL430M

EL-2074

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL431M

EL-2075

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL432M

EL-2076

WARNING CHIME/WAGON AND HARDTOP MODELS
Electrical Components Inspection
KEY SWITCH (insert)
Check continuity between terminals when key is inserted in ignition key cylinder and key is removed from ignition key cylinder.
Terminal No.
1 -V
2
V

Condition

Continuity

Key is inserted.

Yes

Key is removed.

SEL015WB

DRIVER SIDE DOOR SWITCH
Check continuity between terminals when door switch is pushed
and released.
Terminal No.
1 -V
3
V

SEL039X

EL-2077

Condition

Continuity

Door switch is pushed.

Door switch is released.

Yes

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
System Description
WIPER OPERATION
The rear wiper switch is controlled by a ring built into the combination switch.
There are two wiper switch positions:
+ ON (LO speed)
+ INT (Intermittent)
With the ignition switch in the ON position, power is supplied
+ through 10A fuse (No. 18 , located in the fuse block)
4 , and
+ to rear wiper motor terminal V
5 .
+ to rear wiper amplifier terminal V

Low speed wiper operation
Ground is supplied to rear wiper switch terminal V
24 through body grounds.
When the rear wiper is placed in the ON position, ground is supplied
+ through rear wiper switch terminal V
22
6 .
+ to rear wiper relay terminal V
Then ground is supplied
1
+ to rear wiper motor terminal V
2 and V
3 .
+ through rear wiper amplifier terminals V
With power and ground supplied, the wiper motor operates.

Auto stop operation
With the rear wiper switch turned OFF, rear wiper motor will continue to operate until wiper arm reaches
rear window base.
When wiper arm is not located at base of rear window with rear wiper switch OFF, ground is supplied
1
+ to rear wiper motor terminal V
2 ,V
7 and
+ through rear wiper amplifier terminals V
3 , in order to continue rear wiper motor operation at low speed.
+ through rear wiper motor terminal V
Ground is also supplied
2
+ to rear wiper motor terminal V
+ through body grounds.
3 and V
4 are connected instead
When wiper arm reaches base of rear window, rear wiper motor terminals V
2 and V
3 . Rear wiper motor will then stop wiper arm at the PARK position.
of terminals V

Intermittent operation
The rear wiper motor operates the wiper arm one time at low speed at an interval of approximately 7 seconds.
When the rear wiper switch is placed in the INT position, ground is supplied
1
+ to rear wiper amplifier terminal V
+ through rear wiper switch terminal V
21 .
Then the rear wiper motor operates intermittently in the same manner as the low speed wiper operation.

WASHER OPERATION
With the ignition switch in the ACC or ON position, power is supplied
+ through 10A fuse (No. 18 , located in the fuse block)
2 .
+ to rear washer motor terminal V
When the ring is turned WASH position, ground is supplied
1 , and
+ to rear washer motor terminal V
4
+ to rear wiper amplifier terminal V
+ through terminal V
23 of rear wiper switch.
With power and ground is supplied, the rear washer motor operates.
The rear wiper motor operates when the ring is turned to WASH position for one second or more and for
approximately 3 seconds after the ring is released. This feature is controlled by the rear wiper amplifier in
the same manner as the low speed wiper operation.

EL-2078

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R —/LHD Models

TEL460M

EL-2079

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R —/LHD Models
(Cont’d)

TEL461M

EL-2080

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R —/RHD Models

TEL462M

EL-2081

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R —/RHD Models
(Cont’d)

TEL656A

EL-2082

HEADLAMP WIPER AND WASHER
Wiring Diagram — HLC —

TEL463M

EL-2083

HORN
Wiring Diagram — HORN —

TEL457M

EL-2084

CIGARETTE LIGHTER/WAGON AND HARDTOP MODELS
Wiring Diagram — CIGAR —

TEL458M

EL-2085

WIPER DEICER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEICER —

TEL459M

EL-2086

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Electrical Components Inspection
REAR WINDOW DEFOGGER RELAY
3 and V
5 ,V
6 and V
7 .
Check continuity between terminals V
Condition

Continuity

12V direct current supply between
1 and V
2
terminals V

Yes

No current supply

SEC202B

REAR WINDOW DEFOGGER SWITCH
Check continuity between terminals when rear window defogger
switch is pushed and released.
Terminals

1 — 2

V V

SEL430TG

EL-2087

Condition

Continuity

Rear window defogger
switch is pushed

Yes

Rear window defogger
switch is released

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models

TEL451M

EL-2088

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
(Cont’d)

TEL488M

EL-2089

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models

TEL452M

EL-2090

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models
(Cont’d)

TEL489M

EL-2091

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — CD/CHG —/LHD Wagon

TEL453M

EL-2092

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — CD/CHG —/LHD Hardtop

TEL454M

EL-2093

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — CD/CHG —/RHD Hardtop

TEL455M

EL-2094

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — REMOTE —

TEL456M

EL-2095

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — P/ANT —/LHD Models

TEL492M

EL-2096

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — P/ANT —/RHD Models

TEL493M

EL-2097

POWER DOOR MIRROR/WAGON AND HARDTOP MODELS
Wiring Diagram — MIRROR —/LHD Models

TEL465M

EL-2098

POWER DOOR MIRROR/WAGON AND HARDTOP MODELS
Wiring Diagram — MIRROR —/RHD Models

TEL466M

EL-2099

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —

TEL477M

EL-2100

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/LHD Models

TEL281M

EL-2101

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/RHD Models

TEL294M

EL-2102

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Engine Compartment

CEL233M

EL-2103

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — LHD Models

CEL234M

EL-2104

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — LHD Models
(Cont’d)

CEL235M

EL-2105

HARNESS LAYOUT
How to Read Harness Layout
Example:
G2

B/6

: ASCD ACTUATOR

Connector color / Cavity
Connector number
Grid reference

Standard type

Connector type
Male

Female

—

Male

+ Cavity: Less than 4
+ Relay connector
+ Cavity: From 5 to 8
+ Cavity: More than 9
+ Ground terminal etc.

—

EL-2106

Female

HARNESS LAYOUT
How to Read Harness Layout (Cont’d)
NOTE

EL-2107

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models

CEL236M

EL-2108

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

CEL237M

EL-2109

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

CEL238M

EL-2110

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)
NOTE

EL-2111

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models

CEL239M

EL-2112

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

CEL240M

EL-2113

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

CEL241M

EL-2114

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)
NOTE

EL-2115

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models

CEL244M

EL-2116

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)

CEL245M

EL-2117

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)
PASSENGER COMPARTMENT

CEL246M

EL-2118

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)

CEL247M

EL-2119

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/LHD Models
WAGON

CEL254M

EL-2120

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)

CEL255M

EL-2121

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)
HARDTOP

CEL256M

EL-2122

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)

CEL257M

EL-2123

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models
WAGON

CEL258M

EL-2124

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)

CEL259M

EL-2125

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)
HARDTOP

CEL260M

EL-2126

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)

CEL261M

EL-2127

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models
WAGON

CEL262M

EL-2128

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models (Cont’d)
HARDTOP

CEL263M

EL-2129

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/RHD Models
WAGON

CEL264M

EL-2130

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/RHD Models (Cont’d)
HARDTOP

CEL265M

EL-2131

Section

Wiring Diagram Name

Code

Section

Wiring Diagram Name

A/C, A

Auto Air Conditioner

FICD

IACV-FICD Solenoid Valve

A/C, M

Manual Air Conditioner

FPCM

Fuel Pump Control Module

A/CCUT

Air Conditioner Control

GLOW

Quick Glow System

A/T

H/AIM

Headlamp Aiming Control System

AAC/V

IACV-AAC Valve

H/LAMP

Headlamp

ABS

Anti-lock Brake System

HEATUP

Heat up Switch

ACC/SW

Accelerator Switch (F/C)

HLC

Headlamp Cleaner

APS

Accelerator Position Sensor

HORN

Horn

ASCD

Automatic Speed Control Device

IGN

Ignition System

AT/C

A/T Control

IGNSYS

Ignition Signal

AUDIO

Audio

ILL

Illumination

BACK/L

Back-up Lamp

INJECT

Injector

BCDD

BCDD System

INJPMP

BOOST

Turbo Charger Boost Sensor

Electronic Control Fuel Injection
Pump

BRK/SW

Brake Switch Signal

INT/V

Intake Air Control Valve Control
Solenoid Valve

CD/CHG

CD Auto Changer

CHARGE

Charging System

IVC

Intake Valve Timing Control Solenoid
Valve

CHIME

Warning Chime

Knock Sensor

CHOKE

Automatic Choke

LOAD

Load Signal

CIGAR

Cigarette Lighter

MAFS

Mass Air Flow Sensor

CMPS

Camshaft Position Sensor

COMPAS

Compass and Thermometer

MAIN

Main Power Supply and Ground Circuit

COOL/B

Cool Box

METER

COOL/F

Cooling Fan Control

Speedometer, Tachometer, Temp.,
Oil and Fuel Gauges

CORNER

Cornering Lamp

MIL/DL

Mil and Data Link Connectors

D/LOCK

Power Door Lock

MIRROR

Door Mirror

DEICER

Wiper Deicer

MULTI

Multi-remote Control System

DEF

Rear Window Defogger

NATS

Nissan Anti-Theft System

DIFF/L

Differential Lock Control System

P/ANT

Power Antenna

DTRL

Headlamp — With Daytime Light
System

PGC/V

EVAP Canister Purge Volume Control Solenoid Valve

ECMRLY

ECM Relay

PNP/SW

Park/Neutral Position Switch

ECTS

Engine Coolant Temperature Sensor

POWER

Power Supply Routing

EGVC/V

EGR Volume Control Valve

PST/SW

Power Steering Oil Pressure Switch

Rear Cooler System

Electric Controlled Power Steering
system

R/COOL

EPS

R/FOG

Rear Fog Lamp

F/FOG

Front Fog Lamp

R/HEAT

Rear Heater System

F/PUMP

Fuel Pump

REMOTE

Audio (Remote Control Switch)

FCUT

Fuel Cut System

ROOM/L

Interior Room Lamp

EL-2132

WIRING DIAGRAM CODES (CELL CODES)
Wiring Diagram Codes (Cell Codes) (Cont’d)
Code

Section

Wiring Diagram Name

S/SIG

Start Signal

S/TANK

Sub Fuel Tank Control System

SHIFT

A/T Shift Lock System

SRS

Supplemental Restraint System

STAB

Rear Stabilizer Release Device Control System

START

Starting System

SWL/V

Swirl Control Valve Control Solenoid
Valve

TAIL/L

Parking, License and Tail Lamps

TP/SW

Throttle Position Switch

TPS

Throttle Position Sensor

TRQ/SG

Engine Torque Control Signal

TURN

Turn Signal and Hazard Warning
Lamps

VIAS/V

Variable Air Induction Control System

VSS

Vehicle Speed Sensor

WARN

Warning Lamps

WIP/R

Rear Wiper and Washer

EL-2133

FUSE BLOCK — Junction Box (J/B)
Terminal Arrangement

CEL271M

FUSE AND FUSIBLE LINK BOX
Terminal Arrangement

CEL272M

ELECTRICAL UNITS
Terminal Arrangement

CEL273M

ELECTRICAL UNITS
Terminal Arrangement (Cont’d)

CEL274M

JOINT CONNECTOR (J/C)
Terminal Arrangement

CEL275M

Edition: July 2001
Release: September 2001 (01)
Publication No.: SM1E-Y61BE0E
Reference No.: 7711345090

QUICK REFERENCE INDEX

GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL

PATROL GR

ENGINE LUBRICATION &
COOLING SYSTEMS

MODEL Y61 SERIES

ENGINE CONTROL SYSTEM

ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEM

CLUTCH

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

TRANSFER

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

FRONT AXLE & FRONT SUSPENSION

REAR AXLE & REAR SUSPENSION

BRAKE SYSTEM

STEERING SYSTEM

RESTRAINT SYSTEM

BODY & TRIM

HEATER & AIR CONDITIONER

ELECTRICAL SYSTEM

ALPHABETICAL INDEX

IDX

NISSAN EUROPE S.A.S.
© 2001 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.

NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

GENERAL INFORMATION
SECTION

OUTLINE OF MODIFICATIONS:
+EGR cooler has been adopted to ZD30DDTi engine.

APPLIED FROM:
JN1TESY61U0100001
JN1KESY61U0100001

CONTENTS
IDENTIFICATION INFORMATION …………………. 2002
Model Variation ………………………………………… 2002

Identification Number ………………………………… 2003

IDENTIFICATION INFORMATION
Model Variation
Model

Rear seat arrangement
Destination

Steering
position

Hardtop

Station Wagon

2nd seat

2nd center split bench seat

Forward facing

Engine

3rd seat

Side facing or
Seatless

Seatless

Front differential

Forward facing

Side facing

H233B

Rear differential
Transmission

Transfer

FS5R50B

RE4R03A
FS5R50B

RHD

RE4R03A
FS5R50B

FS5R50B
Europe

ZD30DDTi

S
TX12A

FS5R50B
SE
LHD

KWSSREFY61UEA

—

TWSSREFY61UEA

—

TWSSREAY61UEA

—

KWSSRFFY61UEA

—

TWSSRFFY61UEA

—

KWSSRFAY61UEA

—

TWSSRFAY61UEA

—

TWSSRHFY61UEA

—

TWSSRHAY61UEA

—

RE4R03A

H233B/H260

Grade

RE4R03A

KWSSLEFY61UGA KWSSLEFY61USP TWSSLEFY61USP TWSSLEFY61UGA
—

—

KWSSLFFY61UGA

—

TWSSLEAY61UGA

TWSSLFFY61USP TWSSLFFY61UGA
—

TWSSLFFY61USA

—

TWSSLFAY61UGA

—

TWSSLFAY61USA

—

TWSSLHFY61UGA

—

TWSSLHFY61USA

—

TWSSLHAY61UGA

—

TWSSLHAY61USA

—

SE
RE4R03A

Prefix and suffix designations
GN

—
—

KWSSLFAY61UGA

FS5R50B

—
—

Y61

A
A: 3rd seat forward facing
Q: 3rd seat side facing
P: 3rd seat/Rear seat seatless

K: Middle East
E: RHD for Europe
G: Central/South Europe
S: North Europe
E: Multiport fuel injection system engine
N: Diesel engine
U: Turbocharger engine
F: 5-speed floor shift manual transmission
A: 4-speed floor shift automatic transmission
A: S E: GL (SGL), S F: SAFARI, SE
H: S-SAFARI, SE
L: LH drive R: RH drive
S: Long wheelbase (4WD)
GN: TB45E engine VT: TD42 engine
WS: ZD30DDTi engine
GP: TB48DE engine
T: Station Wagon
K: Hardtop

GI-2002

IDENTIFICATION INFORMATION
Identification Number
VEHICLE IDENTIFICATION NUMBER (Chassis number)
Prefix and suffix designations
JN1

Y61

XXXXXX
Vehicle serial number

0: Stopgap (no meaning)
U: Europe
S: Long wheelbase (4WD)
E: ZD30DDTi engine
T: Station Wagon K: Hardtop
JN1: Japan produced vehicle

GI-2003

IDENTIFICATION INFORMATION

GI-2004

HEATER &
AIR CONDITIONER

SECTION

MODIFICATION NOTICE:
+ Wiring diagram has been changed.

CONTENTS
PRECAUTIONS AND PREPARATION …………… 2002
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 2002

Wiring Diagram — A/C, M —/Wagon and
Hardtop Models………………………………………… 2005
AUTO

REAR HEATER
TROUBLE DIAGNOSES ………………………………. 2003
Wiring Diagram — R/HEAT —/LHD Models … 2003
Wiring Diagram — R/HEAT —/RHD Models… 2004

TROUBLE DIAGNOSES ………………………………. 2007
Circuit Diagram — A/C, A —……………………… 2007
Wiring Diagram — A/C, A —……………………… 2008
COOL BOX

MANUAL
TROUBLE DIAGNOSES ………………………………. 2005

TROUBLE DIAGNOSES ………………………………. 2011
Wiring Diagram — COOL/B —…………………… 2011

HA-2002

TROUBLE DIAGNOSES
Wiring Diagram — R/HEAT —/LHD Models

THA055M

HA-2003

TROUBLE DIAGNOSES
Wiring Diagram — R/HEAT —/RHD Models

THA056M

HA-2004

TROUBLE DIAGNOSES
Wiring Diagram — A/C, M —/Wagon and
Hardtop Models

THA027M

HA-2005

TROUBLE DIAGNOSES
Wiring Diagram — A/C, M —/Wagon and
Hardtop Models (Cont’d)

THA059M

HA-2006

TROUBLE DIAGNOSES
Circuit Diagram — A/C, A —

THA062M

HA-2007

TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —

THA083M

HA-2008

TROUBLE DIAGNOSES
Wiring Diagram — A/C, A — (Cont’d)

THA067M

HA-2009

TROUBLE DIAGNOSES
Wiring Diagram — A/C, A — (Cont’d)

THA068M

HA-2010

TROUBLE DIAGNOSES
Wiring Diagram — COOL/B —

THA274

HA-2011

TROUBLE DIAGNOSES

HA-2012

ALPHABETICAL INDEX
SECTION

IDX

ALPHABETICAL INDEX
A

A/T — Wiring diagram ………………………..
A/T control ………………………………………
A/T shift lock system ………………………..
ABS — Wiring diagram ………………………
APS — Wiring diagram ………………………
AT/C — Wiring diagram ……………………..
AUDIO — Wiring diagram …………………..
Accelerator position sensor ………………
Air bag disposal ………………………………
Air bag ……………………………………………
Air flow meter — See Mass air flow
sensor …………………………………………
Anti-lock brake system — Wiring
diagram ………………………………………
Audio ………………………………………………

AT-2003
EC-2021
AT-2013
BR-2003
EC-2019
EC-2021
EL-2088
EC-2019
RS-2009
RS-2003
EC-2006
BR-2002
EL-2088

BACK/L — Wiring diagram ………………….
BOOST — Wiring diagram ………………….
Back-up lamp …………………………………..
Bumper, front …………………………………

EL-2047
EC-2029
EL-2047
BT-2003

Electrical units location …………………….. EL-2103
Electronic fuel injection pump …. EC-2018, 2022,
2023, 2024, 2025, 2026, 2031
Engine control circuit diagram ………….. EC-2003
Engine coolant temperature sensor
(ECTS) ………………………………………. EC-2007
Exterior ………………………………………….. BT-2006

F/FOG — Wiring diagram …………………… EL-2048
Fluids ……………………………………………. MA-2002
Flywheel (clutch) …………………………….. CL-2005
Fog lamp, front ……………………………….. EL-2048
Front bumper ………………………………….. BT-2003
Front fog lamp ………………………………… EL-2048
Front passenger air bag ………………….. RS-2003
Fuel gauge ……………………………………… EL-2062
Fuse block ……………………………………… EL-2134
Fuse ………………………………………………. EL-2135
Fusible link ……………………………………… EL-2135

Gauges ………………………………………….. EL-2062
Grease ………………………………………….. MA-2002
Ground distribution ………………………….. EL-2014

CD/CHG — Wiring diagram ………………… EL-2092
CIGAR — Wiring diagram ………………….. EL-2085
COOL/F — Wiring diagram ………………… EC-2010
Cigarette lighter ………………………………. EL-2085
Clutch cover …………………………………… CL-2005
Clutch damper ………………………………… CL-2004
Clutch master cylinder ……………………… CL-2004
Clutch operating cylinder ………………….. CL-2003
Combination meter ………………………….. EL-2062
Cool box — Wiring diagram ……………….. HA-2011
Coolant replacement ………………………. MA-2003
Cooling circuit (engine) ……………………. LC-2002
Cooling fan control ………………………….. EC-2010

H/LAMP — Wiring diagram ………………… EL-2034
HEAT UP — Wiring diagram ……………… EC-2035
HLC — Wiring diagram ………………………. EL-2083
HORN — Wiring diagram …………………… EL-2084
Harness layout ………………………. EL-2106, 2108
Hazard warning lamp ………………………. EL-2050
Headlamp wiper ………………………………. EL-2083
Headlamp ……………………………… EL-2034, 2037
Heat up switch ……………………………….. EC-2035
Hood ……………………………………………… BT-2003
Horn ………………………………………………. EL-2084

DEICER — Wiring diagram …………………
DTRL — Wiring diagram …………………….
Daytime light system ………………………..
Diagnosis sensor unit ………………………

EL-2086
EL-2037
EL-2037
RS-2005

ILL — Wiring diagram ………………………… EL-2055
Illumination ……………………………………… EL-2054

ECCS-D control module …………. EC-2027, 2028
ECTS — Wiring diagram ……………………. EC-2007
EGR — Wiring diagram …………………….. EC-2030
EGR volume control valve ……………….. EC-2030
Electrical unit ………………………………….. EL-2136

Junction box (J/B) ……………………………. EL-2134

IDX-2002

ALPHABETICAL INDEX
L

License lamp ………………………………….. EL-2041
Location of electrical units ………………… EL-2103
Lubricants ……………………………………… MA-2002

MAFS — Wiring diagram …………………… EC-2006
MAIN — Wiring diagram ……………………. EC-2004
METER — Wiring diagram …………………. EL-2064
MIRROR — Wiring diagram ……………….. EL-2098
Maintenance (engine) ……………………… MA-2003
Mass air flow sensor (MAFS) …………… EC-2006
Meter ……………………………………………… EL-2062
Model variation ………………………………… GI-2002

Seat belt pre-tensioner ……………………. RS-2003
Shift schedule …………………………………. AT-2014
Side air bag ……………………………………. RS-2003
Speedometer ………………………………….. EL-2062
Spiral cable ……………………………………. RS-2006
Stabilizer release device — Wiring
diagram ……………………………………… RA-2002
Stabilizer release device ………………….. RA-2002
Start signal …………………………………….. EC-2033
Starter ……………………………………………. EL-2032
Starting system ……………………………….. EL-2029
Supplemental Restraint System ……….. RS-2003
Supplemental restraint system — Wiring
diagram …………………………….. RS-2020, 2021
Swirl control valve control solenoid
valve ………………………………………….. EC-2036

T
N

NATS (Nissan Anti-theft System) ………. EL-2100
NATS — Wiring diagram ……………………. EL-2100

TAIL/L — Wiring diagram ……………………
TCM circuit diagram …………………………
TURN — Wiring diagram …………………….
Tachometer ……………………………………..
Tail lamp …………………………………………
Thermostat ……………………………………..
Turn signal lamp ………………………………

EL-2041
AT-2002
EL-2050
EL-2062
EL-2041
LC-2003
EL-2050

Oil change (capacity) ………………………. MA-2002
Operating cylinder (clutch) ……………….. CL-2003
V

PNP/SW — Wiring diagram ……………….. EC-2034
POWER — Wiring diagram ………………… EL-2005
Park/Neutral position switch …………….. EC-2034
Parking lamp …………………………………… EL-2041
Power door mirror ……………………………. EL-2098
Power supply routing ………………. EL-2004, 2005
Pressure plate — See Clutch cover …….. CL-2005

R/HEAT — Wiring diagram …………………
Radio — See Audio ……………………………
Rear washer ……………………………………
Rear wiper ………………………………………

HA-2003
EL-2088
EL-2078
EL-2078

VSS — Wiring diagram ……………………… EC-2008
Vehicle identification number ……. GI-2002, 2003
Vehicle speed sensor (VSS) …………….. EC-2008

WARN — Wiring diagram ……………………
WIP/R — Wiring diagram ……………………
Warning lamps …………………………………
Washer, rear ……………………………………
Water temperature gauge …………………
Wiper deicer ……………………………………
Wiper, rear ………………………………………

SHIFT — Wiring diagram ……………………
SRS — See Supplemental Restraint
System ……………………………………….
STAB — Wiring diagram …………………….
SWL/V — Wiring diagram …………………..
Seal — See Exterior …………………………..
Seat belt pre-tensioner disposal ………..

AT-2013
RS-2003
RA-2002
EC-2036
BT-2006
RS-2009

IDX-2003

EL-2069
EL-2079
EL-2067
EL-2078
EL-2062
EL-2086
EL-2078

ALPHABETICAL INDEX

IDX-2004

ENGINE LUBRICATION &
COOLING SYSTEMS

SECTION

MODIFICATION NOTICE:
+

EGR cooler has been added on ZD30DDTi engine models.

CONTENTS
ENGINE COOLING SYSTEM………………………… 2002
Cooling Circuit………………………………………….. 2002

Thermostat ………………………………………………. 2003
EGR Cooler……………………………………………… 2004

ENGINE COOLING SYSTEM
Cooling Circuit

JLC437B

LC-2002

ENGINE COOLING SYSTEM
Thermostat

JLC438B

LC-2003

ENGINE COOLING SYSTEM
EGR Cooler

SLC439B

1
V
2
V
3
V
4
V
5
V
6
V
7
V

EGR tube assembly
Gasket
EGR cooler bracket
Water hose
Clamp
Water hose
Clamp

8
V
9
V
10
V
11
V
12
V
13
V
14
V

Water hose assembly
Clamp
Hose connector
Water hose
Clamp
Clamp
Water hose

LC-2004

15
V
16
V
17
V
18
V
19
V
20
V
21
V

Water tube assembly
Water
Clamp
Water hose
Gasket
EGR cooler bracket
EGR cooler

MAINTENANCE
SECTION

CONTENTS
RECOMMENDED FLUIDS AND LUBRICANTS. 2002
Fluids and Lubricants………………………………… 2002

ENGINE MAINTENANCE ……………………………… 2003
Changing Engine Coolant………………………….. 2003

RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants
Capacity (Approximate)
Imp meaLiter
sure
Engine oil (Refill)
With oil filter
ZD30DDTi
Without oil filter ZD30DDTi
Cooling system (with reservoir tank)
With front heater
ZD30DDTi
Without front
heater
With rear heater

RHD
LHD

ZD30DDTi

RHD
LHD

Manual transmission oil
FS5R50B
Differential carrier gear oil (without limited slip differential)
Without diff. lock
With diff. lock
Transfer fluid
TX12A
Automatic transmission fluid
RE4R03A
Power steering fluid
Brake and clutch fluid
Multi-purpose grease
Propeller shaft grease
Air conditioning system refrigerant
Air conditioning system lubricants

Recommended Fluids/Lubricants
Diesel engine: API CF4 or ACEA
B3-96.98 or ACEA B3/E396.98*4

8.2
7.7

7-1/4 qt
6-3/4 qt

13.0
13.2

11-1/2 qt
11-5/8 qt

12.0

10-5/8 qt

14.1
14.3

12-3/8 qt
12-5/8 qt

3.5

6-1/8 qt

API GL-4, Viscosity SAE 75W-90 only

2.4
3.0

4-1/4 qt
5-1/4 qt

API GL-5*1

1.9

1-5/8 qt

11.8
10-3/8 qt
Refill to the proper oil level
according to the instructions
in the “Do-it-yourself operations” section of the owner’s
manual.
—
—

—

+ Genuine Nissan Anti-freeze Coolant
(L250) or equivalent*5

Genuine Nissan ATF or equivalent*3 or
API GL-4*1
Genuine Nissan ATF or equivalent*3
Type DEXRONTMIII or equivalent
DOT 3 or DOT 4 *6
NLGI No. 2 (Lithium soap base)
NLGI No. 2 (Molybdenum disulphide
lithium soap base)
HFC-134a (R-134a)
Nissan A/C System Oil Type S or
exact equivalent

MA-2002

ENGINE MAINTENANCE
Changing Engine Coolant
Coolant capacity (With reservoir tank): ! (Imp qt)
RHD models
With front heater 13.0 (11-1/2)
With rear heater 14.1 (12-3/8)
LHD models
With front heater 13.2 (11-5/8)
With rear heater 14.3 (12-5/8)

MA-2003

ENGINE MAINTENANCE

MA-2004

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

SECTION

MODIFICATION NOTICE:
+ Wiring Diagrams have been changed.

CONTENTS
DIFFERENTIAL LOCK …………………………………. 2002
Wiring Diagram — DIFF/L — ……………………. 2002

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —

TPD007M

PD-2002

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L — (Cont’d)

TPD008M

PD-2003

DIFFERENTIAL LOCK

PD-2004

REAR AXLE &
REAR SUSPENSION

SECTION

MODIFICATION NOTICE:
+ Wiring diagrams have been changed.

CONTENTS
STABILIZER RELEASE DEVICE…………………… 2002
Wiring Diagram ………………………………………… 2002

STABILIZER RELEASE DEVICE
Wiring Diagram

TRA001

RA-2002

STABILIZER RELEASE DEVICE
Wiring Diagram (Cont’d)

TRA006M

RA-2003

STABILIZER RELEASE DEVICE

RA-2004

RESTRAINT SYSTEM
SECTION

MODIFICATION NOTICE:
+ Diagnosis sensor unit has been changed.
+ Deployment procedure of seat belt pre-tensioner has been changed.

CONTENTS
PRECAUTION……………………………………………… 2002
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” … 2002
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)2003
Precautions for SRS “AIR BAG” and “SEAT
BELT PRE-TENSIONER” Service ………………. 2003
Special Service Tools ……………………………….. 2003
Commercial Service Tool…………………………… 2004
SRS Component Parts Location…………………. 2004
Removal and Installation — Diagnosis Sensor
Unit, Seat Belt Pre-tensioner with Load Limiter2005
Removal — Driver Air Bag Module and Spiral
Cable………………………………………………………. 2006

Installation — Driver Air Bag Module and
Spiral Cable …………………………………………….. 2007
Disposal of Air Bag Module and Seat Belt Pretensioner …………………………………………………. 2009
TROUBLE DIAGNOSES — Supplemental
Restraint System (SRS) ………………………………. 2014
Trouble Diagnoses Introduction………………….. 2014
How to Perform Trouble Diagnoses for Quick
and Accurate Repair …………………………………. 2017
Schematic ……………………………………………….. 2019
Wiring Diagram — SRS —/LHD Models ……… 2020
Wiring Diagram — SRS —/RHD Models …….. 2021

PRECAUTION
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS composition which is available to NISSAN MODEL Y61 is as follows (The composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.

RS-2002

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Precautions for SRS “AIR BAG” and “SEAT
BELT PRE-TENSIONER” Service
+
+

+
+
+
+
+

Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual.
Before servicing the SRS, turn ignition switch “OFF”, disconnect both battery cables and wait at least 3
minutes.
For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt
pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes
have passed.
Diagnosis sensor unit must always be installed with their arrow marks “S” pointing towards the front of
the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before
installation and replace as required.
The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt
to turn steering wheel or column after removal of steering gear.
Handle air bag module carefully. Always place driver and passenger air bag modules with the pad side
facing upward and front side air bag modules (built-in type) with the stud bolt side facing down.
Conduct self-diagnosis to check entire SRS for proper function after replacing any components.
After air bag inflates, the front instrument panel assembly should be replaced if damaged.

Special Service Tools
Tool number
Tool name

Description

KV99106400
Deployment tool

Disposing of air bag module

NT357

KV99105300
Air bag module bracket

Anchoring air bag module

NT354

HT61961000 and
HT62152000 combined
*Special torx bit

Use for special bolts
[TAMPER RESISTANT TORX (Size T50)]
a: 3.5 (0.138) dia.
b: 8.5 — 8.6 (0.335 — 0.339) dia.
c: approx. 10 (0.39) sq.

Unit: mm (in)

NT361

KV99108300
Deployment tool adapters for
built-in type side air bag and
passenger air bag modules

NT780

KV99109800
Deployment tool adapters for
seat belt pre-tensioner

NT846

*: Special tool or commercial equivalent

RS-2003

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Commercial Service Tool
Tool name

Description

Tamper resistant torx socket

Size: T30

NT757

SRS Component Parts Location

SRS972

RS-2004

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal and Installation — Diagnosis
Sensor Unit, Seat Belt Pre-tensioner with
Load Limiter
CAUTION:
+ Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait at least
3 minutes.
+ Do not use old bolts and nuts coated with bonding agent after removal; replace with new ones.
+ Check diagnosis sensor unit, seat belt pre-tensioner with load limiter and satellite sensor for
proper installation.
+ Check diagnosis sensor unit and satellite sensor to ensure they are free of deformities, dents,
cracks or rust. If they show any visible signs of damage, replace them with new ones.
+ Check diagnosis sensor unit brackets to ensure they are free of deformities and rust.
+ After replacement of diagnosis sensor unit, seat belt pre-tensioner and satellite sensor, check
SRS function and perform self-diagnosis for SRS. Refer to “Self-diagnosis” for details.
+ Do not attempt to disassemble diagnosis sensor unit, seat belt pre-tensioner with load limiter and
satellite sensor.
+ Replace diagnosis sensor unit, seat belt pre-tensioner and satellite sensor if it has been dropped
or sustained an impact.
+ Do not expose seat belt pre-tensioner to temperatures exceeding 80°C (176°F).

REMOVAL OF DIAGNOSIS SENSOR UNIT

SRS973

1. Disconnect driver, passenger and side air bag module connectors. Also, disconnect seat belt pre-tensioner connector.
2. Remove console finisher, console box assembly and instrument panel stay cover. Refer to “INSTRUMENT PANEL” in
BT section.
3. Disconnect diagnosis sensor unit connector.
4. Remove bolt and diagnosis sensor unit fixing bolts.
Then remove the diagnosis sensor unit.
NOTE:
+ To install, reverse the removal procedure sequence.
+ After replacement, perform self-diagnosis for SRS. Refer
to “Self-diagnosis” for details.
CAUTION:
Do not use old special bolts coated with bonding agent;
replace with new coated special bolts.

RS-2005

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal — Driver Air Bag Module and Spiral
Cable

SRS904

CAUTION:
+ Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes.
+ Always work from the side of air bag module.
1. Remove lower lid from steering wheel, and disconnect air
bag module connector.

SBF811E

2. Remove side lid, ASCD steering switch and audio steering
switch. Using the TAMPER RESISTANT TORX (Size T30),
remove left and right special bolts. Air bag module can then
be removed.

SRS908

CAUTION:
+ Always place air bag module with pad side facing
upward.
+ Do not attempt to disassemble air bag module.
+ The special bolts are coated with bonding agent. Do not
use old bolts after removal; replace with new ones.
+ Do not insert any foreign objects (screwdriver, etc.) into
air bag module connector.

SRS161

RS-2006

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Removal — Driver Air Bag Module and
Spiral Cable (Cont’d)
+ Replace air bag module if it has been dropped or sustained an impact.
+ Do not expose the air bag module to temperatures
exceeding 90°C (194°F).
+ Do not allow oil, grease or water to come in contact with
the air bag module.

SBF814E

3. Set steering wheel in the neutral position.
4. Disconnect horn connector and remove nuts.
5. Remove dynamic damper. Then using steering wheel puller,
remove steering wheel. Be careful not to over-tighten puller
bolt on steering wheel.
CAUTION:
Do not tap or bump the steering wheel.
6. Remove steering column cover.

SRS676

7. Remove the four screws. Then unlock the spiral cable connector and disconnect connector. The spiral cable can then
be removed.
CAUTION:
+ Do not attempt to disassemble spiral cable.
+ Do not apply lubricant to the spiral cable.

SRS384

RS-2007

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Installation — Driver Air Bag Module and
Spiral Cable (Cont’d)
3. Make sure that the spiral cable is in the neutral position.
The neutral position is detected by turning left about 2.5
revolutions from the right end position. Align the two marks
, ).
(m
CAUTION:
The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
Also, with the steering linkage disconnected, the cable may
snap by turning the steering wheel beyond the limited number of turns.
The spiral cable can be turned up to about 2.5 turns from the
neutral position to both the right and left.
4. Connect spiral cable connector and tighten with screws.
Install steering column cover.

SRS165

SRS231

SRS908

9. Position air bag module and tighten with new special bolts.
+ Always service the air bag module from the side.
10. Connect air bag module connector.
11. Install steering switches and lids.
12. Perform self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or warning lamp check.)
Before performing self-diagnosis, connect both battery
cables.
13. Turn steering wheel to the left end and then to the right end
fully to make sure that spiral cable is set in the neutral position.
If air bag warning lamp blinks or stays ON (at the User
mode), it shows the spiral cable may be snapped due to its
improper position. Perform self-diagnosis again (use CONSULT-II or warning lamp). If a malfunction is detected,
replace the spiral cable with a new one.
14. Perform self-diagnosis again to check that no malfunction is
detected.

RS-2008

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt
Pre-tensioner
+
+
+
+
+
+
+
+
+
+
+
+

Before disposing of air bag module and seat belt pre-tensioner, or vehicles equipped with such systems,
deploy the systems. If such systems have already been deployed due to an accident, dispose of them
as indicated in “DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER” (RS-2013).
When deploying the air bag module and seat belt pre-tensioner, always use the Special Service Tool;
Deployment tool KV99106400.
When deploying the air bag module and seat belt pre-tensioner, stand at least 5 m (16 ft) away from the
deployment component.
When deploying air bag module and seat belt pre-tensioner, a fairly loud noise is made, followed by
smoke being released. The smoke is not poisonous, however, be careful not to inhale smoke since it
irritates the throat and can cause choking.
Always activate one air bag module at a time.
Due to heat, leave air bag module unattended for more than 30 minutes after deployment. Also leave
seat belt pre-tensioner unattended for move than 10 minutes after deployment.
Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner.
Never apply water to the deployed air bag module and seat belt pre-tensioner.
Wash your hands clean after finishing work.
Place the vehicle outdoors with an open space of at least 6 m (20 ft) on all sides when deploying air
bag module and seat belt pre-tensioner while mounted in vehicle.
Use a voltmeter to make sure the vehicle battery is fully charged.
Do not dispose of the air bag module and seat belt pre-tensioner un-deployed.

CHECKING DEPLOYMENT TOOL
Connecting to battery

SRS005-B

CAUTION:
The battery must show voltage of 9.6V or more.
Remove the battery from the vehicle and place it on dry wood
blocks approximately 5 m (16 ft) away from the vehicle.
+ Wait 3 minutes after the vehicle battery is disconnected
before proceeding.
+ Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal.
Make sure the polarity is correct. The right side lamp in the
tool, marked “deployment tool power”, should glow with a
green light. If the right side lamp glows red, reverse the
connections to the battery.

RS-2009

Air bag deployment tool lamp illumination chart
(Battery connected)
SBF266H

Switch operation

Left side lamp, green*
“AIR BAG CONNECTOR
VOLTAGE”

Right side lamp, green*
“DEPLOYMENT TOOL
POWER”

OFF

*: If this lamp glows red, the tool is connected to the battery incorrectly.
Reverse the connections and make sure the lamp glows green.

Deployment of passenger air bag module (outside of
vehicle)
1. Make an 8.5 mm (0.335 in) diameter hole in air bag module
bracket (SST: KV99105300) at the position shown in figure
at left.

SRS236-F

2. Firmly secure air bag module bracket (SST: KV99105300) in
a vise.

SRS310

3. Match the two holes in air bag module bracket (held in vise)
and passenger air bag module and fix them with two bolts
[M8 x 25 — 30 mm (0.98 — 1.18 in)].
CAUTION:
If a gap exists between passenger air bag module and air
bag module bracket, use a piece of wood inserted in the gap
to stabilize the air bag module.

SRS311

RS-2010

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt
Pre-tensioner (Cont’d)

SRS313-A

4. Connect deployment tool adapter (SST: KV99108300) to
deployment tool (SST: KV99106400) connector and connector on either side of air bag module.
5. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal.
6. The lamp on the right side of the tool, marked “deployment
tool power”, should glow green, not red.
7. Press the button on the deployment tool. The left side lamp
on the tool, marked “air bag connector voltage”, will illuminate
and the air bag module will deploy.
CAUTION:
+ When deploying the air bag module, do not stand on the
deploying side.
+ Stand at least 5 m (16 ft) away from the air bag module.

SRS020-A

Deployment of seat belt pre-tensioner (outside of
vehicle)
1. Firmly grip pre-tensioner in a vise.

SRS974

2. Cut the webbing off.

SRS975

3. Connect deployment tool adapter (SST: KV99109800) to
deployment tool (SST: KV99106400) connector and seat belt
pre-tensioner.

SRS976

RS-2011

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt
Pre-tensioner (Cont’d)

SRS242-E

4. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal.
5. The lamp on the right side of the tool, marked “deployment
tool power”, should glow green, not red.
6. Press the button on the deployment tool. The left side lamp
on the tool, marked “seat belt pre-tensioner connector
voltage”, will illuminate and the seat belt pre-tensioner will
deploy.
CAUTION:
When deploying the seat belt pre-tensioner, stand at least 5
m (16 ft) away from the seat belt pre-tensioner.

DEPLOYMENT OF AIR BAG MODULE AND SEAT
BELT PRE-TENSIONER WHILE MOUNTED IN
VEHICLE

SRS006

When disposing of a vehicle, deploy air bag modules and seat
belt pre-tensioners while they are mounted in vehicle.
CAUTION:
When deploying air bag module or seat belt pre-tensioner,
ensure vehicle is empty.
1. Disconnect both the vehicle battery cables and wait 3 minutes.
2. Disconnect air bag modules and seat belt pre-tensioners
connector.
3. Connect deployment tool [SST: KV99106400] to air bag
module or seat belt pre-tensioner.
For front passenger air bag module and side air bag module,
attach deployment tool adapter [SST: KV99108300] to the
tool connector. For seat belt pre-tensioner, attach deployment tool adapter (SST: KV99109800) to the tool connector.
4. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal.
5. The lamp on the right side of the tool, marked “deployment
tool power”, should glow green, not red.
6. Press the button on the deployment tool. The left side lamp
on the tool, marked “air bag connector voltage”, will illuminate
and the air bag module or seat belt pre-tensioner will deploy.
CAUTION:
Activate only one air bag module or seat belt pre-tensioner
at a time.

RS-2012

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module and Seat Belt
Pre-tensioner (Cont’d)
DISPOSING OF AIR BAG MODULE AND SEAT BELT
PRE-TENSIONER

SBF276H

Deployed air bag modules and seat belt pre-tensioners are very
hot. Before disposing of air bag module, and seat belt pretensioner, wait at least 30 minutes, and 10 minutes, respectively.
Seal them in a plastic bag before disposal.
CAUTION:
+ Never apply water to a deployed air bag module and seat
belt pre-tensioner.
+ Be sure to wear gloves when handling a deployed air
bag module and seat belt pre-tensioner.
+ No poisonous gas is produced upon air bag module
deployment. However, be careful not to inhale gas since
it irritates throat and can cause choking.
+ Do not attempt to disassemble air bag module and seat
belt pre-tensioner.
+ Air bag module and seat belt pre-tensioner can not be
re-used.
+ Wash your hands clean after finishing work.

RS-2013

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction
CAUTION:
+ Do not use electrical test equipment to check SRS harness connectors unless instructed to in
this Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
+ Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged,
replace it with a new one.
+ Keep ground portion clean.

DIAGNOSIS FUNCTION
The SRS self-diagnosis results can be read by using “AIR BAG” warning lamp and/or CONSULT-II. The
reading of these results is accomplished using one of two modes — “User mode” and “Diagnosis mode”.
The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a system
malfunction through the operation of the “AIR BAG” warning lamp.
The Diagnosis mode allows the technician to locate and inspect the malfunctioning part.
The mode applications for the “AIR BAG” warning lamp and CONSULT-II are as follows:
User mode

Diagnosis mode

Display type

“AIR BAG” warning lamp

ON-OFF operation

CONSULT-II

—

Monitoring

DIAGNOSIS MODE FOR CONSULT-II
“SELF-DIAG [CURRENT]”
A current Self-diagnosis result (also indicated by the warning lamp flashes in the Diagnosis mode) is
displayed on the CONSULT-II screen in real time. This refers to a malfunctioning part requiring repairs.
+ “SELF-DIAG [PAST]”
Diagnosis results previously stored in the memory are displayed on the CONSULT-II screen. The stored
results are not erased until memory erasing is executed.
+ “TROUBLE DIAG RECORD”
With TROUBLE DIAG RECORD, diagnosis results previously erased by a reset operation can be displayed on the CONSULT-II screen.
+ “ECU DISCRIMINATED NO.”
The diagnosis sensor unit for each vehicle model is assigned with its own, individual classification number.
This number will be displayed on the CONSULT-II screen, as shown at left. When replacing the diagnosis
sensor unit, refer to the part number for the compatibility. After installation, replacement with a correct unit
can be checked by confirming this classification number on the CONSULT-II screen. The diagnosis sensor
unit classification number varies depending on SRS configuration.
For NISSAN MODEL Y61, the diagnosis sensor unit classification numbers are as follows.
+

MODEL

ECU DISCRIMINATED NO.

Model with dual air bags, side air bag and seat belt pre-tensioner

5A35

Model with dual air bags and side air bag

5A34

Model with dual air bags and seat belt pre-tensioner

5A33

Model with dual air bag

5A32

Model with single air bag and pre-tensioner

5A31

Model with single air bag

5A30

RS-2014

SRS803

From Diagnosis mode to User mode
To return to User mode from Diagnosis mode, touch “BACK” key of CONSULT-II until “SELECT SYSTEM”
appears, Diagnosis mode automatically changes to User mode.

SRS804

RS-2015

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction (Cont’d)
Without CONSULT-II

SRS800

From User mode to Diagnosis mode
Diagnosis mode activates only when a malfunction is detected,
by turning ignition switch as follows:
1) Turn ignition switch “ON”.
2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second.
3) Wait more than 3 seconds.
4) Repeat steps 1 to 3 three times.
5) Turn ignition switch “ON”.
SRS will not enter Diagnosis mode, if no malfunction is detected.

From Diagnosis mode to User mode
After a malfunction is repaired, switch the ignition “OFF” for at least one second, then back “ON”. Diagnosis mode is returned to User mode.
If switching Diagnosis mode to User mode is required while malfunction is being detected, by turning ignition switch as follows:
1) Turn ignition switch “ON”.
2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second.
3) Wait more than 3 seconds.
4) Repeat steps 1 to 3 three times.
5) Turn ignition switch “ON”.

RS-2016

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction (Cont’d)
HOW TO ERASE SELF-DIAGNOSIS RESULTS
With CONSULT-II

SRS701

+ “SELF-DIAG [CURRENT]”
A current Self-diagnosis result is displayed on the CONSULT-II screen in real time. After the malfunction is repaired
completely, no malfunction is detected on “SELF-DIAG
[CURRENT]”.
+ “SELF-DIAG [PAST]”
Return to the “SELF-DIAG [CURRENT]” CONSULT-II screen
by pushing “BACK” key of CONSULT-II and select “SELFDIAG [CURRENT]” in “SELECT DIAG MODE”. Touch
“ERASE” in “SELF-DIAG [CURRENT]” mode.
NOTE:
If the memory of the malfunction in “SELF-DIAG [PAST]” is
not erased, the User mode shows the system malfunction by
the operation of the warning lamp even if the malfunction is
repaired completely.
+ “TROUBLE DIAG RECORD”
The memory of “TROUBLE DIAG RECORD” cannot be
erased.

Without CONSULT-II
After a malfunction is repaired, return Diagnosis mode to User
mode by switching the ignition “OFF” for at least 1 second, then
back “ON”. At that time, the self-diagnostic result is cleared.

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a malfunction. It is important to fully understand the symptoms or conditions for a customer complaint.

INFORMATION FROM CUSTOMER
WHAT ……..
WHEN …….
WHERE …..
HOW ……….

Vehicle model
Date, Frequencies
Road conditions
Operating conditions, Symptoms

RS-2017

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
How to Perform Trouble Diagnoses for
Quick and Accurate Repair (Cont’d)
WORK FLOW
NOTE:
Seat belt pre-tensioner malfunction is indicated by “AIR BAG” warning lamp.
ACTION ITEM

REFERENCE ITEM

Check in

Listen to customer complaints and requests.

Perform preliminary check.

Preliminary check (RS-2017)

Check for any Service Bulletin.

Check air bag system operation by using “AIR BAG” warning lamp —
User mode.

DIAGNOSTIC PROCEDURE 1

.
c

Inspect malfunctioning part. — Diagnosis mode

DIAGNOSTIC PROCEDURE 2:
Using CONSULT-II
DIAGNOSTIC PROCEDURE 6:
Using “AIR BAG” warning lamp

Repair/Replace

Final check — Diagnosis mode and User mode
OK

Check out

RS-2018

DIAGNOSTIC PROCEDURE 3:
Using CONSULT-II
DIAGNOSTIC PROCEDURE 7:
Using “AIR BAG” warning lamp

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Schematic

TRS037M

RS-2019

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models
LHD MODELS

TRS038M

RS-2020

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models
RHD MODELS

TRS044M

RS-2021

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)

RS-2022

AUTOMATIC TRANSMISSION
SECTION

MODIFICATION NOTICE:
+

The RE5R05A model has been added.

CONTENTS
PRECAUTIONS ……………………………………………………. 5
Supplemental Restraint System (SRS) ″AIR
BAG″ and ″SEAT BELT PRE-TENSIONER″ ………… 5

RE4R03A
OVERALL SYSTEM ……………………………………………… 6
Circuit Diagram …………………………………………………. 6
Wiring Diagram — A/T — ………………………………………. 7

RE5R05A
PRECAUTIONS ………………………………………………….. 15
Supplemental Restraint System (SRS) ″AIR
BAG″ and ″SEAT BELT PRE-TENSIONER″ ………. 15
Precautions for A/T Assembly Replacement……….. 15
Precautions …………………………………………………….. 16
Wiring Diagrams and Trouble Diagnosis…………….. 17
PREPARATION ………………………………………………….. 18
Special Service Tools ………………………………………. 18
A/T CONTROL SYSTEM……………………………………… 19
Cross-Sectional View……………………………………….. 19
Hydraulic Control Circuit…………………………………… 20
Shift Mechanism ……………………………………………… 21
TCM Function …………………………………………………. 31
CAN Communication ……………………………………….. 32
Line Pressure Control………………………………………. 33
Shift Control ……………………………………………………. 35
Lock-Up Control………………………………………………. 35
Engine Brake Control ………………………………………. 36
Control Valve ………………………………………………….. 37
TROUBLE DIAGNOSIS……………………………………….. 39
DTC Inspection Priority Chart……………………………. 39
Fail-Safe…………………………………………………………. 39

How To Perform Trouble Diagnosis For Quick
and Accurate Repair………………………………………… 42
A/T Electrical Parts Location …………………………….. 48
Circuit Diagram ……………………………………………….. 49
Inspections Before Trouble Diagnosis………………… 50
Check Before Engine is Started ………………………… 54
Check at Idle…………………………………………………… 54
Cruise Test — Part 1 …………………………………………. 55
Cruise Test — Part 2 …………………………………………. 57
Cruise Test — part 3 …………………………………………. 58
Vehicle Speed When Shifting Gears Throttle
Position ………………………………………………………….. 58
Vehicle Speed When Performing and Releasing
Lock-up ………………………………………………………….. 59
Symptom Chart……………………………………………….. 59
TCM Input/Output Signal Reference Values ……….. 64
CONSULT-II……………………………………………………. 68
Diagnostic Procedure Without CONSULT-II ……….. 73
DTC U1000 CAN COMMUNICATION LINE …………… 75
Description ……………………………………………………… 75
On Board Diagnosis Logic………………………………… 75
Possible Cause……………………………………………….. 75
DTC Confirmation Procedure ……………………………. 75
Wiring Diagram — AT — CAN………………………………. 76
Diagnostic Procedure ………………………………………. 77
DTC P0615 START SIGNAL CIRCUIT………………….. 78
Description ……………………………………………………… 78
On Board Diagnosis Logic………………………………… 78
Possible Cause……………………………………………….. 78
DTC Confirmation Procedure ……………………………. 78
Wiring Diagram — AT — STSIG …………………………… 79
Diagnostic Procedure ………………………………………. 80
Component Inspection……………………………………… 81
DTC P0705 PARK/NEUTRAL POSITION SWITCH … 82

AUTOMATIC TRANSMISSION
Description ……………………………………………………… 82
On Board Diagnosis Logic………………………………… 82
Possible Cause……………………………………………….. 82
DTC Confirmation Procedure ……………………………. 82
Wiring Diagram — AT — PNP/SW ………………………… 83
Diagnostic Procedure ………………………………………. 84
Component Inspection……………………………………… 85
DTC P0720 VEHICLE SPEED SENSOR A/T
(REVOLUTION SENSOR) ……………………………………. 86
Description ……………………………………………………… 86
On Board Diagnosis Logic………………………………… 86
Possible Cause……………………………………………….. 86
DTC Confirmation Procedure ……………………………. 86
Wiring Diagram — AT — VSSA/T …………………………. 88
Diagnostic Procedure ………………………………………. 89
DTC P0725 ENGINE SPEED SIGNAL ………………….. 91
Description ……………………………………………………… 91
On Board Diagnosis Logic………………………………… 91
Possible Cause……………………………………………….. 91
DTC Confirmation Procedure ……………………………. 91
Diagnostic Procedure ………………………………………. 92
DTC P0740 TORQUE CONVERTER CLUTCH
SOLENOID VALVE……………………………………………… 94
Description ……………………………………………………… 94
On Board Diagnosis Logic………………………………… 94
Possible Cause……………………………………………….. 94
DTC Confirmation Procedure ……………………………. 94
Wiring Diagram — AT — TCV ………………………………. 95
Diagnostic Procedure ………………………………………. 96
DTC P0745 LINE PRESSURE SOLENOID VALVE … 97
Description ……………………………………………………… 97
On Board Diagnosis Logic………………………………… 97
Possible Cause……………………………………………….. 97
DTC Confirmation Procedure ……………………………. 97
Wiring Diagram — AT — LPSV …………………………….. 98
Diagnostic Procedure ………………………………………. 99
DTC P1701 TRANSMISSION CONTROL MODULE
(POWER SUPPLY) ……………………………………………. 100
Description ……………………………………………………. 100
On Board Diagnosis Logic………………………………. 100
Possible Cause……………………………………………… 100
DTC Confirmation Procedure ………………………….. 100
Wiring Diagram — AT — POWER……………………….. 101
Diagnostic Procedure …………………………………….. 103
Component Inspection……………………………………. 104
DTC P1702 TRANSMISSION CONTROL MODULE
(RAM) ………………………………………………………………. 105
Description ……………………………………………………. 105
On Board Diagnosis Logic………………………………. 105
Possible Cause……………………………………………… 105
DTC Confirmation Procedure ………………………….. 105
Diagnostic Procedure …………………………………….. 105
DTC P1703 TRANSMISSION CONTROL MODULE
(ROM)………………………………………………………………. 106
Description ……………………………………………………. 106
On Board Diagnosis Logic………………………………. 106

Possible Cause……………………………………………… 106
DTC Confirmation Procedure ………………………….. 106
Diagnostic Procedure …………………………………….. 106
DTC P1704 TRANSMISSION CONTROL MODULE107
Description ……………………………………………………. 107
On Board Diagnosis Logic………………………………. 107
Possible Cause……………………………………………… 107
DTC Confirmation Procedure ………………………….. 107
Diagnostic Procedure …………………………………….. 107
DTC P1705 THROTTLE POSITION SENSOR ……… 108
Description ……………………………………………………. 108
On Board Diagnosis Logic………………………………. 108
Possible Cause……………………………………………… 108
DTC Confirmation Procedure ………………………….. 108
Diagnostic Procedure …………………………………….. 108
DTC P1710 A/T FLUID TEMPERATURE SENSOR
CIRCUIT ……………………………………………………….. 110
Description ……………………………………………………. 110
CONSULT-II Reference Value ………………………… 110
On Board Diagnosis Logic………………………………. 110
Possible Cause……………………………………………… 110
DTC Confirmation Procedure ………………………….. 110
Wiring Diagram — AT — FTS …………………………….. 111
Diagnostic Procedure …………………………………….. 112
Component Inspection……………………………………. 114
DTC P1716 TURBINE REVOLUTION SENSOR …… 115
Description ……………………………………………………. 115
On Board Diagnosis Logic………………………………. 115
Possible Cause……………………………………………… 115
DTC Confirmation Procedure ………………………….. 115
Wiring Diagram — AT — TRSA/T ……………………….. 117
Diagnostic Procedure …………………………………….. 118
DTC P1721 VEHICLE SPEED SENSOR MTR ……… 120
Description ……………………………………………………. 120
On Board Diagnosis Logic………………………………. 120
Possible Cause……………………………………………… 120
DTC Confirmation Procedure ………………………….. 120
Diagnostic Procedure …………………………………….. 120
DTC P1730 A/T INTERLOCK …………………………….. 122
Description ……………………………………………………. 122
On Board Diagnosis Logic………………………………. 122
Possible Cause……………………………………………… 122
DTC Confirmation Procedure ………………………….. 122
Wiring Diagram — AT — I/LOCK ………………………… 123
Judgement of A/T Interlock …………………………….. 126
Diagnostic Procedure …………………………………….. 126
DTC P1731 A/T 1ST ENGINE BRAKING…………….. 128
Description ……………………………………………………. 128
On Board Diagnosis Logic………………………………. 128
Possible Cause……………………………………………… 128
DTC Confirmation Procedure ………………………….. 128
Wiring Diagram — AT — E/BRE …………………………. 129
Diagnostic Procedure …………………………………….. 130
DTC P1752 INPUT CLUTCH SOLENOID VALVE … 131
Description ……………………………………………………. 131
On Board Diagnosis Logic………………………………. 131

AT-2

AUTOMATIC TRANSMISSION
Possible Cause……………………………………………… 131
DTC Confirmation Procedure ………………………….. 131
Wiring Diagram — AT — I/C……………………………….. 132
Diagnostic Procedure …………………………………….. 133
DTC P1757 FRONT BRAKE SOLENOID VALVE…. 134
Description ……………………………………………………. 134
On Board Diagnosis Logic………………………………. 134
Possible Cause……………………………………………… 134
DTC Confirmation Procedure ………………………….. 134
Wiring Diagram — AT — FR/B ……………………………. 135
Diagnostic Procedure …………………………………….. 136
DTC P1762 DIRECT CLUTCH SOLENOID VALVE. 137
Description ……………………………………………………. 137
On Board Diagnosis Logic………………………………. 137
Possible Cause……………………………………………… 137
DTC Confirmation Procedure ………………………….. 137
Wiring Diagram — AT — D/C ……………………………… 138
Diagnostic Procedure …………………………………….. 139
DTC P1767 HIGH AND LOW REVERSE CLUTCH
SOLENOID VALVE……………………………………………. 140
Description ……………………………………………………. 140
On Board Diagnosis Logic………………………………. 140
Possible Cause……………………………………………… 140
DTC Confirmation Procedure ………………………….. 140
Wiring Diagram — AT — HLR/C …………………………. 141
Diagnostic Procedure …………………………………….. 142
DTC P1772 LOW COAST BRAKE SOLENOID
VALVE……………………………………………………………… 143
Description ……………………………………………………. 143
On Board Diagnosis Logic………………………………. 143
Possible Cause……………………………………………… 143
DTC Confirmation Procedure ………………………….. 143
Wiring Diagram — AT — LC/B ……………………………. 144
Diagnostic Procedure …………………………………….. 145
DTC P1815 MANUAL MODE SWITCH ……………….. 146
Description ……………………………………………………. 146
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 146
On Board Diagnosis Logic………………………………. 146
Possible Cause……………………………………………… 146
DTC Confirmation Procedure ………………………….. 146
Wiring Diagram — AT — MMSW ………………………… 147
Diagnostic Procedure …………………………………….. 148
Component Inspection……………………………………. 148
Position Indicator Lamp ………………………………….. 149
Position Indicator Lamp Symptom Chart…………… 149
DTC P1841 ATF PRESSURE SWITCH 1…………….. 150
Description ……………………………………………………. 150
On Board Diagnosis Logic………………………………. 150
Possible Cause……………………………………………… 150
DTC Confirmation Procedure ………………………….. 150
Wiring Diagram — AT — FPSW1………………………… 151
Diagnostic Procedure …………………………………….. 152
DTC P1843 ATF PRESSURE SWITCH 3…………….. 154
Description ……………………………………………………. 154
On Board Diagnosis Logic………………………………. 154

Possible Cause……………………………………………… 154
DTC Confirmation Procedure ………………………….. 154
Wiring Diagram — AT — FPSW3………………………… 155
Diagnostic Procedure …………………………………….. 156
DTC P1845 ATF PRESSURE SWITCH 5…………….. 157
Description ……………………………………………………. 157
On Board Diagnosis Logic………………………………. 157
Possible Cause……………………………………………… 157
DTC Confirmation Procedure ………………………….. 157
Wiring Diagram — AT — FPSW5………………………… 158
Diagnostic Procedure …………………………………….. 159
DTC P1846 ATF PRESSURE SWITCH 6…………….. 160
Description ……………………………………………………. 160
On Board Diagnosis Logic………………………………. 160
Possible Cause……………………………………………… 160
DTC Confirmation Procedure ………………………….. 160
Wiring Diagram — AT — FPSW6………………………… 161
Diagnostic Procedure …………………………………….. 162
PARK/NEUTRAL POSITION, MANUAL MODE,
BRAKE AND THROTTLE POSITION SWITCH
CIRCUIT …………………………………………………………… 164
Diagnostic Procedure …………………………………….. 164
TROUBLE DIAGNOSES FOR SYMPTOMS…………. 166
Wiring Diagram — AT — NONDTC……………………… 166
A/T CHECK Indicator Lamp Does not Come on… 168
Engine Cannot Be Started In ″P″ and ″N″
Position ………………………………………………………… 169
In ″P″ Position, Vehicle Moves When Pushed…… 170
In ″N″ Position, Vehicle Moves ……………………….. 171
Large Shock ″N″ to ″D″ Position……………………… 172
Vehicle Does Not Creep Backward In ″R″
Position ………………………………………………………… 173
Vehicle Does Not Creep Forward In ″D″ Position 174
Vehicle Cannot Be Started From D1 ………………… 175
A/T Does Not Shift: D1 -> D2 Or Does Not Kick
down: D4 -> D2 ……………………………………………… 176
A/T Does Not Shift: D2 -> D3…………………………… 177
A/T Does Not Shift: D3 -> D4…………………………… 178
A/T Does Not Shift: D4 -> D5…………………………… 179
A/T Does Not Perform Lock-up ……………………….. 180
A/T Does Not Hold Lock-up Condition ……………… 181
Lock-up Is Not Released ………………………………… 181
Engine Speed Does Not Return To Idle …………… 182
A/T Does Not Shift: D5 -> D4…………………………… 183
A/T Does Not Shift: D4 -> D3…………………………… 184
A/T Does Not Shift: D3 -> D2…………………………… 185
A/T Does Not Shift: D2 -> D1…………………………… 186
Vehicle Does Not Decelerate By Engine Brake…. 187
Component Inspection……………………………………. 187
A/T SHIFT LOCK SYSTEM………………………………… 188
Description ……………………………………………………. 188
Wiring Diagram — SHIFT -……………………………….. 189
Diagnostic Procedure …………………………………….. 190
Component Check …………………………………………. 193
Key Interlock Cable ……………………………………….. 194
ON-VEHICLE SERVICE …………………………………….. 196

AT-3

AUTOMATIC TRANSMISSION
Control Linkage Adjustment ……………………………. 196
A/T FLUID COOLER SYSTEM …………………………… 197
A/T Fluid Cooler…………………………………………….. 197
A/T Fluid Cooler Bypass Valve/For Europe ………. 198
REMOVAL AND INSTALLATION ……………………….. 199
Removal……………………………………………………….. 199
Installation…………………………………………………….. 200
SERVICE DATA AND SPECIFICATIONS (SDS) ….. 201
General Specifications……………………………………. 201

AT-4

Vehicle Speed When Shifting Gears………………… 201
Vehicle Speed When Performing and Releasing
Lock-up ………………………………………………………… 201
Stall Revolution……………………………………………… 201
Line Pressure………………………………………………… 201
Solenoid Valves …………………………………………….. 202
A/T Fluid Temperature Sensor ………………………… 202
Turbine Revolution Sensor ……………………………… 202
Revolution Sensor …………………………………………. 202

PRECAUTIONS
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and
Air Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.

AT-5

OVERALL SYSTEM

RE4R03A

Circuit Diagram

TAT059M

AT-6

OVERALL SYSTEM

RE4R03A

Wiring Diagram — A/T —

TAT061M

AT-7

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT108M

AT-8

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT109M

AT-9

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT122M

AT-10

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT111M

AT-11

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT112M

AT-12

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT128M

AT-13

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT114M

AT-14

RE5R05A

PRECAUTIONS

Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and
Air Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.

Precautions for A/T Assembly Replacement
REPLACEMENT
CAUTION:
+ Check data (Unit ID) in TCM with data monitor of CONSULT-II before replacing A/T assembly.
+ Check if new data (Unit ID) are entered correctly after replacing A/T assembly and erasing data
in TCM.
+ When replacing A/T assembly or TCM, refer to the pattern table below and erase the EEPROM in the
TCM if necessary.

EEPROM erasing patterns
A/T assembly

TCM

Erasing EEPROM in TCM

Remarks

Replaced

Not required

Not required because the EEPROM in the TCM is in the
default state.

Not replaced

Replaced

Not required

Not required because the EEPROM in the TCM is in the
default state.

Replaced

Not replaced

Required

Required because data has been written in the EEPROM in
the TCM and because the TCM cannot write data from the
ROM assembly in the transmission.

Method for erasing the EEPROM in the TCM
1.
2.
3.
4.
5.

Move selector lever in “R” position.
Set the closed throttle position switch to “OFF”. (Depressed accelerator pedal at half throttle)
Ignition switch to “ON” position.
Select “SELF-DIAG RESULTS” mode for A/T with CONSULT-II.
Touch “ERASE” the EEPROM memory.

AT-15

RE5R05A
PRECAUTIONS
Precautions for A/T Assembly Replacement
(Cont’d)

Method for writing data from the ROM assembly in the transmission
With the EEPROM in the TCM erased, the selector lever in “P” position, and the ignition switch “ON” position.
In this state, the TCM reads data from the ROM assembly and writes it to the EEPROM in the TCM.

Check method
Normal: About 2 seconds after the ignition switch to “ON” position, the A/T CHECK indicator lamp lights
up for 2 seconds.
+ Abnormal: Even after the ignition switch to “ON” position, the A/T CHECK indicator lamp does not light
up.
— Replace the A/T assembly.
— Replace the TCM.
+

Precautions
NOTE:
If any problems occur in the RE5R05A model transmission, replace the entire transmission assembly.
+ Before connecting or disconnecting the TCM harness
connector, turn ignition switch to “OFF” position and
disconnect negative battery terminal. Because battery
voltage is applied to TCM even if ignition switch is
turned to “OFF” position.

SEF289H

+ When connecting or disconnecting pin connectors into
or from TCM, take care not to damage pin terminals
(bend or break).
Make sure that there are not any bends or breaks on
TCM pin terminal, when connecting pin connectors.

SEF291H

+ Before replacing TCM, perform TCM input/output signal
inspection and make sure whether TCM functions properly or not. Refer to AT-64, “TCM INSPECTION TABLE”.
+ Always use the specified brand of A/T fluid. Refer to MA
section, “Changing A/T Fluid”.
+ Use paper rags not cloth rags during work.
+ After replacing the A/T fluid, dispose of the waste oil using
the methods prescribed by law, ordinance, etc.

MEF040DA

AT-16

PRECAUTIONS

RE5R05A

Wiring Diagrams and Trouble Diagnosis
When you read wiring diagrams, refer to the following:
+ Read GI section, “HOW TO READ WIRING DIAGRAMS”.
+ See EL section, “POWER SUPPLY ROUTING” for power
distribution circuit.
When you perform trouble diagnosis, refer to the following:
+ Read GI section, “HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES”.

AT-17

RE5R05A

PREPARATION
Special Service Tools
Tool number
Tool name

Description

ST2505S001
Oil pressure gauge set
1 ST25051001
Oil pressure gauge
2 ST25052000
Hose
3 ST25053000
Joint pipe
4 ST25054000
Adapter
5 ST25055000
Adapter

Measuring line pressure

ZZA0600D

KV31103600
Joint pipe adapter
(With ST25054000)

Measuring line pressure

ZZA1227D

AT-18

RE5R05A

A/T CONTROL SYSTEM
Cross-Sectional View

SAT620K

1
V
2
V
3
V
4
V
5
V
6
V

Front planetary gear
Mid planetary gear
Rear planetary gear
Direct clutch
High & low reverse clutch
Reverse brake

7
V
8
V
9
V
10
V
11
V
12
V

Forward brake
Low coast brake
Input shaft
Torque converter
Oil pump
Front brake

AT-19

13
V
14
V
15
V
16
V
17
V
18
V

3rd one-way clutch
Input clutch
1st one-way clutch
Control valve
Forward one-way clutch
Output shaft

A/T CONTROL SYSTEM

RE5R05A

Hydraulic Control Circuit

PCIA0001E

AT-20

RE5R05A

A/T CONTROL SYSTEM
Shift Mechanism

The automatic transmission uses compact, dual planetary gear systems to improve power-transmission
efficiency, simplify construction and reduce weight.
It also employs an optimum shift control and super wide gear ratios. They improve starting performance and
acceleration during medium and high-speed operation.

CONSTRUCTION

PCIA0002J

1
V
2
V
3
V
4
V
5
V
6
V
7
V
8
V

Front brake
Input clutch
Direct clutch
High and low reverse clutch
Reverse brake
Forward brake
Low coast brake
1st one-way clutch

9
V
10
V
11
V
12
V
13
V
14
V
15
V
16
V

Forward one-way clutch
3rd one-way clutch
Front sun gear
Input shaft
Mid internal gear
Front internal gear
Rear carrier
Rear sun gear

17
V
18
V
19
V
20
V
21
V
22
V
23
V

Mid sun gear
Rear sun gear
Mid carrier
Rear internal gear
Output shaft
Parking gear
Parking pole

FUNCTION OF CLUTCH AND BRAKE
Name of the Part

Abbreviation

Function

Front brake (1)

Fr/B

Input clutch (2)

I/C

Connects the input shaft (12), the mid internal gear (13), and the front
internal gear (14).

Direct clutch (3)

D/C

Connects the rear carrier (15) and the rear sun gear (16).

High and low reverse clutch (4)

H & LR/C

Fastens the front sun gear (11)

Connects the mid sun gear (17) and the rear sun gear (16).

Reverse brake (5)

R/B

Fastens the rear carrier (15).

Forward brake (6)

F/B

Fastens the mid sun gear (17).

LC/B

Fastens the mid sun gear (17).

Low coast brake (7)
1st one-way clutch (8)
Forward one-way clutch (9)
3rd one-way clutch (10)

1st/O.C

Allows the rear sun gear (16) to turn freely forward relative to the mid
sun gear (17) but fastens it for reverse rotation.

F/O.C

Allows the mid sun gear (17) to turn freely in the forward direction but
fastens it for reverse rotation

3rd/O.C

Allows the front sun gear (11) to turn freely in the forward direction but
fastens it for reverse rotation

AT-21

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

CLUTCH AND BAND CHART

SCIA0492E

AT-22

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

POWER TRANSMISSION
“N” position
Since both the forward brake and the reverse brake are released, torque from the input shaft drive is not
transmitted to the output shaft.

“P” position
+
+

The same as for the “N” position, both the forward brake and the reverse brake are released, so torque
from the input shaft drive is not transmitted to the output shaft.
The parking pole linked with the select lever meshes with the parking gear and fastens the output shaft
mechanically.

PCIA0003J

AT-23

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

“D”, “M2”, “M3”, “M4”, “M5” POSITIONS 1ST SPEED
+
+
+
+
+

The front brake is fastened.
The forward brake and the forward one-way clutch regulate reverse rotation of the mid sun gear.
The first one-way clutch regulates reverse rotation of the rear sun gear.
The third one-way clutch regulates reverse rotation of the front sun gear.
During deceleration, the mid sun gear turns forward, so the forward one-way clutch idles and the engine
brake is not activated.

PCIA0004E

AT-24

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

“M1” POSITION 1ST SPEED
+
+
+
+
+
+
+

The front brake is applied.
The forward brake and the forward one-way clutch regulate reverse rotation of the mid sun gear.
The first one-way clutch regulates reverse rotation of the rear sun gear.
The third one-way clutch regulates reverse rotation of the front sun gear.
During deceleration, the mid sun gear turns forward, so the forward one-way clutch idles and the engine
brake is not activated.
The low coast brake fastens the mid sun gear.
During deceleration, the low coast brake regulates forward rotation of the mid sun gear and the engine
brake functions.

PCIA0004E

AT-25

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

“D”, “M3”, “M4”, “M5” POSITIONS 2ND SPEED
+
+
+
+

The
The
The
The

front brake is applied.
forward brake and the forward one-way clutch regulate reverse rotation of the mid sun gear.
third one-way clutch regulates reverse rotation of the front sun gear.
direct clutch is coupled and the rear carrier and rear sun gear are connected.

PCIA0004E

AT-26

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

“M2” POSITION 2ND SPEED
+
+
+
+
+
+

The front brake is applied.
The forward brake and the forward one-way clutch regulate reverse rotation of the mid sun gear.
The third one-way clutch regulates reverse rotation of the front sun gear.
The direct clutch is coupled, and the rear carrier and rear sun gear are connected.
The low coast brake functions.
Engine brake function.

PCIA0004E

AT-27

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

“D”, “M3”, “M4”, “M5” POSITIONS 3RD SPEED
+
+
+

The front brake is applied.
The third one-way clutch regulates reverse rotation of the front sun gear.
The high and low reverse clutch is coupled and the mid sun gear and rear sun gear are connected.

PCIA0004E

AT-28

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

“D”, “M4”, “M5” POSITIONS 4TH SPEED
+
+
+

The front brake is released and the sun gears rotate forward.
The input clutch is coupled and the front internal gear and mid internal gear are connected.
The drive power is conveyed to the front internal gear, mid internal gear, and rear carrier and the three
planetary gears rotate as one unit.

PCIA0004E

AT-29

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

“D”, “M5” POSITIONS 5TH SPEED
+
+

The front brake fastens the front sun gear.
The direct clutch is released and the connection between the rear carrier and the rear sun gear is
released.

PCIA0005E

AT-30

A/T CONTROL SYSTEM
Shift Mechanism (Cont’d)

RE5R05A

“R” POSITION
+
+
+

The front brake fastens the front sun gear.
The high and low reverse clutch is coupled and the mid sun gear and rear sun gear are connected.
The reverse brake fastens the rear carrier.

PCIA0006E

TCM Function
The function of the TCM is to:
+ Receive input signals sent from various switches and sensors.
+ Determine required line pressure, shifting point, lock-up operation, and engine brake operation.
+ Send required output signals to the respective solenoids and sensors.

CONTROL SYSTEM OUTLINE
The automatic transmission senses vehicle operating conditions through various sensors. It always controls
the optimum shift position and reduces shifting and lock-up shocks.
SENSORS
PNP switch
Throttle position sensor
Closed throttle position switch
Wide open throttle position
switch
Engine speed signal
A/T fluid temperature sensor
Revolution sensor
Vehicle speed sensor
Manual mode switch
Stop lamp switch
Turbine revolution sensor

TCM

→

Shift control
Line pressure control
Lock-up control
Engine brake control
Timing control
Fail-safe control
Self-diagnosis
CONSULT-II communication
line
Duet-EA control
CAN system

AT-31

ACTUATORS

→

Input clutch solenoid valve
Direct clutch solenoid valve
Front brake solenoid valve
High & low reverse clutch solenoid valve
Low coast brake solenoid valve
Torque converter clutch solenoid valve
Line pressure solenoid valve
A/T CHECK indicator lamp

RE5R05A

A/T CONTROL SYSTEM
CONTROL SYSTEM DIAGRAM

SAT621K

CAN Communication
SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle
multiplex communication line with high data communication speed and excellent error detection ability. Many
electronic control units are equipped onto a vehicle, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected
with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with
less wiring. Each control unit transmits/receives data but selectively reads required data only.

System diagramË

SEL599Y

INPUT/OUTPUT SIGNAL CHART
T: Transmit
Signals

R: Receive

Combination meter

TCM

ECM

Engine speed signal

Engine coolant temperature signal

Accelerator pedal position signal

Closed throttle position signal

Wide open throttle position signal

A/T fluid temperature warning lamp signal

AT-32

A/T CONTROL SYSTEM
CAN Communication (Cont’d)
Signals
Current gear position signal

RE5R05A

Combination meter

TCM

ECM

Shift change signal
Air conditioner switch signal

Headlamp switch signal

Rear window defogger switch signal

Brake switch signal

Vehicle speed signal

A/T self diagnosis signal
Manual mode signal

Line Pressure Control
+
+

When an input torque signal equivalent to the engine drive force is sent from the ECM to the TCM, the
TCM controls the line pressure solenoid.
This line pressure solenoid controls the pressure regulator valve as the signal pressure and adjusts the
pressure of the operating oil discharged from the oil pump to the line pressure most appropriate to the
driving state.

PCIA0007E

LINE PRESSURE CONTROL IS BASED ON THE TCM LINE PRESSURE CHARACTERISTIC
PATTERN
+
+

The TCM has stored in memory a number of patterns for the optimum line pressure characteristic for
the driving state.
In order to obtain the line pressure characteristic that the TCM has selected as being the most appropriate characteristic in the current driving state, the TCM controls the line pressure solenoid current value
and thus controls the line pressure.

AT-33

A/T CONTROL SYSTEM
Line Pressure Control (Cont’d)

RE5R05A

Normal Control
Each clutch is adjusted to the necessary pressure to match the
engine drive force.

PCIA0008E

Back-up Control (Engine Brake)
When the select operation is executed during driving and the
transmission is shifted down, the line pressure is set according
to the vehicle speed.

PCIA0009E

During Shift Change
The necessary and adequate line pressure for speed change is
set. Therefore, the line pressure characteristic is set according
to the input torque and speed change type.

PCIA0010E

At Low Fluid Temperature
When the A/T fluid temperature drops below the prescribed
temperature, in order to speed up the action of each friction
element, the line pressure is set higher than the normal line
pressure characteristic.

PCIA0011E

AT-34

RE5R05A

A/T CONTROL SYSTEM
Shift Control

The clutch pressure control solenoid is driven by the signals from the switches and sensors. Thus, as the
clutch pressure is adjusted to be appropriate to the engine load state and vehicle driving state. It becomes
possible to finely control the clutch hydraulic pressure with high precision and a smoother speed change
characteristic is attained.

PCIA0012E

SHIFT CHANGE
The clutch is controlled with the optimum timing and oil pressure for the engine speed, engine torque
information, etc.

Shift Change System Diagram

PCIA0013E

*1: Full phase real-time feedback control monitors movement of gear ratio at gear change, and controls oil pressure at real-time to
achieve the best gear ratio.

Lock-Up Control
Lock-up control means that torque converter sliding is eliminated and coupling the lock-up piston in the
torque converter raises the power transmission efficiency.
The lock-up solenoid is controlled by a signal from the TCM, the lock-up control valve operation is controlled,
and the torque converter lock-up piston is coupled or released.

Lock-Up Operation Condition Table
Select lever

D position

M position

Gear position

Lock-up

—

AT-35

A/T CONTROL SYSTEM
Lock-Up Control (Cont’d)

RE5R05A

TORQUE CONVERTER CLUTCH CONTROL VALVE CONTROL
+
+

The circuit that supplies operating oil pressure to the lock-up piston chamber is connected to the lock-up
control valve. This valve is switched by the lock-up solenoid with signals from the TCM.
In this way, the circuit that supplies operating oil pressure to the lock-up piston chamber is controlled to
the released side or the coupled side.

Lock-Up Control System Diagram

PCIA0014E

Lock-Up Released
+

In the lock-up released state, the lock-up control valve is set into the un-locked state by the lock-up
solenoid and the lock-up apply pressure is drained.
In this way, the lock-up piston is not coupled.

Lock-Up Applied
+

In the lock-up coupled state, the lock-up control valve is set into the locked state by the lock-up solenoid
and lock-up apply pressure is generated.
In this way, the lock-up piston is pressed and coupled.

SMOOTH LOCK-UP CONTROL
When shifting from the lock-up release state to the lock-up coupled state, the current output to the lock-up
solenoid is controlled with the TCM. In this way, when shifting to the lock-up coupled state, the lock-up clutch
is temporarily set to the half-clutched state to reduce the shock.

Half Clutched State
+

The current output from the TCM to the lock-up solenoid is varied to steadily increase the lock-up solenoid pressure.
In this way, the lock-up apply pressure steadily rises and while the lock-up piston is put into half-clutched
status, the force pressing on the lock-up piston is increased and the coupling is completed smoothly.

Engine Brake Control
+

The forward one-way clutch transmits the drive force from the engine to the rear wheels. But the reverse
drive from the rear wheels is not transmitted to the engine because the one-way clutch is idling.
Therefore, the low coast brake solenoid is operated to prevent the forward one-way clutch from idling
and the engine brake is operated in the same manner as conventionally.

AT-36

A/T CONTROL SYSTEM
Engine Brake Control (Cont’d)

RE5R05A

PCIA0015E

The operation of the low coast brake solenoid switches the low coast brake switch valve and controls
the coupling and releasing of the low coast brake.
The low coast brake reducing valve controls the low coast brake coupling force.

Control Valve
FUNCTION OF CONTROL VALVE
Name

Function

Torque converter regulator valve

In order to prevent the pressure supplied to the torque converter from being
excessive, the line pressure is adjusted to the optimum pressure (torque converter
operating pressure).

Pressure regulator valve
Pressure regulator plug
Pressure regulator sleeve

Adjusts the oil discharged from the oil pump to the optimum pressure (line pressure)
for the driving state.

Front brake control valve

When the front brake is coupled, adjusts the line pressure to the optimum pressure
(front brake pressure) and supplies it to the front brake.

Accumulator control valve

Adjusts the pressure (accumulator control pressure) acting on the accumulator piston
and low coast reducing valve to the pressure appropriate to the driving state (adjusts
the clutch pressure for 1st, 2nd, 3rd, and 5th speeds).

Pilot valve A

Adjusts the line pressure and produces the constant pressure (pilot pressure)
required for line pressure control, speed change control, and lock-up control.

Pilot valve B

Adjusts the line pressure and produces the constant pressure (pilot pressure)
required for speed change control.

Low coast brake switching valve

During engine braking, supplies the line pressure to the low coast brake reducing
valve.

Low coast brake reducing valve

When the low coast brake is coupled, adjusts the line pressure to the optimum pressure (low coast brake pressure) and supplies it to the low coast brake.

N-R accumulator

Produces the stabilizing pressure for when N-R is selected.

Direct clutch piston switching valve

Operates in 4th speed and switches the direct clutch coupling capacity.

High and low reverse clutch control valve

When the high and low reverse clutch is coupled, adjusts the line pressure to the
optimum pressure (high and low reverse clutch pressure) and supplies it to the high
and low reverse clutch. (In 1st, 2nd, 3rd, and 5th speeds, adjusts the clutch pressure.)

AT-37

A/T CONTROL SYSTEM
Control Valve (Cont’d)
Name

RE5R05A

Function

Input clutch control valve

When the input clutch is coupled, adjusts the line pressure to the optimum pressure
(input clutch pressure) and supplies it to the input clutch. (In 4th and 5th speeds,
adjusts the clutch pressure.)

Direct clutch control valve

When the direct clutch is coupled, adjusts the line pressure to the optimum pressure
(direct clutch pressure) and supplies it to the direct clutch. (In 2nd, 3rd, and 4th
speeds, adjusts the clutch pressure.)

TCC control valve
TCC control plug
TCC control sleeve

Switches the lock-up to operating or released. Also, by executing the lock-up operation transiently, lock-up smoothly.

Torque converter lubrication valve

Operated during lock-up to switch the torque converter, cooling, and lubrication system oil path.

Cool bypass valve

Set for securing oil lubrication flow at low temperatures.

Line pressure relief valve

Set for securing line pressure.

N-D accumulator

Produces the stabilizing pressure for when N-D is selected.

Manual valve

Sends line pressure to each circuit according to the select position. The circuits to
which the line pressure is not sent drain.

FUNCTION OF PRESSURE SWITCH
Name

Function

Pressure switch 1 (FR/B)

Detects any abnormality in the front brake hydraulic pressure. When it detects any
abnormality, it puts the system into fail-safe mode.

Pressure switch 2 (LC/B)

Detects any abnormality in the low coast brake hydraulic pressure. When it detects
any abnormality, it puts the system into fail-safe mode.

Pressure switch 3 (I/C)

Detects any abnormality in the input clutch hydraulic pressure. When it detects any
abnormality, it puts the system into fail-safe mode.

Pressure switch 5 (D/C)

Detects any abnormality in the direct clutch hydraulic pressure. When it detects any
abnormality, it puts the system into fail-safe mode.

Pressure switch 6 (H & LR/C)

Detects any abnormality in the high & low reverse clutch hydraulic pressure. When it
detects any abnormality, it puts the system into fail-safe mode.

AT-38

RE5R05A

TROUBLE DIAGNOSIS
DTC Inspection Priority Chart

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart.
NOTE:
If DTC U1000 is displayed with other DTCs, first perform the trouble diagnosis for DTC U1000. Refer
to AT-75, “DTC U1000 CAN COMMUNICATION LINE”.
Priority

Detected items (DTC)

U1000 CAN communication line

Except above

Fail-Safe
The TCM has an electrical fail safe mode. This mode makes it possible to operate even if there is a breakdown in a main electronic control input/output signal path.
In fail-safe mode, even if the select lever is “D” or “M” mode, the transmission is fixed in 2nd, 4th, or 5th
(depending on the breakdown position), so the customer should feel “slipping” or “detective acceleration”.
When fail-safe mode is triggered, when the ignition switch is switched “ON”, the A/T malfunction CHECK
indicator lamp flashes for about 8 seconds. (Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT
CONSULT-II)”). Even when the electronic circuits are normal, under special conditions (for example, when
slamming on the brake with the wheels spinning drastically and stopping the tire rotation), the transmission
can go into fail-safe mode. If this happens, switch “OFF” the ignition switch for 10 seconds, then switch it
“ON” again to return to the normal shift pattern. Also, the A/T CHECK indicator lamp flashes for about 8
seconds once, then is cleared. Therefore, the customer’s vehicle has returned to normal, so handle according to the “diagnostics flow” (Refer to AT-43, “WORK FLOW”).

FAIL-SAFE FUNCTION
If any abnormality occurs in a sensor or solenoid, this function controls the A/T without interfering with drivability.

Fail-Safe Chart
Control item

Line pressure control

Vehicle
speed
control

Shift control

Lock-up
control

Engine
brake control

Fail-safe
function
(*3)

Self-diagnostics
function

Throttle position sensor

Vehicle speed sensor A/T (revolution sensor)

Vehicle speed sensor MTR (*1)

Closed throttle position switch

(*2) X

(*4) X

Wide open throttle position switch

(*2) X

(*4) X

Turbine revolution sensor 1

Turbine revolution sensor 2 (for
4th or 5th speed only)

Input

Engine speed signals
PNP switch

X
X

Brake switch

Fluid temperature sensors 1 or 2

TCM power supply voltage signal

AT-39

X
X

(*4) X
(*4) X

RE5R05A

TROUBLE DIAGNOSIS
Fail-Safe (Cont’d)
Line pressure control

Vehicle
speed
control

Shift control

Lock-up
control

Fail-safe
function
(*3)

Self-diagnostics
function

Direct clutch solenoid (oil pressure
switch 5)

Input clutch solenoid (oil pressure
switch 3)

High & low reverse clutch solenoid
(oil pressure switch 6)

Front brake solenoid (oil pressure
switch 1)

Low coast brake solenoid (oil pressure switch 2)

Line pressure solenoid

Control item

Output

TCC solenoid

Engine
brake control

Self-diagnostics table

*1:
*2:
*3:
*4:

Spare for vehicle speed sensorzA/T (revolution sensor)
Spare for throttle position sensor
If these input and output signals are different, the TCM triggers the fail-safe function.
Used as a condition for starting self-diagnostics; if self-diagnostics are not started, it is judged that there is some kind of error.

VEHICLE SPEED SENSOR A/T (REVOLUTION SENSOR)
Signals are input from two systems — from vehicle speed sensor A/T (revolution sensor) installed on the
transmission and from COMBINATION METER so normal driving is possible even if there is an error in one
of the systems.

ACCELERATOR PEDAL POSITION SENSOR
If an error occurs in the accelerator sensor signal, the accelerator degree of opening is detected from the
wide open throttle position switch signal (input by CAN communications) and the closed throttle position
switch signal transmitted from the ECM and the line pressure is controlled according to the table below to
make driving possible.
Closed throttle position switch

Wide open throttle position
switch

OFF

Line pressure

Remarks
Accelerator degree of opening 4/8

Maximum hydraulic pressure
OFF

OFF

Accelerator degree of opening 2/8
Minimum hydraulic pressure

Accelerator degree of opening 0/8

PNP SWITCH
In the unlikely event that an error signal enters the TCM, the position indicator is switched “OFF”, the PNP
relay is switched “OFF” (starter starting disabled), and the position is fixed to the “D” speed to make driving possible.

PNP RELAY
The PNP relay is switched “OFF”. (Starter starting is disabled.)

A/T INTERLOCK
If there is an A/T interlock judgment error, the transmission is fixed in 2nd speed, 4th speed, or 5th speed
to make driving possible.
NOTE:
When the vehicle is driven fixed in 2nd speed or 5th speed, a turbine revolution sensor error is displayed but this is not a turbine revolution sensor error.
When the coupling pattern below is detected, the fail-safe action corresponding to the pattern is executed.

AT-40

RE5R05A

TROUBLE DIAGNOSIS
Fail-Safe (Cont’d)
A/T interlock coupling pattern table

+: NG, X: OK
Clutch pressure output pattern after fail-safe
function

Hydraulic pressure switch output
Gear position
SW3
(I/C)
+

SW6
SW5
(H & LR
(D/C)
/C)
X

Fail-safe
function

SW1
SW2
(Fr/B) (LC/B)
X

I/C

H&
LR/C

D/C

Fr/B

LC/B

L/U

Held in 4th
speed

OFF

1st
X

Held in 4th
speed

OFF

Held in 4th
speed

OFF

Held in 4th
speed

OFF

Held in 2nd
speed

OFF

Held in 4th
speed

OFF

Held in 2nd
speed

OFF

Held in 5th
speed

OFF

Held in 2nd
speed

OFF

Held in 4th
speed

OFF

2nd
X

+
X
A/T interlock
coupling pattern

3rd
X

+
X

4th
X
X

X
X

+
X

5th
X

A/T 1ST ENGINE BRAKING
When there is an A/T first speed engine brake judgment error, the low coast brake solenoid is switched “OFF”
to avoid switching on the engine brake.

LINE PRESSURE SOLENOID
The solenoid is switched “OFF” and the line pressure is set to the maximum hydraulic pressure to make
driving possible.

TORQUE CONVERTER CLUTCH SOLENOID
The solenoid is switched “OFF” to release the lock-up.

LOW COAST BRAKE SOLENOID
When an electrical error occurs, in order to make driving possible, if the solenoid is “ON”, the transmission
is held in 2nd speed; if the solenoid is “OFF”, the transmission is held in 4th speed.

INPUT CLUTCH SOLENOID
If an electrical error occurs with the solenoid either “ON” or “OFF”, the transmission is held in 4th speed to
make driving possible.

DIRECT CLUTCH SOLENOID
If an electrical error occurs with the solenoid either “ON” or “OFF”, the transmission is held in 4th speed to
make driving possible.

AT-41

TROUBLE DIAGNOSIS
Fail-Safe (Cont’d)

RE5R05A

FRONT BRAKE SOLENOID
If an electrical error occurs with the solenoid “ON”, in order to make driving possible, the A/T is held in 5th
speed; if the solenoid is “OFF”, 4th speed.

HIGH & LOW REVERSE CLUTCH SOLENOID
If an electrical error occurs with the solenoid either “ON” or “OFF”, the transmission is held in 4th speed to
make driving possible.

TURBINE REVOLUTION SENSOR 1 OR 2
The control is the same as if there were no turbine revolution sensors and control is from vehicle speed
sensorzA/T.

How To Perform Trouble Diagnosis For
Quick and Accurate Repair
INTRODUCTION

SAT631IB

The TCM receives a signal from the vehicle speed sensor,
throttle position sensor or PNP switch and provides shift control
or lock-up control via A/T solenoid valves.
The TCM also communicates with the ECM by means of a signal sent from sensing elements used with the OBD-related parts
of the A/T system for malfunction-diagnostic purposes. The TCM
is capable of diagnosing malfunctioning parts while the ECM can
store malfunctions in its memory.
Input and output signals must always be correct and stable in the
operation of the A/T system. The A/T system must be in good
operating condition and be free of valve seizure, solenoid valve
malfunction, etc.

It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A
road test with CONSULT-II (or GST) or a circuit tester connected
should be performed. Follow the AT-43, “WORK FLOW”.

SAT632I

SEF234G

Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The
customer can supply good information about such problems,
especially intermittent ones. Find out what symptoms are present
and under what conditions they occur. A “Diagnostic Worksheet”
as shown on the example (Refer to AT-45, “DIAGNOSTIC
WORKSHEET”) should be used.
Start your diagnosis by looking for “conventional” problems first.
This will help troubleshoot driveability problems on an electronically controlled engine vehicle.
Also check related Service bulletins.

AT-42

RE5R05A
TROUBLE DIAGNOSIS
How To Perform Trouble Diagnosis For
Quick and Accurate Repair (Cont’d)

WORK FLOW
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is important to fully understand the symptoms
or conditions for a customer complaint.
Make good use of the two sheets provided, “Information From Customer” (Refer to AT-45, “Information From
Customer”) and “Diagnostic Worksheet” (Refer to AT-45, “Diagnostic Worksheet Chart”), to perform the best
troubleshooting possible.

AT-43

RE5R05A
TROUBLE DIAGNOSIS
How To Perform Trouble Diagnosis For
Quick and Accurate Repair (Cont’d)

Work Flow Chart

SCIA0573E

*1
*2
*3
*4
*5
*6

AT-45
AT-45
AT-39
MA section
AT-50
AT-52

*13
*14
*15
*16
*17

*7 AT-53
*8 AT-68
*9 AT-75
*10 AT-164
*11 AT-166
*12 AT-187

AT-44

AT-59
AT-73
AT-73
AT-75
AT-160

RE5R05A
TROUBLE DIAGNOSIS
How To Perform Trouble Diagnosis For
Quick and Accurate Repair (Cont’d)

DIAGNOSTIC WORKSHEET
Information From Customer
KEY POINTS
+ WHAT … Vehicle & A/T model
+ WHEN … Date, Frequencies
+ WHERE … Road conditions
+ HOW … Operating conditions, Symptoms
Customer name

MR/MS

Model & Year

VIN

Trans. model

Engine

Mileage

Incident Date

Manuf. Date

In Service Date

Frequency

N Continuous

N Intermittent

N Vehicle does not move.
N No up-shift

times a day)

(N Any position

(N 1st → 2nd

N No down-shift

(

N 2nd → 3rd

(N 5th → 4th

N 4th → 3rd

N Particular position)
N 3rd → 4th
N 3rd → 2nd

N 4th → 5th)
N 2nd → 1st)

N Lock-up malfunction
N Shift point too high or too low.
Symptoms

N Shift shock or slip

(N N → D

N Lock-up

N Any drive position)

N Noise or vibration
N No kickdown
N No pattern select
N Others
(

)

Blinks for about 8 seconds.
A/T CHECK indicator lamp
Malfunction indicator lamp (MIL)

N Continuously lit

N Not lit

N Continuously lit

N Not lit

Diagnostic Worksheet Chart
1

N Read the item on “cautions concerning fail-safe” and understand the customer’s complaint.

AT-39

N A/T FLUID CHECK

MA section,
“Checking A/T
Fluid”.

N Leak (Repair leak location.)
N State
N Amount
3

N Stall test and line pressure test

AT-50, 52

N Stall test
N
N
N
N
N
N
N
N

Torque converter one-way clutch
Input clutch
Front brake
Direct clutch
High & low reverse clutch
Low coast brake
Forward brake
Forward one-way clutch

N Line pressure inspection — Suspected part:

AT-45

N 1st one-way clutch
N 3rd one-way clutch
N Engine
N Line pressure low
N Except for input clutch and front
brake, clutches and brakes OK

RE5R05A
TROUBLE DIAGNOSIS
How To Perform Trouble Diagnosis For
Quick and Accurate Repair (Cont’d)
4

N Execute all road tests and enter checks in required inspection items.

AT-53

4-1.

AT-54

Check before engine is started
N Execute self-diagnostics
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N

4-2.

Vehicle speed sensorzA/T, AT-86.
Vehicle speed sensorzMTR, AT-120.
Direct clutch solenoid valve, AT-137.
TCC solenoid valve, AT-94.
Line pressure solenoid valve, AT-97.
Input clutch solenoid valve, AT-131.
Front brake solenoid valve, AT-134.
Low coast brake solenoid valve, AT-143.
High & low reverse clutch solenoid valve, AT-140.
PNP switch, AT-82.
A/T Fluid temperature sensors 1, 2, AT-110.
Turbine revolution sensors 1, 2, AT-115.
A/T interlock, AT-122.
A/T 1st engine braking, AT-128.
Start signal, AT-78.
Throttle position sensor, AT-108.
Engine speed signal, AT-91.
CAN communication, AT-75.
TCM power supply, AT-100.
Battery
Other

Check at idle
N
N
N
N
N
N
N

4-3.

Enter checks for detected items.

AT-54

The A/T CHECK Indicator Lamp does come on, AT-168.
Engine Cannot Be Started in “P” and “N” Position, AT-169.
In “P” Position, Vehicle Moves When Pushed, AT-170.
In “N” Position Vehicle Moves, AT-171.
Large Shock “N” to “D” Position, AT-172.
Vehicle Does Not Creep Backward In “R” Position, AT-173.
Vehicle Does Not Creep Forward In “D” Position, AT-174.

Cruise test

AT-55

Part 1
N
N
N
N
N
N
N
N
N

Vehicle Cannot Be Started From D1, AT-175.
A/T Does Not Shift: D1 → D2 Or Does Not Kick Down D4 → D2, AT-176.
A/T Does Not Shift: D2 → D3, AT-177.
A/T Does Not Shift: D3 → D4, AT-178.
A/T Does Not Shift: D4 → D5, AT-179.
A/T Does Not Perform Lock-up, AT-180.
A/T Does Not Hold Lock-up Condition, AT-181.
Lock-up Is Not Released, AT-181.
Engine Speed Does Not Return To Idle, AT-182.

AT-46

RE5R05A
TROUBLE DIAGNOSIS
How To Perform Trouble Diagnosis For
Quick and Accurate Repair (Cont’d)
4

4-3

Part 2
N
N
N
N
N

AT-57

Part 3
N
N
N
N
N
N
N

AT-58

Engine rotation does not drop to idle rotation, AT-182.
A/T Does Not Shift: D5 → D4, AT-183.
A/T Does Not Shift: D4 → D3, AT-184.
A/T Does Not Shift: D3 → D2, AT-185.
A/T Does Not Shift: D2 → D1, AT-186.
Vehicle Does Not Decelerate By Engine Brake, AT-187.
Execute self-diagnostics Enter checks for detected items.
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N

Vehicle speed sensorzA/T, AT-86.
Vehicle speed sensorzMTR, AT-120.
Direct clutch solenoid valve, AT-137.
TCC solenoid valve, AT-94.
Line pressure solenoid valve, AT-97.
Input clutch solenoid valve, AT-131.
Front brake solenoid valve, AT-134.
Low coast brake solenoid valve, AT-143.
High & low reverse clutch solenoid valve, AT-140.
PNP switch, AT-82.
A/T fluid temperature sensors 1, 2, AT-110.
Turbine revolution sensors 1, 2, AT-115.
A/T interlock, AT-122.
A/T 1st engine braking, AT-128.
Start signal, AT-78.
Throttle position sensor, AT-108.
Engine speed signal, AT-91.
CAN communication, AT-75.
TCM power supply, AT-100.
Battery
Other

N Inspect each system for items found to be NG in the self-diagnostics and repair or replace the malfunction parts.

N Execute all road tests and enter the checks again for the required items.

AT-53

N For any remaining NG items, execute the “diagnostics procedure” and repair or replace the malfunction
parts. See the chart for breakdown diagnostics by symptoms. (This chart also contains other symptoms
and inspection procedures.)

AT-59

N Erase the results of the self-diagnostics from the TCM.

AT-73, AT-74

AT-47

TROUBLE DIAGNOSIS

RE5R05A

A/T Electrical Parts Location

SAT649K

AT-48

TROUBLE DIAGNOSIS

RE5R05A

Circuit Diagram

TAT060M

AT-49

RE5R05A

TROUBLE DIAGNOSIS

Inspections Before Trouble Diagnosis
A/T FLUID CHECK
Fluid Leakage and Fluid Level Check
Inspect for fluid leakage and check the fluid level. Refer to MA section, “Checking A/T Fluid”.
Inspect the amount of A/T fluid under the hot conditions 50 to 80°C (122 to 176°F) according to the
instructions below.
1. After engine warm-up is complete, drive around the city for about 10 minutes. The automatic fluid temperature rises to 50 to 80°C (122 to 176°F) during 10 minutes of driving.
2. Place the vehicle on a level location.
3. Brake securely with the parking brake.
4. Put the engine in idle and while pressing the brake pedal, shift the selector lever from “P” to “D” position.
5. Check that when the selector lever is in the “P” or “N” position, then the amount of transmission fluid is
in the position of the oil level gauge (hot side).
CAUTION:
+ If it is necessary to check the amount of A/T fluid with the A/T fluid at low temperature 30 to 50°C
(86 to 122°F), after adjusting within the cold level of the level gauge, then always check the
amount of A/T fluid under the above hot condition.
+ When wiping away the oil level gauge, always use a paper rag, not a cloth one.
+ Always secure the oil level gauge in the charging pipe with the stopper.
+

Fluid Condition Check
Inspect the fluid status.
Fluid status

SAT638A

Conceivable
Cause

Required Operation

Varnished (viscous Clutch, parking
varnish state)
brake scorched

Replace the A/T fluid and check the
A/T main unit and the vehicle for
problems (wire harnesses, cooler
pipes, etc.)

Milky white or
cloudy

Water in the fluid

Replace the A/T fluid and check for
places where water is getting in.

Large amount of
metal powder
mixed in

Abnormal wear of
sliding parts within
A/T

Replace the A/T fluid and check for
improper operation of the A/T.

STALL TEST
Stall Test Procedure
1. Inspect the amount of engine oil. Replenish the engine oil if
necessary.
2. Drive for about 10 minutes to warm-up the vehicle so that the
A/T fluid temperature is 50 to 80°C (122 to 176°F). Inspect
the amount of A/T fluid. Replenish if necessary.

SAT647B

AT-50

RE5R05A
TROUBLE DIAGNOSIS
Inspections Before Trouble Diagnosis
(Cont’d)
3. Securely engage the parking brake so that the tires do not
turn.

SAT513G

SAT514G

4. Engine start, apply foot brake, and place selector lever in “P”
position.
5. While holding down the foot brake, gradually press down the
accelerator pedal.
6. Quickly read off the stall speed, then quickly remove your
foot from the accelerator pedal.
CAUTION:
Do not hold down the accelerator pedal for more than 5
seconds during this test.
7. Move the selector lever to the “N” position.
8. Cool down the A/T fluid.
CAUTION:
Run the engine at idle for at least one minute.
Stall revolution: 1,900 — 2,200 rpm

Judgement Stall Test
Selector lever position
Expected problem location
D, M

Stall rotation

R
Forward brake
Forward one-way clutch
1st one-way clutch
3rd one-way clutch

+
+
+
+

+ Front brake front brake
+ Reverse clutch
+ 1st one-way clutch

+ Engine and torque converter one-way clutch

+ Line pressure low

+ One-way clutch in torque converter stuck or check with individual item tests

O: Stall speed within standard value position
H: Stall speed higher than standard value
L: Stall speed lower than standard value

Stall test standard value position
Does not shift up D, M position 1 → 2

Slipping in 2nd, 3rd, 4th speeds

Direct clutch slippage

Does not shift up D, M position 2 → 3

Slipping in 3rd, 4th, 5th speeds

High & low reverse clutch slippage

Does not shift up D, M position 3 → 4

Slipping in 4th, 5th speeds

Input clutch slippage

Does not shift up D, M position 4 → 5

Slipping in 5th speeds

Front brake slippage

AT-51

RE5R05A
TROUBLE DIAGNOSIS
Inspections Before Trouble Diagnosis
(Cont’d)

LINE PRESSURE TEST
Line Pressure Test Port

PCIA0017E

Line Pressure Test Procedure
1. Inspect the amount of engine oil and replenish if necessary.
2. Drive the car for about 10 minutes to warm it up so that the A/T fluid reaches in range of 50 to 80°C
(122 to 176°F), then inspect the amount of A/T fluid and replenish if necessary.
NOTE:
The automatic fluid temperature rises in range of 50 to 80°C (122 to 176°F) during 10 minutes of
driving.
3. After warming up your A/T, remove the oil pressure detection
plug and install the oil pressure gauge.
CAUTION:
When using the oil pressure gauge, be sure to use the
O-ring attached to the oil pressure detection plug.

SCIA0574E

4. Securely engage the parking brake so that the tires do not
turn.

SAT513G

SAT493G

5. Start the engine, then measure the line pressure at both idle
and the stall speed.
CAUTION:
+ Keep the brake pedal pressed all the way down during
measurement.
+ When measuring the line pressure at the stall speed,
refer to AT-50, “Stall Test”.
6. After the measurements are complete, install the oil pressure
detection plug and tighten to the regulation torque below.
Plug: 4.8 — 9.8 Nzm (0.45 — 0.99 kg-m, 39 — 86 in-lb)
CAUTION:
Do not reuse the O-ring.

AT-52

Line Pressure

RE5R05A
TROUBLE DIAGNOSIS
Inspections Before Trouble Diagnosis
(Cont’d)
Line Pressure kPa (bar, kg/cm2, psi)

Engine speed rpm
Idling Revolution

“R” position

“D”, “M” positions

392 — 441 (3.9 — 4.4, 4.0 — 4.5, 57 — 64)

373 — 422 (3.7 — 4.2, 3.8 — 4.3, 54 — 61)

Stall Revolution

1,310 — 1,500 (13.1 — 15.0, 13.4 — 15.3, 191 — 218)

Judgement of Line Pressure Test
Judgement

Low for all positions
(P, R, N, D, M)

Idle speed

Stall speed

Possible cause
Possible causes include problems in the pressure supply system and low oil pump output.
For example
+ Oil pump wear
+ Pressure regulator valve or plug sticking or spring fatigue
+ Oil strainer → oil pump → pressure regulator valve path oil leak
+ Engine idle speed too low

Only low for a specific Possible causes include an oil pressure leak in a path or device related to the position after
position
the pressure is distributed by the manual valve.

High

Possible causes include a sensor problem or problem in the pressure adjustment function.
For example
+ Accelerator sensor malfunction
+ ATF temperature sensor breakdown
+ Line pressure solenoid malfunction (sticking in “OFF” state, filter clog, cut line)
+ Pressure regulator valve or plug sticking

Oil pressure does not
rise higher than the
oil pressure for idle.

Possible causes include a sensor problem or problem in the pressure adjustment function.
For example
+ Accelerator sensor malfunction
+ TCM breakdown
+ Line pressure solenoid malfunction (shorting, sticking in “ON” state)
+ Pressure regulator valve or plug sticking
+ Pilot valve sticking or pilot filter clogged

Possible causes include problems in the pressure supply system and problems in the pressure adjustment function.
For example
The pressure rises,
but does not enter the + Accelerator pedal position sensor malfunction
+ Line pressure solenoid malfunction (sticking, filter clog)
standard position.
+ Pressure regulator valve or plug sticking
+ Pilot valve sticking or pilot filter clogged
Only low for a specific Possible causes include an oil pressure leak in a path or device related to the position after
position
the pressure is distributed by the manual valve.

ROAD TEST
Description
+
+
1.
2.
3.

+
+

The road test inspects overall performance of the A/T and analyzes possible breakdown causes.
The road test is carried out in the following three stages.
Check before engine is started. Refer to AT-54, “Check Before Engine is Started”.
Check at idle. Refer to AT-54, “Check at Idle”.
Cruise test.
+ Inspect all the items from Part 1 to Part 3. Refer to AT-55, “Cruise Test — Part 1”, AT-57, “Cruise
Test — Part 2”, AT-58, “Cruise Test — Part 3”.
Before beginning the road test, check the test procedure and inspection items.
Test all inspection items until the symptom is uncovered. Diagnose NG items when all road tests are
complete.

AT-53

TROUBLE DIAGNOSIS

RE5R05A

Check Before Engine is Started

1.CHECK A/T CHECK INDICATOR LAMP STEP 1
1. Park vehicle on level surface.
2. Move selector lever to “P” position.
3. Turn ignition switch to “OFF” position and wait at least 10 seconds.
4. Turn ignition switch to “ON” position. (Do not start engine.)
Does A/T CHECK indicator lamp light up for about 2 seconds?
YES
>> GO TO 2.
NO
>> Stop the road test and go to AT-168, “A/T CHECK Indicator Lamp does not come on”.

2.CHECK A/T CHECK INDICATOR LAMP STEP 2
Does A/T CHECK indicator lamp flash for about 8 seconds?
YES
>> Carry out the self-diagnostics and record all NG items on the diagnostics sheet. Refer to
AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
NO
>> 1. Turn ignition switch to “OFF” position.
2. Carry out the self-diagnostics and record all NG items on the diagnostics sheet. Refer
to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
3. GO TO “Check at Idle”. Refer to AT-54.

Check at Idle

1.CHECK STARTING THE ENGINE
1. Park vehicle on level surface.
2. Move selector lever to “P” position.
3. Turn ignition switch to “OFF” position.
4. Turn ignition switch to “START” position.
Does the engine start?
YES
>> GO TO 2.
NO
>> Stop the road test and go to AT-169, “Engine Cannot Be Started In “P” and “N” Position”.

2.CHECK STARTING THE ENGINE
1. Turn ignition switch to “ACC” position.
2. Move selector lever in “D” or “R” position.
3. Turn ignition switch to “START” position.
Does the engine start in either position?
YES
>> Stop the road test and go to AT-169, “Engine Cannot Be Started In “P” and “N” Position”.
NO
>> GO TO 3.

3.CHECK “P” POSITION FUNCTIONS
1. Move selector lever to “P” position.
2. Turn ignition switch to “OFF” position.
3. Disengage the parking brake.
4. Push the vehicle forward or backward.
5. Engage the parking brake.
When you push the vehicle, does it move?
YES
>> Stop the road test and go to AT-170, “In “P” Position, Vehicle Moves When Pushed”.
NO
>> GO TO 4.

AT-54

TROUBLE DIAGNOSIS
Check at Idle (Cont’d)

RE5R05A

4.CHECK “N” POSITION FUNCTIONS

1. Start the engine.
2. Move selector lever to “N” position.
3. Disengage the parking brake.
Does the vehicle move?
YES
>> Stop the road test and go to AT-171, “In “N” Position, Vehicle Moves”.
NO
>> GO TO 5.

5.CHECK SHIFT SHOCK
1. Engage the brake.
2. Move selector lever to “D” position.
When the transmission is shifted from “N” to “D”, is there an excessive shock?
YES
>> Stop the road test and go to AT-172, “Large Shock “N” to “D” Position”.
NO
>> GO TO 6.

6.CHECK “R” POSITION FUNCTIONS
Disengage the brake for 4 to 5 seconds.
Does the vehicle creep backward?
YES
>> GO TO 7.
NO
>> Stop the road test and go to AT-173, “Vehicle Does Not Creep Backward In “R” Position”.

7.CHECK “D”, “M” POSITION FUNCTIONS
Inspect whether the vehicle moves forward when the transmission is put into the “D” or “M” position.
Does the vehicle move forward in the “D” and “M” positions?
YES
>> GO TO “Cruise test — Part 1” (Refer to AT-55), “Cruise Test — Part 2” (Refer to AT-57),
and Cruise test — Part 3 (Refer to AT-58).
NO
>> Stop the road test and go to AT-174, “Vehicle Does Not Creep Forward In “D” Position”.

Cruise Test — Part 1
Cruise test Part 1

1.CHECK STARTING OUT FROM D1
1. Drive the car for about 10 minutes to warm up the engine oil and A/T fluid.
Appropriate temperature for the A/T fluid: (50 — 80°F)
2. Park the vehicle on a level surface.
3. Move selector lever to “P” position.
4. Engage the engine.
5. Move selector lever to “D” position.
6. Press the accelerator pedal about half way down to accelerate the vehicle.
With CONSULT-II
Read off the gear positions.
Starts from D1?
YES
>> GO TO 2.
NO
>> Stop the road test and go to AT-175, “Vehicle Cannot Be Started From D1”.

AT-55

2.CHECK SHIFT UP D1 → D2

TROUBLE DIAGNOSIS
Cruise Test — Part 1 (Cont’d)

RE5R05A

Press down the accelerator pedal about half way and inspect if the vehicle shifts up (D1 → D2) at the
appropriate speed.
+ See AT-58, “Vehicle Speed When Shifting Gears Throttle Position”.
With CONSULT-II
Read the gear position, throttle degree of opening, and vehicle speed.
Does the A/t shift up D1 → D2 at the correct speed?
YES
>> GO TO 3.
NO
>> Stop the road test and go to AT-176, “A/T Does Not Shift: D1 → D2 Or Does Not Kick
down: D4 → D2”.

3.CHECK SHIFT UP D2 → D3
Press down the accelerator pedal about half way and inspect if the vehicle shifts up (D2 → D3) at the
appropriate speed.
+ See AT-58, “Vehicle Speed When Shifting Gears Throttle Position”.
With CONSULT-II
Read the gear position, throttle degree of opening, and vehicle speed.
Does the A/t shift up D2 → D3 at the correct speed?
YES
>> GO TO 4.
NO
>> Stop the road test and go to AT-177, “A/T Does Not Shift: D2 → D3”.

4.CHECK SHIFT UP D3 → D4
Press down the accelerator pedal about half way and inspect if the vehicle shifts up (D3 → D4) at the
appropriate speed.
+ See AT-58, “Vehicle Speed When Shifting Gears Throttle Position”.
With CONSULT-II
Read the gear position, throttle degree of opening, and vehicle speed.
Does the A/t shift up D3 → D4 at the correct speed?
YES
>> GO TO 5.
NO
>> Stop the road test and go to AT-178, “A/T Does Not Shift: D3 → D4”.

5.CHECK SHIFT UP D4 → D5
Press down the accelerator pedal about half way and inspect if the vehicle shifts up (D4 → D5) at the
appropriate speed.
+ See AT-58, “Vehicle Speed When Shifting Gears Throttle Position”.
With CONSULT-II
Read the gear position, throttle degree of opening, and vehicle speed.
Does the A/T shift up D4 → D5 at the correct speed?
YES
>> GO TO 6.
NO
>> Stop the road test and go to AT-179, “A/T Does Not Shift: D4 → D5”.

6.CHECK LOCK-UP
Press down the accelerator pedal about half way and inspect if the vehicle lock-up (D5 → L/U) at the
appropriate speed.
+ See AT-58, “Vehicle Speed When Shifting Gears Throttle Position”.
With CONSULT-II
Select “TCC SOL 0.00A” with the “MAIN SIGNAL” mode for A/T.
Does the A/T lock-up at the correct speed?
YES
>> GO TO 7.
NO
>> Stop the road test and go to AT-180, “A/T Does Not Perform Lock-up”.

AT-56

7.CHECK LOCK-UP HOLD

TROUBLE DIAGNOSIS
Cruise Test — Part 1 (Cont’d)

RE5R05A

Is the lock-up held for at least 30 seconds?
YES
>> GO TO 8.
NO
>> Stop the road test and go to AT-181, “A/T Does Not Hold Lock-up Condition”.

8.CHECK LOCK-UP RELEASE
Release the accelerator pedal.
When you release the accelerator pedal, is the lock-up released?
YES
>> GO TO 9.
NO
>> Stop the road test and go to AT-181, Lock-up Is Not Released.

9.CHECK SHIFT DOWN D5 → D4
Decelerate by pressing lightly on the brake pedal.
With CONSULT-II
Read the gear position and engine speed.
When the A/T shift down D5 → D4, does the engine speed drop smoothly back to idle?
YES
>> 1. Stop the car.
2. GO TO “Cruise test — Part 2” (Refer to AT-57).
NO
>> Stop the road test and go to AT-183, “A/T Does Not Shift: D5 → D4”.

Cruise Test — Part 2
Cruise Test Part 2

1.CHECK STARTING FROM D1
1. Move selector lever the “D” position.
2. Accelerate at half throttle.
With CONSULT-II
Read the gear position.
Does it start from D1?
YES
>> GO TO 2.
NO
>> Stop the road test and go to AT-175, “Vehicle Cannot Be Started From D1”.

2.CHECK SHIFT UP D3 → D4 AND SHIFT DOWN D4 → D3
1. Accelerate to 80 km/h (50 MPH).
2. Release the accelerator pedal once, then quickly press it down again all the way.
With CONSULT-II
Read the gear position and throttle position.
When you press the accelerator pedal, does the transmission immediately shift down D4 → D2?
YES
>> GO TO 3.
NO
>> Stop the road test and go to AT-176, “A/T Does Not Shift: D1 → D2 Or Does Not Kick
Down D4 → D2”.

AT-57

3.CHECK SHIFT UP D2 → D3

RE5R05A

TROUBLE DIAGNOSIS
Cruise Test — Part 2 (Cont’d)

Press the accelerator pedal down all the way and inspect whether or not the transmission shifts up (D2 →
D3) at the correct speed.
+ See AT-177, “Vehicle Speed When Shifting Gears Throttle Position”.
With CONSULT-II
Read the gear position, throttle position and vehicle speed.
Does the A/T shift up D2 → D3 at the correct speed?
YES
>> GO TO 4.
NO
>> Stop the road test and go to AT-177, “A/T Does Not Shift: D2 → D3”.

4.CHECK SHIFT UP D3 → D4 AND ENGINE BRAKE
When the transmission changes speed D3 → D4, return the accelerator pedal.
Does the A/T shift up D3 → D4 and apply the engine brake?
YES
>> 1. Stop the vehicle.
2. GO TO “Cruise Test — part 3” (Refer to AT-58).
NO
>> Stop the road test and go to AT-178, “A/T Does Not Shift: D3 → D4”.

Cruise Test — part 3
Driving test part 3

1.CHECK SHIFT DOWN
Shift down one while driving in each position.
With CONSULT-II
Read the gear position.
Shift down?
YES
>> GO TO 2.
NO
>> Stop the road test and go to AT-183, “A/T Does Not Shift: D5 → D4”, AT-184, “A/T Does
Not Shift: D4 → D3”, AT-185, “A/T Does Not Shift: D3 → D2”, AT-186, “A/T Does Not Shift:
D2 → D1”.

2.CHECK ENGINE BRAKE
Does the engine brake work to decelerate the vehicle?
YES
>> 1. Stop the vehicle.
2. Perform self-diagnostics. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
NO
>> Stop the road test and go to AT-187, “Vehicle Does Not Decelerate By Engine Brake”.

Vehicle Speed When Shifting Gears Throttle
Position
Vehicle Speed km/h (MPH)
Throttle position

D 1 → D2

D2 → D3

D3 → D4

D4 → D5

D5 → D4

D4 → D3

D3 → D2

D2 → D1

Full throttle

52 — 56
(32 — 35)

81 — 89
(50 — 55)

126 — 136
(78 — 85)

188 — 198
(117 — 123)

184 — 194
(114 — 121)

116 — 126
(72 — 78)

70 — 78
(43 — 48)

36 — 40
(22 — 25)

Half throttle

32 — 36
(20 — 22)

62 — 68
(39 — 42)

104 — 112
(65 — 70)

126 — 134
(78 — 83)

100 — 108
(62 — 67)

61 — 69
(38 — 43)

37 — 43
(23 — 27)

10 — 14
(6 — 9)

At half throttle, the accelerator opening is 4/8 of the full opening.

AT-58

RE5R05A

TROUBLE DIAGNOSIS
Vehicle Speed When Performing and
Releasing Lock-up
Vehicle speed km/h (MPH)
Throttle position
Closed throttle
Half throttle

Lock-up “ON”

Lock-up “OFF”

64 — 72 (39 — 45)

61 — 69 (38 — 43)

164 — 172 (102 — 107)

130 — 138 (81 — 86)

+When throttle is closed, the accelerator opening is 1/8 or lower of the full opening, and the closed throttle
position switch is turned “OFF”.
+ At half throttle, the accelerator opening is 4/8 of the full opening.

Symptom Chart
The diagnostics item numbers show the sequence for inspection. Inspect in order from Item 1.
CAUTION:
+ If a problem occurs in the RE5R05A transmission, replace the transmission assembly.
+ Condition for “on vehicle” only
Symptom

Engine does not start in “N”, “P” position.

Engine starts in positions other than “N” or
“P”.

Diagnostic Item
1. Ignition switch and starter

—

2. Control linkage adjustment

AT-196

3. PNP switch

AT-82

1. Control linkage adjustment

AT-196

2. PNP switch

AT-82

1. Fluid level

Strange noise in “P” or “N” position

Vehicle not parked when transmission in “P”
position or vehicle is parked even when transmission put into position other than P

Reference page

MA section

2. Line pressure inspection

AT-52

3. Accelerator pedal position sensor

AT-108

4. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-120

5. Engine speed signal

AT-91

1. Control linkage adjustment

AT-196

2. PNP switch

AT-82

1. Control linkage adjustment

AT-196

2. PNP switch

AT-82

1. Control linkage adjustment

AT-196

2. PNP switch

AT-82

1. Control linkage adjustment

AT-196

2. Line pressure inspection

AT-52

3. Line pressure solenoid valve

AT-97

4. PNP switch

AT-82

Vehicle runs with transmission in “P” position

Vehicle runs with transmission in “N” position

Vehicle cannot run in “R” position

AT-59

TROUBLE DIAGNOSIS
Symptom Chart (Cont’d)
Symptom

Diagnostic Item
1. Engine idle speed
2. Accelerator pedal position sensor
3. Throttle position sensor adjustment

Large shock (“N” → “D” position)

4. Line pressure test
5. ATF temperature sensor
6. ATF pressure switch 1 and front brake solenoid

Extremely large creep

EC section
AT-108
EC section
AT-52
AT-110
AT-150, AT-134
AT-91

8. Line pressure solenoid valve

AT-97
MA section

2. Line pressure test

AT-52

3. Line pressure solenoid valve

AT-97

4. PNP switch

AT-82

1. Fluid level and state

When vehicle starts out, clutch and brake slip

Reference page

7. Engine speed signal

1. Fluid level and state
Vehicle cannot run in “D” position.
Clutch slips
Extreme acceleration malfunction

RE5R05A

MA section

2. Control linkage adjustment

AT-196

3. Accelerator pedal position sensor

AT-108

4. Line pressure test

AT-52

5. Line pressure solenoid valve

AT-97

Engine idle speed

EC section

1. Fluid level and state

MA section

2. Line pressure test

AT-52

3. Engine speed signal

AT-91

No creep at all
4. ATF pressure switch 5 and direct clutch solenoid

1 → 2 vehicle speed change malfunction

1. PNP switch

AT-82

2. Control linkage adjustment

AT-196

3. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

4. ATF pressure switch 5 and direct clutch solenoid

AT-157, AT-137

1. Control linkage adjustment
2 → 3 vehicle speed change malfunction

AT-86, AT-120

3. ATF pressure switch 6 and high & low reverse clutch solenoid

AT-160, AT-140

“D” position vehicle speed change point is too
high
“D” position vehicle speed change point is too
low

AT-196

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

3. ATF pressure switch 3 and input clutch solenoid

AT-154, AT-131

1. Control linkage adjustment
4 → 5 vehicle speed change malfunction

AT-196

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

1. Control linkage adjustment
3 → 4 vehicle speed change malfunction

AT-157, AT-137

AT-196

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

3. ATF pressure switch 1 and front brake solenoid

AT-150, AT-134

1. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

2. Accelerator pedal position sensor

AT-108

3. ATF temperature sensor

AT-110

1. Vehicle speed sensor A/T and vehicle speed sensor MTR
2. Accelerator sensor adjustment

AT-60

AT-86, AT-120
EC section

TROUBLE DIAGNOSIS
Symptom Chart (Cont’d)
Symptom
Shock is too large when changing 1 → 2.

Diagnostic Item

AT-108

2. Line pressure test

AT-52

AT-108

2. Line pressure test

AT-52

AT-108

2. Line pressure test

AT-52

AT-108

2. Line pressure test

AT-52

1. Fluid level and state

AT-150, AT-134
MA section

2. Accelerator pedal position sensor

AT-108

3. Line pressure test

AT-52

4. Engine speed

AT-91

5. Turbine revolution sensor
1. Fluid level and state
Shock is too large for upshift when brake
pedal is released.

AT-154, AT-131

1. Accelerator pedal position sensor

3. ATF pressure switch 1 and front brake solenoid

Shock is too large for downshift when brake
pedal is pressed.

AT-160, AT-140

1. Accelerator pedal position sensor

3. ATF pressure switch 3 and input clutch solenoid
Shock is too large when changing 4 → 5.

AT-157, AT-137

1. Accelerator pedal position sensor

3. ATF pressure switch 6 and high & low reverse clutch solenoid
Shock is too large when changing 3 → 4.

Reference page

1. Accelerator pedal position sensor

3. ATF pressure switch 5 and direct clutch solenoid

Shock is too large when changing 2 → 3.

RE5R05A

AT-115
MA section

2. Accelerator pedal position sensor

AT-108

3. Line pressure test

AT-52

4. Engine speed

AT-91

5. Turbine revolution sensor

AT-115

1. Fluid level and state

MA section

2. Accelerator sensor adjustment

AT-108

3. Line pressure test

AT-52

4. Engine speed

AT-91

5. Turbine revolution sensor

AT-115

6. TCC solenoid valve

AT-94

1. Fluid level and state

MA section

Shock is too large for lock-up.

Shock is too large when engine brake is
selected.

2. Accelerator pedal position sensor
3. Line pressure inspection
1. Fluid level and state

No shock at all or the clutch slips when
vehicle changes speed 1 → 2.

AT-86, AT-120

3. ATF pressure switch 5 and direct clutch solenoid

AT-157, AT-137
MA section

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

3. ATF pressure switch 6 and high & low reverse clutch solenoid

AT-160, AT-140

1. Fluid level and state
No shock at all or the clutch slips when
vehicle changes speed 3 → 4.

AT-52
MA section

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

1. Fluid level and state
No shock at all or the clutch slips when
vehicle changes speed 2 → 3.

AT-108

MA section

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

3. ATF pressure switch 3 and input clutch solenoid

AT-154, AT-131

AT-61

TROUBLE DIAGNOSIS
Symptom Chart (Cont’d)
Symptom

Diagnostic Item
1. Fluid level and state

No shock at all or the clutch slips when
vehicle changes speed 4 → 5.

RE5R05A

Reference page
MA section

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

3. ATF pressure switch 1 and front brake solenoid

AT-150, AT-134

1. Fluid level and state

MA section

2. Line pressure test

AT-52

3. Accelerator pedal position sensor

AT-108

Maximum speed low
4. ATF pressure switch 5 and direct clutch solenoid
1. Fluid level and state
Does not change 5 → 4.

AT-86, AT-120

3. ATF pressure switch 3 and input clutch solenoid

AT-154, AT-131

Does not change 4, 3, 2 → 1.
When you press the accelerator pedal and
shift speed 5 → 4, the engine idles or the
transmission slips.

AT-86, AT-120

3. ATF pressure switch 6 and high & low reverse clutch solenoid

AT-160, AT-140
MA section

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

3. ATF pressure switch 5 and direct clutch solenoid

AT-157, AT-137

1. Fluid level and state
2. Vehicle speed sensor A/T and vehicle speed sensor MTR
1. Fluid level and state

MA section
AT-86, AT-120
MA section

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

AT-86, AT-120

3. ATF pressure switch 3 and input clutch solenoid

AT-154, AT-131

1. Fluid level and state
When you press the accelerator pedal and
shift speed 5, 4 → 3, the engine idles or the
transmission slips.

MA section

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

1. Fluid level and state
Does not change 5, 4, 3 → 2.

MA section

2. Vehicle speed sensor A/T and vehicle speed sensor MTR

1. Fluid level and state
Does not change 5, 4 → 3.

AT-157, AT-137

MA section

2. PNP switch

AT-82

3. Control linkage adjustment

AT-196

4. Manual mode switch

AT-146

5. ATF pressure switch 3 and input clutch solenoid

AT-154, AT-131

6. ATF pressure switch 1 and front brake solenoid

AT-150, AT-134

1. Fluid level and state
2.
When you press the accelerator pedal and
3.
shift speed 5, 4, 3 → 2, the engine idles or the
4.
transmission slips.
5.

MA section

Control linkage adjustment

AT-196

PNP switch

AT-82

Manual mode switch

AT-146

ATF pressure switch 3 and input clutch solenoid

AT-154, AT-134

6. ATF pressure switch 1 and front brake solenoid

AT-150, AT-134

1. Fluid level and state
2. Control linkage adjustment
3. PNP switch
When you press the accelerator pedal and
shift speed 4, 3, 2 → 1, the engine idles or the 4. Manual mode switch
transmission slips.
5. ATF pressure switch 3 and input clutch solenoid
6. ATF pressure switch 6 and high & low reverse clutch solenoid

AT-62

MA section
AT-196
AT-82
AT-146
AT-154, AT-131
AT-134, AT-140

TROUBLE DIAGNOSIS
Symptom Chart (Cont’d)
Symptom

Diagnostic Item
1. Fluid level and state

RE5R05A

Reference page
MA section

2. Control linkage adjustment

AT-196

3. Line pressure test

AT-52

4. PNP switch

AT-82

Vehicle runs in all positions.

Loud, strange noise in “D”, “R” position

1. Fluid level and state
1. PNP switch

Engine brake does not work 5 → 4.

2. Fluid level and state

4. Manual mode switch

AT-146

1. PNP switch

AT-82

AT-196

4. Manual mode switch

AT-146

5. ATF pressure switch 3 and input clutch solenoid

AT-160, AT-131

6. ATF pressure switch 1 and front brake solenoid

AT-150, AT-134

3. Control linkage adjustment
4. Manual mode switch

AT-82
MA section
AT-196
AT-146

5. ATF pressure switch 3 and input clutch solenoid

AT-154, AT-131

6. ATF pressure switch 1 and front brake solenoid

AT-150, AT-134

1. PNP switch
2. Fluid level and state

Engine stalls when select lever shifted “N” →
“D”, “R”

MA section

3. Control linkage adjustment

2. Fluid level and state

Engine brake does not work 4, 3, 2 → 1.

MA section
AT-196

1. PNP switch

Engine brake does not work 5, 4, 3 → 2.

AT-82

3. Control linkage adjustment

2. Fluid level and state
Engine brake does not work 5, 4 → 3.

MA section

AT-82
MA section

3. Control linkage adjustment

AT-196

4. Manual mode switch

AT-146

5. ATF pressure switch 3 and input clutch solenoid

AT-160, AT-131

6. ATF pressure switch 6 and high & low reverse clutch solenoid

AT-160, AT-140

1. Fluid level and state

MA section

2. Engine speed signal

AT-91

3. TCC solenoid valve

AT-94

4. Turbine revolution sensor

AT-115

AT-63

RE5R05A

TROUBLE DIAGNOSIS

TCM Input/Output Signal Reference Values
TCM TERMINAL CONNECTOR LAYOUT

SCIA0495E

TCM INSPECTION TABLE
Data are reference value.
Terminal
No.

Wire color

L/B

Item

Condition

Line pressure solenoid
valve

Data (Approx.)

After warming up the engine,
release your foot from the
accelerator pedal.

After warming up the engine,
press the accelerator pedal all
the way down.

0.7V

—
2

LG/R

Power supply

Measure 3 seconds after
switching “OFF” the ignition
switch.
—

LG/R

Power supply

Measure 3 seconds after
switching “OFF” the ignition
switch.

Battery voltage

SEL3 (pressure switches
2, 3, 5)

—

Ground

—

G/B

CAN-H

—

W/R

CAN-L

—

G/R

R/Y

Fluid temperature sensor
1

Power supply
(Memory back-up)

When ATF temperature 0°C
(32°F)

3.3V

When ATF temperature 20°C
(68°F)

2.7V

When ATF temperature 80°C
(176°F)

0.9V

—

AT-64

Battery voltage

RE5R05A
TROUBLE DIAGNOSIS
TCM Input/Output Signal Reference Values
(Cont’d)
Terminal
No.

Wire color

W/B

Item

Condition

When the solenoid valve operating (in 1st speed, 2nd
More than 2V
speed, or 3rd speed)

Input clutch solenoid
valve

When the solenoid valve is not
operating (4th speed or 5th
0V
speed)
When vehicle
starts

P/B

W/L

Data (Approx.)

High & low reverse clutch
solenoid valve

When the solenoid valve operating [6 km/h (4 MPH) or
More than 2V
faster in 1st speed or 2nd
speed]
When the solenoid valve is not
operating [6 km/h (4 MPH) or
0V
slower in 1st speed or 3rd,
4th, or 5th speed]
—

Battery voltage

—

Power supply (out)

Low coast brake solenoid
valve

When vehicle
starts

When the solenoid valve is
operating (when running in
M1-1st speed or M2-2nd
speed)

Battery voltage

When the solenoid valve is not
operating (when running in
0V
“D”)
14

B/W

Ground

—

SEL4

—

SEL1 (pressure switches
2, 3, 5)

—

Fluid temperature sensor
2

Front brake solenoid
valve

When ATF temperature about
0°C (32°F)

3.3V

When ATF temperature about
20°C (68°F)

2.5V

When ATF temperature about
80°C (176°F)

0.7V

When the solenoid valve is
operating (other than 4th
speed)

More than 2V

When the solenoid valve is not
0V
operating (4th speed)
20

TCC solenoid valve

When vehicle
starts

Direct clutch solenoid
valve

When lock-up

More than 2V

When not lock-up

When the solenoid valve is
operating (1st speed or 5th
speed)

More than 2V

When the solenoid valve is not
operating (2nd speed, 3rd
0V
speed, or 4th speed)

AT-65

RE5R05A
TROUBLE DIAGNOSIS
TCM Input/Output Signal Reference Values
(Cont’d)
Terminal
No.

Wire color

G/Y

Item
SEL2
K-line (CONSULT-II signal)
Ground

Condition
—

R/L

Vehicle speed sensor A/T
(revolution sensor)

R/W

PNP switch 1

R/G

G/OR

B/Y

—

Transfer 4LO switch

Turbine revolution sensor
1

PNP switch 3

When high & low reverse
clutch solenoid valve “ON”.

When high & low reverse
clutch solenoid valve “OFF”.

Battery voltage

When moving at 20 km/h (12
MPH), use the CONSULT-II
pulse frequency measuring
function.
149 (Hz)
CAUTION:
Connect the diagnosis data
link connector to the vehicle
diagnosis connector.
Selector lever in “P” position.

Battery voltage

Selector lever in “N” position.

Less than 2.5V

Selector lever in “P” position.

Battery voltage

Selector lever in “D” position.

Less than 2.5V

When shifting transfer lever to
the “4LO” position.

When vehicle
starts

When shifting transfer lever to
other positions.

Battery voltage

—

Battery voltage

—

When front brake solenoid
valve “OFF”.

Battery voltage

When front brake solenoid
valve “ON”.

PSB2 (pressure switch 1)

L/Y

—

Power supply

BR/W

—

PNP switch 2

When vehicle
starts

—

PSC2 (pressure switch 6)

—

The terminal is connected to the data link connector for CONSULT-II

When vehicle
starts

Data (Approx.)

When moving at 20 km/h (12
MPH) in 1st speed with the
closed throttle position switch
“OFF”, use the CONSULT-II
pulse frequency measuring
1.1 (kHz)
function.
CAUTION:
Connect the diagnosis data
link connector to the vehicle
diagnosis connector.
Selector lever in “D” position.

Battery voltage

Selector lever in “R” position.

Less than 2.5V

Selector lever in “D” position.

More than 2.5V

Selector lever in “R” position.

Less than 2.5V

PNP switch 4
DATA BIT1

—

AT-66

—

RE5R05A
TROUBLE DIAGNOSIS
TCM Input/Output Signal Reference Values
(Cont’d)
Terminal
No.

Wire color

LG/R

G/OR

G/W

GY/L

Item

Condition

Back-up lamp relay

Data (Approx.)

Selector lever in “R” position.

Battery voltage

Selector lever in other position.

Less than 2V

—

Battery voltage

—

Power supply

Turbine revolution sensor
2

Ground

When vehicle
starts

—

When running at 50 km/h (31
MPH) in 4th speed with the
closed throttle position switch
“OFF”, use the CONSULT-II
pulse frequency measuring
1.1 (kHz)
function.
CAUTION:
Connect the diagnosis data
link connector to the vehicle
diagnosis connector.
—

—

Selector lever in “D” position.

Battery voltage

Selector lever in “R” position.

Less than 2.5V

Selector lever in “N”, “P” position.

Battery voltage

Selector lever in other position.

PNP switch 3 (monitor)

PNP relay
(Starter relay)

AT-67

RE5R05A

TROUBLE DIAGNOSIS
CONSULT-II

After performing refer to AT-68, “SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)”, place check
marks for results on the AT-45, “DIAGNOSTIC WORKSHEET”. Reference pages are provided following the
items.
NOTICE:
1. The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each
solenoid).
Check for time difference between actual shift timing and the CONSULT-II display. If the difference is
noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service
Manual may differ slightly. This occurs because of the following reasons:
— Actual shift schedule has more or less tolerance or allowance,
— Shift schedule indicated in Service Manual refers to the point where shifts start, and
— Gear position displayed on CONSULT-II indicates the point where shifts are completed.
3. Display of solenoid valves on CONSULT-II changes at the start of shifting, while gear position is
displayed upon completion of shifting (which is computed by TCM).
4. Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II
unit.
CAUTION:
In CONSULT-II diagnostic mode “WORK SUPPORT” and “DTC WORK SUPPORT” can be selected,
but they are not used.

CONSULT-II REFERENCE VALUE
Item name

Condition

Display value (Approx.) (V)

Fluid temperature sensor 1

3.3 — 2.7 — 0.9
0°C (32°F) — 20°C (68°F) — 80°C (176°F)

Fluid temperature sensor 2

3.3 — 2.5 — 0.7

SELF-DIAGNOSTIC PROCEDURE (WITH
CONSULT-II)
CONSULT-II Setting Procedure
+ For details, refer to the separate “CONSULT-II Operations
Manual”.
1. Turn ignition switch to “OFF” position.
2. Connect CONSULT-II to data link connector, which is located
in instrument lower panel on driver side.
SAT619K

3. Turn ignition switch to “ON” position.
4. Touch “START”.

SAT586J

AT-68

RE5R05A

TROUBLE DIAGNOSIS
CONSULT-II (Cont’d)

5. Touch “A/T” and on the CONSULT-II screen in that order.
6. Turn on CONSULT-II and touch “A/T” for TCM self-diagnosis.
If A/T is not displayed, check TCM power supply and ground
circuit. Refer to AT-64. If result is NG, refer to EL section
“POWER SUPPLY ROUTING”.

SAT014K

7. Touch “SELF-DIAG RESULTS”.
Display shows malfunction experienced since the last erasing operation.
CONSULT-II performs “REAL-TIME DIAG”.
Also, any malfunction detected while in this mode will be
displayed at real time.

SAT987J

Self-Diagnostic Result Test Mode
X: Applicable, —: Not applicable
TCM self-diagnosis
Items (CONSULT-II screen
terms)

Malfunction is detected when…

A/T CHECK
indicator lamp

“A/T” with
CONSULT-II

CAN COMM CIRCUIT

+ When an abnormality is detected in CAN communications

U1000

STARTER RELAY/CIRC
(PNP relay)

+ If this signal is “ON” other than in “P” or “N” position, this is
judged to be an abnormality.
(And if it is “OFF” in “P” or “N” position, this too is judged to be
an abnormality.)

P0615

PNP SW/CIRC

+ PNP switch 1-4 signals input with impossible pattern
+ PNP switch 3 monitor terminal cut line
+ “P” position is detected from “3” position or “N” position without
any other position being detected in between

P0705

VEH SPD SEN/CIR AT
(Revolution sensor)

+ Signal from vehicle sensor 1 not input due to cut line or the like
+ Abnormal signal input during running
+ After ignition switch is turned “ON”, abnormal signal input from
vehicle sensor MTR before the vehicle starts moving

P0720

ENGINE SPEED SIG

+ TCM does not receive the proper voltage signal from the ECM.

P0725

TCC SOLENOID/CIRC

+ Normal voltage not applied to solenoid due to functional
problem, cut line, short, or the like

P0740

L/PRESS SOL/CIRC

+ Normal voltage not applied to solenoid due to functional
problem, cut line, short, or the like

P0745

TCM-POWER SUPPLY

+ When the power supply to the TCM is cut “OFF”, for example
because the battery is removed, and the self-diagnostics
memory function stops
+ This is not a malfunction message (Whenever shutting “OFF” a
power supply to the TCM, this message appears on the screen.)

—

P1701

TCMzRAM

+ TCM memory (RAM) is malfunctioning.

—

P1702

AT-69

RE5R05A

TROUBLE DIAGNOSIS
CONSULT-II (Cont’d)

TCM self-diagnosis
Items (CONSULT-II screen
terms)

Malfunction is detected when…

A/T CHECK
indicator lamp

“A/T” with
CONSULT-II

TCMzROM

+ TCM memory (ROM) is malfunctioning.

—

P1703

TCMzEEPROM

+ TCM memory (EEPROM) is malfunctioning.

—

P1704

TP SEN/CIRC A/T

+ Voltage for accelerator sensor signal abnormally high
+ Voltage for accelerator sensor signal abnormally low when idle
signal OFF or full switch signal ON

P1705

ATF TEMP SEN/CIRC

+ During running, the ATF temperature sensor signal voltage is
abnormally high or low

P1710

TURBINE REV S/CIRC

+ TCM does not receive the proper voltage signal from the sensor.

P1716

VEH SPD SE/CIRzMTR

+ Signal from vehicle sensor MTR not input due to cut line or the
like
+ Abnormal signal input during running

—

P1721

A/T INTERLOCK

+ Except during speed change, the gear position and hydraulic
switch states are monitored and comparative judgement made.

P1730

A/T 1ST E/BRAKING

Each hydraulic switch and solenoid current is monitored and if a
pattern is detected having engine braking other than in the 1
position, this is judged to be an abnormality.

P1731

I/C SOLENOID/CIRC

Normal voltage not applied to solenoid due to functional problem,
cut line, short, or the like

P1752

FR/B SOLENOID/CIRC

Normal voltage not applied to solenoid due to functional problem,
cut line, short, or the like

P1757

D/C SOLENOID/CIRC

Normal voltage not applied to solenoid due to functional problem,
cut line, short, or the like

P1762

HLR/C SOL/CIRC

Normal voltage not applied to solenoid due to functional problem,
cut line, short, or the like

P1767

LC/B SOLENOID/CIRC

Normal voltage not applied to solenoid due to functional problem,
cut line, short, or the like

P1772

MANU MODE SW/CIRC

When an impossible pattern of switch signals is detected, this is
judged to be an abnormality.

—

P1815

—

P1841

—

P1843

—

P1845

—

P1846

—

ATF PRES SW 1/CIRC
ATF PRES SW 3/CIRC
ATF PRES SW 5/CIRC

When there is a difference found in the comparison between a
pressure switch state and the electrical current monitor value,
(Other than during speed change)

ATF PRES SW 6/CIRC
NO DTC IS DETECTED
FURTHER TESTING MAY
BE REQUIRED

No NG item has been detected.

AT-70

RE5R05A

TROUBLE DIAGNOSIS
CONSULT-II (Cont’d)
Data Monitor Mode (A/T)

X: Standard, —: Not applicable
Monitor Item Selection
Monitored item (Unit)

TCM
INPUT
SIGNALS

MAIN
SIGNALS

CAN
COMM
SIGNALS

SELECTION
FROM
MENU

Remarks

VHCL/S SEzA/T (km/h)

—

VHCL/S SEzMTR (km/h)

—

ACCELE POSI (0.0/8)

—

Accelerator pedal position sensor signal

THROTTLE POS (0.0/8)

—

Throttle position is recognized by the
TCM. For fail-safe operation, the specific
value used for control is displayed.

BATTERY BOLT (V)

—

ENGINE SPEED (rpm)

—

TURBINE REV (rpm)

—

ATF TEMP 1 (V)

—

ATF TEMP 2 (V)

—

OUTPUT REV (rpm)

—

ATF TEMP SE 1 (V)

—

ATF TEMP SE 2 (V)

—

ATF PRES SW 1 (ON-OFF display)

—

(for FR/B solenoid)

ATF PRES SW 2 (ON-OFF display)

—

(for LC/B solenoid)

ATF PRES SW 3 (ON-OFF display)

—

(for I/C solenoid)

ATF PRES SW 5 (ON-OFF display)

—

(for D/C solenoid)

ATF PRES SW 6 (ON-OFF display)

—

(for HLR/C solenoid)

PNP SW 1 (ON-OFF display)

—

PNP SW 2 (ON-OFF display)

—

PNP SW 3 (ON-OFF display)

—

PNP SW 4 (ON-OFF display)

—

1 POSITION SW (ON-OFF display)

—

ASCDzCRUISE (ON-OFF display)

—

ASCDzOD CUT (ON-OFF display)

—

OD CONT SW (ON-OFF display)

—

MANU MODE SW (ON-OFF display)

—

NON M-MODE SW (ON-OFF display)

—

UP SW LEVER (ON-OFF display)

—

DOWN SE LEVER (ON-OFF display)

—

POWER SHIFT SW (ON-OFF display)

—

Not mounted but displayed

CLSO THL POS (ON-OFF display)

—

Signal input with CAN communications

W/O THL POS (ON-OFF display)

—

Signal input with CAN communications

TCC SOLENOID (A)

—

LINE PRES SOL (A)

—

I/C SOLENOID (A)

—

FR/B SOLENOID (A)

—

AT-71

Revolution sensor

Not mounted but displayed.

RE5R05A

TROUBLE DIAGNOSIS
CONSULT-II (Cont’d)
Monitor Item Selection
Monitored item (Unit)

D/C SOLENOID (A)

TCM
INPUT
SIGNALS

MAIN
SIGNALS

CAN
COMM
SIGNALS

SELECTION
FROM
MENU

—

HLR/C SOL (A)

Remarks

HOLD SW (ON-OFF display)

—

Not mounted but displayed

BRAKE SW (ON-OFF display)

—

Stop lamp switch

GEAR

—

Gear position recognized by the TCM
updated after gear-shifting

GEAR RATIO

—

SLCTLVR POSI

—

Selector lever position is recognized by
the TCM.
For fail-safe operation, the specific value
used for control is displayed.

VEHICLE SPEED (km/h)

—

Vehicle speed recognized by the TCM.

TC SLIP SPEED (rpm)

—

Difference between engine speed and
torque converter input shaft speed

CAN COMM (OK-NG)

—

CAN CIRC 1 (OK-UNKWN)

—

CAN CIRC 2 (OK-UNKWN)

—

CAN CIRC 3 (OK-UNKWN)

—

CAN CIRC 4 (OK-UNKWN)

—

CAN CIRC 5 (OK-UNKWN)

—

CAN CIRC 6 (OK-UNKWN)
Voltage (V)

—

F SUN GW REV (rpm)

—

F CARR GR REV (rpm)

—

SFT UP ST SW

—

SFT DWN ST SW

—

ABS SIGNAL

—

ACC OD CUT

—

ACC SIGNAL

—

TCS GR/P KEEP

—

TCS SIGNAL 2

—

TCS SIGNAL 1

—

ON OFF SOL (ON-OFF display)

—

TCC SOL MON

—

L/P SOL MON

—

I/C SL MON

—

FR/B SOL MON

—

D/C SOL MON

—

HLR/C SOL MON

—

ONOFF SOL MON

—

Displays the value measured by the voltage probe.

Not mounted but displayed

AT-72

LC/B solenoid

RE5R05A

TROUBLE DIAGNOSIS
CONSULT-II (Cont’d)
Monitor Item Selection
TCM
INPUT
SIGNALS

MAIN
SIGNALS

CAN
COMM
SIGNALS

SELECTION
FROM
MENU

P POSI IND

—

R POSI IND

—

Monitored item (Unit)

Remarks

HOW TO ERASE SELF-DIAGNOSTIC RESULTS
(WITH CONSULT-II)
1. If the ignition switch stays “ON” after repair work, be sure to
turn ignition switch “OFF” once. Wait at least 10 seconds and
then turn it “ON” (engine stopped) again.
2. Turn CONSULT-II “ON” and touch “A/T”.

SAT014K

3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. (The self-diagnostic results will be erased.)

SCIA0511E

Diagnostic Procedure Without CONSULT-II
SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)
Description
In the unlikely event of an abnormality in the electrical system, when the ignition switch to “ON” position, the
A/T CHECK indicator lamp lights up for 2 seconds, then flashes for 8 seconds. If there is no abnormality,
when the ignition switch to “ON” position, the indicator lamp lights up for 2 seconds. As a method for locating the problem position, when the self-diagnostics start signal is input, the memory for the breakdown location is output and the A/T CHECK indicator lamp flashes to display the problem position.

Diagnostic Procedure

1.CHECK A/T CHECK INDICATOR LAMP
1. Start the engine with selector lever in “P” position. Warm engine to normal operating temperature.
2. Ignition switch to “ON” and “OFF” position at least twice, then leave it in the “OFF” position.
3. Wait 10 seconds.
4. Turn ignition switch to “ON” position.
(Do not start engine.)
5. Does A/T CHECK indicator lamp come on for about 2 seconds?
Yes or No?
Yes
>> GO TO 2.
No
>> GO TO AT-168, “A/T CHECK Indicator Lamp does not come on”.

AT-73

RE5R05A
TROUBLE DIAGNOSIS
Diagnostic Procedure Without CONSULT-II
(Cont’d)

2.JUDGEMENT PROCEDURE STEP 1

1. Turn ignition switch to “OFF” position.
2. Push shift lock release button.
3. Move selector lever from “P” to “D” position.
4. Release accelerator pedal. (Set the closed throttle position signal «ON».
5. Depressed brake pedal. (Brake switch to “ON” position.)
6. Turn ignition switch to “ON” position.
7. Wait 3 seconds.
8. Manual mode switch to “ON” position. (Move the selector lever to “M” position.)
9. Released brake pedal. (Brake switch to “OFF” position.)
10. Manual mode switch to “OFF” position. (Move the selector lever to “D” position.)
11. Depressed brake pedal. (Brake switch to “ON” position.)
12. Released brake pedal. (Brake switch to “OFF” position.)
13. Depress accelerator pedal fully and release it.
>> GO TO 3.

3.CHECK SELF-DIAGNOSIS CODE
Check A/T CHECK indicator lamp.
Refer to AT-74, “Judgement Self-Diagnosis Code”.
If the system does not go into self-diagnostics. Refer to AT-164, “PARK/NEUTRAL POSITION,
MANUAL MODE, BRAKE AND THROTTLE POSITION SWITCH CIRCUIT”.
>> DIAGNOSIS END

Judgement Self-Diagnosis Code
If there is an abnormality, the lamp lights up for the time corresponding to the problem path.

SCIA0497E

HOW TO ERASE SELF-DIAGNOSTIC RESULTS (WITHOUT CONSULT-II)
The A/T CHECK indicator lamp is located on the instrument panel.
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
10 seconds and then turn it “ON” (engine stopped) again.
2. Perform self-diagnostic procedure. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT
CONSULT-II)”. (The engine warm-up step can be skipped when performing the diagnosis only to erase
the DTC.)
3. Turn ignition switch to “OFF” position. (The self-diagnostic results will be erased.)

AT-74

DTC U1000 CAN COMMUNICATION LINE

RE5R05A

Description
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle
multiplex communication line with high data communication speed and excellent error detection ability. Many
electronic control units are equipped onto a vehicle, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected
with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with
less wiring. Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic
+
+

This is a self-diagnostic item.
Diagnostic trouble code “CAN COMM CIRCUIT” with CONSULT-II or “17th judgment flicker” without
CONSULT-II is detected when TCM cannot communicate to other control unit.

Possible Cause
Harness or connectors
(CAN communication line is open or shorted.)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine and wait for at least 6 seconds.
If DTC is detected, go to AT-77, “Diagnostic Procedure”.

SAT014K

WITHOUT CONSULT-II
1. Start engine and wait for at least 6 seconds.
2. Perform self-diagnosis.
Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
3. If DTC is detected, go to AT-77, “Diagnostic Procedure”.

AT-75

DTC U1000 CAN COMMUNICATION LINE

RE5R05A

Wiring Diagram — AT — CAN

TAT082M

AT-76

DTC U1000 CAN COMMUNICATION LINE

RE5R05A

Diagnostic Procedure

1.CHECK CAN COMMUNICATION CIRCUIT (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. The “CAN COMM CIRCUIT” is detected.
Yes or No?
Yes
>> Print out CONSULT-II screen, go to 3.
No
>> INSPECTION END

PCIA0061E

2.CHECK CAN COMMUNICATION CIRCUIT (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Perform self-diagnosis.
Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
3. The DTC is detected.
Yes or No?
Yes
>> GO TO “CAN SYSTEM”.
No
>> INSPECTION END

3.CHECK CAN COMMUNICATION SIGNALS (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “CAN COMM SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
>> Print out CONSULT-II screen, go to “CAN SYSTEM”.

SCIA0511E

CAN Communication Signals
Normal conditions

Abnormal conditions (examples)

CAN COMM: OK

CAN CIRC 1: OK

CAN CIRC 1: UNKWN

CAN CIRC 2: OK

CAN CIRC 2: UNKWN

CAN CIRC 3: OK

CAN CIRC 3: UNKWN

CAN CIRC 4: OK

CAN CIRC 4: UNKWN

CAN CIRC 5: UNKWN

CAN CIRC 6: UNKWN

AT-77

DTC P0615 START SIGNAL CIRCUIT

RE5R05A

Description
Prohibits cranking other at “P” or “N” position.

On Board Diagnosis Logic
+
+

This is a self-diagnosis item.
Diagnostic trouble code “STARTER RELAY/CIRC” with CONSULT-II or “14th judgement flicker” without
CONSULT-II is detected when detects as abnormal when switched “ON” other than at “P” or “N” position. (Or when switched “OFF” at “P” or “N” position).

Possible Cause
Check the following items.
+ Harness or connectors
(PNP relay and TCM circuit is open or shorted.)
+ PNP relay

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine.
Drive vehicle for at least 2 consecutive seconds.
If DTC is detected, go to AT-80, “Diagnostic Procedure”.

SAT014K

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle for at least 2 consecutive seconds.
3. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-80, “Diagnostic Procedure”.

AT-78

DTC P0615 START SIGNAL CIRCUIT

RE5R05A

Wiring Diagram — AT — STSIG

TAT083M

AT-79

RE5R05A

DTC P0615 START SIGNAL CIRCUIT
Diagnostic Procedure

1.CHECK PNP RELAY (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “SELECTION FROM MENU” in “DATA MONITOR”
mode for “A/T” with CONSULT-II and check monitor
“STARTER RELAY” (PNP relay) ON/OFF.
OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

PCIA0056E

2.CHECK PNP RELAY (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Check the voltage between the TCM connector and ground.
Connector
No.

Item
PNP relay
(Starter
relay)
PCIA0060E

E124

Terminal No.

Shift position

Voltage
(Approx.)

N and P

Battery
voltage

R and D

Ground

OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

3.DETECT MALFUNCTIONING ITEM
Check the following items.
1. PNP relay.
2. Disconnections or short-circuits in the main harness between TCM and the PNP relay.
3. Ground circuit for the PNP relay.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.

4.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-80

DTC P0615 START SIGNAL CIRCUIT

RE5R05A

Component Inspection
PNP RELAY
Check continuity between PNP relay harness connector terminals. Refer to AT-79, “Wiring Diagram — AT
— STSIG”.
Item

Shift position

Ignition switch

Connector No.

Terminal No.

Continuity

E52

1-2

Yes

3-5

OFF
PNP relay

P and N
E51
ON

No
3-5
Yes

AT-81

DTC P0705 PARK/NEUTRAL POSITION SWITCH

RE5R05A

Description
+
+

The park/neutral position (PNP) switch includes a transmission position switch.
The transmission range switch detects the selector lever position and sends a signal to the TCM.

On Board Diagnosis Logic
+
+
+
+

This is a self-diagnostic item.
Diagnostic trouble code “PNP SW/CIRC” with CONSULT-II or “9th judgment flicker” without CONSULT-II
is detected when TCM does not receive the correct voltage signal from the PNP switch 1, 2, 3, 4 based
on the gear position.
When monitor terminal of PNP switch 3 is disconnected.
When no other position but “P” position is detected from “3” or “N” positions.

Possible Cause
Check the following items.
+ Harness or connectors
(PNP switch 1, 2, 3, 4 and TCM circuit is open or shorted.)
+ PNP switch 1, 2, 3, 4
+ PNP switch 3 monitor terminal disconnected

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “ENGINE” with CONSULT-II.
3. Start engine.
4. Vehicle start and maintain the following conditions for at least
2 consecutive seconds.
THRTL POS SEN: More than 1.2V
5. If DTC is detected, go to AT-84, “Diagnostic Procedure”.
SAT014K

WITHOUT CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
3. If DTC is detected, go to AT-84, “Diagnostic Procedure”.

AT-82

DTC P0705 PARK/NEUTRAL POSITION SWITCH

RE5R05A

Wiring Diagram — AT — PNP/SW

TAT084M

AT-83

RE5R05A

DTC P0705 PARK/NEUTRAL POSITION SWITCH
Diagnostic Procedure

1.CHECK PNP SW CIRCUIT (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T”
with CONSULT-II.
3. Read out “NzP”, “R” and “D” position switches moving selector lever to each position.
OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.
PCIA0034E

2.CHECK PNP SW CIRCUIT (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Selector lever to “P“, “R”, “N”, or “D” position to check the
voltage between the TCM connector terminals and ground.
Connector No.

E124

Shift
position

PCIA0035E

Terminal No.
30 — Ground

31 — Ground

38 — Ground

39 — Ground

Battery voltage

—

Less than 2.5V

—

Less than 2.5V

Battery voltage More than 2.5V

OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

3.DETECT MALFUNCTIONING ITEM
Check the following items.
+ Disconnection or short-circuit in the main harness between TCM and PNP switch 1, 2, 3, 4.
+ Disconnection or short-circuit in the main harness between the PNP switch 3 monitor and TCM.
+ PNP switch.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.

4.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-84

DTC P0705 PARK/NEUTRAL POSITION SWITCH
Diagnostic Procedure (Cont’d)

RE5R05A

5.CHECK TCM INSPECTION
1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>> 1. Repair or replace damaged parts.
2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

Component Inspection
PNP SWITCH
1. Selector lever to various positions to check the continuity
between terminals on the PNP switch and ground.
PNP SW

Shift position

Connector
No.

Terminal No.

Continuity

19 — Ground

SW 1
P
SW 2
SAT622K

20 — Ground

SW 3

E240

21 — Ground

D
SW 4

22 — Ground
Yes

SW 3 Monitor

P, R, N, D

21 — 23

2. If NG, check the continuity with the control cable disconnected. (Refer to Step 1 above.)
3. If OK with the control cable disconnected, adjust the control
cable.
4. If NG even when the control cable is disconnected, replace
the transmission assembly. Refer to AT-15, “Precautions for
A/T Assembly Replacement”.

AT-85

DTC P0720 VEHICLE SPEED SENSOR A/T
(REVOLUTION SENSOR)

RE5R05A

Description
The revolution sensor detects the revolution of the out put shaft parking pawl lock gear and emits a pulse
signal. The pulse signal is sent to the TCM which converts it into vehicle speed.

On Board Diagnosis Logic
+
+
+

This is a self-diagnostic item.
Diagnostic trouble code “VEH SPD SEN/CIR AT” with CONSULT-II or “1st judgement flicker” without
CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor.
After ignition switch is turned “ON”, abnormal signal input from vehicle sensor MTR before the vehicle
starts moving.

Possible Cause
Check the following items.
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Revolution sensor

DTC Confirmation Procedure
CAUTION:
+ Always drive vehicle at a safe speed.
+ Be careful not to rev engine into the red zone on the tachometer.
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.
4.

SAT014K

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine.
Drive vehicle and check for an increase of “VHCL/S SEzMTR”
value.
If the check result is NG, go to AT-120, “DTC P1721
VEHICLE SPEED SENSOR MTR”.
If the check result is OK, go to following step.
5. Turn ignition switch to “OFF” position and wait at least 10
seconds.
6. Turn ignition switch to “ON” position. (Do not start engine.)
7. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
8. Start engine.
9. Drive vehicle and maintain the following conditions for at
least 5 consecutive seconds.
VHCL SPEED SE: 30 km/h (19 MPH) or more
THRTL POS SEN: More than 1.0/8
Selector lever: “D” position
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
If the check result is NG, go to AT-89, “Diagnostic Procedure”.
If the check result is OK, go to following step.
10. Turn ignition switch to “OFF” position and wait at least 10
seconds.
11. Turn ignition switch to “ON” position. (Do not start engine.)
12. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.

AT-86

DTC P0720 VEHICLE SPEED SENSOR A/T
RE5R05A
(REVOLUTION SENSOR)
DTC Confirmation Procedure (Cont’d)
13. Start engine.
14. Drive vehicle and maintain the following conditions for at
least 5 consecutive seconds.
ENGINE SPEED: 3,500 rpm or more
THRTL POS SEN: More than 1.0/8
Selector lever: “D” position
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
If the check result is NG, go to AT-89, “Diagnostic Procedure”.

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following conditions:
Selector lever “D” position, vehicle speed higher than 30
km/h (19 MPH), throttle opening greater than 1/8 of the full
throttle position and driving for at least 5 consecutive seconds.
3. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-89, “Diagnostic Procedure”.

AT-87

DTC P0720 VEHICLE SPEED SENSOR A/T
(REVOLUTION SENSOR)

RE5R05A

Wiring Diagram — AT — VSSA/T

TAT085M

AT-88

DTC P0720 VEHICLE SPEED SENSOR A/T
(REVOLUTION SENSOR)

RE5R05A

Diagnostic Procedure

1.CHECK INPUT SIGNALS (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Start the engine.
4. Read out the value of “VHCL/S SEzA/T” while driving.
Check the value changes according to driving speed.
OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.
PCIA0033E

2.CHECK INPUT SIGNALS (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULTII)”.
OK or NG?
OK
>> GO TO 4.
NG
>> + Harness for short or open between TCM and revolution sensor (Main harness)
+ Repair or replace damaged parts.

3.CHECK REVOLUTION SENSOR (WITH CONSULT-II)
With CONSULT-II
1. Start the engine.
Condition

Connector No.

Terminal
No.

Data
(Approx.)

When moving at 20 km/h (12 MPH), use the
CONSULT-II pulse frequency measuring
function.
CAUTION:
Connect the data link connector to the
vehicle-side diagnosis connector.

E124

149 (Hz)

PCIA0018E

OK or NG?
OK
>> GO TO 4.
NG
>> + Harness for short or open between TCM and
revolution sensor (Main harness)
+ Repair or replace damaged parts.

4.CHECK DTC
Perform DTC confirmation procedure. Refer to AT-89, “DTC Confirmation Procedure”.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-89

DTC P0720 VEHICLE SPEED SENSOR A/T
(REVOLUTION SENSOR)
Diagnostic Procedure (Cont’d)

RE5R05A

5.CHECK TCM INSPECTION
1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>> + Repair or replace damaged parts.
+ Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-90

DTC P0725 ENGINE SPEED SIGNAL

RE5R05A

Description
The engine speed signal is sent from the ECM to the TCM.

On Board Diagnosis Logic
+
+

This is a self-diagnostic item.
Diagnostic trouble code “ENGINE SPEED SIG” with CONSULT-II or “16th judgement flicker” without
CONSULT-II is detected when TCM does not receive the ignition signal in the primary circuit is not sent
to ECM during engine cranking or running.

Possible Cause
Check harness or connectors. (The ECM to the TCM circuit is open or shorted.)

WITH CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Start engine and maintain the following conditions for at least
10 consecutive seconds.
VHCL SPEED SE: 10 km/h (6 MPH) or more
ACCELE POSI: More than 1.0/8
Selector lever: “D” position
4. If DTC is detected, go to AT-92, “Diagnostic Procedure”.
SAT014K

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following condition:
Selector lever “D” position, vehicle speed higher than 10
km/h (6 MPH), throttle opening greater than 1/8 of the full
throttle position and driving for at least 10 consecutive seconds.
3. Perform self-diagnosis.
Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-92, “Diagnostic Procedure”.

AT-91

DTC P0725 ENGINE SPEED SIGNAL

RE5R05A

Diagnostic Procedure

1.CHECK DTC WITH ECM (WITH CONSULT-II)

SAT014K

With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “SELF-DIAG RESULTS” mode for “ENGINE” with
CONSULT-II. Refer to CONSULT-II Function.
OK or NG?
OK
>> GO TO 3.
NG
>> Check the DTC detected item, go to CONSULT-II
Function.
+ If CAN communication line is detected, go to
AT-75, “DTC U1000 CAN COMMUNICATION
LINE”.

2.CHECK DTC WITH ECM (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Perform self-diagnosis.
OK or NG?
OK
>> GO TO 4.
NG
>> Check the DTC detected item, go to CONSULT-II Function.
+ If CAN communication line is detected, go to AT-75, “DTC U1000 CAN COMMUNICATION LINE”.

3.CHECK DTC WITH TCM (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
2. Select “SELF-DIAG RESULTS” mode for “A/T” with CONSULT-II.
OK or NG?
OK
>> GO TO 5.
NG
>> Check the ignition signal circuit.
+ Refer to DTC P1320 IGNITION SIGNAL.

SAT014K

4.CHECK DTC WITH TCM (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULTII)”.
OK or NG?
OK
>> GO TO 5.
NG
>> Check the ignition signal circuit.
+ Refer to DTC P1320 IGNITION SIGNAL.

AT-92

5.CHECK DTC

DTC P0725 ENGINE SPEED SIGNAL
Diagnostic Procedure (Cont’d)

Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-93

RE5R05A

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID
VALVE

RE5R05A

Description
+
+
+

The torque converter clutch solenoid valve is activated, with the gear in D4, D5, by the TCM in response
to signals sent from the vehicle speed and throttle position sensors. Lock-up piston operation will then
be controlled.
Lock-up operation, however, is prohibited when A/T fluid temperature is too low.
When the accelerator pedal is depressed (less than 1/8) in lock-up condition, the engine speed should
not change abruptly. If there is a big jump in engine speed, there is no lock-up.

On Board Diagnosis Logic
+
+
+

This is a self-diagnosis item.
Diagnostic trouble code “TCC SOLENOID/CIRC” with CONSULT-II or “3rd judgement flicker” without
CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.
Detects as abnormal by comparing target value with monitor value.

Possible Cause
Check the following items.
+ Torque converter clutch solenoid valve
+ Harness or connectors
(The solenoid circuit is open or shorted.)

WITH CONSULT-II
1.
2.
3.
4.

SAT014K

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine.
Drive vehicle and maintain the following conditions for at
least 5 consecutive seconds.
VHCL SPEED SE: 80 km/h (50 MPH) or more
ACCELE POS: 0.5/8 — 1.0/8
Selector lever: “D” position
Gear position: Lock-up position
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
5. If DTC is detected go to AT-96 “Diagnostic Procedure”.

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following conditions:
Selector lever “D” position, vehicle speed higher than 80
km/h (50 MPH) (Lock-up position), throttle opening greater
than 1/8 of the full throttle position and driving for at least 5
consecutive seconds.
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
3. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-96, “Diagnostic Procedure”.

AT-94

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID
VALVE

RE5R05A

Wiring Diagram — AT — TCV

TAT086M

AT-95

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID
VALVE

RE5R05A

Diagnostic Procedure

1.CHECK VALVE RESISTANCE
1. Turn ignition switch to “OFF” position.
2. Disconnect A/T solenoid valve harness connector 2 at the
transmission right side.
3. Check the resistance between terminal and ground.
Solenoid Valve
Torque converter
clutch solenoid valve

Connector No.

Terminal No.

Resistance
(Approx.)

E239

18 — Ground

3 — 9Ω

OK or NG?
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

SAT623K

2.CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM connector.
3. Check continuity between A/T solenoid valve harness connector 2 and TCM connector.
Item

SAT624K

Connector No.

Terminal No.

TCM

E123

A/T solenoid valve
harness connector 2

E239

Continuity

Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG?
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to
power in harness or connectors.

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

4.CHECK TCM INSPECTION
1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>> 1. Repair or replace damaged parts.
2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-96

DTC P0745 LINE PRESSURE SOLENOID VALVE

RE5R05A

Description
The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in
response to a signal sent from the TCM.
The line pressure duty cycle value is not consistent when the closed throttle position switch is “ON”.
To confirm the line pressure duty cycle at low pressure, the accelerator (throttle) should be open until
the closed throttle position switch is “OFF”.

On Board Diagnosis Logic
+
+
+

This is a self-diagnosis item.
Diagnostic trouble code “L/PRESS SOL/CIRC” with CONSULT-II or “4th judgement flicker” without
CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.
Detects as abnormal by comparing target value with monitor value.

Possible Cause
Check the following items.
+ Harness or connectors
(The solenoid circuit is open or shorted.)
+ Line pressure solenoid valve

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine and wait at least 5 consecutive seconds.
If DTC is detected, go to AT-99, “Diagnostic Procedure”.

SAT014K

WITHOUT CONSULT-II
1. Start engine and wait at least 5 consecutive seconds.
2. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
3. If DTC is detected, go to AT-99, “Diagnostic Procedure”.

AT-97

DTC P0745 LINE PRESSURE SOLENOID VALVE

RE5R05A

Wiring Diagram — AT — LPSV

TAT087M

AT-98

DTC P0745 LINE PRESSURE SOLENOID VALVE

RE5R05A

Diagnostic Procedure

SAT625K

Solenoid Valve

Connector No.

Terminal No

Resistance
(Approx.)

Line pressure
solenoid valve

E239

17 — Ground

3 — 9Ω

OK or NG?
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

2.CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM connector.
3. Check continuity between A/T solenoid valve harness connector 2 and TCM connector.

SAT626K

Item

Connector No.

Terminal No.

TCM

E123

A/T solenoid valve
harness connector 2

E239

Continuity

Yes

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-99

DTC P1701 TRANSMISSION CONTROL MODULE
(POWER SUPPLY)

RE5R05A

Description
When the power supply to the TCM is cut “OFF”, for example because the battery is removed, and the selfdiagnostics memory function stops.

On Board Diagnosis Logic
+
+
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “TCM-POWER SUPPLY” with CONSULT-II is detected.
TCM does not receive the voltage signal from the battery power supply.
This is not a malfunction message. (Whenever shutting “OFF” a power supply to the TCM, this message
appears on the screen.)

Possible Cause
Check harness or connectors.
(Battery or ignition switch and TCM circuit is open or shorted.)

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Wait for at least 2 consecutive seconds.
If DTC is detected, go to AT-103, “Diagnostic Procedure”.

SAT014K

AT-100

DTC P1701 TRANSMISSION CONTROL MODULE
(POWER SUPPLY)

RE5R05A

Wiring Diagram — AT — POWER

TAT088M

AT-101

DTC P1701 TRANSMISSION CONTROL MODULE
RE5R05A
(POWER SUPPLY)
Wiring Diagram — AT — POWER (Cont’d)

TAT115M

AT-102

DTC P1701 TRANSMISSION CONTROL MODULE
(POWER SUPPLY)

RE5R05A

Diagnostic Procedure

1.CHECK TCM POWER SOURCE STEP 1
1. Turn ignition switch to “OFF” position. (Do not start engine.)
2. Check voltage between TCM terminal and ground.
Item

Connector No.

Terminal No.

Voltage

TCM

E123

9 — Ground

Battery voltage

OK or NG?
OK
>> GO TO 2.
NG
>> GO TO 3.
PCIA0063E

2.CHECK TCM POWER SOURCE STEP 2
1. Turn ignition switch to “ON” position.
2. Check voltage between TCM terminal and ground.
Item

Connector No.

E123
TCM
E124
PCIA0063E

Terminal No.
2 — Ground
3 — Ground
9 — Ground
12 — Ground

Voltage

Battery voltage

33 — Ground
42 — Ground

OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

3.DETECT MALFUNCTIONING ITEM
Check the following items:
+ Harness for short or open between battery and TCM terminal 9 (Main harness)
+ Harness for short or open between ignition switch and TCM terminals 2, 3, 12, 33 and 42 (Main harness)
+ 7.5A fuse [No. 12 located in the fuse block (J/B)], 10A fuse (No. 45 fuse and fusible link box), 10A
fuse (No. 50 fuse and fusible link box) and 15A fuse (No. 49 fuse and fusible link box).
+ Ignition switch
+ A/T PV IGN relay.
+ ECM relay, Refer to EC section.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.

4.CHECK TCM GROUND CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM harness connector.
3. Check continuity between TCM terminals 5, 14, 24, 46 and ground.
Continuity should exist.
If OK, check harness for short to ground and short to power.
OK or NG?
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

AT-103

DTC P1701 TRANSMISSION CONTROL MODULE
(POWER SUPPLY)
Diagnostic Procedure (Cont’d)

RE5R05A

5.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 6.

Component Inspection
A/T PV IGN RELAY
Check continuity between A/T PV IGN relay harness connector terminals. Refer to AT-101, “Wiring Diagram
— AT — POWER”.
Item

Ignition switch

Connector No.

Terminal No.

Continuity

1-2

Yes

3-5

Yes

OFF
A/T PV IGN relay

E150
ON

AT-104

DTC P1702 TRANSMISSION CONTROL MODULE (RAM)

RE5R05A

Description
The TCM consists of a microcomputer and connectors for signal
input and output and for power supply. The TCM controls the
A/T.

SAT574J

On Board Diagnosis Logic
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “TCMzRAM” with CONSULT-II is detected when TCM memory RAM is malfunctioning

Possible Cause
Check TCM.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for A/T with CONSULT-II.
Start engine.
Run engine for at least 2 consecutive seconds at idle speed.
If DTC is detected, go to AT-105, “Diagnostic Procedure”.

SAT014K

Diagnostic Procedure

1.CHECK DTC

SCIA0511E

With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “SELF DIAG RESULTS” mode for “A/T” with CONSULT-II.
3. Touch “ERASE”.
4. Turn ignition switch to “OFF” position and wait at least 10
seconds.
5. Perform DTC confirmation procedure.
Is the “TCMzRAM” displayed again?
Yes
>> Replace TCM.
No
>> INSPECTION END

AT-105

DTC P1703 TRANSMISSION CONTROL MODULE (ROM)

RE5R05A

Description
The TCM consists of a microcomputer and connectors for signal
input and output and for power supply. The TCM controls the
A/T.

SAT574J

On Board Diagnosis Logic
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “TCMzROM” with CONSULT-II is detected when TCM memory ROM is malfunctioning.

Possible Cause
Check TCM.

WITH CONSULT-II
1.
2.
3.
4.
5.

SAT014K

Diagnostic Procedure

1.CHECK DTC

SCIA0511E

With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “SELF DIAG RESULTS” mode for “A/T” with CONSULT-II.
3. Touch “ERASE”.
4. Turn ignition switch to “OFF” position and wait at least 10
seconds.
5. Perform DTC confirmation procedure.
Is the “TCMzROM” displayed again?
Yes
>> Replace TCM.
No
>> INSPECTION END

AT-106

DTC P1704 TRANSMISSION CONTROL MODULE
(EEPROM)

RE5R05A

Description
The TCM consists of a microcomputer and connectors for signal
input and output and for power supply. The TCM controls the
A/T.

SAT574J

On Board Diagnosis Logic
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “TCMzEEPROM” with CONSULT-II is detected when TCM memory EEPROM is
malfunctioning.

Possible Cause
Check TCM.

WITH CONSULT-II
1.
2.
3.
4.
5.

SAT014K

Diagnostic Procedure

1.CHECK DTC

SCIA0511E

With CONSULT-II
1. Turn ignition switch to “ON” position and select “SELF DIAGNOSIS” mode for “A/T” with CONSULT-II.
2. Move selector lever to “R” position.
3. Depress accelerator pedal (Full throttle position).
4. Touch “ERASE”.
5. Turn ignition switch to “OFF” position and wait at least 10
seconds.
6. Perform DTC Confirmation Procedure.
Is the “TCMzEEPROM” displayed again?
Yes
>> Replace TCM.
No
>> INSPECTION END

AT-107

DTC P1705 THROTTLE POSITION SENSOR

RE5R05A

Description
Electric throttle control actuator consists of throttle control motor, acceleration pedal position sensor, throttle
position sensor, etc. The actuator sends a signal to the TCM.

On Board Diagnosis Logic
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “TP SEN/CIRC A/T” with CONSULT-II or “15th judgement flicker” without CONSULT-II is detected when TCM receives an excessively low or high voltage from the sensor.

Possible Cause
Harness or connectors
(The sensor circuit is open or shorted.)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected go to AT-108, “Diagnostic Procedure”.

WITHOUT CONSULT-II

SAT014K

1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Start engine and let it idle for 1 second.
3. Perform self-diagnosis.
Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-108, “Diagnostic Procedure”.

Diagnostic Procedure

1.CHECK DTC WITH ECM (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “SELF-DIAG RESULTS” mode for “ENGINE” with
CONSULT-II.
OK or NG?
OK
>> GO TO 3.
NG
>> Check the DTC detected item.
+ If CAN communication line is detected, go to
AT-75, “DTC U1000 CAN COMMUNICATION
LINE”.
SAT014K

AT-108

DTC P1705 THROTTLE POSITION SENSOR
Diagnostic Procedure (Cont’d)

RE5R05A

2.CHECK DTC WITH ECM (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Perform self-diagnosis.
Refer to AT-73, SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II).
OK or NG?
OK
>> GO TO 4.
NG
>> Check the DTC detected item.
+ If CAN communication line is detected, go to AT-75, “DTC U1000 CAN COMMUNICATION LINE”.

3.CHECK DTC WITH TCM (WITH CONSULT-II)
WITH CONSULT-II

PCIA0070E

1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Depressed accelerator pedal and read out the value of
“ACCLE POS SEN” and “THROTTLE POSI”.
Check engine speed changes according to throttle position.
4. Select “SELF-DIAG RESULTS” mode for “ENGINE” with
CONSULT-II.
OK or NG?
OK
>> GO TO 5.
NG
>> Check the accelerator pedal position sensor circuit.

4.CHECK DTC WITH TCM (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Perform self-diagnosis.
Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
OK or NG?
OK
>> GO TO 5.
NG
>> Check the accelerator pedal position sensor circuit.

5.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-109

DTC P1710 A/T FLUID TEMPERATURE SENSOR CIRCUIT

RE5R05A

Description
The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM.

CONSULT-II Reference Value
Item name

Condition

Display value (Approx.) (V)

Fluid temperature sensor 1

3.3 — 2.7 — 0.9
0°C (32°F) — 20°C (68°F) — 80°C (176°F)

Fluid temperature sensor 2

3.3 — 2.5 — 0.7

On Board Diagnosis Logic
+
+

This is a self-diagnosis item.
Diagnostic trouble code “ATF TEMP SEN/CIRC” with CONSULT-II or “10th judgement flicker” without
CONSULT-II is detected when TCM receives an excessively low or high voltage from the sensor.

Possible Cause
Check the following items.
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ A/T fluid temperature sensors 1, 2

WITH CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Start engine and maintain the following conditions for at least
10 minutes (Total). (It is not necessary to maintain continuously.)
VHCL SPEED SE: 10 km/h (6 MPH) or more
THRTL POS SEN: More than 1.0/8
Selector lever: “D” position
4. If DTC is detected, go to AT-112, “Diagnostic Procedure”.
SAT014K

WITHOUT CONSULT-II
1. Start engine.
2. Selector lever “D” position, vehicle speed higher than 10
km/h (6 MPH), throttle opening greater than 1/8 of the full
throttle position and driving for at least 10 minutes (Total).
3. Perform self-diagnosis.
Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-112, “Diagnostic Procedure”.

AT-110

DTC P1710 A/T FLUID TEMPERATURE SENSOR CIRCUIT

RE5R05A

Wiring Diagram — AT — FTS

TAT090M

AT-111

DTC P1710 A/T FLUID TEMPERATURE SENSOR CIRCUIT

RE5R05A

Diagnostic Procedure

1.CHECK FLUID TEMPERATURE SENSOR (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Read out the value of “ATF TEMP SE 1” or “ATF TEMP SE
2”.

PCIA0039E

Display value
(Approx.) V

Item name

Condition °C (°F)

Fluid temperature sensor 1

0 (32) — 20 (68) — 80
(176)

Fluid temperature sensor 2

3.3 — 2.7 — 0.9
3.3 — 2.5 — 0.7

OK or NG?
OK
>> GO TO 4.
NG
>> Check the fluid temperature sensor.

2.CHECK FLUID TEMPERATURE SENSOR (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “OFF” position.
2. Disconnect A/T solenoid valve harness connector 1, 2 at the
transmission right side.
3. Check the resistance between terminals and ground.

SAT627K

Name

Connector
No.

Fluid temperature sensor 1

E238
A/T solenoid
valve harness
connector 1

Fluid temperature sensor 2

E239
A/T solenoid
valve harness
connector 2

Terminal No.

9 — Ground

11 — Ground

Temperature
°C (°F)

Resistance
(kΩ) (Approx.)

0 (32)

20 (68)

6.5

80 (176)

0.9

0 (32)

10.5

20 (68)

4.3

80 (176)

0.5

4. Reinstall any part removed.
OK or NG?
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

AT-112

DTC P1710 A/T FLUID TEMPERATURE SENSOR CIRCUIT
Diagnostic Procedure (Cont’d)

RE5R05A

3.INPUT SIGNALS FROM THE OIL TEMPERATURE SENSOR (WITHOUT CONSULT-II)
Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector and ground while warming up A/T.
Name

Connector No.

Fluid temperature sensor 1

Terminal No.

8 — 24 or 46 (ground)

Temperature °C (°F)

Voltage (V) (Approx.)

0 (32)

3.3V

20 (68)

2.7V

80 (176)

0.9V

0 (32)

3.3V

20 (68)

2.5V

80 (176)

0.7V

E123
Fluid temperature sensor 2

17 — 24 or 46 (ground)

3. Turn ignition switch to “OFF” position.
4. Disconnect the TCM connector.
5. Check if there is continuity between the connector terminals and ground.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4.DETECT MALFUNCTIONING ITEM
Check the following item:
Harness for short to ground or short to power or open between TCM and A/T solenoid valve harness connector 1, 2 (Main harness).
OK or NG?
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

5.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 6.

6.CHECK TCM INSPECTION
1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>> 1. Repair or replace damaged parts.
2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-113

DTC P1710 A/T FLUID TEMPERATURE SENSOR CIRCUIT

RE5R05A

Component Inspection
FLUID TEMPERATURE SENSOR
Check the resistance between terminals and ground.
Name

Connector
No.

Fluid temperature sensor 1

E238
A/T solenoid
valve harness
connector 1

Fluid temperature sensor 2

E239
A/T solenoid
valve harness
connector 2

SAT627K

AT-114

Terminal No.

9 — Ground

11 — Ground

Temperature
°C (°F)

Resistance
(kΩ) (Approx.)

0 (32)

20 (68)

6.5

80 (176)

0.9

0 (32)

10.5

20 (68)

4.3

80 (176)

0.5

DTC P1716 TURBINE REVOLUTION SENSOR

RE5R05A

Description
The turbine revolution sensor detects input shaft rpm (revolutions per minute). It is located on the input side
of the automatic transmission. Display revolution of sensor 1 and sensor 2 abnormality.

On Board Diagnosis Logic
+
+
+

This is a self-diagnosis item.
Diagnostic trouble code “TURBINE REV S/CIRC” with CONSULT-II or “11th judgement flicker” without
CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor.
Detects abnormality only at position of 4th gear for turbine revolution sensor 2.

Possible Cause
Check the following items.
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Turbine revolution sensor 1, 2

WITH CONSULT-II

SAT014K

1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Start engine and maintain the following conditions for at least
5 consecutive seconds.
VHCL SPEED SE: 40 km/h (25 MPH) or more
ENGINE SPEED: 1,500 rpm or more
Selector lever: “D” position
Gear position (Turbine revolution sensor 1):
All position
Gear position (Turbine revolution sensor 2):
4th or 5th position
Driving location:
Driving the vehicle uphill (increased engine load)
will help maintain the driving conditions required
for this test.
4. If DTC is detected, go to AT-118, “Diagnostic Procedure”.

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following condition:
Selector lever “D” position, vehicle speed higher than 40
km/h (25 MPH), engine speed more than 1,500 rpm and
driving for at least 5 consecutive seconds.
Gear position (Turbine revolution sensor 1):
All position
Gear position (Turbine revolution sensor 2):
4th or 5th position
Driving location:
Driving the vehicle uphill (increased engine load)
will help maintain the driving conditions required
for this test.

AT-115

RE5R05A
DTC P1716 TURBINE REVOLUTION SENSOR
DTC Confirmation Procedure (Cont’d)
3. Perform self-diagnosis.
Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-118, “Diagnostic Procedure”.

AT-116

DTC P1716 TURBINE REVOLUTION SENSOR

RE5R05A

Wiring Diagram — AT — TRSA/T

TAT091M

AT-117

DTC P1716 TURBINE REVOLUTION SENSOR

RE5R05A

Diagnostic Procedure

1.CHECK INPUT SIGNALS (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Vehicle start and read out the value of “TURBINE REV”.
OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

PCIA0041E

2.CHECK INPUT SIGNALS (WITHOUT CONSULT-II)
Without CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Perform self-diagnosis.
Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
OK or NG?
OK
>> GO TO 4.
NG
>> + Harness for short or open between TCM and turbine revolution sensor (Main harness).
+ Repair or replace damaged parts.

3.CHECK TURBINE REVOLUTION SENSOR (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “OFF” position.
2. Start engine.
3. Check the frequency.
Name

Condition

Turbine
revolution
sensor 1

When moving at 20 km/h (12 MPH) in 1st speed with the closed
throttle position switch “OFF”, use the CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle
diagnosis connector.

Turbine
revolution
sensor 2

When running at 50 km/h (31 MPH) in 4th speed with the closed
throttle position switch “OFF”, use the CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle
diagnosis connector.

PCIA0042E

Item Connector No.

TCM

Terminal
No.

Name

Turbine revolution sensor 1

Turbine revolution sensor 2

E124

Data
(Approx.)
1.1 (kHz)

OK or NG?
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to
power in harness or connectors.

AT-118

DTC P1716 TURBINE REVOLUTION SENSOR
Diagnostic Procedure (Cont’d)

RE5R05A

4.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-119

DTC P1721 VEHICLE SPEED SENSOR MTR

RE5R05A

Description
The vehicle speed sensorzMTR is built into the speedometer assembly. The sensor functions as an auxiliary
device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent from the vehicle
speed sensorzMTR.

On Board Diagnosis Logic
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “VHE SPD SEzMTR” with CONSULT-II is detected when TCM does not receive
the proper voltage signal from the sensor.

Possible Cause
Check the following items.
+ Harness or connectors
(The sensor circuit is open or shorted.)

WITH CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Start engine and maintain the following conditions for at least
5 consecutive seconds.
ACCELE POS: 1/8 or less
VHCL SPEED SE: 30 km/h (17 MPH) or more
4. If DTC is detected, go to AT-120, “Diagnostic Procedure”.

SAT014K

Diagnostic Procedure

1.CHECK INPUT SIGNALS (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Vehicle start and read out the value of “VHCL/S SEzMTR”.
OK or NG?
OK
>> GO TO 3.
NG
>> GO TO 2.

PCIA0033E

AT-120

DTC P1721 VEHICLE SPEED SENSOR MTR
Diagnostic Procedure (Cont’d)

RE5R05A

2.CHECK DTC STEP 1
Check following items.
1. Refer to AT-75, “DTC U1000 CAN COMMUNICATION LINE”.
2. Wheel sensors.
3. Combination meter.
OK or NG?
OK
>> INSPECTION END
NG
>> If NG, recheck pin terminals for damage or loose connection with harness connector.

3.CHECK DTC STEP 2
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> If NG, recheck pin terminals for damage or loose connection with harness connector.

AT-121

DTC P1730 A/T INTERLOCK

RE5R05A

Description
+
+

Fail-safe function to detect interlock conditions.
Fail-safe function to the transmission range switch detects the selector position and sends a signal to
the TCM.

On Board Diagnosis Logic
+
+
+

This is a self-diagnosis item.
Diagnostic trouble code “A/T INTERLOCK” with CONSULT-II or “12th judgement flicker” without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor and switch.
Monitors and compares gear position and conditions of each pressure switch when gear is steady.

Possible Cause
Check the following items.
+ Harness or connectors
(The solenoid and switch circuit is open or shorted.)
+ Input clutch, direct clutch, high & low reverse clutch, front brake, low coast brake solenoid valves
+ Pressure switch 1, 3, 5 and 6

WITH CONSULT-II
1.
2.
3.
4.

SAT014K

AT-122

DTC P1730 A/T INTERLOCK

RE5R05A

Wiring Diagram — AT — I/LOCK

TAT092M

AT-123

RE5R05A
DTC P1730 A/T INTERLOCK
Wiring Diagram — AT — I/LOCK (Cont’d)

TAT093M

AT-124

RE5R05A
DTC P1730 A/T INTERLOCK
Wiring Diagram — AT — I/LOCK (Cont’d)

TAT094M

AT-125

RE5R05A

DTC P1730 A/T INTERLOCK
Judgement of A/T Interlock

When A/T Interlock is judged to be abnormal, the vehicle should be fixed in 2nd, 4th, or 5th gear, and should
be set in a condition in which it can travel.
When one of the following fastening patterns is detected, the fail-safe function in correspondence with the
individual pattern should be executed.

A/T interlock coupling pattern table
+: NG, X: OK
Clutch pressure output pattern after fail-safe
function

Hydraulic pressure switch output
Gear position

1st

SW3
(I/C)

SW6
(H &
LR/C)

2nd

SW1
SW2
(Fr/B) (LC/B)
X

D/C

Fr/B

LC/B

L/U

Held in 4th speed

OFF

Held in 4th speed

OFF

Held in 4th speed

OFF

Held in 4th speed

OFF

Held in 2nd speed

OFF

Held in 4th speed

OFF

Held in 2nd speed

OFF

Held in 5th speed

OFF

Held in 2nd speed

OFF

Held in 4th speed

OFF

X
X

4th
X

X
X

+
X

5th
X

H&
LR/C

3rd

I/C

+
A/T interlock
coupling
patterns

Fail-safe function
SW5
(D/C)

Diagnostic Procedure

1.SELF-DIAGNOSIS (WITH CONSULT-II)

SAT014K

With CONSULT-II
1. Start engine.
2. Select “SELF-DIAG RESULTS” mode for “A/T” with CONSULT-II.
3. Drive vehicle.
OK or NG?
OK
>> GO TO 3.
NG
>> + Check pressure switch, Refer to AT-150, “DTC
P1841 ATF PRESSURE SWITCH 1”, AT-154,
“DTC P1843 ATF PRESSURE SWITCH 3”,
AT-157, “DTC P1845 ATF PRESSURE
SWITCH 5”, AT-160, “DTC P1846 ATF PRESSURE SWITCH 6”.
+ Check each solenoid valves, Refer to AT-131,
“DTC P1752 INPUT CLUTCH SOLENOID
VALVE”, AT-134, “DTC P1757 FRONT BRAKE
SOLENOID VALVE”, AT-137, “DTC P1762
DIRECT CLUTCH SOLENOID VALVE”,
AT-140, “DTC P1767 HIGH AND LOW
REVERSE CLUTCH SOLENOID VALVE”,
AT-143, “DTC P1772 LOW COAST BRAKE
SOLENOID VALVE”.

AT-126

DTC P1730 A/T INTERLOCK
Diagnostic Procedure (Cont’d)

RE5R05A

2.SELF-DIAGNOSIS (WITHOUT CONSULT-II)
Without CONSULT-II

SAT014K

1. Start engine.
2. Perform self-diagnosis.
3. Drive vehicle.
OK or NG?
OK
>> GO TO 3.
NG
>> + Check pressure switch, Refer to AT-150, “DTC
P1841 ATF PRESSURE SWITCH 1”, AT-154,
“DTC P1843 ATF PRESSURE SWITCH 3”,
AT-157, “DTC P1845 ATF PRESSURE
SWITCH 5”, AT-160, “DTC P1846 ATF PRESSURE SWITCH 6”.
+ Check each solenoid valves, Refer to AT-131,
“DTC P1752 INPUT CLUTCH SOLENOID
VALVE”, AT-134, “DTC P1757 FRONT BRAKE
SOLENOID VALVE”, AT-137, “DTC P1762
DIRECT CLUTCH SOLENOID VALVE”,
AT-143, “DTC P1767 HIGH AND LOW
REVERSE CLUTCH SOLENOID VALVE”,
AT-143, “DTC P1772 LOW COAST BRAKE
SOLENOID VALVE”.

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-127

DTC P1731 A/T 1ST ENGINE BRAKING

RE5R05A

Description
Fail-safe function to prevent sudden decrease in speed by engine brake other than at 1st position or at 1st
gear.

On Board Diagnosis Logic
+
+
+

This is a self-diagnostic item.
Diagnostic trouble code “A/T 1ST E/BRAKING” with CONSULT-II or “13th judgement flicker” without
CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor.
Monitors each pressure switch and solenoid monitor value, and detects as abnormal when engine brake
acts other than at 1st position.

Possible Cause
Check the following items.
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Low coast brake solenoid valve
+ Pressure switch 2

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine.
Drive vehicle and maintain the following conditions for at
least 2 consecutive seconds.
ENGINE SPEED: 1,200 rpm
Selector lever: “M” position
Gear position: “M1-1st” or “M2-2nd” gear position
5. If DTC is detected, go to AT-130, “Diagnostic Procedure”.

SAT014K

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following conditions:
Selector lever “M” position, gear position “M1-1st” or “M22nd”, engine speed more than 1,200 rpm and driving for at
least 2 consecutive seconds.
3. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-130, “Diagnostic Procedure”.

AT-128

DTC P1731 A/T 1ST ENGINE BRAKING

RE5R05A

Wiring Diagram — AT — E/BRE

TAT095M

AT-129

DTC P1731 A/T 1ST ENGINE BRAKING

RE5R05A

Diagnostic Procedure

1.CHECK SELF-DIAGNOSIS (WITH CONSULT-II)

SAT014K

With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “SELF-DIAG RESULTS” mode for “A/T” with CONSULT-II.
3. Start engine and drive vehicle.
OK or NG?
OK
>> GO TO 3.
NG
>> + Check the pressure switch. Refer to AT-150,
“DTC P1841 ATF PRESSURE SWITCH 1”,
AT-154, “DTC P1843 ATF PRESSURE
SWITCH 3”, AT-157, “DTC P1845 ATF PRESSURE SWITCH 5”, AT-160, “DTC P1846 ATF
PRESSURE SWITCH 6”.
+ Check the low coast brake solenoid. Refer to
AT-143, “DTC P1772 LOW COAST BRAKE
SOLENOID VALVE”.

2.CHECK SELF-DIAGNOSIS (WITHOUT CONSULT-II)
WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle.
3. Perform self-diagnosis.
OK or NG?
OK
>> GO TO 3.
NG
>> + Check the pressure switch. Refer to AT-150, “DTC P1841 ATF PRESSURE SWITCH
1”, AT-154, “DTC P1843 ATF PRESSURE SWITCH 3”, AT-157, “DTC P1845 ATF
PRESSURE SWITCH 5”, AT-160, “DTC P1846 ATF PRESSURE SWITCH 6”.
+ Check the low coast brake solenoid. Refer to AT-143, DTC P1772 LOW COAST BRAKE
SOLENOID VALVE.

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-130

DTC P1752 INPUT CLUTCH SOLENOID VALVE

RE5R05A

Description
Input clutch solenoid valve operation by the TCM in response to signals sent from the PNP switch, vehicle
speed and accelerator pedal position sensors. Gears will then be shifted to the optimum position.

On Board Diagnosis Logic
+
+
+

This is a self-diagnosis item.
Diagnostic trouble code “I/C SOLENOID/CIRC” with CONSULT-II or “5th judgement flicker” without
CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.
Detects as abnormal by comparing target value with monitor value.

Possible Cause
Check the following items.
+ Harness or connectors
(The solenoid circuit is open or shorted.)
+ Input clutch solenoid valve

WITH CONSULT-II
1.
2.
3.
4.

SAT014K

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine.
Drive vehicle and maintain the following conditions for at
least 5 consecutive seconds.
ACCELE POS: 1.5/8 — 2.0/8
Selector lever: “D” position
Gear position: 3rd → 4th Gear (I/C ON/OFF)
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
5. If DTC is detected go to AT-133, “Diagnostic Procedure”.

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following conditions:
Selector lever “D” position, gear position 3rd → 4th, throttle
opening greater than 1.5/8 — 2/8 of the full throttle position
and driving for at least 5 consecutive seconds.
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
3. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-133, “Diagnostic Procedure”.

AT-131

DTC P1752 INPUT CLUTCH SOLENOID VALVE

RE5R05A

Wiring Diagram — AT — I/C

TAT096M

AT-132

DTC P1752 INPUT CLUTCH SOLENOID VALVE

RE5R05A

Diagnostic Procedure

Connector No.

Terminal No.

Resistance
(Approx.)

Input clutch solenoid valve

E239

16 — Ground

3 — 9Ω

OK or NG?
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

SAT628K

2.CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM connector.
3. Check continuity between A/T solenoid valve harness connector 2 and TCM connector.

SAT629K

Item

Connector No.

Terminal No.

TCM

E123

A/T solenoid valve
harness connector
2

E239

Continuity

Yes

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-133

DTC P1757 FRONT BRAKE SOLENOID VALVE

RE5R05A

Description
Front brake solenoid valve operation by the TCM in response to signals sent from the PNP switch, vehicle
speed and throttle position sensors. Gears will then be shifted to the optimum position.

On Board Diagnosis Logic
+
+
+

This is a self-diagnosis item.
Diagnostic trouble code “FR/B SOLENOID/CIRC” with CONSULT-II or “6th judgement flicker” without
CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.
Detects as abnormal by comparing target value with monitor value.

Possible Cause
Check the following items.
+ Harness or connectors
(The solenoid circuit is open or shorted.)
+ Front brake solenoid valve

WITH CONSULT-II
1.
2.
3.
4.

SAT014K

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine.
Drive vehicle and maintain the following conditions for at
least 5 consecutive seconds.
ACCELE POS: 1.5/8 — 2.0/8
Selector lever: “D” position
Gear position: 1st → 3rd Gear (FR/B ON/OFF)
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
5. If DTC is detected go to AT-136, “Diagnostic Procedure”.

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following conditions:
Selector lever “D” position, gear position 1st → 3rd, throttle
opening greater than 1.5/8 — 2/8 of the full throttle position
and driving for at least 5 consecutive seconds.
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
3. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-136, “Diagnostic Procedure”.

AT-134

DTC P1757 FRONT BRAKE SOLENOID VALVE

RE5R05A

Wiring Diagram — AT — FR/B

TAT097M

AT-135

DTC P1757 FRONT BRAKE SOLENOID VALVE

RE5R05A

Diagnostic Procedure

SAT630K

Solenoid Valve

Connector No.

Terminal No.

Resistance
(Approx.)

Front brake solenoid valve

E239

15 — Ground

3 — 9Ω

OK or NG?
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

2.CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM connector.
3. Check continuity between A/T solenoid valve harness connector 2 and TCM connector.

SAT631K

Item

Connector No.

Terminal No.

TCM

E123

A/T solenoid valve
harness connector 2

E239

Continuity

Yes

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-136

DTC P1762 DIRECT CLUTCH SOLENOID VALVE

RE5R05A

Description
Direct clutch solenoid valve operation by the TCM in response to signals sent from the PNP switch, vehicle
speed and throttle position sensors. Gears will then be shifted to the optimum position.

On Board Diagnosis Logic
+
+
+

This is a self-diagnosis item.
Diagnostic trouble code “D/C SOLENOID/CIRC” with CONSULT-II or “2nd judgement flicker” without
CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.
Detects as abnormal by comparing target value with monitor value.

Possible Cause
Check the following items.
+ Harness or connectors
(The solenoid circuit is open or shorted.)
+ Direct clutch solenoid valve

WITH CONSULT-II
1.
2.
3.
4.

SAT014K

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine.
Drive vehicle and maintain the following conditions for at
least 5 consecutive seconds.
ACCELE POS: 1.5/8 — 2.0/8
Selector lever: “D” position
Gear position: 1st → 2nd Gear (D/C ON/OFF)
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
5. If DTC is detected, go to AT-139, “Diagnostic Procedure”.

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following conditions:
Selector lever “D” position, gear position 1st → 2nd, throttle
opening greater than 1.5/8 — 2/8 of the full throttle position
and driving for at least 5 consecutive seconds.
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
3. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-139, “Diagnostic Procedure”.

AT-137

DTC P1762 DIRECT CLUTCH SOLENOID VALVE

RE5R05A

Wiring Diagram — AT — D/C

TAT098M

AT-138

DTC P1762 DIRECT CLUTCH SOLENOID VALVE

RE5R05A

Diagnostic Procedure

SAT632K

Solenoid Valve

Connector No.

Terminal No.

Resistance
(Approx.)

Direct clutch solenoid valve

E239

14 — Ground

3 — 9Ω

OK or NG?
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

2.CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM connector.
3. Check continuity between A/T solenoid valve harness connector 2 and TCM connector.

SAT633K

Item

Connector No.

Terminal No.

TCM

E123

A/T solenoid valve
harness connector 2

E239

Continuity

Yes

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-139

DTC P1767 HIGH AND LOW REVERSE CLUTCH
SOLENOID VALVE

RE5R05A

Description
High & low reverse clutch solenoid valve operation by the TCM in response to signals sent from the PNP
switch, vehicle speed and throttle position sensors. Gears will then be shifted to the optimum position.

On Board Diagnosis Logic
+
+
+

This is a self-diagnosis item.
Diagnostic trouble code “HLR/C SOL/CIRC” with CONSULT-II or “8th judgement flicker” without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid
valve.
Detects as abnormal by comparing target value with monitor value.

Possible Cause
Check the following items.
+ Harness or connectors
(The solenoid circuit is open or shorted.)
+ High & low reverse clutch solenoid valve

WITH CONSULT-II
1.
2.
3.
4.

SAT014K

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Start engine.
Drive vehicle and maintain the following conditions for at
least 5 consecutive seconds.
ACCELE POS: 1.5/8 — 2.0/8
Selector lever: “D” position
Gear position: 1st → 3rd Gear (HLR/C ON/OFF)
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
5. If DTC is detected, go to AT-142, “Diagnostic Procedure”.

AT-140

DTC P1767 HIGH AND LOW REVERSE CLUTCH
SOLENOID VALVE

RE5R05A

Wiring Diagram — AT — HLR/C

TAT099M

AT-141

DTC P1767 HIGH AND LOW REVERSE CLUTCH
SOLENOID VALVE

RE5R05A

Diagnostic Procedure

SAT634K

Solenoid Valve

Connector No.

Terminal No.

Resistance
(Approx.)

High & low
reverse clutch
solenoid valve

E239

13 — Ground

13 — 9Ω

OK or NG?
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

2.CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM connector.
3. Check continuity between A/T solenoid valve harness connector 2 and TCM connector.

SAT635K

Item

Connector No.

Terminal No.

TCM

E123

A/T solenoid valve
harness connector 2

E239

Continuity

Yes

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-142

DTC P1772 LOW COAST BRAKE SOLENOID VALVE

RE5R05A

Description
Low coast brake solenoid valve a turned “ON” or “OFF” by the TCM in response to signals sent from the
PNP switch, vehicle speed and throttle position sensors. Gears will then be shifted to the optimum position.

On Board Diagnosis Logic
+
+

This is a self-diagnosis item.
Diagnostic trouble code “LC/B SOLENOID/CIRC” with CONSULT-II or “7th judgement flicker” without
CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.

Possible Cause
Check the following items.
+ Harness or connectors
(The solenoid circuit is open or shorted.)
+ Low coast brake solenoid valve

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T ” with CONSULT-II.
Start engine.
Drive vehicle and maintain the following conditions for at
least 5 consecutive seconds.
Selector lever: “M” position
Gear position: “M1-1st” or “M2-2nd” gear (LC/B
ON/OFF)
5. If DTC is detected, go to AT-145, “Diagnostic Procedure”.

SAT014K

WITHOUT CONSULT-II
1. Start engine.
2. Drive vehicle under the following conditions:
Selector lever “M” position, gear position “M1-1st” or “M22nd”, throttle opening greater than 1.5/8 — 2/8 of the full
throttle position and driving for at least 5 consecutive seconds.
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
3. Perform self-diagnosis. Refer to AT-73, “SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)”.
4. If DTC is detected, go to AT-145, “Diagnostic Procedure”.

AT-143

DTC P1772 LOW COAST BRAKE SOLENOID VALVE

RE5R05A

Wiring Diagram — AT — LC/B

TAT100M

AT-144

DTC P1772 LOW COAST BRAKE SOLENOID VALVE

RE5R05A

Diagnostic Procedure

SAT636K

Solenoid Valve

Connector No.

Terminal No.

Resistance
(Approx.)

Low coast brake
solenoid valve

E239

12 — Ground

20 — 40Ω

OK or NG?
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

2.CHECK POWER SOURCE CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect TCM connector.
3. Check continuity between A/T solenoid valve harness connector 2 and TCM connector.

SAT637K

Item

Connector No.

Terminal No.

TCM

E123

A/T solenoid valve
harness connector 2

E239

Continuity

Yes

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-145

RE5R05A

DTC P1815 MANUAL MODE SWITCH
Description
When an impossible pattern of switch signals is detected, this is judged to be an abnormality.

CONSULT-II Reference Value in Data Monitor
Mode
Monitor Item

Condition

Reference Value

Manual shift gate position (neutral)
MANU MODE SW

NON M-MODE SW

UP SW LEVER

DOWN SW LEVER

[ON — OFF]
Other than the above

OFF

Manual shift gate position

OFF

Other than the above

Select lever: + side

Other than the above

OFF

Select lever: − side

Other than the above

OFF

[ON — OFF]

On Board Diagnosis Logic
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “MANU MODE SW/CIR” with CONSULT-II is detected when monitors Manual
mode, Non manual mode, Up or Down switch signal and detects as abnormal when impossible input
pattern occurs 1 second or more.

Possible Cause
Check the following items.
+ Harness or connectors
(These switches circuit is open or shorted.)
+ Manual mode switch
+ Non manual mode switch
+ Up switch
+ Down switch

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch to “ON” position. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Move selector lever to “M” position.
Start engine and vehicle start for at least 2 consecutive seconds.
5. If DTC is detected, go to AT-148, “Diagnostic Procedure”.

SAT014K

AT-146

DTC P1815 MANUAL MODE SWITCH

RE5R05A

Wiring Diagram — AT — MMSW

TAT118M

AT-147

DTC P1815 MANUAL MODE SWITCH

RE5R05A

Diagnostic Procedure

1.CHECK MANUAL MODE SWITCH CIRCUIT (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Read out ON/OFF switching action of the “MANU MODE
SW”, “NON M-MODE SW”, “UP SW LEVER”, “DOWN SW
LEVER”.
OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.
PCIA0064E

2.CHECK MANUAL MODE SWITCH CIRCUIT (WITHOUT CONSULT-II)
Without CONSULT-II
Drive the vehicle in the manual mode, and confirm that the actual gear position and the meter’s indication
of the position mutually coincide when the selector lever is shifted to the “+ (up)” or “− (down)” side (1st ↔
5th gear).
OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

3.DETECT MALFUNCTIONING ITEM
Check the following items.
+ Combination meter.
+ Manual mode switch.
+ Check pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.

4.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> Replace the control device assembly.

Component Inspection
MANUAL MODE SWITCH
Check continuity between terminals. Refer to AT-147, “Wiring Diagram — AT — MMSW”.
Item

Position

Connector No.

Terminal No. (Unit side)

Auto

11 — 12

Manual

8 — 11

Continuity

Manual mode (select) SW
Neutral
UP SW

8 — 11
B25

Yes

10 — 11

Neutral

8 — 11

Down

9 — 11

DOWN SW

AT-148

DTC P1815 MANUAL MODE SWITCH

RE5R05A

Position Indicator Lamp
DIAGNOSTIC PROCEDURE

1.CHECK INPUT SIGNALS (WITH CONSULT-II)

PCIA0065E

With CONSULT-II
1. Start the engine.
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for A/T
with CONSULT-II and read out the value of “GEAR”.
3. Drive the vehicle in the manual mode, and confirm that the
actual gear position and the meter’s indication of the position
mutually coincide when the select lever is shifted to the “+
(up)” or “− (down)” side (1st ↔ 5th gear).
OK or NG?
OK
>> INSPECTION END
NG
>> Check the following items.

Position Indicator Lamp Symptom Chart
Items

Presumed Location of Trouble

The actual gear position does not change, or shifting into the
manual mode is not possible (no gear shifting in the manual
mode possible).
The position indicator lamp is not indicated.

Manual mode SW
Refer to AT-146, “DTC P1815 MANUAL MODE SWITCH”.
A/T main system (Fail-safe function actuated)
+ Refer to AT-68, “SELF-DIAGNOSTIC PROCEDURE (WITH
CONSULT-II)”.

Execute the self-diagnosis function.
The actual gear position changes, but the position indicator lamp
+ Refer to AT-68, “SELF-DIAGNOSTIC PROCEDURE (WITH
is not indicated.
CONSULT-II)”.
The actual gear position and the indication on the position indicator lamp do not coincide.

Execute the self-diagnosis function.
+ Refer to AT-68, “SELF-DIAGNOSTIC PROCEDURE (WITH
CONSULT-II)”.

Only a specific position or positions is/are not indicated on the
position indicator lamp.

Check the meter Control unit.

AT-149

DTC P1841 ATF PRESSURE SWITCH 1

RE5R05A

Description
Fail-safe function to detect front brake clutch solenoid valve condition.

On Board Diagnosis Logic
+
+
+

This is not a self-diagnostic item.
Diagnostic trouble code “ATF PRES SW 1/CIRC” with CONSULT-II is detected.
When condition of pressure switch 1 is different from monitor value, and relation between gear position
and actual gear ratio is abnormal. (Other than during speed change)

Possible Cause
+
+

Pressure switch 1
Harness or connectors
(The switch circuit is open or shorted.)

WITH CONSULT-II

SAT014K

1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Start engine and maintain the following conditions for at least
4 consecutive seconds. (Other than during speed change).
ACCELE POS: 1.5/8 — 2.0/8
Selector lever: “D” position
Gear position: 1st → 3rd Gear (FR/B ON/OFF)
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
4. If P1841 is detected, go to AT-152, “Diagnostic Procedure”.
If P1757 is detected, go to AT-136, “Diagnostic Procedure”.

AT-150

DTC P1841 ATF PRESSURE SWITCH 1

RE5R05A

Wiring Diagram — AT — FPSW1

TAT102M

AT-151

RE5R05A

DTC P1841 ATF PRESSURE SWITCH 1
Diagnostic Procedure

1.INPUT SIGNALS (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” or “MAIN SIGNALS” in “DATA
MONITOR” mode for “A/T” with CONSULT-II.
3. Drive vehicle in the “D” position (1st → 3rd gear), and confirm
the ON/OFF actuation of the “ATF PRES SW 1”.
OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.
PCIA0067E

2.INPUT SIGNALS (WITHOUT CONSULT-II)
Without CONSULT-II
1. Start engine.
2. Drive the vehicle in the “D” position (1st → 3rd gear).
Solenoid Valve

Front brake
solenoid valve

Terminal No.

Voltage

E124

35 — Ground

Battery
voltage

OFF
ON

PCIA0066E

Connector
No.

Approx. 0V

OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

3.DETECT MALFUNCTIONING ITEM
Check the following items.
1. Check disconnection or short-circuit in the main harness between pressure switch 1 (FR/B) (PSB2) and
TCM.
2. Check the connector housing for missing, loosening, bending or falling down of any terminal.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.

4.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-152

DTC P1841 ATF PRESSURE SWITCH 1
Diagnostic Procedure (Cont’d)

RE5R05A

2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-153

DTC P1843 ATF PRESSURE SWITCH 3

RE5R05A

Description
Fail-safe function to detect input clutch solenoid valve condition.

On Board Diagnosis Logic
+
+
+

This is not a self-diagnostic item.
Diagnostic trouble code “ATF PRES SW 3/CIRC” with CONSULT-II is detected.
When condition of pressure switch 3 is different from monitor value, and relation between gear position
and actual gear ratio is abnormal. (Other than during speed change)

Possible Cause
Check the following items.
+ Pressure switch 3
+ Harness or connectors
(The switch circuit is open or shorted.)

WITH CONSULT-II

SAT014K

1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Start engine and maintain the following conditions for at least
4 consecutive seconds. (Other than during speed change).
ACCELE POS: 1.5/8 — 2.0/8
Selector lever: “D” position
Gear position: 3rd → 4th Gear (I/C ON/OFF)
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
4. If P1843 is detected, go to AT-156, “Diagnostic Procedure”.
If P1752 is detected, go to AT-133, “Diagnostic Procedure”.

AT-154

DTC P1843 ATF PRESSURE SWITCH 3

RE5R05A

Wiring Diagram — AT — FPSW3

TAT103M

AT-155

DTC P1843 ATF PRESSURE SWITCH 3

RE5R05A

Diagnostic Procedure

1.INPUT SIGNALS (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” or “MAIN SIGNALS” in “DATA
MONITOR” mode for “A/T” with CONSULT-II.
3. Drive the vehicle in the “D” position (3rd → 4th gear), and
confirm the ON/OFF actuation of the “ATF PRES SW 3”.
OK or NG?
OK
>> GO TO 3.
NG
>> GO TO 2.
PCIA0067E

2.DETECT MALFUNCTIONING ITEM
Check the following items.
1. Check disconnection or short-circuit in the main harness between pressure switch 3 (I/C) (SEL 3 or
DATA BIT 1) and TCM.
2. Check the connector housing for missing, loosening, bending or falling down of any terminal.
OK or NG?
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-156

DTC P1845 ATF PRESSURE SWITCH 5

RE5R05A

Description
Fail-safe function to detect direct clutch solenoid valve condition.

On Board Diagnosis Logic
+
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “ATF PRES SW 5/CIRC” with CONSULT-II is detected.
When condition of pressure switch 1 is different from monitor value, and relation between gear position
and actual gear ratio is abnormal. (Other than during speed change)

Possible Cause
Check the following items.
+ Pressure switch 5
+ Harness or connectors
(The switch circuit is open or shorted.)

WITH CONSULT-II

SAT014K

1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Start engine and maintain the following conditions for at least
4 consecutive seconds. (Other than during speed change).
ACCELE POS: 1.5/8 — 2.0/8
Selector lever: “D” position
Gear position: 1st → 2nd Gear (D/C ON/OFF)
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
4. If P1845 is detected, go to AT-159, “Diagnostic Procedure”.
If P1762 is detected, go to AT-139, “Diagnostic Procedure”.

AT-157

DTC P1845 ATF PRESSURE SWITCH 5

RE5R05A

Wiring Diagram — AT — FPSW5

TAT104M

AT-158

DTC P1845 ATF PRESSURE SWITCH 5

RE5R05A

Diagnostic Procedure

1.INPUT SIGNALS (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” or “MAIN SIGNALS” in “DATA
MONITOR” mode for “A/T” with CONSULT-II.
3. Drive vehicle in the “D” position (1st → 2nd gear), and confirm the ON/OFF actuation of the “ATF PRES SW 5”.
OK or NG?
OK
>> GO TO 3.
NG
>> GO TO 2.
PCIA0067E

2.DETECT MALFUNCTIONING ITEM
Check the following items.
1. Check disconnection or short-circuit in the main harness between pressure switch 5 (D/C) (SEL 2
or DATA BIT 1) and TCM.
2. Check the connector housing for missing, loosening, bending or falling down of any terminal.
OK or NG?
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

3.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-159

DTC P1846 ATF PRESSURE SWITCH 6

RE5R05A

Description
Fail-safe function to detect high & low reverse clutch solenoid valve condition.

On Board Diagnosis Logic
+
+
+

This is not a self-diagnosis item.
Diagnostic trouble code “ATF PRES SW 6/CIRC” with CONSULT-II is detected.
When condition of pressure switch 6 is different from monitor value, and relation between gear position
and actual gear ratio is abnormal. (Other than during speed change)

Possible Cause
Check the following items.
+ Pressure switch 6
+ Harness or connectors
(The switch circuit is open or shorted.)

WITH CONSULT-II

SAT014K

1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Start engine and maintain the following conditions for at least
4 consecutive seconds. (Other than during speed change).
ACCELE POS: 1.5/8 — 2.0/8
Selector lever: “D” position
Gear position: 1st → 3rd Gear (HLR/C ON/OFF)
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
4. If P1846 is detected, go to AT-162, “Diagnostic Procedure”.
If P1767 is detected, go to AT-142, “Diagnostic Procedure”.

AT-160

DTC P1846 ATF PRESSURE SWITCH 6

RE5R05A

Wiring Diagram — AT — FPSW6

TAT105M

AT-161

RE5R05A

DTC P1846 ATF PRESSURE SWITCH 6
Diagnostic Procedure

1.INPUT SIGNALS (WITH CONSULT-II)
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” or “MAIN SIGNALS” in “DATA
MONITOR” mode for “A/T” with CONSULT-II.
3. Drive vehicle in the “D” position (1st → 3rd gear), and confirm
the ON/OFF actuation of the “ATF PRES SW 6”.
OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.
PCIA0067E

2.INPUT SIGNALS (WITHOUT CONSULT-II)
Without CONSULT-II
1. Start engine.
2. Drive vehicle in the “D” position (1st → 3rd gear).
Solenoid Valve
High & low
reverse clutch
solenoid valve
PCIA0068E

Connector
No.

Terminal No.

Voltage

E124

26 — Ground

Battery voltage

OFF
ON

Approx. 0V

OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

3.DETECT MALFUNCTIONING ITEM
Check the following items.
1. Check disconnection or short-circuit in the main harness between pressure switch 6 (HLR/C) (PSC
2) and TCM.
2. Check the connector housing for missing, loosening, bending or falling down of any terminal.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.

4.CHECK DTC
Perform DTC confirmation procedure.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-162

DTC P1846 ATF PRESSURE SWITCH 6
Diagnostic Procedure (Cont’d)

RE5R05A

2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-163

PARK/NEUTRAL POSITION, MANUAL MODE, BRAKE
AND THROTTLE POSITION SWITCH CIRCUIT

RE5R05A

Diagnostic Procedure

1.CHECK PNP SW CIRCUIT (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T”
with CONSULT-II.
3. Read out “PzN”, “R” and “D” position switches moving selector lever to each position.
OK or NG?
OK
>> GO TO 3.
NG
>> GO TO 2.
PCIA0034E

2.DETECT MALFUNCTIONING ITEM
Check the following items.
+ Disconnection or short-circuit in the main harness between TCM and PNP switch 1, 2, 3, 4.
+ Disconnection or short-circuit in the main harness between PNP switch 3 monitor and TCM.
+ PNP switch. Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION SWITCH”.
OK or NG?
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

3.CHECK MANUAL MODE SWITCH CIRCUIT (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Read out ON/OFF switching action of the “MANU MODE
SW”, “NON M-MODE SW”, “UP SW LEVER”, “DOWN SW
LEVER”.
OK or NG?
OK
>> GO TO 5.
NG
>> GO TO 4.
PCIA0064E

4.DETECT MALFUNCTIONING ITEM
Check the following items.
+ Manual mode switch. Refer to AT-146, “DTC P1815 MANUAL MODE SWITCH”.
+ Check the connector housing for missing, loosening, bending or falling down of any terminal.
OK or NG?
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

AT-164

PARK/NEUTRAL POSITION, MANUAL MODE, BRAKE
AND THROTTLE POSITION SWITCH CIRCUIT
Diagnostic Procedure (Cont’d)

RE5R05A

5.CHECK BRAKE SWITCH CIRCUIT (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Read out ON/OFF switching action of the “BRAKE SW”.
OK or NG?
OK
>> GO TO 6.
NG
>> Refer to BR section.

PCIA0070E

6.CHECK CLOSED THROTTLE POSITION SWITCH CIRCUIT (WITH CONSULT-II)
With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode
for “A/T” with CONSULT-II.
3. Depressed accelerator pedal and read out the value of “CLSO
THL POS” and “W/O THL POS”.

PCIA0070E

Monitor Item

Accelerator Pedal
Operation

CLSD THL POS

W/O THL POS

Released

OFF

Fully depressed

OFF

4. Select “SELF-DIAG RESULTS” mode for “ENGINE” with
CONSULT-II.
5. If P0121 is detected, go to EC section, “DTC P0121 ACCELERATOR PEDAL POSITION (APP) SENSOR”.
OK or NG?
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.

7.CHECK DTC
Perform DTC confirmation procedure.
+ Refer to AT-75, “CONSULT-II”.
+ CAN Communication Line. Refer to AT-75, “DTC U1000 CAN COMMUNICATION LINE”.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 8.

8.CHECK TCM INSPECTION
1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>> 1. Repair or replace damaged parts.
2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-165

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

Wiring Diagram — AT — NONDTC

TAT106M

AT-166

RE5R05A
TROUBLE DIAGNOSES FOR SYMPTOMS
Wiring Diagram — AT — NONDTC (Cont’d)

TAT116M

AT-167

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T CHECK Indicator Lamp Does not Come
on
SYMPTOM
A/T CHECK indicator lamp does not come on for about 2 seconds when turning ignition switch to
“ON”.

DIAGNOSTIC PROCEDURE

1.CHECK TCM POWER SOURCE STEP 1
1. Turn ignition switch to “OFF” position.
2. Check the voltage between TCM connector and ground. Refer to AT-101, “Wiring Diagram — AT
— POWER”.
Item

Connector No.

Terminal No.

Voltage

TCM

E123

9 — Ground

Battery voltage

OK or NG?
OK
>> GO TO 2.
NG
>> GO TO 3.

2.CHECK TCM POWER SOURCE STEP 2
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Check the voltage between TCM connector terminals 33, 42 and ground. Refer to AT-101, “Wiring
Diagram — AT — POWER”.
Item

Connector No.

TCM

E124

Terminal No.

Voltage

33 — Ground
Battery voltage
42 — Ground

OK or NG?
OK
>> GO TO 4.
NG
>> GO TO 3.

3.DETECT MALFUNCTIONING ITEM
Check the following items:
+ Harness for short or open between battery and TCM terminal 9 (Main harness)
+ Harness for short or open between ignition switch and TCM terminals 33 and 42 (Main harness)
+ 10A fuse [No. 45] or 7.5A fuse [No. 12, located in the fuse block (J/B)]
+ Ignition switch
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.

4.CHECK TCM GROUND CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Disconnect the TCM connector.
3. Check continuity between terminals 5, 14, 24, 46 and ground. Refer to AT-101, “Wiring Diagram —
AT — POWER”.
4. If OK, check the harness for short-circuit to ground or the power source.
OK or NG?
OK
>> GO TO 5.
NG
>> Repair the short-circuit(s) in the harness or connector to ground or the power source.

AT-168

RE5R05A
TROUBLE DIAGNOSES FOR SYMPTOMS
A/T CHECK Indicator Lamp Does not Come
on (Cont’d)

5.CHECK A/T CHECK INDICATOR LAMP CIRCUIT
1. Turn ignition switch to “OFF” position.
2. Check the combination meter.
OK or NG?
OK
>> GO TO 6.
NG
>> Check the following item.
+ Refer to AT-75, “DTC U1000 CAN COMMUNICATION LINE”.

6.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 7.

7.CHECK TCM INSPECTION
1. Perform TCM input/output signal inspection. Refer to AT-101.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>> 1. Repair or replace damaged parts.
2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

Engine Cannot Be Started In “P” and “N”
Position
SYMPTOM
+
+

Engine cannot be started with selector lever in “P” or “N” position.
Engine can be started with selector lever in “D” or “R” position.

DIAGNOSTIC PROCEDURE

1.CHECK PNP SWITCH CIRCUIT
With CONSULT-II
Does “TCM INPUT SIGNALS” in “DATA MONITOR” show damage to PNP switch circuit?
Without CONSULT-II
Does self-diagnosis show damage to PNP switch circuit?
Yes or No?
Yes
>> Check PNP switch circuit. Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION
SWITCH”.
No
>> GO TO 2.

2.CHECK STARTING SYSTEM
Check starting system.
OK or NG?
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-169

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

In “P” Position, Vehicle Moves When Pushed
SYMPTOM
Even though the selector lever is set in the “P” position, the parking mechanism is not actuated,
allowing the vehicle to be moved when it is pushed.

DIAGNOSTIC PROCEDURE

1.CHECK PNP SW CIRCUIT
With CONSULT-II
Does “TCM INPUT SIGNALS” in “DATA MONITOR” show damage to PNP switch circuit?
Without CONSULT-II
Does self-diagnosis show damage to PNP switch circuit?
Yes or No?
Yes
>> Check PNP switch circuit. Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION
SWITCH”.
No
>> GO TO 2.

2.CHECK CONTROL CABLE
Check control linkage. Refer to AT-196, “Control Linkage Adjustment”.
OK or NG?
OK
>> GO TO 3.
NG
>> + Adjust control linkage. Refer to AT-196, “Control Linkage Adjustment”.
+ Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

3.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-170

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

In “N” Position, Vehicle Moves
SYMPTOM
Vehicle moves forward or backward when selecting “N” position.

DIAGNOSTIC PROCEDURE

3.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

4.CHECK TCM INSPECTION
1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>>1. Repair or replace damaged parts.
2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

AT-171

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

Large Shock “N” to “D” Position
SYMPTOM
A noticeable shock occurs when the selector lever is shifted from the “N” to “D” position.

DIAGNOSTIC PROCEDURE

1.CHECK SELF-DIAGNOSIS RESULTS
Execute self-diagnosis.
Do the self-diagnosis results indicate A/T fluid temperature sensor, line pressure solenoid valve, or
throttle position sensor?
Yes
>> Check the malfunctioning system. Refer to AT-97, “DTC P0745 LINE PRESSURE SOLENOID VALVE”, AT-108, “DTC P1705 THROTTLE POSITION SENSOR”, AT-110, “DTC
P1710 A/T FLUID TEMPERATURE SENSOR CIRCUIT”.
No
>> GO TO 2.

2.CHECK ACCELERATOR PEDAL POSITION SENSOR
Check the accelerator pedal position sensor. Refer to EC section, “DTC P0121 ACCELERATOR PEDAL
POSITION (APP) SENSOR”.
OK or NG?
OK
>> GO TO 3.
NG
>> Repair or replace the accelerator pedal position sensor.

3.CHECK LINE PRESSURE
Check the line pressure with the engine idling in the “D” position. Refer to AT-52, “LINE PRESSURE TEST”.
OK or NG?
OK
>> GO TO 4.
NG
>> Check line pressure solenoid valve. Refer to AT-97, “DTC P0745 LINE PRESSURE
SOLENOID VALVE”.

4.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-172

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

Vehicle Does Not Creep Backward In “R”
Position
SYMPTOM
The vehicle does not creep in the “R” position. Or an extreme lack of acceleration is observed.

DIAGNOSTIC PROCEDURE

1.CHECK A/T FLUID LEVER
Check A/T fluid level again. Refer to MA section, “Checking A/T Fluid”.
OK or NG?
OK
>> GO TO 2.
NG
>> Refill ATF.

2.CHECK STALL TEST
Check the number of revolutions when the engine is stalled. Refer to AT-50, “STALL TEST”.
OK or NG?
OK
>> GO TO 3.
NG
>> GO TO 4.

3.CHECK LINE PRESSURE
Check the line pressure with the engine idling. Refer to AT-52, “LINE PRESSURE TEST”.
OK or NG?
OK
>> GO TO 4.
NG
>> Check line pressure solenoid valve. Refer to AT-97, “DTC P0745 LINE PRESSURE
SOLENOID VALVE”.

4.CHECK PNP SWITCH CIRCUIT
With CONSULT-II
Does “TCM INPUT SIGNALS” in “DATA MONITOR” show damage to PNP switch circuit?
Without CONSULT-II
Does self-diagnosis show damage to PNP switch circuit?
Yes or No?
Yes
>> Check PNP switch circuit. Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION
SWITCH”.
No
>> GO TO 5.

5.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-173

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

Vehicle Does Not Creep Forward In “D”
Position
SYMPTOM
Vehicle does not creep forward when selecting “D” position.

DIAGNOSTIC PROCEDURE

1.CHECK A/T FLUID LEVEL
Check A/T fluid level again. Refer to MA section, “Checking A/T Fluid”.
OK or NG?
OK
>> GO TO 2.
NG
>> Refill ATF.

2.CHECK STALL TEST
Check stall revolution with selector lever in “D” position. Refer to AT-50, “STALL TEST”.
OK or NG?
OK
>> GO TO 3.
NG
>> GO TO 4.

3.CHECK LINE PRESSURE
Check line pressure at idle with selector lever in “R” position. Refer to AT-52, “LINE PRESSURE TEST”.
OK or NG?
OK
>> GO TO 4.
NG
>> Check line pressure solenoid valve. Refer to AT-97, “DTC P0745 LINE PRESSURE
SOLENOID VALVE”.

5.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-174

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

Vehicle Cannot Be Started From D1
SYMPTOM
Vehicle cannot be started from D1 on cruise test — Part 1.

DIAGNOSTIC PROCEDURE

1.CHECK CONFIRM THE PROBLEM
Vehicle does not creep in “R” position.
OK or NG?
OK
>> GO TO 2.
NG
>> Refer to AT-173, “Vehicle Does Not Creep Backward In “R” Position”.

2.CHECK SELF-DIAGNOSIS RESULTS
Execute self-diagnosis.
Do the self-diagnosis results indicate vehicle speed sensor A/T (revolution sensor), line pressure solenoid?
Yes
>> Check the malfunctioning system. Refer to AT-86, “DTC P0720 VEHICLE SPEED SENSOR A/T (REVOLUTION SENSOR)”, AT-97, “DTC P0745 LINE PRESSURE SOLENOID
VALVE”.
No
>> GO TO 2.

3.CHECK ACCELERATOR PEDAL POSITION SENSOR
Check the accelerator pedal position sensor. Refer to EC section, “DTC P0121 ACCELERATOR PEDAL
POSITION (APP) SENSOR”.
OK or NG?
OK
>> GO TO 3.
NG
>> Repair or replace the accelerator pedal position sensor.

4.CHECK LINE PRESSURE
Check the line pressure at the engine stall point. Refer to AT-52, “LINE PRESSURE TEST”.
OK or NG?
OK
>> GO TO 5.
NG
>> Replace the transmission assembly. Refer to AT-15, Precautions for A/T Assembly
Replacement”.

5.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-175

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Shift: D1 → D2 Or Does Not
Kick down: D4 → D2
SYMPTOM
The vehicle does not shift up from the D1 to D2 at the specified speed, or it does not kick down from
the D4 to D2 even when the accelerator pedal is fully depressed.

DIAGNOSTIC PROCEDURE

1.CHECK CONFIRM THE PROBLEM
Vehicle does not creep forward in “D” position and vehicle cannot be started from D1.
OK or NG?
OK
>> GO TO 2.
NG
>> Refer to AT-174, “Vehicle Does Not Creep Forward In “D” Position”, AT-175, “Vehicle
Cannot Be Started From D1”.

2.CHECK PNP SWITCH CIRCUIT
With CONSULT-II
Does “TCM INPUT SIGNALS” in “DATA MONITOR” show damage to PNP switch circuit?
Without CONSULT-II
Does self-diagnosis show damage to PNP switch circuit?
Yes or No?
Yes
>> Check PNP switch circuit. Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION
SWITCH”.
No
>> GO TO 3.

3.CHECK SELF-DIAGNOSIS RESULTS
Check vehicle speed sensor A/T (revolution sensor) and vehicle speed sensor MTR circuits.
Refer to AT-86, “DTC P0720 VEHICLE SPEED SENSOR A/T (REVOLUTION SENSOR)”, AT-120,
“DTC P1721 VEHICLE SPEED SENSOR MTR”.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace vehicle speed sensor A/T (revolution sensor) or vehicle speed sensor
MTR.

4.CHECK ACCELERATOR PEDAL POSITION SENSOR
Check the accelerator pedal position sensor. Refer to EC section, “DTC P0121 ACCELERATOR PEDAL
POSITION (APP) SENSOR”.
OK or NG?
OK
>> GO TO 5.
NG
>> Repair or replace the accelerator pedal position sensor.

5.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-176

RE5R05A
TROUBLE DIAGNOSES FOR SYMPTOMS
A/T Does Not Shift: D1 → D2 Or Does Not
Kick down: D4 → D2 (Cont’d)

6.CHECK TCM INSPECTION

1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>> 1. Repair or replace damaged parts.
2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

SYMPTOM

A/T Does Not Shift: D2 → D3

A/T does not shift up from the D2 to D3 at the specified speed.

DIAGNOSTIC PROCEDURE

2.CHECK PNP SWITCH CIRCUIT

With CONSULT-II
Does “TCM INPUT SIGNALS” in “DATA MONITOR” show damage to PNP switch circuit?
Without CONSULT-II
Does self-diagnosis show damage to PNP switch circuit?
Yes or No?
Yes
>> Check PNP switch circuit. Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION
SWITCH”.
No
>> GO TO 3.

3.CHECK ACCELERATOR PEDAL POSITION SENSOR
Check the accelerator pedal position sensor. Refer to EC section, “DTC P0121 ACCELERATOR PEDAL
POSITION (APP) SENSOR”.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace the accelerator pedal position sensor.

4.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-177

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Shift: D3 → D4
SYMPTOM
+
+

The vehicle does not shift up from the D3 to D4 at the specified speed.
The vehicle does not shift up from the D3 to D4 unless A/T is warmed up.

DIAGNOSTIC PROCEDURE

2.PNP SWITCH CIRCUIT
With CONSULT-II
Does “TCM INPUT SIGNALS” in “DATA MONITOR” show damage to PNP switch circuit?
Without CONSULT-II
Does self-diagnosis show damage to PNP switch circuit?
Yes or No?
Yes
>> Check PNP switch circuit. Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION
SWITCH”.
No
>> GO TO 3.

3.CHECK ACCELERATOR PEDAL POSITION SENSOR
Check the accelerator pedal position sensor. Refer to EC section, “DTC P0121 ACCELERATOR PEDAL
POSITION (APP) SENSOR”.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace the accelerator pedal position sensor.

4.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-178

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Shift: D4 → D5
SYMPTOM
+
+

The vehicle does not shift up from the D4 to D5 at the specified speed.
The vehicle does not shift up from the D4 to D5 unless A/T is warmed up.

DIAGNOSTIC PROCEDURE

1.CHECK CONFIRM THE PROBLEM
Vehicle does not creep forward In “D” position and vehicle cannot be started from D1.
OK or NG?
OK
>> GO TO 2.
NG
>> Refer to AT-174, “Vehicle Does Not Creep Forward In “D” Position”, AT-175, “Vehicle
Cannot Be Started From D1”.

2.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT-II
After executing a traveling test, confirm that the self-diagnosis results indicate the following defective items:
+ PNP switch
+ A/T fluid temperature sensor
+ Vehicle speed sensor A/T (revolution sensor)
+ Vehicle speed sensor MTR
Without CONSULT-II
Execute the self-diagnosis and confirm that a malfunction is indicated in the results.
Yes or No?
Yes
>> Check the defective system(s). Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION
SWITCH”, AT-86, “DTC P0720 VEHICLE SPEED SENSOR A/T (REVOLUTION
SENSOR)”, AT-110, “DTC P1710 A/T FLUID TEMPERATURE SENSOR CIRCUIT”,
AT-120, “DTC P1721 VEHICLE SPEED SENSOR MTR”.
No
>> GO TO 3.

3.CHECK ACCELERATOR PEDAL POSITION SENSOR
Check the accelerator pedal position sensor. Refer to EC section, “DTC P0121 ACCELERATOR PEDAL
POSITION (APP) SENSOR”.
OK or NG?
OK
>> GO TO 4.
NG
>> Repair or replace the accelerator pedal position sensor.

4.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-179

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Perform Lock-up
SYMPTOM
A/T does not lock-up at the specified speed.

DIAGNOSTIC PROCEDURE

1.CHECK SELF-DIAGNOSIS RESULTS
Execute self-diagnosis results indicate TCC solenoid valve.
Yes or No?
Yes
>> Check the TCC solenoid valve circuit. Refer to AT-94, “DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE”.
No
>> GO TO 2.

3.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-180

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Hold Lock-up Condition
SYMPTOM
A/T lock-up condition cannot be maintained for more than 30 seconds.

DIAGNOSTIC PROCEDURE

1.CHECK SELF-DIAGNOSIS RESULTS
Does self-diagnosis show damage to engine speed signal circuit after cruise test.
Yes or No?
Yes
>> Check the engine speed signal circuit. Refer to AT-120, “DTC P0725 ENGINE SPEED
SIGNAL”.
No
>> GO TO 2.

2.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 3.

3.CHECK TCM INSPECTION
1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG?
OK
>> INSPECTION END
NG
>> 1. Repair or replace damaged parts.
2. Replace the transmission assembly. Refer to AT-15, “Precautions for A/T Assembly
Replacement”.

Lock-up Is Not Released
SYMPTOM
A/T lock-up condition cannot be cancelled even after releasing the accelerator pedal.

DIAGNOSTIC PROCEDURE

1.CHECK SELF-DIAGNOSIS RESULTS
With CONSULT-II
Does “TCM INPUT SIGNALS” in “DATA MONITOR” show damage to closed throttle position and wide open
throttle position switch circuit. Refer to AT-75, “DTC U1000 CAN COMMUNICATION LINE”.
Without CONSULT-II
Execute the self-diagnosis and confirm that a malfunction in the CAN communication is indicated in the
results.
Yes or No?
Yes
>> Check the CAN communication line. Refer to AT-75, “DTC U1000 CAN COMMUNICATION LINE”.
No
>> GO TO 2.

2.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 3.

AT-181

TROUBLE DIAGNOSES FOR SYMPTOMS
Lock-up Is Not Released (Cont’d)

RE5R05A

Engine Speed Does Not Return To Idle
SYMPTOM
When a shift down is performed, the engine speed does not smoothly return to the idling speed.

DIAGNOSTIC PROCEDURE

1.CHECK SELF-DIAGNOSIS RESULTS
Execute self-diagnosis.
Do the self-diagnosis results indicate a malfunction in the manual mode SW?
Yes
>> Check the manual mode switch. Refer to AT-146, “DTC P1815 MANUAL MODE
SWITCH”.
No
>> GO TO 2.

3.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-182

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Shift: D5 → D4
SYMPTOM
The vehicle does not shift down from the D5 to D4.

DIAGNOSTIC PROCEDURE

1.CHECK SELF-DIAGNOSIS
With CONSULT-II
After executing a traveling test, confirm that the self-diagnosis results indicate the following malfunctioning
items:
+ Input clutch solenoid valve
+ Vehicle speed sensor A/T (revolution sensor)
+ Vehicle speed sensor MTR
Without CONSULT-II
Execute the self-diagnosis and confirm that a malfunction is indicated in the results.
Yes or No?
Yes
>> Check the malfunctioning system(s). Refer to AT-86, “DTC P0720 VEHICLE SPEED
SENSOR A/T (REVOLUTION SENSOR)”, AT-120, “DTC P1721 VEHICLE SPEED SENSOR MTR”, AT-131, “DTC P1752 INPUT CLUTCH SOLENOID VALVE”.
No
>> GO TO 2.

2.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 3.

AT-183

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Shift: D4 → D3
SYMPTOM
The vehicle does not shift down from the D4 to D3.

DIAGNOSTIC PROCEDURE

1.CHECK SELF-DIAGNOSIS
With CONSULT-II
After executing a traveling test, confirm that the self-diagnosis results indicate the following malfunctioning
items:
+ High & low reverse clutch solenoid valve
+ Vehicle speed sensor A/T (revolution sensor)
+ Vehicle speed sensor MTR
Without CONSULT-II
Execute the self-diagnosis and confirm that a malfunction is indicated in the results.
Yes or No?
Yes
>> Check the defective system(s). Refer to AT-86, “DTC P0720 VEHICLE SPEED SENSOR
A/T (REVOLUTION SENSOR)”, AT-120, “DTC P1721 VEHICLE SPEED SENSOR MTR”,
AT-140, “DTC P1767 HIGH AND LOW REVERSE CLUTCH SOLENOID VALVE”.
No
>> GO TO 2.

2.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 3.

AT-184

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Shift: D3 → D2
SYMPTOM
The vehicle does not shift down from the D3 to D2.

DIAGNOSTIC PROCEDURE

1.CHECK SELF-DIAGNOSIS
With CONSULT-II
After executing a traveling test, confirm that the self-diagnosis results indicate the following malfunctioning
items:
+ Direct clutch solenoid valve
+ Vehicle speed sensor A/T (revolution sensor)
+ Vehicle speed sensor MTR
Without CONSULT-II
Execute the self-diagnosis and confirm that a malfunction is indicated in the results.
Yes or No?
Yes
>> Check the malfunctioning system(s). Refer to AT-86, “DTC P0720 VEHICLE SPEED
SENSOR A/T (REVOLUTION SENSOR)”, AT-120, “DTC P1721 VEHICLE SPEED SENSOR MTR”, AT-140, “DTC P1762 DIRECT CLUTCH SOLENOID VALVE”.
No
>> GO TO 2.

2.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 3.

AT-185

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

A/T Does Not Shift: D2 → D1
SYMPTOM
The vehicle does not shift down from the D2 to D1.

DIAGNOSTIC PROCEDURE

1.PNP SWITCH CIRCUIT
With CONSULT-II
Does “TCM INPUT SIGNALS” in “DATA MONITOR” show damage to PNP switch circuit?
Without CONSULT-II
Does self-diagnosis show damage to PNP switch circuit?
Yes or No?
Yes
>> Check PNP switch circuit. Refer to AT-82, “DTC P0705 PARK/NEUTRAL POSITION
SWITCH”.
No
>> GO TO 3.

2.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 3.

AT-186

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

Vehicle Does Not Decelerate By Engine
Brake
SYMPTOM
No engine brake is applied when the gear is shifted from the D2 to D1.

DIAGNOSTIC PROCEDURE

2.CHECK SYMPTOM
Check again.
OK or NG?
OK
>> INSPECTION END
NG
>> GO TO 3.

Component Inspection
BACK-UP LAMP RELAY
Check continuity between BACK-UP LAMP relay harness connector terminals. Refer to AT-166, “Wiring
Diagram — AT — NONDTC”.
Item

Ignition switch

Shift position

OFF

—

Connector No.

BACK-UP LAMP relay

Terminal No.

Continuity

1-2

Yes

3-5

E149
“R” position
ON

Yes
3-5

Except “R” position

AT-187

A/T SHIFT LOCK SYSTEM

RE5R05A

Description
+ The mechanical key interlock mechanism also operates as a
shift lock:
With the key switch turned to “ON”, the selector lever cannot
be shifted from “P” (parking) to any other position unless the
brake pedal is depressed.
With the key removed, the selector lever cannot be shifted
from “P” to any other position.
The key cannot be removed unless the selector lever is
placed in “P”.
+ The shift lock and key interlock mechanisms are controlled
by the ON-OFF operation of the shift lock solenoid and by the
operation of the rotator and slider located inside the key
cylinder, respectively.

SAT638K

AT-188

A/T SHIFT LOCK SYSTEM

RE5R05A

Wiring Diagram — SHIFT —

TAT117M

AT-189

RE5R05A

A/T SHIFT LOCK SYSTEM
Diagnostic Procedure

SAT915J

SYMPTOM 1:
+ Selector lever cannot be moved from “P” position with
key in “ON” position and brake pedal applied.
+ Selector lever can be moved from “P” position with key
in “ON” position and brake pedal released.
+ Selector lever can be moved from “P” position when key
is removed from key cylinder.
SYMPTOM 2:
Ignition key cannot be removed when selector lever is set to
“P” position. It can be removed when selector lever is set to
any position except “P”.
Check key interlock cable for damage.

NG
c

OK
.

Check selector lever position for damage.

NG
c

SAT639K

CHECK POWER SOURCE.
1. Turn ignition switch to “OFF” position.
(Do not start engine.)
2. Check voltage between stop lamp
switch harness terminal V
1 and
ground.
Voltage: Battery voltage

NG
c

Repair key interlock cable.
Refer to “Key Interlock
Cable”, AT-194.

Check selector lever.
Refer to “Control Linkage
Adjustment”.

Check the following items:
1. Harness for short or
open between battery
and stop lamp switch
harness terminal V
1
2. 10A fuse

OK
.

CHECK INPUT SIGNAL
(STOP LAMP SWITCH).
Turn ignition switch to “OFF” position.
(Do not start engine.)
+ Check voltage between shift lock relay
harness terminal V
2 and ground.
Brake pedal

Voltage

Released

Depressed

Battery voltage

OK
.

A
V

AT-190

NG
c

Check the following items:
1. Harness for short or
open between shift lock
relay harness connector
2 and stop lamp
V
switch harness connector V
2
2. Stop lamp switch
(Refer to “Component
Check”, AT-193.)

RE5R05A

A/T SHIFT LOCK SYSTEM
Diagnostic Procedure (Cont’d)
A
V

CHECK POWER SOURCE.
1. Turn ignition switch to “ON” position.
(Do not start engine.)
2. Check voltage between shift lock relay
harness terminal V
4 and ground.
Voltage: Battery voltage
SAT640K

CHECK INPUT SIGNAL-1
(SHIFT LOCK RELAY).
Turn ignition switch to “ON” position.
(Do not start engine.)
+ Check voltage between A/T device harness terminal V
4 and ground.
SAT641K

Brake pedal

Voltage

Released

Battery voltage

Depressed

NG
c

Check the following items:
1. Harness for short or
open between battery
and shift lock relay harness terminal V
4
2. 7.5A fuse
3. Ignition switch (Refer to
EL section.)

Check the following items:
1. Harness for short or
open between A/T
device harness connector V
4 and shift lock
relay harness connector
3
V

2. Shift lock relay
(Refer to EL section.)

OK
.

CHECK INPUT SIGNAL-2
(SHIFT LOCK RELAY).
Turn ignition switch to “OFF” position.
+ Check voltage between A/T device harness terminal V
5 and ground.
SAT642K

Brake pedal

Voltage

Released

Depressed

Battery voltage

NG
c

Check the following items:
1. Harness for short or
open between A/T
device harness connector V
5 and shift lock
relay harness connector
1
V

2. Shift lock relay
(Refer to EL section.)
3. Diode-1

OK
.

SAT643K

CHECK INPUT SIGNAL
(DIODE-2).
Turn ignition switch to “OFF” position.
(Do not start engine.)
+ Check continuity between A/T device
harness terminals V
3 and V
5 .
OK
.

B
V

AT-191

NG
c

Check the following item:
1. Diode-2

A/T SHIFT LOCK SYSTEM
Diagnostic Procedure (Cont’d)

RE5R05A

B
V

CHECK GROUND CIRCUIT.
1. Turn ignition switch to “OFF” position.
2. Disconnect A/T device harness connector.
3. Check continuity between A/T device
harness terminal V
6 and ground.
SAT644K

NG
c

Repair harness or connector.

Replace park position
switch.

Replace shift lock solenoid.

OK
.

CHECK PARK POSITION SWITCH.
(Refer to “Component Check”, AT-193.)

OK
.

CHECK SHIFT LOCK SOLENOID.
(Refer to “Component Check”, AT-193.)

OK
.

Reconnect shift lock harness connector.

Turn ignition switch from “OFF” to “ON”
position. (Do not start engine.)

Recheck shift lock operation.
OK
.

INSPECTION END

AT-192

NG
c

1. Perform A/T device
input/output signal
inspection test.
2. If NG, recheck harness
connector connection.

A/T SHIFT LOCK SYSTEM

RE5R05A

Component Check
SHIFT LOCK SOLENOID
+ Check operation by applying battery voltage between A/T
3 and V
4 .
device harness connector terminals V

SAT645K

PARK POSITION SWITCH
+ Check continuity between A/T device harness connector ter5 and V
6 .
minals V
Condition

Continuity

When selector lever is set in “P” position and selector lever button is released

Yes

Except above

SAT646K

STOP LAMP SWITCH
+ Check continuity between stop lamp switch harness connector terminals V
1 and V
2 .
Condition

SAT925J

Continuity

When brake pedal is released

When brake pedal is depressed

Yes

Check stop lamp switch after adjusting brake pedal — refer
to BR section.

AT-193

A/T SHIFT LOCK SYSTEM

RE5R05A

Key Interlock Cable

SAT650K

REMOVAL
Unlock slider from adjuster holder and remove rod from cable.

SAT651K

AT-194

A/T SHIFT LOCK SYSTEM
Key Interlock Cable (Cont’d)

RE5R05A

INSTALLATION
1. Set key interlock cable to steering lock assembly and install
lock plate.
2. Clamp cable to steering column and fix to control cable with
band.
3. Set selector lever to P position.

SAT920J

4. Insert interlock rod into adjuster holder.
5. Install casing cap to bracket.
6. Move slider in order to fix adjuster holder to interlock rod.

SAT652K

AT-195

ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
Control Valve Assembly

PFP:31020
ACS004LN

REMOVAL
1.
2.
3.
4.

Disconnect the negative battery terminal
Disconnect heated oxygen sensor 2 harness connector.
Drain ATF through drain plug.
Remove oil pan and oil pan gasket.

SCIA2308E

Disconnect terminal cord assembly connectors.
CAUTION:
Be careful not to damage connector.

SCIA3412E

Disconnect fluid temperature sensor 2 connector.
CAUTION:
Be careful not to damage connector.

SCIA2581E

Remove terminal cord assembly connectors from bracket.
CAUTION:
Be careful not to damage connector.

SCIA2584E

AT-2

ON-VEHICLE SERVICE
8.

Disconnect revolution sensor connector.
CAUTION:
Be careful not to damage connector.

AT
SCIA2313E

Straighten terminal clips to free terminal cord assembly and revolution sensor harness then remove terminal clips.
CAUTION:
Hang down terminal cord assembly and revolution sensor
harness toward outside so as not to disturb removal of control valve assembly.

G
SCIA2314E

10. Remove bolts A, B and C from control valve assembly.
Bolt symbol

Length mm (in)

Number of bolts

42 (1.65)

55 (2.17)

40 (1.57)

SCIA2312E

11. Remove control valve assembly from transmission case.
CAUTION:
When removing, be careful with the manual valve notch and
manual plate height. Remove it vertically.

SCIA2315E

12. Remove fluid temperature sensor 2 with bracket from control
valve assembly.

SCIA2582E

AT-3

ON-VEHICLE SERVICE
13. Remove bracket from fluid temperature sensor 2.

SCIA2583E

INSTALLATION
1.

Install fluid temperature sensor 2 in bracket.

SCIA2813E

Install fluid temperature sensor 2 in control valve assembly.
(With bracket.)
: 6.9 — 8.8 N·m (0.71 — 0.89 kg-m, 61 — 77 in-lb)

SCIA2582E

3.
a.

Install control valve assembly.
Install control valve assembly in transmission case.

SCIA2315E

CAUTION:
Hang down terminal cord assembly and revolution sensor harness toward outside so as not to
disturb installation of control valve assembly.
● Make sure that turbine revolution sensor securely installs turbine revolution sensor hole.
●

AT-4

ON-VEHICLE SERVICE
●

Assemble it so that manual valve cutout is engaged with
manual plate projection.

AT
SCIA2479E

Install bolts A, B and C in control valve assembly.
Bolt symbol

Length mm (in)

Number of bolts

42 (1.65)

55 (2.17)

40 (1.57)

G
SCIA2312E

Tighten bolt 1, 2 and 3 temporarily to prevent dislocation. After
that tighten them in order (1 → 2 → 3), and then tighten other
bolts.

: 6.9 — 8.8 N·m (0.71 — 0.89 kg-m, 61 — 77 in-lb)

SCIA3170E

Install terminal cord assembly connectors in bracket.
L

SCIA2584E

AT-5

ON-VEHICLE SERVICE
5.

Connect terminal cord assembly connectors.

SCIA3412E

Connect fluid temperature sensor 2 connector.

SCIA2581E

Connect revolution sensor connector.

SCIA2313E

Securely fasten terminal harness with terminal clips.

SCIA2314E

9.
a.

Install oil pan in transmission case.
Install oil pan gasket in oil pan.
CAUTION:
● Do not reuse oil pan gasket.
● Install it in the direction to align hole positions.

AT-6

ON-VEHICLE SERVICE
b.

Install oil pan (with oil pan gasket) in transmission case.
CAUTION:
● Install it so that drain plug comes to the position as
shown in the figure.
● Be careful not to pinch harnesses.

AT
SCIA2308E

Tighten oil pan mounting bolts to the specified torque in numerical order shown in the figure after temporarily tightening them.
CAUTION:
Do not reuse oil pan mounting bolts.

: 6.9 — 8.8 N·m (0.71 — 0.89 kg-m, 61 — 77 in-lb)
F

10. Install drain plug in oil pan.
CAUTION:
Do not reuse drain plug gasket.

: 29 — 39 N·m (3.0 — 4.0 kg-m, 22 — 29 ft-lb)
11. Connect heated oxygen sensor 2 harness connector.
12. Connect the negative battery terminal

SCIA2492E

AT-7

ON-VEHICLE SERVICE

RE5R05A

Control Linkage Adjustment

SAT262JA

Move selector lever from “P” position to “D” position. You should
be able to feel the detents in each position.
If the detents cannot be felt or the pointer indicating the position
is improperly aligned, the linkage needs adjustment.
1. Place selector lever in “P” position.
2. Loosen lock nut.
3. Place manual shaft in “P” position.
4. Tighten lock nut to the specified torque.
5. Move selector lever from “P” position to “D” position. Make
sure that selector lever can move smoothly.

AT-196

A/T FLUID COOLER SYSTEM

RE5R05A

A/T Fluid Cooler

SAT647K

REMOVAL AND INSTALLATION
1.
2.
3.
4.
5.
6.
7.
+
+

Remove front radiator grill. Refer to BT section.
Disconnect fluid hoses from A/T fluid cooler unit.
Remove A/T fluid cooler unit.
Remove clips securing fluid hose (A/T fluid cooler unit to
radiator) and loosen hose clamps, then remove the fluid
hose.
Loosen clamps securing fluid hose (A/T assembly to A/T fluid
cooler unit), then remove the fluid hose.
Remove bolts securing A/T fluid cooler tube bracket.
Remove fluid hose with bracket.
Reverse the removal procedure to install the A/T fluid cooler
unit. Refer to the component drawing and specified tightening torque.
Check A/T fluid level and refill if necessary. Refer to MA
section (“CHASSIS AND BODY MAINTENANCE”).

AT-197

A/T FLUID COOLER SYSTEM

RE5R05A

A/T Fluid Cooler Bypass Valve/For Europe

SAT736K

AT-198

REMOVAL AND INSTALLATION

RE5R05A

Removal

SAT653K

1.
2.
3.
4.
5.
6.
7.

Remove battery negative terminal.
Remove exhaust tube.
Remove fluid charging pipe from A/T assembly.
Remove oil cooler pipe from A/T assembly.
Plug up openings such as the fluid charging pipe hole, etc.
Remove propeller shaft. Refer to PD section.
Remove transfer control linkage and transfer harness connectors from transfer. Refer to TF section.
8. Remove A/T control linkage from A/T assembly.
9. Disconnect A/T solenoid valve (A/T unit assembly) harness
connectors.
10. Remove starter motor. Refer to EL section.
11. Remove bolts securing torque converter to drive plate.
+ Remove the bolts by turning crankshaft.

12. Support A/T and transfer assembly with a jack.
13. Remove engine rear mounting member from body and A/T
assembly. Refer to EM section.
14. Remove bolts securing A/T assembly to engine.
+ Secure torque converter to prevent it from dropping.
+ Secure A/T assembly to a jack.
15. Lower A/T assembly with transfer.

SAT801C

AT-199

REMOVAL AND INSTALLATION

RE5R05A

Installation
+ Drive plate runout
Maximum allowable runout:
Refer to EM section, “DRIVE PLATE RUNOUT”.
If this runout is out of specification, replace drive plate with
ring gear.

SAT977H

+ When connecting torque converter to transmission, measure
distance “A” to be certain that they are correctly assembled.
Distance “A”:
25.0 mm (0.984 in) or more
+ Install converter to drive plate.
+ After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that transmission rotates freely without binding.

SAT017B

+ Tighten bolts securing transmission.

SAT648K

Bolt No.

Tightening torqueNzm (kg-m, ft-lb)

Bolt length “!”mm (in)

1
V
2
V
3
V
4
V

83 — 113 (8.5 — 11.5, 62 — 83)

62 (2.44)

29 — 39 (3.0 — 3.9, 22 — 28)

63 (2.48)

29 — 39 (3.0 — 3.9, 22 — 28)

43 (1.69)

29 — 39 (3.0 — 3.9, 22 — 28)

50 (1.97)

Reinstall any part removed.
Check fluid level in transmission.
Check fluid leakage.
Move selector lever through all positions to be sure that
transmission operates correctly.
With parking brake applied, rotate engine at idling. Move
selector lever through “N” to “D” and to “R” positions. A slight
shock should be felt by hand gripping selector each time
transmission is shifted.
+ Perform road test. Refer to “ROAD TEST”, AT-53.
+ When replacing the A/T assembly, erase EFP ROM in TCM.
Refer to AT-15, “Precautions for A/T Assembly Replacement”.
+
+
+
+

AT-200

RE5R05A

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Engine

TB48DE

Automatic transmission model

RE5R05A

Destination

Except for Europe

For Europe

90X07

90X21

Transmission model code number
Stall torque ratio

2.0 : 1
1st

3.540

2nd

2.264

3rd

1.471

4th

1.000

5th

0.834

Reverse

2.370

Transmission gear ratio

Recommended fluid

Nissan Matic Fluid J*1

Fluid capacity

10.4 — 10.7 liter (9-1/8 — 9-3/8 Imp qt)

CAUTION:
+ Use only Nissan Genuine ATF Matic Fluid J. Do not mix with other fluid.
+ Using automatic transmission fluid other than Nissan Genuine ATF Matic Fluid J will deteriorate in driveability and automatic transmission durability, and may damage the automatic transmission, which is not covered by the warranty.
*1: Refer to MA section, “Fluids and Lubricants”.

Vehicle Speed When Shifting Gears
Vehicle Speed km/h (MPH)

Throttle position

D 1 → D2

D 2 → D3

D3 → D 4

D4 → D 5

D5 → D 4

D4 → D 3

D3 → D 2

D2 → D 1

Full throttle

52 — 56
(32 — 35)

81 — 89
(50 — 55)

126 — 136
(78 — 85)

188 — 198
(117 — 123)

184 — 194
(114 — 121)

116 — 126
(72 — 78)

70 — 78
(43 — 48)

36 — 40
(22 — 25)

Half throttle

32 — 36
(20 — 22)

62 — 68
(39 — 42)

104 — 112
(65 — 70)

126 — 134
(78 — 83)

100 — 108
(62 — 67)

61 — 69
(38 — 43)

37 — 43
(23 — 27)

10 — 14
(6 — 9)

+At half throttle, the accelerator opening is 4/8 of the full opening.

Vehicle Speed When Performing and
Releasing Lock-up
Vehicle speed km/h (MPH)
Throttle position
Closed throttle
Half throttle

Lock-up “ON”

Lock-up “OFF”

64 — 72 (39 — 45)

61 — 69 (38 — 43)

164 — 172 (102 — 107)

130 — 138 (81 — 86)

+At closed throttle, the accelerator opening is less than 1/8.
+ At half throttle, the accelerator opening is 4/8 of the full opening.

Stall Revolution
Stall revolution

1,900 — 2,200 rpm

Line Pressure
Line Pressure kpa (bar, kg/cm2, psi)
Engine speed (rpm)
Idling Revolution
Stall Revolution

“R” position

“D”, “M” positions

392 — 441 (3.9 — 4.4, 4.0 — 4.5, 57 — 64)

373 — 422 (3.7 — 4.2, 3.8 — 4.3, 54 — 61)

1,310 — 1,500 (13.1 — 15.0, 13.4 — 15.3, 191 — 218)

AT-201

RE5R05A

SERVICE DATA AND SPECIFICATIONS (SDS)
Solenoid Valves
Name

Resistance (Approx.) (Ω)

Terminal No.

Line pressure solenoid valve

Torque converter clutch solenoid valve

Input clutch solenoid valve

6
3-9

High & low reverse clutch solenoid valve

Front brake solenoid valve

Direct clutch solenoid valve

Low coast brake solenoid valve

20 — 40

A/T Fluid Temperature Sensor
Name

A/T fluid temperature sensor-1

A/T fluid temperature sensor-2

Condition

CONSULT-II “DATA MONITOR”
(Approx.) (V)

Resistance (Approx.) (kΩ)

0°C (32°F)

2.2

20°C (68°F)

1.8

0.6

80°C (176°F)

0.6

0.9

0°C (32°F)

2.2

20°C (68°F)

1.7

80°C (176°F)

0.45

0.5

Turbine Revolution Sensor
Name

Condition

Turbine revolution
sensor-1

When moving at 50 km/h (31 MPH) in 4th gear with the closed throttle position signal “OFF”, use the
CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle diagnosis connector.

Turbine revolution
sensor-2

When running at 20 km/h (12 MPH) in 1st gear with the closed throttle position signal “OFF”, use the
CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle diagnosis connector.

Data (Approx.)

1.1 (kHz)

Revolution Sensor
Name
Revolution sensor

Condition
When moving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle diagnosis connector.

AT-202

Data (Approx.)
149 (Hz)

BRAKE SYSTEM
SECTION

MODIFICATION NOTICE:
+
+
+
+

Front disc brake and rear disc brake have been changed.
Parking brake has been changed.
Wiring Diagrams have been changed.
Service data and specification (SDS) have been changed.

CONTENTS
FRONT DISC BRAKE …………………………………………… 2
REAR DISC BRAKE……………………………………………… 3
PARKING BRAKE CONTROL ……………………………….. 4
TROUBLE DIAGNOSES ……………………………………….. 5

Schematic ………………………………………………………… 5
Wiring Diagram — ABS -……………………………………… 6
SERVICE DATA AND SPECIFICATIONS (SDS) ……. 11
General Specifications……………………………………… 11

FRONT DISC BRAKE

SBR235F

1
V
2
V
3
V
4
V
5
V
6
V

Main pin
Pin boot
Shim cover
Inner shim
Inner pad
Torque member fixing bolt

7
V
8
V
9
V
10
V
11
V
12
V

Washer
Torque member
Outer pad
Outer shim
Pad retainer
Connecting bolt

BR-2

13
V
14
V
15
V
16
V
17
V
18
V

Copper washer
Main pin bolt
Cylinder body
Piston seal
Piston
Piston boot

REAR DISC BRAKE

SBR236F

1
V
2
V
3
V
4
V
5
V
6
V

Main pin
Pin boot
Shim cover
Inner shim
Inner pad
Torque member fixing bolt

7
V
8
V
9
V
10
V
11
V
12
V

Washer
Torque member
Outer pad
Outer shim
Pad retainer
Connecting bolt

BR-3

13
V
14
V
15
V
16
V
17
V
18
V

Copper washer
Main pin bolt
Cylinder body
Piston seal
Piston
Piston boot

PARKING BRAKE CONTROL

SBR240F

SBR241F

BR-4

TROUBLE DIAGNOSES
Schematic

TBR041M

BR-5

TROUBLE DIAGNOSES
Wiring Diagram — ABS —

TBR042M

BR-6

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR043M

BR-7

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR044M

BR-8

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR045M

BR-9

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR046M

BR-10

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Body

Wagon/Hardtop
TB48 engine

Except TB48 engine

Applied model
Standard

Standard

Option*

Front brake
Type
Cylinder bore diameter
mm (in)

CL41VA disc brake

CL36VE disc brake

51.1 (2.012) x 2

48.1 (1.894) x 2

Pad dimension
Length x width x thick145 x 56.5 x 10 (5.79 x 2.224 x 0.39)
ness
mm (in)
Rotor outer diameter x
thickness
mm (in)

147 x 56.5 x 12 (5.79 x 2.224 x 0.47)

316 x 34 (12.44 x 1.34)

306 x 32 (12.05 x 1.26)

Rear brake
Type

CL20VA disc brake

CL18VF disc brake

LT30 drum brake

Cylinder bore diameter
mm (in)

51.1 (2.012)

48.1 (1.894)

25.4 (1.00)

Lining or pad dimension
Length x width x thickness
mm (in)

111 x 34 x 11
(4.37 x 1.34 x 0.43)

111 x 41.8 x 10
(4.37 x 1.646 x 0.39)

296 x 50 x 6.1
(11.65 x 1.97 x 0.240)

Drum inner diameter
mm (in)

—

295 (11.61)

Rotor outer diameter x
thickness
mm (in)

330 x 18 (12.99 x 0.71)

316 x 18 (12.44 x 0.71)

—

Brake booster
Model

235T

Diaphragm diameter
mm (in)

Primary: 252 (9.92)
Secondary: 230 (9.06)

Master cylinder bore diameter
mm (in)

26.9 (17/16)

Control valve
Type
Split point x reducing
ratio
kPa (bar, kg/cm2, psi)

LSV
(Variable) x 0.3

(Variable) x 0.3

Recommended brake fluid

DOT 3 or DOT 4

*: When ABS, diff. lock or rear disc brake is fitted as an option.

BR-11

(Variable) x 0.15

CLUTCH
SECTION

MODIFICATION NOTICE:
+

The TB48DE engine model has been added.

CONTENTS
SERVICE DATA AND SPECIFICATIONS (SDS) ……… 2
General Specifications……………………………………….. 2

Inspection and Adjustment …………………………………. 2

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
CLUTCH DISC

CLUTCH COVER
TB48DE

Applied model

TB48DE

300

Applied model

300

Wagon
Facing size
(Outer dia. x inner dia. x thickness)
mm (in)

300 x 190 x 3.5
(11.81 x 7.48 x 0.14)

Thickness of disc assembly with load
mm (in)/N (kg, lb)

7.7 — 8.3
(0.30 — 0.33)
/8,336 (850, 1,874)

Wagon
Full load
N (kg, lb)

7,649 — 9,022
(780 — 920, 1,720 — 2,029)

Inspection and Adjustment
CLUTCH PEDAL

CLUTCH COVER
Unit: mm (in)

Unit: mm (in)

TB48DE

Applied model
Wagon
Pedal height “H*”
Pedal free play “A” (at pedal pad)

Applied model

200 — 210
(7.87 — 8.27)

Wagon
Diaphragm spring height “A”

1.0 — 3.0 (0.039 — 0.118)

Uneven limit of diaphragm spring
toe height

*: Measured from surface of melt sheet to pedal pad

CLUTCH DISC
Unit: mm (in)

TB48DE
Applied model

300
Wagon

Wear limit of facing surface to rivet
head

0.3 (0.012)

Runout limit of facing

1.3 (0.051)

Distance of runout check point
(from the hub center)
Maximum backlash of spline
(at outer edge of disc)

300

145 (5.71)
1.2 (0.047)

CL-2

44 — 46 (1.732 — 1.811)
1.0 (0.039)

ENGINE CONTROL SYSTEM
SECTION

MODIFICATION NOTICE:
+

TB48DE engine models have been applied to Europe.

CONTENTS
TB48DE A/T
ENGINE AND EMISSION CONTROL OVERALL……… 7
Circuit Diagram …………………………………………………. 7

TB48DE A/T (WITH EURO-OBD)
INDEX FOR DTC ………………………………………………….. 9
Alphabetical Index …………………………………………….. 9
DTC No. Index………………………………………………… 12
PRECAUTIONS ………………………………………………….. 15
Precautions for Supplemental Restraint System
(SRS) ″AIR BAG″ and ″SEAT BELT
PRE-TENSIONER″ ………………………………………….. 15
On Board Diagnostic (OBD) System of Engine
and A/T ………………………………………………………….. 15
Precaution………………………………………………………. 16
Wiring Diagrams and Trouble Diagnosis…………….. 19
PREPARATION ………………………………………………….. 20
Special Service Tools ………………………………………. 20
Commercial Service Tools………………………………… 20
ENGINE CONTROL…………………………………………….. 22
System Diagram ……………………………………………… 22
Vacuum Hose Drawing…………………………………….. 23
System Chart ………………………………………………….. 24
Multiport Fuel Injection (MFI) System ………………… 24
Electronic Ignition (EI) System ………………………….. 27
Air Conditioning Cut Control……………………………… 28
Fuel Cut Control (at No Load and High Engine
Speed) …………………………………………………………… 28
CAN Communication ……………………………………….. 29
BASIC SERVICE ………………………………………………… 30
Idle Speed and Ignition Timing Check ……………….. 30
Accelerator Pedal Released Position Learning……. 31
Throttle Valve Closed Position Learning …………….. 31

Idle Air Volume Learning ………………………………….. 31
Fuel Pressure Check ……………………………………….. 34
Injector Removal and Installation ………………………. 35
ON BOARD DIAGNOSTIC (OBD) ………………………… 37
Introduction …………………………………………………….. 37
Two Trip Detection Logic………………………………….. 37
Emission-related Diagnostic Information …………….. 38
NATS (Nissan Anti-theft System) ………………………. 50
Malfunction Indicator (MI) …………………………………. 51
OBD System Operation Chart …………………………… 54
TROUBLE DIAGNOSIS ……………………………………. 59
Trouble Diagnosis Introduction………………………….. 59
DTC Inspection Priority Chart……………………………. 64
Fail-safe Chart ………………………………………………… 65
Basic Inspection………………………………………………. 66
Symptom Matrix Chart……………………………………… 71
Engine Control Component Parts Location…………. 74
Circuit Diagram ……………………………………………….. 78
ECM Harness Connector Terminal Layout …………. 80
ECM Terminals and Reference Value………………… 80
CONSULT-II Function………………………………………. 89
Generic Scan Tool (GST) Function………………….. 101
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 103
Major Sensor Reference Graph in Data Monitor
Mode ……………………………………………………………. 106
TROUBLE DIAGNOSIS — SPECIFICATION
VALUE …………………………………………………………….. 108
Description ……………………………………………………. 108
Testing condition……………………………………………. 108
Inspection Procedure……………………………………… 108
Diagnostic Procedure …………………………………….. 109
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT…………………………………………………………. 112

ENGINE CONTROL SYSTEM
Description ……………………………………………………. 112
Diagnostic Procedure …………………………………….. 112
POWER SUPPLY CIRCUIT FOR ECM………………… 113
Wiring Diagram ……………………………………………… 113
Diagnostic Procedure …………………………………….. 116
Component Inspection……………………………………. 120
DTC U1000 CAN COMMUNICATION LINE …………. 121
Description ……………………………………………………. 121
On Board Diagnosis Logic………………………………. 121
DTC Confirmation Procedure ………………………….. 121
Wiring Diagram ……………………………………………… 122
Diagnostic Procedure …………………………………….. 123
DTC P0031, P0032, P0051, P0052 HO2S1
HEATER…………………………………………………………… 124
Description ……………………………………………………. 124
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 124
On Board Diagnosis Logic………………………………. 124
DTC Confirmation Procedure ………………………….. 124
Wiring Diagram ……………………………………………… 126
Diagnostic Procedure …………………………………….. 129
Component Inspection……………………………………. 131
DTC P0037, P0038, P0057, P0058 HO2S2
HEATER…………………………………………………………… 132
Description ……………………………………………………. 132
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 132
On Board Diagnosis Logic………………………………. 132
DTC Confirmation Procedure ………………………….. 132
Wiring Diagram ……………………………………………… 134
Diagnostic Procedure …………………………………….. 137
Component Inspection……………………………………. 139
DTC P0102, P0103 MAF SENSOR……………………… 140
Component Description ………………………………….. 140
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 140
On Board Diagnosis Logic………………………………. 140
DTC Confirmation Procedure ………………………….. 140
Wiring Diagram ……………………………………………… 142
Diagnostic Procedure …………………………………….. 143
Component Inspection……………………………………. 146
DTC P0112, P0113 IAT SENSOR……………………….. 147
Component Description ………………………………….. 147
On Board Diagnosis Logic………………………………. 147
DTC Confirmation Procedure ………………………….. 147
Wiring Diagram ……………………………………………… 149
Diagnostic Procedure …………………………………….. 150
Component Inspection……………………………………. 151
DTC P0117, P0118 ECT SENSOR ……………………… 152
Component Description ………………………………….. 152
On Board Diagnosis Logic………………………………. 152
DTC Confirmation Procedure ………………………….. 153
Wiring Diagram ……………………………………………… 154
Diagnostic Procedure …………………………………….. 155
Component Inspection……………………………………. 156
DTC P0122, P0123 TP SENSOR………………………… 157

Component Description ………………………………….. 157
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 157
On Board Diagnosis Logic………………………………. 157
DTC Confirmation Procedure ………………………….. 158
Wiring Diagram ……………………………………………… 159
Diagnostic Procedure …………………………………….. 160
Component Inspection……………………………………. 162
DTC P0132, P0152 HO2S1 ………………………………… 163
Component Description ………………………………….. 163
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 163
On Board Diagnosis Logic………………………………. 163
DTC Confirmation Procedure ………………………….. 164
Wiring Diagram ……………………………………………… 165
Diagnostic Procedure …………………………………….. 168
Component Inspection……………………………………. 170
DTC P0133, P0153 HO2S1 ………………………………… 172
Component Description ………………………………….. 172
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 172
On Board Diagnosis Logic………………………………. 172
DTC Confirmation Procedure ………………………….. 173
Overall Function Check ………………………………….. 174
Wiring Diagram ……………………………………………… 175
Diagnostic Procedure …………………………………….. 178
Component Inspection……………………………………. 183
DTC P0134, P0154 HO2S1 ………………………………… 185
Component Description ………………………………….. 185
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 185
On Board Diagnosis Logic………………………………. 185
DTC Confirmation Procedure ………………………….. 186
Overall Function Check ………………………………….. 187
Wiring Diagram ……………………………………………… 188
Diagnostic Procedure …………………………………….. 191
Component Inspection……………………………………. 193
DTC P0138, P0158 HO2S2 ………………………………… 195
Component Description ………………………………….. 195
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 195
On Board Diagnosis Logic………………………………. 195
DTC Confirmation Procedure ………………………….. 196
Wiring Diagram ……………………………………………… 197
Diagnostic Procedure …………………………………….. 200
Component Inspection……………………………………. 203
DTC P0139, P0159 HO2S2 ………………………………… 205
Component Description ………………………………….. 205
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 205
On Board Diagnosis Logic………………………………. 205
DTC Confirmation Procedure ………………………….. 206
Overall Function Check ………………………………….. 207
Wiring Diagram ……………………………………………… 209
Diagnostic Procedure …………………………………….. 212
Component Inspection……………………………………. 215

EC-2

ENGINE CONTROL SYSTEM
DTC P0171, P0174 FUEL INJECTION SYSTEM
FUNCTION ……………………………………………………….. 218
On Board Diagnosis Logic………………………………. 218
DTC Confirmation Procedure ………………………….. 218
Wiring Diagram ……………………………………………… 220
Diagnostic Procedure …………………………………….. 222
DTC P0172, P0175 FUEL INJECTION SYSTEM
FUNCTION ……………………………………………………….. 227
On Board Diagnosis Logic………………………………. 227
DTC Confirmation Procedure ………………………….. 227
Wiring Diagram ……………………………………………… 229
Diagnostic Procedure …………………………………….. 231
DTC P0222, P0223 TP SENSOR………………………… 235
Component Description ………………………………….. 235
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 235
On Board Diagnosis Logic………………………………. 235
DTC Confirmation Procedure ………………………….. 235
Wiring Diagram ……………………………………………… 237
Diagnostic Procedure …………………………………….. 238
Component Inspection……………………………………. 240
DTC P0300 — P0306 MULTIPLE CYLINDER
MISFIRE, NO. 1 — 6 CYLINDER MISFIRE ……………. 241
On Board Diagnosis Logic………………………………. 241
DTC Confirmation Procedure ………………………….. 241
Diagnostic Procedure …………………………………….. 242
DTC P0327, P0328, P0332, P0333 KS………………… 247
Component Description ………………………………….. 247
On Board Diagnosis Logic………………………………. 247
DTC Confirmation Procedure ………………………….. 247
Wiring Diagram ……………………………………………… 248
Diagnostic Procedure …………………………………….. 249
Component Inspection……………………………………. 250
DTC P0335 CKP SENSOR (OBD)………………………. 251
Component Description ………………………………….. 251
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 251
On Board Diagnosis Logic………………………………. 251
DTC Confirmation Procedure ………………………….. 251
Wiring Diagram ……………………………………………… 253
Diagnostic Procedure …………………………………….. 254
Component Inspection……………………………………. 256
DTC P0340 CAMSHAFT POSITION……………………. 257
Component Description ………………………………….. 257
ECM Terminals and Reference Value………………. 257
On Board Diagnosis Logic………………………………. 258
DTC Confirmation Procedure ………………………….. 258
Wiring Diagram ……………………………………………… 260
Diagnostic Procedure …………………………………….. 261
Component Inspection……………………………………. 262
DTC P0420, P0430 THREE WAY CATALYST
FUNCTION ……………………………………………………….. 264
On Board Diagnosis Logic………………………………. 264
DTC Confirmation Procedure ………………………….. 264
Overall Function Check ………………………………….. 265
Diagnostic Procedure …………………………………….. 266

DTC P0444, P0445 EVAP CANISTER PURGE
VOLUME CONTROL SOLENOID VALVE ……………. 269
Description ……………………………………………………. 269
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 269
On Board Diagnosis Logic………………………………. 269
DTC Confirmation Procedure ………………………….. 270
Wiring Diagram ……………………………………………… 271
Diagnostic Procedure …………………………………….. 273
Component Inspection……………………………………. 275
DTC P0500 VSS ……………………………………………….. 276
Description ……………………………………………………. 276
On Board Diagnosis Logic………………………………. 276
DTC Confirmation Procedure ………………………….. 276
Overall Function Check ………………………………….. 277
Diagnostic Procedure …………………………………….. 277
DTC P0550 PSP SENSOR…………………………………. 278
Component Description ………………………………….. 278
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 278
On Board Diagnosis Logic………………………………. 278
DTC Confirmation Procedure ………………………….. 278
Wiring Diagram ……………………………………………… 279
Diagnostic Procedure …………………………………….. 280
Component Inspection……………………………………. 282
DTC P0605 ECM ………………………………………………. 283
Component Description ………………………………….. 283
On Board Diagnosis Logic………………………………. 283
DTC Confirmation Procedure ………………………….. 283
Diagnostic Procedure …………………………………….. 285
DTC P0650 MI ………………………………………………….. 286
Component Description ………………………………….. 286
On Board Diagnosis Logic………………………………. 286
DTC Confirmation Procedure ………………………….. 286
Wiring Diagram ……………………………………………… 287
Diagnostic Procedure …………………………………….. 288
DTC P1065 ECM POWER SUPPLY ……………………. 290
Component Description ………………………………….. 290
On Board Diagnosis Logic………………………………. 290
DTC Confirmation Procedure ………………………….. 290
Wiring Diagram ……………………………………………… 291
Diagnostic Procedure …………………………………….. 292
DTC P1111 IVT CONTROL SOLENOID VALVE…… 294
Description ……………………………………………………. 294
Operation ……………………………………………………… 294
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 295
On Board Diagnosis Logic………………………………. 295
DTC Confirmation Procedure ………………………….. 295
Wiring Diagram ……………………………………………… 296
Diagnostic Procedure …………………………………….. 297
Component Inspection……………………………………. 298
DTC P1121 ELECTRIC THROTTLE CONTROL
ACTUATOR ……………………………………………………… 299
Component Description ………………………………….. 299
On Board Diagnosis Logic………………………………. 299

EC-3

ENGINE CONTROL SYSTEM
DTC Confirmation Procedure ………………………….. 299
Diagnostic Procedure …………………………………….. 300
DTC P1122 ELECTRIC THROTTLE CONTROL
FUNCTION ……………………………………………………….. 301
Description ……………………………………………………. 301
On Board Diagnosis Logic………………………………. 301
DTC Confirmation Procedure ………………………….. 301
Wiring Diagram ……………………………………………… 302
Diagnostic Procedure …………………………………….. 303
Component Inspection……………………………………. 308
DTC P1124, P1126 THROTTLE CONTROL
MOTOR RELAY………………………………………………… 309
Component Description ………………………………….. 309
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 309
On Board Diagnosis Logic………………………………. 309
DTC Confirmation Procedure ………………………….. 309
Wiring Diagram ……………………………………………… 311
Diagnostic Procedure …………………………………….. 312
Component Inspection……………………………………. 314
DTC P1128 THROTTLE CONTROL MOTOR……….. 315
Component Description ………………………………….. 315
On Board Diagnosis Logic………………………………. 315
DTC Confirmation Procedure ………………………….. 315
Wiring Diagram ……………………………………………… 316
Diagnostic Procedure …………………………………….. 317
Component Inspection……………………………………. 319
DTC P1143, P1163 HO2S1 ………………………………… 320
Component Description ………………………………….. 320
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 320
On Board Diagnosis Logic………………………………. 320
DTC Confirmation Procedure ………………………….. 321
Overall Function Check ………………………………….. 322
Diagnostic Procedure …………………………………….. 322
Component Inspection……………………………………. 325
DTC P1144, P1164 HO2S1 ………………………………… 327
Component Description ………………………………….. 327
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 327
On Board Diagnosis Logic………………………………. 327
DTC Confirmation Procedure ………………………….. 328
Overall Function Check ………………………………….. 329
Diagnostic Procedure …………………………………….. 329
Component Inspection……………………………………. 332
DTC P1146, P1166 HO2S2 ………………………………… 335
Component Description ………………………………….. 335
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 335
On Board Diagnosis Logic………………………………. 335
DTC Confirmation Procedure ………………………….. 336
Overall Function Check ………………………………….. 337
Wiring Diagram ……………………………………………… 339
Diagnostic Procedure …………………………………….. 342
Component Inspection……………………………………. 345
DTC P1147, P1167 HO2S2 ………………………………… 348

Component Description ………………………………….. 348
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 348
On Board Diagnosis Logic………………………………. 348
DTC Confirmation Procedure ………………………….. 349
Overall Function Check ………………………………….. 350
Wiring Diagram ……………………………………………… 352
Diagnostic Procedure …………………………………….. 355
Component Inspection……………………………………. 358
DTC P1217 ENGINE OVER TEMPERATURE
(OVERHEAT) ……………………………………………………. 361
System Description………………………………………… 361
Operation ……………………………………………………… 361
CONSULT-II Reference Value In Data Monitor
Mode ……………………………………………………………. 361
ECM Terminals and Reference Value………………. 362
On Board Diagnosis Logic………………………………. 362
Overall Function Check ………………………………….. 363
Wiring Diagram ……………………………………………… 364
Diagnostic Procedure …………………………………….. 365
Main 12 Causes of Overheating………………………. 370
Component Inspection……………………………………. 371
DTC P1225 TP SENSOR …………………………………… 372
Component Description ………………………………….. 372
On Board Diagnosis Logic………………………………. 372
DTC Confirmation Procedure ………………………….. 372
Diagnostic Procedure …………………………………….. 373
DTC P1226 TP SENSOR …………………………………… 374
Component Description ………………………………….. 374
On Board Diagnosis Logic………………………………. 374
DTC Confirmation Procedure ………………………….. 374
Diagnostic Procedure …………………………………….. 375
DTC P1229 SENSOR POWER …………………………… 376
On Board Diagnosis Logic………………………………. 376
DTC Confirmation Procedure ………………………….. 376
Wiring Diagram ……………………………………………… 377
Diagnostic Procedure …………………………………….. 378
DTC P1336 CKP SENSOR (OBD)………………………. 381
Component Description ………………………………….. 381
ECM Terminals and Reference Value………………. 381
On Board Diagnosis Logic………………………………. 382
DTC Confirmation Procedure ………………………….. 382
Wiring Diagram ……………………………………………… 383
Diagnostic Procedure …………………………………….. 384
DTC P1706 PNP SWITCH………………………………….. 388
Component Description ………………………………….. 388
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 388
On Board Diagnosis Logic………………………………. 388
DTC Confirmation Procedure ………………………….. 388
Overall Function Check ………………………………….. 389
Wiring Diagram ……………………………………………… 390
Diagnostic Procedure …………………………………….. 392
DTC P1805 BRAKE SWITCH …………………………….. 395
Description ……………………………………………………. 395

EC-4

ENGINE CONTROL SYSTEM
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 395
On Board Diagnosis Logic………………………………. 395
DTC Confirmation Procedure ………………………….. 395
Wiring Diagram ……………………………………………… 396
Diagnostic Procedure …………………………………….. 397
Component Inspection……………………………………. 399
DTC P2122, P2123 APP SENSOR ……………………… 401
Component Description ………………………………….. 401
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 401
On Board Diagnosis Logic………………………………. 401
DTC Confirmation Procedure ………………………….. 402
Wiring Diagram ……………………………………………… 403
Diagnostic Procedure …………………………………….. 405
Component Inspection……………………………………. 407
DTC P2127, P2128 APP SENSOR ……………………… 408
Component Description ………………………………….. 408
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 408
On Board Diagnosis Logic………………………………. 408
DTC Confirmation Procedure ………………………….. 409
Wiring Diagram ……………………………………………… 410
Diagnostic Procedure …………………………………….. 411
Component Inspection……………………………………. 414
DTC P2135 TP SENSOR …………………………………… 415
Component Description ………………………………….. 415
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 415
On Board Diagnosis Logic………………………………. 415
DTC Confirmation Procedure ………………………….. 416
Wiring Diagram ……………………………………………… 417
Diagnostic Procedure …………………………………….. 418
Component Inspection……………………………………. 420
DTC P2138 APP SENSOR…………………………………. 421
Component Description ………………………………….. 421
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 421
On Board Diagnosis Logic………………………………. 421
DTC Confirmation Procedure ………………………….. 422
Wiring Diagram ……………………………………………… 423
Diagnostic Procedure …………………………………….. 425
Component Inspection……………………………………. 427
IGNITION SIGNAL…………………………………………….. 428
Component Description ………………………………….. 428
Wiring Diagram ……………………………………………… 429
Diagnostic Procedure …………………………………….. 435
Component Inspection……………………………………. 441
SNOW MODE SWITCH ………………………………….. 442
Component Description ………………………………….. 442
ECM Terminals and Reference Value………………. 442
Wiring Diagram ……………………………………………… 443
Diagnostic Procedure …………………………………….. 444
VARIABLE INDUCTION AIR CONTROL SYSTEM
(VIAS)………………………………………………………………. 446
Description ……………………………………………………. 446

ECM Terminals and Reference Value………………. 447
Wiring Diagram ……………………………………………… 448
Diagnostic Procedure …………………………………….. 449
START SIGNAL………………………………………………… 450
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 450
ECM Terminals and Reference Value………………. 450
Wiring Diagram ……………………………………………… 451
Diagnostic Procedure …………………………………….. 452
INJECTOR CIRCUIT………………………………………….. 453
Component Description ………………………………….. 453
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 453
Wiring Diagram ……………………………………………… 454
Diagnostic Procedure …………………………………….. 455
Component Inspection……………………………………. 458
FUEL PUMP……………………………………………………… 459
System Description………………………………………… 459
Component Description ………………………………….. 459
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 459
ECM Terminals and Reference Value………………. 460
Wiring Diagram ……………………………………………… 461
Diagnostic Procedure …………………………………….. 462
Component Inspection……………………………………. 464
REFRIGERANT PRESSURE SENSOR ……………….. 465
Component Description ………………………………….. 465
Wiring Diagram ……………………………………………… 466
Diagnostic Procedure …………………………………….. 467
ELECTRICAL LOAD SIGNAL…………………………….. 470
Description ……………………………………………………. 470
CONSULT-II Reference Value in Data Monitor
Mode ……………………………………………………………. 470
Wiring Diagram ……………………………………………… 471
Diagnostic Procedure …………………………………….. 473
DATA LINK CONNECTORS ………………………………. 477
Wiring Diagram ……………………………………………… 477
EVAPORATIVE EMISSION ………………………………… 478
Description ……………………………………………………. 478
Component Inspection……………………………………. 480
POSITIVE CRANKCASE VENTILATION……………… 481
Description ……………………………………………………. 481
Component Inspection……………………………………. 482
SERVICE DATA AND SPECIFICATIONS ……………. 483
Fuel Pressure Regulator…………………………………. 483
Idle Speed and Ignition Timing………………………… 483
Mass Air Flow Sensor ……………………………………. 483
Engine Coolant Temperature Sensor……………….. 483
Heated Oxygen Sensor 1 ……………………………….. 483
Heated Oxygen Sensor 2 ……………………………….. 483
Fuel Pump ……………………………………………………. 483
EVAP Canister Purge Volume Control Solenoid
Valve ……………………………………………………………. 484
Injector …………………………………………………………. 484
Ignition Coil with Power Transistor…………………… 484
Condenser ……………………………………………………. 484

EC-5

ENGINE CONTROL SYSTEM
Throttle Control Motor…………………………………….. 484

ZD30DDTi
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM…………………………………………………………… 485
Circuit Diagram ……………………………………………… 485
TROUBLE DIAGNOSIS FOR POWER SUPPLY…… 486
Main Power Supply and Ground Circuit……………. 486
DTC 0102 MASS AIR FLOW SEN………………………. 487
Wiring Diagram ……………………………………………… 487
DTC 0104 VEHICLE SPEED SEN ………………………. 488
Wiring Diagram ……………………………………………… 488
DTC 0208 OVER HEAT……………………………………… 489
Wiring Diagram ……………………………………………… 489

Diagnostic Procedure …………………………………….. 490
Component Inspection……………………………………. 495
Main 12 Causes of Overheating………………………. 496
DTC 0402 P9zFUEL TEMP SEN …………………………. 497
Wiring Diagram ……………………………………………… 497
DTC 0403 ACCEL POS SENSOR ………………………. 498
Wiring Diagram ……………………………………………… 498
DTC 0902 ECM RLY …………………………………………. 499
Wiring Diagram ……………………………………………… 499
DTC 1003 EGR VOLUME CONT/V……………………… 500
Wiring Diagram ……………………………………………… 500
MI (MIL) & DATA LINK CONNECTORS ……………… 501
Wiring Diagram ……………………………………………… 501

EC-6

ENGINE AND EMISSION CONTROL OVERALL
SYSTEM

TB48DE A/T

Circuit Diagram

TEC241M

EC-7

ENGINE AND EMISSION CONTROL OVERALL
SYSTEM
Circuit Diagram (Cont’d)

TB48DE A/T

TEC372M

EC-8

INDEX FOR DTC

TB48DE A/T (WITH EURO-OBD)

Alphabetical Index
Check if the vehicle is a model with Euro-OBD (E-OBD) system or not by the “Type approval number” on
the identification plate. Refer to GI section.
NOTE:
If DTC U1000 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000. Refer
to EC-121, “DTC U1000 CAN COMMUNICATION LINE”.
x: Applicable —: Not applicable
DTC*1
Items
(CONSULT-II screen terms)

Trip

MI lighting up

2122

EC-401

P2123

2123

EC-401

APP SEN 2/CIRC

P2127

2127

EC-408

APP SEN 2/CIRC

P2128

2128

EC-408

APP SENSOR

P2138

2138

EC-421

BRAKE SW/CIRCUIT

P1805

1805

—

EC-395

CAN COMM CIRCUIT

U1000

1000*5

EC-121

CKP SEN/CIRCUIT

P0335

0335

EC-251

CKP SENSOR (COG)

P1336

1336

EC-381

CMP SEN/CIRC-B1

P0340

0340

EC-257

CTP LEARNING

P1225

1225

—

EC-372

CTP LEARNING

P1226

1226

—

EC-374

CYL 1 MISFIRE

P0301

0301

EC-241

CYL 2 MISFIRE

P0302

0302

EC-241

CYL 3 MISFIRE

P0303

0303

EC-241

CYL 4 MISFIRE

P0304

0304

EC-241

CYL 5 MISFIRE

P0305

0305

EC-241

CYL 6 MISFIRE

P0306

0306

EC-241

ECM

P0605

0605

1 or 2

x or —

EC-283

ECM BACK UP/CIRC

P1065

1065

EC-290

ECT SEN/CIRCUIT

P0117

0117

EC-152

ECT SEN/CIRCUIT

P0118

0118

EC-152

ENG OVER TEMP

P1217

1217

EC-361

ETC ACTR

P1121

1121

1 or 2

EC-299

ETC FUNCTION/CIRC

P1122

1122

EC-301

ETC MOT

P1128

1128

EC-315

ETC MOT PWR

P1124

1124

EC-309

ETC MOT PWR

P1126

1126

EC-309

FUEL SYS-LEAN-B1

P0171

0171

EC-218

FUEL SYS-LEAN-B2

P0174

0174

EC-218

FUEL SYS-RICH-B1

P0172

0172

EC-227

FUEL SYS-RICH-B2

P0175

0175

EC-227

HO2S1 (B1)

P0132

0132

EC-163

HO2S1 (B1)

P0133

0133

EC-172

HO2S1 (B1)

P0134

0134

EC-172

CONSULT-II
GST*2

ECM*3

APP SEN 1/CIRC

P2122

APP SEN 1/CIRC

EC-9

Reference page

TB48DE A/T (WITH EURO-OBD)
INDEX FOR DTC
Alphabetical Index (Cont’d)
DTC*1
Items
(CONSULT-II screen terms)

Trip

MI lighting up

1143

EC-320

P1144

1144

EC-327

P0152

0152

EC-163

HO2S1 (B2)

P0153

0153

EC-172

HO2S1 (B2)

P0154

0154

EC-172

HO2S1 (B2)

P1163

1163

EC-320

HO2S1 (B2)

P1164

1164

EC-327

HO2S1 HTR (B1)

P0031

0031

EC-124

HO2S1 HTR (B1)

P0032

0032

EC-124

HO2S1 HTR (B2)

P0051

0051

EC-124

HO2S1 HTR (B2)

P0052

0052

EC-124

HO2S2 (B1)

P0138

0138

EC-195

HO2S2 (B1)

P0139

0139

EC-205

HO2S2 (B1)

P1146

1146

EC-335

HO2S2 (B1)

P1147

1147

EC-348

HO2S2 (B2)

P0158

0158

EC-195

HO2S2 (B2)

P0159

0159

EC-205

HO2S2 (B2)

P1166

1166

EC-335

HO2S2 (B2)

P1167

1167

EC-348

HO2S2 HTR (B1)

P0037

0037

EC-132

HO2S2 HTR (B1)

P0038

0038

EC-132

HO2S2 HTR (B2)

P0057

0057

EC-132

HO2S2 HTR (B2)

P0058

0058

EC-132

IAT SEN/CIRCUIT

P0112

0112

EC-147

IAT SEN/CIRCUIT

P0113

0113

EC-147

INT/V TIM V/CIR-B1

P1111

1111

EC-294

KNOCK SEN/CIRC-B1

P0327

0327

—

EC-247

KNOCK SEN/CIRC-B1

P0328

0328

—

EC-247

KNOCK SEN/CIRC-B2

P0332

0332

—

EC-247

KNOCK SEN/CIRC-B2

P0333

0333

—

EC-247

L/PRESS SOL/CIRC

P0745

0745

AT section

MAF SEN/CIRCUIT

P0102

0102

EC-140

MAF SEN/CIRCUIT

P0103

0103

EC-140

MIL/CIRC

P0650

0650

—

EC-286

MULTI CYL MISFIRE

P0300

0300

EC-241

NATS MALFUNCTION

P1610 — P1615

1610 — 1615

—

EC-50

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

No DTC

Flashing*4

—

Flashing*4

EC-51

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

CONSULT-II
GST*2

ECM*3

HO2S1 (B1)

P1143

HO2S1 (B1)
HO2S1 (B2)

EC-10

Reference page

—

TB48DE A/T (WITH EURO-OBD)
INDEX FOR DTC
Alphabetical Index (Cont’d)
DTC*1
Items
(CONSULT-II screen terms)

Trip

MI lighting up

1706

EC-388

P0444

0444

EC-269

P0445

0445

EC-269

PW ST P SEN/CIRC

P0550

0550

—

EC-401

SENSOR POWER/CIRC

P1229

1229

EC-376

TCC SOLENOID/CIRC

P0740

0740

AT section

TP SEN 1/CIRC

P0222

0222

EC-235

TP SEN 1/CIRC

P0223

0223

EC-235

TP SEN 2/CIRC

P0122

0122

EC-157

TP SEN 2/CIRC

P0123

0123

EC-157

TP SENSOR

P2135

2135

EC-415

TW CATALYST SYS-B1

P0420

0420

EC-264

TW CATALYST SYS-B2

P0430

0430

EC-264

VEH SPEED SEN/CIRC

P0500

0500

EC-276

CONSULT-II
GST*2

ECM*3

P-N POS SW/CIRCUIT

P1706

PURG VOLUME CONT/V
PURG VOLUME CONT/V

Reference page

*1: 1st trip DTC No. is the same as DTC No.
*2: These numbers are prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN.
*4: When engine is running.
*5: The trouble shooting for these DTCs needs CONSULT-II.
NOTE:
Regarding Y61 models with TB48DE engine, “B1” indicates bank 1 (cylinders number 1, 2 and 3), “B2” indicates bank 2
(cylinders number 4, 5 and 6).

EC-11

INDEX FOR DTC

TB48DE A/T (WITH EURO-OBD)

DTC No. Index
Check if the vehicle is a model with Euro-OBD (E-OBD) system or not by the “Type approval number” on
the identification plate. Refer to GI section.
NOTE:
If DTC U1000 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000. Refer
to EC-121, “DTC U1000 CAN COMMUNICATION LINE”.
x: Applicable —: Not applicable
DTC*1
Items
(CONSULT-II screen terms)

Trip

MI lighting up

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

—

Flashing*4

EC-51

CAN COMM CIRCUIT

EC-121

0000

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

—

P0031

0031

HO2S1 HTR (B1)

EC-124

P0032

0032

HO2S1 HTR (B1)

EC-124

P0037

0037

HO2S2 HTR (B1)

EC-132

P0038

0038

HO2S2 HTR (B1)

EC-132

P0051

0051

HO2S1 HTR (B2)

EC-124

P0052

0052

HO2S1 HTR (B2)

EC-124

P0057

0057

HO2S2 HTR (B2)

EC-132

P0058

0058

HO2S2 HTR (B2)

EC-132

P0102

0102

MAF SEN/CIRCUIT

EC-140

P0103

0103

MAF SEN/CIRCUIT

EC-140

P0112

0112

IAT SEN/CIRCUIT

EC-147

P0113

0113

IAT SEN/CIRCUIT

EC-147

P0117

0117

ECT SEN/CIRCUIT

EC-152

P0118

0118

ECT SEN/CIRCUIT

EC-152

P0122

0122

TP SEN 2/CIRC

EC-157

P0123

0123

TP SEN 2/CIRC

EC-157

P0132

0132

HO2S1 (B1)

EC-163

P0133

0133

HO2S1 (B1)

EC-172

P0134

0134

HO2S1 (B1)

EC-172

P0138

0138

HO2S2 (B1)

EC-195

P0139

0139

HO2S2 (B1)

EC-205

P0152

0152

HO2S1 (B2)

EC-163

P0153

0153

HO2S1 (B2)

EC-172

P0154

0154

HO2S1 (B2)

EC-172

P0158

0158

HO2S2 (B2)

EC-195

P0159

0159

HO2S2 (B2)

EC-205

P0171

0171

FUEL SYS-LEAN-B1

EC-218

P0172

0172

FUEL SYS-RICH-B1

EC-227

P0174

0174

FUEL SYS-LEAN-B2

EC-218

CONSULT-II
GST*2

ECM*3

No DTC

Flashing*4

U1000

1000*5

P0000

EC-12

Reference page

TB48DE A/T (WITH EURO-OBD)
INDEX FOR DTC
DTC No. Index (Cont’d)
DTC*1
Items
(CONSULT-II screen terms)

Trip

MI lighting up

FUEL SYS-RICH-B2

EC-227

0222

TP SEN 1/CIRC

EC-235

0223

TP SEN 1/CIRC

EC-235

P0300

0300

MULTI CYL MISFIRE

EC-241

P0301

0301

CYL 1 MISFIRE

EC-241

P0302

0302

CYL 2 MISFIRE

EC-241

P0303

0303

CYL 3 MISFIRE

EC-241

P0304

0304

CYL 4 MISFIRE

EC-241

P0305

0305

CYL 5 MISFIRE

EC-241

P0306

0306

CYL 6 MISFIRE

EC-241

P0327

0327

KNOCK SEN/CIRC-B1

—

EC-247

P0328

0328

KNOCK SEN/CIRC-B1

—

EC-247

P0332

0332

KNOCK SEN/CIRC-B2

—

EC-247

P0333

0333

KNOCK SEN/CIRC-B2

—

EC-247

P0335

0335

CKP SEN/CIRCUIT

EC-251

P0340

0340

CMP SEN/CIRC-B1

EC-257

P0420

0420

TW CATALYST SYS-B1

EC-264

P0430

0430

TW CATALYST SYS-B2

EC-264

P0444

0444

PURG VOLUME CONT/V

EC-269

P0445

0445

PURG VOLUME CONT/V

EC-269

P0500

0500

VEH SPEED SEN/CIRC

EC-276

P0550

0550

PW ST P SEN/CIRC

—

EC-278

P0605

0605

ECM

1 or 2

x or —

EC-283

P0650

0650

MIL/CIRC

—

EC-286

P0740

0740

TCC SOLENOID/CIRC

AT section

P0745

0745

L/PRESS SOL/CIRC

AT section

P1065

1065

ECM BACK UP/CIRC

EC-290

P1111

1111

INT/V TIM V/CIR-B1

EC-294

P1121

1121

ETC ACTR

1 or 2

EC-299

P1122

1122

ETC FUNCTION/CIRC

EC-301

P1124

1124

ETC MOT PWR

EC-309

P1126

1126

ETC MOT PWR

EC-309

P1128

1128

ETC MOT

EC-315

P1143

1143

HO2S1 (B1)

EC-320

P1144

1144

HO2S1 (B1)

EC-327

P1146

1146

HO2S2 (B1)

EC-335

P1147

1147

HO2S2 (B1)

EC-348

P1163

1163

HO2S1 (B2)

EC-320

P1164

1164

HO2S1 (B2)

EC-327

P1166

1166

HO2S2 (B2)

EC-335

P1167

1167

HO2S2 (B2)

EC-348

CONSULT-II
GST*2

ECM*3

P0175

0175

P0222
P0223

EC-13

Reference page

TB48DE A/T (WITH EURO-OBD)
INDEX FOR DTC
DTC No. Index (Cont’d)
DTC*1
Items
(CONSULT-II screen terms)

Trip

MI lighting up

ENG OVER TEMP

EC-361

1225

CTP LEARNING

—

EC-372

1226

CTP LEARNING

—

EC-374

P1229

1229

SENSOR POWER/CIRC

EC-376

P1336

1336

CKP SENSOR (COG)

EC-381

P1610 — P1615

1610 — 1615

NATS MALFUNCTION

—

EC-50

P1706

1706

P-N POS SW/CIRCUIT

EC-388

P1805

1805

BRAKE SW/CIRCUIT

—

EC-395

P2122

2122

APP SEN 1/CIRC

EC-401

P2123

2123

APP SEN 1/CIRC

EC-401

P2127

2127

APP SEN 2/CIRC

EC-408

P2128

2128

APP SEN 2/CIRC

EC-408

P2135

2135

TP SENSOR

EC-415

P2138

2138

APP SENSOR

EC-421

CONSULT-II
GST*2

ECM*3

P1217

1217

P1225
P1226

Reference page

*1: 1st trip DTC No. is the same as DTC No.
*2: These numbers are prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN.
*4: When engine is running.
*5: The trouble shooting for these DTCs need CONSULT-II.
NOTE:
Regarding Y61 models with TB48DE engine, “B1” indicates bank 1 (cylinders number 1, 2 and 3), “B2” indicates bank 2
(cylinders number 4, 5 and 6).

EC-14

PRECAUTIONS

TB48DE A/T (WITH EURO-OBD)

Precautions for Supplemental Restraint
System (SRS) “AIR BAG” and “SEAT BELT
PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and
Air Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.

On Board Diagnostic (OBD) System of
Engine and A/T
The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver
of a malfunction causing emission deterioration.
CAUTION:
+ Be sure to turn the ignition switch OFF and disconnect the battery ground cable before any repair
or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will
cause the MI to light up.
+ Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector
will cause the MI to light up due to the open circuit. (Be sure the connector is free from water,
grease, dirt, bent terminals, etc.)
+ Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to EL section.
+ Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
+ Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber
tube may cause the MI to light up due to the malfunction of the fuel injection system, etc.
+ Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.

EC-15

PRECAUTIONS

TB48DE A/T (WITH EURO-OBD)

Precaution

SEF289H

+ Always use a 12 volt battery as power source.
+ Do not attempt to disconnect battery cables while engine
is running.
+ Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect battery ground cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition switch is turned off.
+ Before removing parts, turn ignition switch OFF and
then disconnect battery ground cable.
+ Do not disassemble ECM.
+ If battery cable is disconnected, the memory will return
to the initial ECM values.
The ECM will now start to self-control at its initial values.
Engine operation can vary slightly when the cable is
disconnected. However, this is not an indication of a
malfunction. Do not replace parts because of a slight
variation.

SEF707Y

+ When connecting ECM harness connector, fasten it
securely with levers as far as they will go as shown at
right.

PBIB1162E

PBIB1163E

EC-16

TB48DE A/T (WITH EURO-OBD)
PRECAUTIONS
Precaution (Cont’d)

PBIB0090E

MEF040D

+ When connecting or disconnecting pin connectors into
or from ECM, take care not to damage pin terminals
(bend or break).
Make sure that there are not any bends or breaks on
ECM pin terminal, when connecting pin connectors.
+ Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting
in damage to ICs.
+ Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control
system malfunctions due to receiving external noise,
degraded operation of ICs, etc.
+ Keep engine control system parts and harness dry.

+ Before replacing ECM, perform “ECM Terminals and Reference Value” inspection and make sure ECM functions
properly. Refer to EC-80, “ECM Terminals and Reference
Value”.
+ Handle mass air flow sensor carefully to avoid damage.
+ Do not disassemble mass air flow sensor.
+ Do not clean mass air flow sensor with any type of detergent.
+ Do not disassemble electric throttle control actuator.
+ Even a slight leak in the air intake system can cause
serious incidents.
+ Do not shock or jar the camshaft position sensor, crankshaft position sensor (OBD).

+ After performing each TROUBLE DIAGNOSIS, perform
“DTC Confirmation Procedure” or “Overall Function
Check”.
The DTC should not be displayed in the “DTC Confirmation Procedure” if the repair is completed. The “Overall
Function Check” should be a good result if the repair is
completed.

SAT652J

EC-17

TB48DE A/T (WITH EURO-OBD)
PRECAUTIONS
Precaution (Cont’d)
+ When measuring ECM signals with a circuit tester, connect a break-out box (SST) and Y-cable adapter (SST)
between the ECM and ECM harness connector.
+ When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit
and damage the ECM power transistor.
+ Do not use ECM ground terminals when measuring
input/output voltage. Doing so may result in damage to
the ECM’s transistor. Use a ground other than ECM
terminals, such as the ground.

SEF348N

+ Do not operate fuel pump when there is no fuel in lines.
+ Tighten fuel hose clamps to the specified torque.

SEC686C

+ Do not depress accelerator pedal when starting.
+ Immediately after starting, do not rev up engine unnecessarily.
+ Do not rev up engine just prior to shutdown.

SEF709Y

SEF708Y

+ When installing C.B. ham radio or a mobile phone, be
sure to observe the following as it may adversely affect
electronic control systems depending on installation
location.
— Keep the antenna as far as possible from the electronic
control units.
— Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
— Adjust the antenna and feeder line so that the standingwave radio can be kept smaller.
— Be sure to ground the radio to vehicle body.

EC-18

TB48DE A/T (WITH EURO-OBD)
PRECAUTIONS
Precaution (Cont’d)
+ Regarding Y61 models with TB48DE engine, “B1” indicates bank 1 (cylinders number 1, 2, 3), “B2” indicates
bank 2 (cylinders number 4, 5, 6).

SEC888C

SEC889C

Wiring Diagrams and Trouble Diagnosis
When you read wiring diagrams, refer to the following:
+ “How to Read Wiring Diagrams” in GI section
+ “POWER SUPPLY ROUTING” for power distribution circuit in
EL section
When you perform trouble diagnosis, refer to the following:
+ “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” in GI section
+ “How to Perform Efficient Diagnosis for an Electrical Incident”
in GI section

EC-19

PREPARATION

TB48DE A/T (WITH EURO-OBD)

Special Service Tools
Tool number
Tool name

Description

KV10117100
Heated oxygen sensor
wrench

Loosening or tightening heated oxygen sensors
with 22 mm (0.87 in) hexagon nut

NT379

KV10114400
Heated oxygen sensor
wrench

Loosening or tightening heated oxygen sensors
a: 22 mm (0.87 in)

NT636

Commercial Service Tools
Tool name

Description

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening
pressure

NT653

Socket wrench

Removing and installing engine coolant temperature sensor

NT705

Oxygen sensor thread
cleaner
ie: (J-43897-18)
(J-43897-12)

Reconditioning the exhaust system threads
before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor
AEM488

EC-20

TB48DE A/T (WITH EURO-OBD)
PREPARATION
Commercial Service Tools (Cont’d)
Tool name

Description

Anti-seize lubricant
ie: (PermatexTM 133AR
or equivalent meeting
MIL specification MIL-A907)

Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads.

NT779

EC-21

ENGINE CONTROL
SYSTEM

TB48DE A/T (WITH EURO-OBD)

System Diagram

SEC745D

EC-22

ENGINE CONTROL
SYSTEM

TB48DE A/T (WITH EURO-OBD)

Vacuum Hose Drawing

Refer to EC-22, “System Diagram” for Vacuum Control System.
SEC665D

EC-23

ENGINE CONTROL
SYSTEM

TB48DE A/T (WITH EURO-OBD)

System Chart
Input (Sensor)
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+

Camshaft position sensor
Crankshaft position sensor (OBD)
Mass air flow sensor
Engine coolant temperature sensor
Heated oxygen sensor 1
Throttle position sensor
Accelerator pedal position sensor
Park/neutral position (PNP) switch
Intake air temperature sensor
Power steering pressure sensor
Ignition switch
Stop lamp switch
Battery voltage
Knock sensor
Refrigerant pressure sensor
Heated oxygen sensor 2*1
TCM (Transmission control module)*2
Air conditioner switch*2
Vehicle speed sensor*2
Electrical load signal*2

ECM Function

Output (Actuator)

Fuel injection & mixture ratio control

Fuel injectors

Electronic ignition system

Power transistor

Fuel pump control

Fuel pump relay

On board diagnostic system

MI (On the instrument panel)

Intake valve timing control

Intake valve timing control solenoid valve

Heated oxygen sensor 1 heater control

Heated oxygen sensor 1 heater

Heated oxygen sensor 2 heater control

Heated oxygen sensor 2 heater

EVAP canister purge flow control

EVAP canister purge volume control solenoid valve

Air conditioning cut control

Air conditioner relay

Power valve control

VIAS control solenoid valve

Cooling fan control

Cooling fan relay

*1: This sensor is not used to control the engine system under normal conditions.
*2: The signals are sent to the ECM through CAN communication line.

Multiport Fuel Injection (MFI) System
INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed and piston
position

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Heated oxygen sensor 1

Density of oxygen in
exhaust gas

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Park/neutral position (PNP) switch

Gear position

Knock sensor

Engine knocking condition

Battery

Battery voltage

Power steering pressure sensor

Power steering operation

Heated oxygen sensor 2*1

Density of oxygen in
exhaust gas

Vehicle speed sensor*2

Vehicle speed

Air conditioner switch*2

Air conditioner operation

Ignition switch

Start signal

ECM Function

Actuator

Fuel injection & mixture ratio
Fuel injectors
control

*1: Under normal conditions, this sensor is not for engine control operation.
*2: This signal is sent to the ECM through CAN communication line.

EC-24

SYSTEM DESCRIPTION

ENGINE CONTROL
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Multiport Fuel Injection (MFI) System
(Cont’d)

The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length
of time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in
the ECM memory. The program value is preset by engine operating conditions. These conditions are determined by input signals (for engine speed and intake air) from both the camshaft position sensor and the mass
air flow sensor.

VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below.

+ During warm-up
+ When starting the engine
+ During acceleration
+ Hot-engine operation
+ When selector lever is changed from “N” to “D”
+ High-load, high-speed operation

+ During deceleration
+ During high engine speed operation

MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)

PBIB0121E

The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses
heated oxygen sensor 1 in the exhaust manifold to monitor if the engine operation is rich or lean. The ECM
adjusts the injection pulse width according to the sensor voltage signal. For more information about heated
oxygen sensor 1, refer to EC-163. This maintains the mixture ratio within the range of stoichiometric (ideal
air-fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal
from heated oxygen sensor 2.

Open loop control
The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
+ Deceleration and acceleration
+ High-load, high-speed operation
+ Malfunction of heated oxygen sensor 1 or its circuit
+ Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
+ High engine coolant temperature
+ During warm-up
+ After shifting from “N” to “D”
+ When starting the engine

EC-25

ENGINE CONTROL
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Multiport Fuel Injection (MFI) System
(Cont’d)
MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close
to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as
originally designed. Both manufacturing differences (i.e., mass air flow sensor hot film) and characteristic
changes during operation (i.e., injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This
is then computed in terms of “injection pulse duration” to automatically compensate for the difference
between the two ratios.
“Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel
trim includes short term fuel trim and long term fuel trim.
“Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN
compared to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is
rich, and an increase in fuel volume if it is lean.
“Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation of the short term fuel trim from the central value. Such deviation will occur due to individual engine
differences, wear over time and changes in the usage environment.

FUEL INJECTION TIMING

SEF179U

Two types of systems are used.

Sequential multiport fuel injection system
Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used
when the engine is running.

Simultaneous multiport fuel injection system
Fuel is injected simultaneously into all six cylinders twice each engine cycle. In other words, pulse signals
of the same width are simultaneously transmitted from the ECM.
The six injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.

FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.

EC-26

ENGINE CONTROL
SYSTEM

TB48DE A/T (WITH EURO-OBD)

Electronic Ignition (EI) System
INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

ECM Function

Camshaft position sensor

Engine speed and piston position

Mass air flow sensor

Amount of intake air

Engine coolant temperature
sensor

Engine coolant temperature

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Knock sensor

Engine knocking

Park/neutral position (PNP)
switch

Gear position

Battery

Battery voltage

Vehicle speed sensor*1

Vehicle speed

Ignition switch

Start signal

Ignition timing control

Actuator

Power transistor

*1: This signal is sent to the ECM through CAN communication line.

SYSTEM DESCRIPTION

SEF742M

The ignition timing is controlled by the ECM to maintain the best
air-fuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. This data forms the map
shown.
The ECM receives information such as the injection pulse width
and camshaft position sensor signal. Computing this information,
ignition signals are transmitted to the power transistor.
e.g., N: 1,800 rpm, Tp: 1.50 msec
A °BTDC
During the following conditions, the ignition timing is revised by
the ECM according to the other data stored in the ECM.
+ At starting
+ During warm-up
+ At idle
+ At low battery voltage
+ During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed within the antiknocking zone, if recommended fuel is used under dry conditions. The retard system does not operate under normal driving
conditions. If engine knocking occurs, the knock sensor monitors
the condition. The signal is transmitted to the ECM. The ECM
retards the ignition timing to eliminate the knocking condition.

EC-27

ENGINE CONTROL
SYSTEM

TB48DE A/T (WITH EURO-OBD)

Air Conditioning Cut Control
INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

ECM Function

Air conditioner switch*1

Air conditioner “ON” signal

Throttle position sensor

Throttle valve opening angle

Camshaft position sensor

Engine speed

Engine coolant temperature
sensor

Engine coolant temperature

Battery

Battery voltage

Refrigerant pressure sensor

Refrigerant pressure

Power steering pressure sensor

Power steering operation

Vehicle speed sensor*1

Vehicle speed

Ignition switch

Start signal

Air conditioner cut control

Actuator

Air conditioner relay

*1: These signals are sent to the ECM through CAN communication line.

SYSTEM DESCRIPTION
This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned off.
+ When the accelerator pedal is fully depressed.
+ When cranking the engine.
+ At high engine speeds.
+ When the engine coolant temperature becomes excessively high.
+ When operating power steering during low engine speed or low vehicle speed.
+ When engine speed is excessively low.
+ When refrigerant pressure is excessively low or high.

Fuel Cut Control (at No Load and High
Engine Speed)
INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

ECM Function

Park/neutral position (PNP)
switch

Neutral position

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Engine coolant temperature
sensor

Engine coolant temperature

Camshaft position sensor

Engine speed

Vehicle speed sensor*1

Vehicle speed

Fuel cut control

Actuator

Fuel injectors

*1: This signal is sent to the ECM through CAN communication line.

SYSTEM DESCRIPTION
If the engine speed is above 3,950 rpm with no load (for example, in neutral and engine speed over 3,950
rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed.
Fuel cut will operate until the engine speed reaches 1,500 rpm, then fuel cut is cancelled.
NOTE:
This function is different from deceleration control listed under “Multiport Fuel Injection (MFI)
System”, EC-24.

EC-28

ENGINE CONTROL
SYSTEM

TB48DE A/T (WITH EURO-OBD)

SYSTEM DIAGRAM

SEL599Y

Input/output signal chart
T: Transmit R: Receive
Signals

Combination meter

TCM

ECM

Engine speed signal

Engine coolant temperature signal

Accelerator pedal position signal

Closed throttle position signal

Wide open throttle position signal

A/T fluid temperature warning lamp signal

Current gear position signal

Shift change signal
Air conditioner switch signal

Headlamp switch signal

Rear window defogger switch signal

Brake switch signal

Vehicle speed signal

A/T self diagnosis signal
Manual mode signal

EC-29

BASIC SERVICE
PROCEDURE

TB48DE A/T (WITH EURO-OBD)

Idle Speed and Ignition Timing Check
IDLE SPEED
With CONSULT-II
Check idle speed in “DATA MONITOR” mode with CONSULT-II.

With GST
Check idle speed with GST.
SEF058Y

IGNITION TIMING
Any of following two methods may be used.

Method A
1. Slide the harness protector of ignition coil No. 1 to clear the
wires.
2. Attach timing light to the wires as shown.
3. Check ignition timing.
SEC560C

Method B
1. Remove No. 1 ignition coil.
2. Connect No. 1 ignition coil and No. 1 spark plug with suitable
high-tension wire as shown, and attach timing light clamp to
this wire.

SEC561C

SEF166Y

3. Check ignition timing.

SEC536DA

EC-30

BASIC SERVICE
PROCEDURE

TB48DE A/T (WITH EURO-OBD)

Accelerator Pedal Released Position
Learning
DESCRIPTION
“Accelerator Pedal Released Position Learning” is an operation to learn the fully released position of the
accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed
each time harness connector of accelerator pedal position sensor or ECM is disconnected.

OPERATION PROCEDURE
1.
2.
3.
4.
5.

Make sure that accelerator pedal is fully released.
Turn ignition switch “ON” and wait at least 2 seconds.
Turn ignition switch “OFF” wait at least 10 seconds.
Turn ignition switch “ON” and wait at least 2 seconds.
Turn ignition switch “OFF” wait at least 10 seconds.

Throttle Valve Closed Position Learning
DESCRIPTION
“Throttle Valve Closed Position Learning” is an operation to learn the fully closed position of the throttle valve
by monitoring the throttle position sensor output signal. It must be performed each time harness connector
of electric throttle control actuator or ECM is disconnected.

OPERATION PROCEDURE
1. Make sure that accelerator pedal is fully released.
2. Turn ignition switch “ON”.
3. Turn ignition switch “OFF” wait at least 10 seconds.
Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.

Idle Air Volume Learning
DESCRIPTION
“Idle Air Volume Learning” is an operation to learn the idle air volume that keeps each engine within the
specific range. It must be performed under any of the following conditions:
+ Each time electric throttle control actuator or ECM is replaced.
+ Idle speed or ignition timing is out of specification.

PREPARATION
Before performing “Idle Air Volume Learning”, make sure that all of the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are missed for even a moment.
+ Battery voltage: More than 12.9V (At idle)
+ Engine coolant temperature: 70 — 95°C (158 — 203°F)
+ PNP switch: ON
+ Electric load switch: OFF
(Air conditioner, headlamp, rear window defogger)
On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light
only small lamps.
+ Steering wheel: Neutral (Straight-ahead position)
+ Vehicle speed: Stopped
+ Transmission: Warmed-up
For models with CONSULT-II, drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “A/T”
system indicates less than 0.9V.
For A/T models without CONSULT-II, drive vehicle for 10 minutes.

EC-31

BASIC SERVICE
TB48DE A/T (WITH EURO-OBD)
PROCEDURE
Idle Air Volume Learning (Cont’d)
OPERATION PROCEDURE
With CONSULT-II
1.
2.
3.
4.

Perform EC-31, “Accelerator Pedal Released Position Learning”.
Perform EC-31, “Throttle Valve Closed Position Learning”.
Start engine and warm it up to normal operating temperature.
Check that all items listed under the topic “PREPARATION” (previously mentioned) are in good order.
5. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode.

SEF217Z

6. Touch “START” and wait 20 seconds.

SEF454Y

7. Make sure that “CMPLT” is displayed on CONSULT-II
screen. If “CMPLT” is not displayed, “Idle Air Volume Learning” will not be carried out successfully. In this case, find the
cause of the incident by referring to the “Diagnostic Procedure” below.
8. Rev up the engine two or three times and make sure that idle
speed and ignition timing are within the specifications.
ITEM

MBIB0238E

SPECIFICATION

Idle speed

675±50 rpm (in “P” or “N” position)

Ignition timing

10±5° BTDC (in “P” or “N” position)

EC-32

BASIC SERVICE
TB48DE A/T (WITH EURO-OBD)
PROCEDURE
Idle Air Volume Learning (Cont’d)
Without CONSULT-II
NOTE:
+ It is better to count the time accurately with a clock.
+ It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
1. Perform EC-31, “Accelerator Pedal Released Position Learning”.
2. Perform EC-31, “Throttle Valve Closed Position Learning”.
3. Start engine and warm it up to normal operating temperature.
4. Check that all items listed under the topic “PREPARATION” (previously mentioned) are in good order.
5. Turn ignition switch “OFF” and wait at least 10 seconds.
6. Confirm that accelerator pedal is fully released, turn ignition switch “ON” and wait 3 seconds.
7. Repeat the following procedure quickly five times within 5 seconds.
a. Fully depress the accelerator pedal.
b. Fully release the accelerator pedal.
8. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops
blinking and turned ON.
9. Fully release the accelerator pedal within 3 seconds after the MI turned ON.
10. Start engine and let it idle.
11. Wait 20 seconds.

PBIB0665E

12. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the
specifications.
ITEM

SPECIFICATION

Idle speed

675±50 rpm (in “P” or “N” position)

Ignition timing

10±5° BTDC (in “P” or “N” position)

13. If idle speed and ignition timing are not within the specification, “Idle Air Volume Learning” will not be
carried out successfully. In this case, find the cause of the incident by referring to the “Diagnostic Procedure” below.

DIAGNOSTIC PROCEDURE
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle valve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttle valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident.
It is useful to perform EC-108, “TROUBLE DIAGNOSIS — SPECIFICATION VALUE”.
5. If any of the following conditions occur after the engine has started, eliminate the cause of the
incident and perform “Idle air volume learning” all over again:
— Engine stalls.
— Erroneous idle.

EC-33

BASIC SERVICE
PROCEDURE

TB48DE A/T (WITH EURO-OBD)

Fuel Pressure Check
FUEL PRESSURE RELEASE
Before disconnecting fuel line, release fuel pressure from
fuel line to eliminate danger.

With CONSULT-II

SEF214Y

1. Turn ignition switch “ON”.
2. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II.
3. Start engine.
4. After engine stalls, crank it two or three times to release all
fuel pressure.
5. Turn ignition switch “OFF”.

Without CONSULT-II
1. Remove fuel pump fuse located in fuse box.
2. Start engine.
3. After engine stalls, crank it two or three times to release all
fuel pressure.
4. Turn ignition switch “OFF”.
5. Reinstall fuel pump fuse after servicing fuel system.

SEC550C

FUEL PRESSURE CHECK

SEC551C

SEF718BA

+ When reconnecting fuel line, always use new clamps.
+ Make sure that clamp screw does not contact adjacent
parts.
+ Use a torque driver to tighten clamps.
+ Use Pressure Gauge to check fuel pressure.
1. Release fuel pressure to zero, refer to above.
2. Disconnect fuel hose between fuel filter and fuel tube (engine
side).
3. Install pressure gauge between fuel filter and fuel tube.
4. Start engine and check for fuel leakage.
5. Read the indication of fuel pressure gauge.
At idling:
Approximately 245 kPa (2.45 bar, 2.5 kg/cm2, 36
psi)
A few seconds after ignition switch is turned OFF to
ON:
Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43
psi)
6. Stop engine and disconnect fuel pressure regulator vacuum
hose from intake manifold.
7. Plug intake manifold with a rubber cap.
8. Connect variable vacuum source to fuel pressure regulator.

EC-34

BASIC SERVICE
PROCEDURE

TB48DE A/T (WITH EURO-OBD)

9. Start engine and read indication of fuel pressure gauge as
vacuum is changed.
Fuel pressure should decrease as vacuum increases. If
results are unsatisfactory, replace fuel pressure regulator.

Injector Removal and Installation
1.
2.
3.
4.
5.

Release fuel pressure to zero.
Disconnect harness connector clip.
Disconnect injector harness connectors.
Disconnect fuel hoses from fuel tube assembly.
Remove fuel tube assemblies in reverse numerical sequence
of that shown in the figure at left.

SEC552C

6.
7.
+
+

Expand and remove clips securing fuel injectors.
Extract fuel injectors straight from fuel tubes.
Do not extract injector by pinching connector.
Be careful not to damage injector nozzles during
removal.
+ Do not bump or drop fuel injectors.

SEC553C

SEC559C

8. Install injector to fuel tube assembly.
+ Lubricate O-rings with a smear of silicone oil.
+ Be careful not to damage O-rings with service tools, finger nails or clips. Do not expand or twist O-rings.
+ Discard old clips, replace with new ones.
9. Position clips in grooves on fuel injectors.
+ Make sure that protrusions of fuel injectors are aligned
with cutouts of clips after installation.
10. Align protrusions of fuel tubes with those of fuel injectors.
Insert fuel injectors straight into fuel tubes.
11. After properly inserting fuel injectors, check to make sure that
fuel tube protrusions are engaged with those of fuel injectors,
and that flanges of fuel tube are engaged with clips.

SEC554C

EC-35

BASIC SERVICE
TB48DE A/T (WITH EURO-OBD)
PROCEDURE
Injector Removal and Installation (Cont’d)

SEC552C

12. Tighten fuel tube assembly mounting nuts in numerical
sequence (indicated in the figure at left) and in two stages.
: Tightening torque Nzm (kg-m, ft-lb)
1st stage:
9 — 20 (0.9 — 2.1, 7 — 15)
2nd stage:
21 — 26 (2.1 — 2.7, 16 — 19)
13. Insert fuel hoses into fuel tubes so that ends of fuel hoses
butt up against fuel tubes; fasten with clamps, avoiding
bulges.
CAUTION:
After properly connecting fuel tube assembly to injector and
fuel hose, check connection for fuel leakage.

EC-36

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Introduction
The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or
actuators. The ECM also records various emission-related diagnostic information including:
Emission-related diagnostic information

ISO Standard

Diagnostic Trouble Code (DTC)

Mode 3 of ISO 15031-5

Freeze Frame data

Mode 2 of ISO 15031-5

System Readiness Test (SRT) code

Mode 1 of ISO 15031-5

1st Trip Diagnostic Trouble Code (1st Trip DTC)

Mode 7 of ISO 15031-5

1st Trip Freeze Frame data
Test values and Test limits

Mode 6 of ISO 15031-5

Calibration ID

Mode 9 of ISO 15031-5

The above information can be checked using procedures listed in the table below.
x: Applicable —: Not applicable
DTC

Freeze Frame
data

1st trip DTC

1st trip Freeze
Frame data

SRT code

Test value

CONSULT-II

—

GST

x*1

—

ECM

x*2

—

*1: 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display.
*2: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.

The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in
two consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-65.)

Two Trip Detection Logic
When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in
the ECM memory. The MI will not light up at this stage. <1st trip>
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored
in the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd
trip> The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed
during vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MI,
and store DTC and Freeze Frame data, even in the 1st trip, as shown below.
x: Applicable —: Not applicable
MI

DTC

1st trip

Items

1st trip DTC

2nd trip
1st trip
displaying

2nd trip
displaying

1st trip
displaying

2nd trip
displaying

—

Blinking

Lighting
up

Blinking

Lighting
up

Misfire (Possible three way catalyst damage) — DTC: P0300 P0306 is being detected

—

Misfire (Possible three way catalyst damage) — DTC: P0300 P0306 is being detected

—

One trip detection diagnoses
(Refer to EC-9.)

—

Except above

—

EC-37

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS
DTC*1
SRT code

Test Value/
Test Limit
(GST only)

1st trip DTC

Reference
page

1000*3

—

EC-121

P0000

0000

—

HO2S1 HTR (B1)

P0031

0031

x*4

EC-124

HO2S1 HTR (B1)

P0032

0032

x*4

EC-124

HO2S2 HTR (B1)

P0037

0037

x*4

EC-132

HO2S2 HTR (B1)

P0038

0038

x*4

EC-132

HO2S1 HTR (B2)

P0051

0051

x*4

EC-124

HO2S1 HTR (B2)

P0052

0052

x*4

EC-124

HO2S2 HTR (B2)

P0057

0057

x*4

EC-132

HO2S2 HTR (B2)

P0058

0058

x*4

EC-132

MAF SEN/CIRCUIT

P0102

0102

—

EC-140

MAF SEN/CIRCUIT

P0103

0103

—

EC-140

IAT SEN/CIRCUIT

P0112

0112

—

EC-147

IAT SEN/CIRCUIT

P0113

0113

—

EC-147

ECT SEN/CIRCUIT

P0117

0117

—

EC-152

ECT SEN/CIRCUIT

P0118

0118

—

EC-152

TP SEN 2/CIRC

P0122

0122

—

EC-157

TP SEN 2/CIRC

P0123

0123

—

EC-157

HO2S1 (B1)

P0132

0132

x*4

EC-163

HO2S1 (B1)

P0133

0133

x*4

EC-172

HO2S1 (B1)

P0134

0134

x*4

EC-172

HO2S2 (B1)

P0138

0138

x*4

EC-195

HO2S2 (B1)

P0139

0139

x*4

EC-205

HO2S1 (B2)

P0152

0152

x*4

EC-163

HO2S1 (B2)

P0153

0153

x*4

EC-172

HO2S1 (B2)

P0154

0154

x*4

EC-172

HO2S2 (B2)

P0158

0158

x*4

EC-195

HO2S2 (B2)

P0159

0159

x*4

EC-205

FUEL SYS-LEAN-B1

P0171

0171

—

EC-218

FUEL SYS-RICH-B1

P0172

0172

—

EC-227

FUEL SYS-LEAN-B2

P0174

0174

—

EC-218

FUEL SYS-RICH-B2

P0175

0175

—

EC-227

TP SEN 1/CIRC

P0222

0222

—

EC-235

TP SEN 1/CIRC

P0223

0223

—

EC-235

MULTI CYL MISFIRE

P0300

0300

—

EC-241

CYL 1 MISFIRE

P0301

0301

—

EC-241

CYL 2 MISFIRE

P0302

0302

—

EC-241

Items
(CONSULT-II screen terms)

CONSULT-II
GST*2

ECM

CAN COMM CIRCUIT

U1000

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

EC-38

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
DTC*1
Items
(CONSULT-II screen terms)

SRT code

Test Value/
Test Limit
(GST only)

1st trip DTC

Reference
page

CONSULT-II
GST*2

ECM

CYL 3 MISFIRE

P0303

0303

—

EC-241

CYL 4 MISFIRE

P0304

0304

—

EC-241

CYL 5 MISFIRE

P0305

0305

—

EC-241

CYL 6 MISFIRE

P0306

0306

—

EC-241

KNOCK SEN/CIRC-B1

P0327

0327

—

EC-247

KNOCK SEN/CIRC-B1

P0328

0328

—

EC-247

KNOCK SEN/CIRC-B2

P0332

0332

—

EC-247

KNOCK SEN/CIRC-B2

P0333

0333

—

EC-247

CKP SEN/CIRCUIT

P0335

0335

—

EC-251

CMP SEN/CIRC-B1

P0340

0340

—

EC-257

TW CATALYST SYS-B1

P0420

0420

x*4

EC-264

TW CATALYST SYS-B2

P0430

0430

x*4

EC-264

PURG VOLUME CONT/V

P0444

0444

—

EC-269

PURG VOLUME CONT/V

P0445

0445

—

EC-269

VEH SPEED SEN/CIRC

P0500

0500

—

EC-276

PW ST P SEN/CIRC

P0550

0550

—

EC-278

ECM

P0605

0605

—

EC-283

MIL/CIRC

P0650

0650

—

EC-286

TCC SOLENOID/CIRC

P0740

0740

—

AT section

L/PRESS SOL/CIRC

P0745

0745

—

AT section

ECM BACK UP/CIRC

P1065

1065

—

EC-290

INT/V TIM V/CIR-B1

P1111

1111

—

EC-294

ETC ACTR

P1121

1121

—

EC-299

ETC FUNCTION/CIRC

P1122

1122

—

EC-301

ETC MOT PWR

P1124

1124

—

EC-309

ETC MOT PWR

P1126

1126

—

EC-309

ETC MOT

P1128

1128

—

EC-315

HO2S1 (B1)

P1143

1143

x*4

EC-320

HO2S1 (B1)

P1144

1144

x*4

EC-327

HO2S2 (B1)

P1146

1146

x*4

EC-335

HO2S2 (B1)

P1147

1147

x*4

EC-348

HO2S1 (B2)

P1163

1163

x*4

EC-320

HO2S1 (B2)

P1164

1164

x*4

EC-327

HO2S2 (B2)

P1166

1166

x*4

EC-335

HO2S2 (B2)

P1167

1167

x*4

EC-348

ENG OVER TEMP

P1217

1217

—

EC-361

CTP LEARNING

P1225

1225

—

EC-372

CTP LEARNING

P1226

1226

—

EC-374

SENSOR POWER/CIRC

P1229

1229

—

EC-376

CKP SENSOR (COG)

P1336

1336

—

EC-381

EC-39

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
DTC*1
Items
(CONSULT-II screen terms)

SRT code

Test Value/
Test Limit
(GST only)

1st trip DTC

Reference
page

CONSULT-II
GST*2

ECM

NATS MALFUNCTION

P1610 P1615

1610 — 1615

—

EC-50

P-N POS SW/CIRCUIT

P1706

1706

—

EC-388

BRAKE SW/CIRCUIT

P1805

1805

—

EC-395

APP SEN 1/CIRC

P2122

2122

—

EC-401

APP SEN 1/CIRC

P2123

2123

—

EC-401

APP SEN 2/CIRC

P2127

2127

—

EC-408

APP SEN 2/CIRC

P2128

2128

—

EC-408

TP SENSOR

P2135

2135

—

EC-415

APP SENSOR

P2138

2138

—

EC-421

*1: 1st trip DTC No. is the same as DTC No.
*2: These numbers are prescribed by ISO 15031-5.
*3: The trouble shooting for these DTCs need CONSULT-II.
*4: These are not displayed with GST.
NOTE:
Regarding Y61 models with TB48DE engine, “B1” indicates bank 1 (cylinders number 1, 2 and 3), “B2” indicates bank 2
(cylinders number 4, 5 and 6).

DTC AND 1ST TRIP DTC
The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st
trip DTC will not be displayed.
If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will
not light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the
required driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is
detected in the 2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up.
In other words, the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs
in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the
1st and 2nd trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the
MI during the 1st trip, the DTC and 1st trip DTC are stored in the ECM memory.
Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-49, “HOW
TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
For malfunctions in which 1st trip DTCs are displayed, refer to EC-38, “EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS. These items are required by legal regulations to continuously monitor the
system/component. In addition, the items monitored non-continuously are also displayed on CONSULT-II.
1st trip DTC is specified in Mode 7 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the MI
and therefore does not warn the driver of a problem. However, 1st trip DTC detection will not prevent the
vehicle from being tested, for example during Inspection/Maintenance (I/M) tests.
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in “Work Flow” procedure Step II, refer to EC-60, “WORK FLOW”. Then perform “DTC
Confirmation Procedure” or “Overall Function Check” to try to duplicate the malfunction. If the malfunction
is duplicated, the item requires repair.

How to read DTC and 1st trip DTC
DTC and 1st trip DTC can be read by the following methods.

With CONSULT-II
With GST
CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P0705, P0750, etc.
These DTCs are prescribed by ISO 15031-5.
(CONSULT-II also displays the malfunctioning component or system.)

EC-40

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
No Tools
The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC.
Example: 0102, 0340 etc.
These DTCs are controlled by NISSAN.
+ 1st trip DTC No. is the same as DTC No.
+ Output of a DTC indicates a malfunction. However, GST or the Diagnostic Test Mode II do not
indicate whether the malfunction is still occurring or has occurred in the past and has returned
to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended.
A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many
times the vehicle was driven after the last detection of a DTC.
If the DTC is being detected currently, the time data will be “0”.
If a 1st trip DTC is stored in the ECM, the time data will be “[1t]”.

PBIB0911E

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA
The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant
temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and
intake air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II
or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST.
For details, see EC-92, “Freeze Frame Data and 1st Trip Freeze Frame Data”.
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in
the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no
priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However,
once freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data
is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has
the following priorities to update the data.
Priority
1

Items
Freeze frame data

2
3

Misfire — DTC: P0300 — P0306
Fuel Injection System Function — DTC: P0171, P0172, P0174, P0175
Except the above items (Includes A/T related items)

1st trip freeze frame data

For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the
2nd trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be
updated from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different malfunction is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame
data is stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame
data or 1st trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM
memory and freeze frame data with the same priority occurs later, the first (original) freeze frame data
remains unchanged in the ECM memory.

EC-41

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM
memory is erased. Procedures for clearing the ECM memory are described in EC-52, “HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION”.

SYSTEM READINESS TEST (SRT) CODE
System Readiness Test (SRT) code is specified in Mode 1 of ISO 15031-5.
As part of an enhanced emissions test for Inspection & Maintenance (I/M), certain states require the status
of SRT be used to indicate whether the ECM has completed self-diagnosis of major emission systems and
components. Completion must be verified in order for the emissions inspection to proceed.
If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “INCMP”,
use the information in this Service Manual to set the SRT to “CMPLT”.
In most cases the ECM will automatically complete its self-diagnosis cycle during normal usage, and the SRT
status will indicate “CMPLT” for each application system. Once set as “CMPLT”, the SRT status remains
“CMPLT” until the self-diagnosis memory is erased.
Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer’s
normal driving pattern; the SRT will indicate “INCMP” for these items.
NOTE:
+ The SRT will also indicate “INCMP” if the self-diagnosis memory is erased for any reason or if
the ECM memory power supply is interrupted for several hours.
If, during the state emissions inspection, the SRT indicates “CMPLT” for all test items, the
inspector will continue with the emissions test. However, if the SRT indicates “INCMP” for one
or more of the SRT items the vehicle is returned to the customer untested.
+ If MI is “ON” during the state emissions inspection, the vehicle is also returned to the customer
untested even though the SRT indicates “CMPLT” for all test items. Therefore, it is important to
check SRT (“CMPLT”) and DTC (No DTCs) before the inspection.

SRT item
The table below shows required self-diagnostic items to set the SRT to “CMPLT”.
SRT item
(CONSULT-II indication)
CATALYST

HO2S

HO2S HTR

Performance Priority*1
2

Required self-diagnostic items to set the SRT to
“CMPLT”

Corresponding DTC No.

Three way catalyst function

P0420, P0430

Heated oxygen sensor 1

P0132, P0152

Heated oxygen sensor 1

P0133, P0153

Heated oxygen sensor 1

P0134, P0154

Heated oxygen sensor 1

P1143, P1163

Heated oxygen sensor 1

P1144, P1164

Heated oxygen sensor 2

P0138, P0158

Heated oxygen sensor 2

P0139, P0159

Heated oxygen sensor 2

P1146, P1166

Heated oxygen sensor 2

P1147, P1167

Heated oxygen sensor 1 heater

P0031, P0032, P0051,
P0052

Heated oxygen sensor 2 heater

P0037, P0038, P0057,
P0058

*1: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure), one by one based on the priority for models with CONSULT-II.

EC-42

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
SRT set timing
SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT is
done regardless of whether the result is OK or NG. The set timing is different between OK and NG results
and is shown in the table below.
Example
Self-diagnosis result

Ignition cycle
← ON → OFF ← ON →

Diagnosis

← ON →

P0400

OK (1)

— (1)

OK (2)

— (2)

P0402

OK (1)

— (1)

OK (2)

P1402

OK (1)

OK (2)

— (2)

SRT of EGR

“CMPLT”

P0400

OK (1)

— (1)

P0402

— (0)

OK (1)

— (1)

P1402

OK (1)

OK (2)

— (2)

SRT of EGR

“INCMP”

“CMPLT”

P0400

—

P0402

—

P1402

—

NG
(Consecutive
NG)

(1st trip)
DTC

1st trip DTC

—

1st trip DTC

DTC
(= MI “ON”)

SRT of EGR

“INCMP”

“CMPLT”

OFF

← ON →

Case 1

All OK

Case 2

NG exists

Case 3

OK: Self-diagnosis is carried out and the result is OK.
NG: Self-diagnosis is carried out and the result is NG.
—: Self-diagnosis is not carried out.

When all SRT related self-diagnoses showed OK results in a single cycle (Ignition OFF-ON-OFF), the SRT
will indicate “CMPLT”. → Case 1 above
When all SRT related self-diagnoses showed OK results through several different cycles, the SRT will indicate “CMPLT” at the time the respective self-diagnoses have at least one OK result. → Case 2 above
If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also
indicate “CMPLT”. → Case 3 above
The table above shows that the minimum number of cycles for setting SRT as “INCMP” is one (1) for each
self-diagnosis (Case 1 & 2) or two (2) for one of self-diagnoses (Case 3). However, in preparation for the
state emissions inspection, it is unnecessary for each self-diagnosis to be executed twice (Case 3) for the
following reasons:
+ The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result.
+ The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis results.
+ When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis memory must be erased from ECM after repair.
+ If the 1st trip DTC is erased, all the SRT will indicate “INCMP”.
NOTE:
SRT can be set as “CMPLT” together with the DTC(s). Therefore, DTC check must always be carried
out prior to the state emission inspection even though the SRT indicates “CMPLT”.

SRT service procedure
If a vehicle has failed the state emissions inspection due to one or more SRT items indicating “INCMP”,
review the flowchart diagnostic sequence on the next page.

EC-43

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)

SEF573XB

*1EC-40

*2EC-45

*3EC-45

EC-44

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
How to display SRT code

PBIB0666E

WITH CONSULT-II
Selecting “SRT STATUS” in “DTC CONFIRMATION” mode with
CONSULT-II.
For items whose SRT codes are set, a “CMPLT” is displayed on
the CONSULT-II screen; for items whose SRT codes are not set,
“INCMP” is displayed.
A sample of CONSULT-II display for SRT code is shown at right.
“INCMP” means the self-diagnosis is incomplete and SRT is not
set. “CMPLT” means the self-diagnosis is complete and SRT is
set.
WITH GST
Selecting Mode 1 with GST (Generic Scan Tool)

How to set SRT code
To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times.
Each diagnosis may require a long period of actual driving under various conditions.
WITH CONSULT-II
Perform corresponding DTC Confirmation Procedure one by one based on “Performance Priority” in the table
on EC-42, “SRT Item”.
WITHOUT CONSULT-II
The most efficient driving pattern in which SRT codes can be properly set is explained on the next page.
The driving pattern should be performed one or more times to set all SRT codes.

EC-45

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
Driving pattern

MBIB0241E

EC-46

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
The time required for each diagnosis varies with road surface conditions, weather, altitude, individual
driving habits, etc.
Zone A refers to the range where the time, required for the diagnosis under normal conditions*, is the
shortest.
Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed
within zone A.
*: Normal conditions refer to the following:
+ Sea level
+ Flat road
+ Ambient air temperature: 20 — 30°C (68 — 86°F)
+ Diagnosis is performed as quickly as possible under normal conditions.
Under different conditions [For example: ambient air temperature other than 20 — 30°C (68 — 86°F)],
diagnosis may also be performed.
Pattern 1:
+ The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F)
(where the voltage between the ECM terminal 121 and ground is 3.0 — 4.3V).
+ The engine must be operated at idle speed until the engine coolant temperature is greater than
70°C (158°F) (where the voltage between the ECM terminal 121 and ground is lower than 1.4V).
Pattern 2:
+ When steady-state driving is performed again even after it is interrupted, each diagnosis can be conducted. In this case, the time required for diagnosis may be extended.
*1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal
and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90
km/h (56 MPH) again.
*2: Checking the vehicle speed with GST is advised.
+

Suggested Transmission Gear Position
Set the selector lever in the “D” position with the overdrive switch turned ON.

EC-47

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)
The following is the information specified in Mode 6 of ISO 15031-5.
The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG”
while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored.
Items for which these data (test value and test limit) are displayed are the same as SRT code items.
These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be
displayed on the GST screen.
x: Applicable —: Not applicable
Test value (GST display)
SRT item

Self-diagnostic test item

Test limit

Application

01H

Max.

02H

81H

Min.

03H

02H

Max.

04H

82H

Min.

09H

04H

Max.

0AH

84H

Min.

0BH

04H

Max.

0CH

04H

Max.

0DH

04H

Max.

11H

05H

Max.

12H

85H

Min.

13H

05H

Max.

14H

05H

Max.

15H

05H

Max.

19H

86H

Min.

1AH

86H

Min.

1BH

06H

Max.

1CH

06H

Max.

21H

87H

Min.

22H

87H

Min.

23H

07H

Max.

24H

07H

Max.

29H

08H

Max.

2AH

88H

Min.

2BH

09H

Max.

2CH

89H

Min.

2DH

0AH

Max.

2EH

8AH

Min.

2FH

0BH

Max.

30H

8BH

Min.

TID

CID

01H
Three way catalyst function (Bank1)
CATALYST
Three way catalyst function (Bank2)

Heated oxygen sensor 1 (Bank 1)

Heated oxygen sensor 1 (Bank 2)
HO2S

Heated oxygen sensor 2 (Bank 1)

Heated oxygen sensor 2 (Bank 2)

Heated oxygen sensor 1 heater (Bank 1)

Heated oxygen sensor 1 heater (Bank 2)
HO2S HTR
Heated oxygen sensor 2 heater (Bank 1)

Heated oxygen sensor 2 heater (Bank 2)

EC-48

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION
How to Erase DTC (With CONSULT-II)
The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II.
If DTCs are displayed for both ECM and TCM (Transmission control module), they need to be erased individually from the ECM and TCM (Transmission control module).
NOTE:
If the DTC is not for A/T related items (see EC-9, “INDEX FOR DTC”), skip steps 2 through 4.
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
10 seconds and then turn it “ON” (engine stopped) again.
2. Turn CONSULT-II “ON” and touch “A/T”.
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. [The DTC in the TCM (Transmission control module) will be erased.] Then touch
“BACK” twice.
5. Touch “ENGINE”.
6. Touch “SELF-DIAG RESULTS”.
7. Touch “ERASE”. (The DTC in the ECM will be erased.)

SEF966X

EC-49

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Emission-related Diagnostic Information
(Cont’d)
How to erase DTC (With GST)
The emission related diagnostic information in the ECM can be erased by selecting Mode 4 with GST.
NOTE:
If the DTC is not for A/T related items (see EC-9, “INDEX FOR DTC”), skip step 2.
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
10 seconds and then turn it “ON” (engine stopped) again.
2. Perform “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)” in AT section titled “TROUBLE
DIAGNOSIS”, “Self-diagnosis”. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.)
3. Select Mode 4 with GST (Generic Scan Tool).

How to erase DTC (No Tools)
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch OFF” once.
2. Wait at least 10 seconds and then turn it “ON” (engine stopped) again.
3. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to
EC-52, “HOW TO SWITCH DIAGNOSTIC TEST MODE”.
+ If the battery is disconnected, the emission-related diagnostic information will be lost after
approx. 24 hours.
+ The following data are cleared when the ECM memory is erased.
1. Diagnostic trouble codes
2. 1st trip diagnostic trouble codes
3. Freeze frame data
4. 1st trip freeze frame data
5. System readiness test (SRT) codes
6. Test values
7. Others
Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but
all of the data listed above, are cleared from the ECM memory during work procedures.

NATS (Nissan Anti-theft System)

SEF515Y

+ If the security indicator lights up with the ignition switch
in the “ON” position or “NATS MALFUNCTION” is displayed on “SELF-DIAG RESULTS” screen, perform selfdiagnostic results mode with CONSULT-II using NATS
program card. Refer to EL section, “NATS (NISSAN
ANTI-THEFT SYSTEM)”.
+ Confirm no self-diagnostic results of NATS is displayed
before touching “ERASE” in “SELF-DIAG RESULTS”
mode with CONSULT-II.
+ When replacing ECM, initialization of NATS system and
registration of all NATS ignition key IDs must be carried
out with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle
owner. Regarding the procedures of NATS initialization
and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.

EC-50

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Malfunction Indicator (MI)
DESCRIPTION

SAT652J

ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following four functions.
Diagnostic
Test Mode

KEY and ENG. Status

Function

Explanation of Function

Ignition switch in “ON” position

Engine stopped

BULB CHECK

This function checks the MI bulb for damage
(blown, open circuit, etc.).
If the MI does not come on, check MI circuit.

MALFUNCTION WARNING

This is a usual driving condition. When a malfunction is detected twice in two consecutive driving
cycles (two trip detection logic), the MI will light up
to inform the driver that a malfunction has been
detected.
The following malfunctions will light up or blink the
MI in the 1st trip.
+ “Misfire (Possible three way catalyst damage)”
+ “One trip detection diagnoses”

SELF-DIAGNOSTIC RESULTS

This function allows DTCs and 1st trip DTCs to be
read.

Mode I
Engine running

Ignition switch in “ON” position

Engine stopped
Mode II
Engine running

This function allows the fuel mixture condition (lean
HEATED OXYGEN SENSOR 1
or rich), monitored by heated oxygen sensor 1, to
MONITOR
be read.

MI flashing without DTC
If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM
diagnostic test mode, EC-52 “HOW TO SWITCH DIAGNOSTIC TEST MODE”.
How to switch the diagnostic test (function) modes, and details of the above functions are described later,
EC-52 “HOW TO SWITCH DIAGNOSTIC TEST MODE”.
The following emission-related diagnostic information is cleared when the ECM memory is erased.
+ Diagnostic trouble codes
+ 1st trip diagnostic trouble codes
+ Freeze frame data
+ 1st trip freeze frame data
+ System readiness test (SRT) codes
+ Test values
+ Others

EC-51

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Malfunction Indicator (MI) (Cont’d)
HOW TO SWITCH DIAGNOSTIC TEST MODE
NOTE:
+ It is better to count the time accurately with a clock.
+ It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
+ Always ECM returns to Diagnostic Test Mode I after ignition switch is turned “OFF”.

How to set diagnostic test mode II (Self-diagnostic results)
1.
2.
a.
b.
3.

Confirm that accelerator pedal is fully released, turn ignition switch “ON” and wait 3 seconds.
Repeat the following procedure quickly five times within 5 seconds.
Fully depress the accelerator pedal.
Fully release the accelerator pedal.
Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts
blinking.
4. Fully release the accelerator pedal.
ECM has entered to Diagnostic Test Mode II (Self-diagnostic results).

PBIB0092E

How to set diagnostic test mode II (Heated oxygen sensor 1 monitor)
1. Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-52, “How to set diagnostic test mode II (Self-diagnostic results)”.
2. Start Engine.
ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor).
ECM will start heated oxygen sensor 1 monitoring from the bank 1 sensor.

How to switch monitored sensor from bank 1 to bank 2 or vice versa
1. Fully depress the accelerator pedal quickly and then release it immediately.
2. Make sure that monitoring sensor has changed by MI blinking as follows.

PBIB0093E

How to erase diagnostic test mode II (Self-diagnostic results)
1. Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-52, “How to set diagnostic test
mode II (Self-diagnostic results)”.
2. Fully depress the accelerator pedal and keep it for more than 10 seconds.
The emission-related diagnostic information has been erased from the backup memory in the ECM.
3. Fully release the accelerator pedal, and confirm the DTC 0000 is displayed.

EC-52

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Malfunction Indicator (MI) (Cont’d)
DIAGNOSTIC TEST MODE I — BULB CHECK
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EL
section or see EC-286.

DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING
MI

Condition

When the malfunction is detected.

OFF

No malfunction.

+ These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS)

DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS
In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test
mode I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the
MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes
are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These
unidentified codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example
for how to read a code.

SEF952W

A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2
seconds consisting of an ON (0.6-second) — OFF (0.6-second) cycle.
The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle.
A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the
later numeral appears on the display 1.3 seconds after the former numeral has disappeared.
A change from one trouble code to another occurs at an interval of 1.8-second OFF.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC “0000” refers to no
malfunction. (See EC-9.)

How to erase diagnostic test mode II (Self-diagnostic results)
The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to
EC-52, “HOW TO SWITCH DIAGNOSTIC TEST MODE”.
+ If the battery is disconnected, the DTC will be lost from the backup memory after approx 24 hours.
+ Be careful not to erase the stored memory before starting trouble diagnoses.

EC-53

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Malfunction Indicator (MI) (Cont’d)
DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR
In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated
oxygen sensor 1.
MI

Fuel mixture condition in the exhaust gas

Lean

OFF

Rich

*Remains ON or OFF

Any condition

Air fuel ratio feedback control condition
Closed loop system
Open loop system

*: Maintains conditions just before switching to open loop.

To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up
until engine coolant temperature indicator points to the middle of the gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Then make sure that the
MI comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no-load.

OBD System Operation Chart
RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS
+
+
+
+

When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are
stored in the ECM memory.
When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are
stored in the ECM memory, and the MI will come on. For details, refer to EC-37, “Two Trip Detection
Logic”.
The MI will go off after the vehicle is driven 3 times with no malfunction. The drive is counted only when
the recorded driving pattern is met (as stored in the ECM). If another malfunction occurs while counting,
the counter will reset.
The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A)
without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and
Fuel Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times
(driving pattern C) without the same malfunction recurring. The “TIME” in “SELF-DIAGNOSTIC
RESULTS” mode of CONSULT-II will count the number of times the vehicle is driven.
The 1st trip DTC is not displayed when the self-diagnosis results in “OK” for the 2nd trip.

SUMMARY CHART
Items
MI (goes off)
DTC, Freeze Frame Data (no
display)
1st Trip DTC (clear)
1st Trip Freeze Frame Data
(clear)

Fuel Injection System

Misfire

Other

3 (pattern B)

80 (pattern C)

40 (pattern A)

1 (pattern C), *1

1 (pattern B)

*1, *2

1 (pattern B)

For details about patterns “B” and “C” under “Fuel Injection System” and “Misfire”, see EC-56.
For details about patterns “A” and “B” under “Other”, see EC-58.
*1: Clear timing is at the moment OK is detected.
*2: Clear timing is when the same malfunction is detected in the 2nd trip.

EC-54

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
OBD System Operation Chart (Cont’d)
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR
“MISFIRE” , “FUEL INJECTION SYSTEM”

SEF392SA

*1:When the same malfunction is
detected in two consecutive trips, MI
will light up.
*2:MI will go off after vehicle is driven
3 times (pattern B) without any malfunctions.
*3:When the same malfunction is
detected in two consecutive trips, the
DTC and the freeze frame data will be
stored in ECM.

*4:The DTC and the freeze frame data
will not be displayed any longer after
vehicle is driven 80 times (pattern C)
without the same malfunction. (The
DTC and the freeze frame data still
remain in ECM.)
*5:When a malfunction is detected for
the first time, the 1st trip DTC and the
1st trip freeze frame data will be stored
in ECM.

EC-55

*6:The 1st trip DTC and the 1st trip
freeze frame data will be cleared at the
moment OK is detected.
*7:When the same malfunction is
detected in the 2nd trip, the 1st trip
freeze frame data will be cleared.
*8:1st trip DTC will be cleared when
vehicle is driven once (pattern C) without the same malfunction after DTC is
stored in ECM.

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
OBD System Operation Chart (Cont’d)
EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
+ The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
+ The B counter will be counted up when driving pattern B is satisfied without any malfunction.
+ The MI will go off when the B counter reaches 3. (*2 in “OBD SYSTEM OPERATION CHART”)

Driving pattern C means the vehicle operation as follows:
1. The following conditions should be satisfied at the same time:
Engine speed: (Engine speed in the freeze frame data) ±375 rpm
Calculated load value: (Calculated load value in the freeze frame data) x (1±0.1) [%]
Engine coolant temperature (T) condition:
+ When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F).
+ When the freeze frame data shows higher than or equal to 70°C (158°F), “T” should be higher than or
equal to 70°C (158°F).
Example:
If the stored freeze frame data is as follows:
Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80°C (176°F)
To be satisfied with driving pattern C, the vehicle should run under the following conditions:
Engine speed: 475 — 1,225 rpm, Calculated load value: 27 — 33%, Engine coolant temperature: more than
70°C (158°F)
+ The C counter will be cleared when the malfunction is detected regardless of (1).
+ The C counter will be counted up when (1) is satisfied without the same malfunction.
+ The DTC will not be displayed after C counter reaches 80.
+ The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC
is stored in ECM.

EC-56

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
OBD System Operation Chart (Cont’d)
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT
FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

SEF393SA

*4:The DTC and the freeze frame data
will not be displayed any longer after
vehicle is driven 40 times (pattern A)
without the same malfunction.
(The DTC and the freeze frame data
still remain in ECM.)
*5:When a malfunction is detected for
the first time, the 1st trip DTC and the
1st trip freeze frame data will be stored
in ECM.

EC-57

*6:1st trip DTC will be cleared after
vehicle is driven once (pattern B) without the same malfunction.
*7:When the same malfunction is
detected in the 2nd trip, the 1st trip
freeze frame data will be cleared.

ON BOARD DIAGNOSTIC (OBD)
TB48DE A/T (WITH EURO-OBD)
SYSTEM
OBD System Operation Chart (Cont’d)
EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

AEC574

+
+
+

The A counter will be cleared when the malfunction is detected regardless of (1) — (4).
The A counter will be counted up when (1) — (4) are satisfied without the same malfunction.
The DTC will not be displayed after the A counter reaches 40.

Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
+ The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
+ The B counter will be counted up when driving pattern B is satisfied without any malfunctions.
+ The MI will go off when the B counter reaches 3 (*2 in “OBD SYSTEM OPERATION CHART”).

EC-58

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

Trouble Diagnosis Introduction
INTRODUCTION

MEF036D

SEF233G

The engine has an ECM to control major systems such as fuel
control, ignition control, idle air control system, etc. The ECM
accepts input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper
and stable. At the same time, it is important that there are no
malfunctions such as vacuum leaks, fouled spark plugs, or other
malfunctions with the engine.
It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the incidents. A
roadtest with CONSULT-II (or GST) or a circuit tester connected
should be performed. Follow the “Work Flow” on EC-60.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The
customer can supply good information about such incidents,
especially intermittent ones. Find out what symptoms are present
and under what conditions they occur. A “Diagnostic Worksheet”
like the example on EC-63 should be used.
Start your diagnosis by looking for “conventional” malfunctions
first. This will help troubleshoot driveability malfunctions on an
electronically controlled engine vehicle.

SEF234G

EC-59

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Trouble Diagnosis Introduction (Cont’d)
WORK FLOW
Flow chart

MBIB0159E

*1:If time data of “SELF-DIAG
RESULTS” is other than “0” or “[1t]”,
perform EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
*2:If time data of “SELF-DIAG
RESULTS” is other than “0” or “[1t]”,
perform EC-112, “TROUBLE DIAGNO-

SIS FOR INTERMITTENT INCIDENT”.
*3:If the on board diagnostic system
cannot be performed, check main
power supply and ground circuit. Refer
to EC-113, “POWER SUPPLY CIRCUIT FOR ECM”.
*4:If malfunctioning part cannot be

EC-60

detected, perform EC-112, “TROUBLE
DIAGNOSIS FOR INTERMITTENT
INCIDENT”.
*5:EC-46, “Driving Pattern”
*6:EC-108, “TROUBLE DIAGNOSIS —
SPECIFICATION VALUE”

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Trouble Diagnosis Introduction (Cont’d)
Description for work flow
STEP

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using the
“DIAGNOSTIC WORK SHEET”, EC-62.

STEP II

Before confirming the concern, check and write down (print out using CONSULT-II or GST) the (1st trip) DTC and
the (1st trip) freeze frame data, then erase the DTC and the data. (Refer to EC-49, “HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION”.) The (1st trip) DTC and the (1st trip) freeze frame data can be used
when duplicating the incident at STEP III & IV.
If the incident cannot be verified, perform EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
Study the relationship between the cause, specified by (1st trip) DTC, and the symptom described by the customer. (The “Symptom Matrix Chart” will be useful. See EC-71.)
Also check related service bulletins for information.

STEP III

Try to confirm the symptom and under what conditions the incident occurs.
The “DIAGNOSTIC WORK SHEET” and the freeze frame data are useful to verify the incident. Connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
If the malfunction code is detected, skip STEP IV and perform STEP V.

STEP IV

Try to detect the (1st trip) DTC by driving in (or performing) the “DTC Confirmation Procedure”. Check and read
the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT-II or GST.
During the (1st trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO
TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
In case the “DTC Confirmation Procedure” is not available, perform the “Overall Function Check” instead. The (1st
trip) DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative.
The “NG” result of the “Overall Function Check” is the same as the (1st trip) DTC detection.

STEP V

Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC PXXXX.
If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-66.) If CONSULT-II is available,
perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS —
SPECIFICATION VALUE”. (Refer to EC-108) (If malfunction is detected, proceed to “PERAIR/REPLACE”.) Then
perform inspections according to the Symptom Matrix Chart. (Refer to EC-71.)

STEP VI

Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect
the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR
(AUTO TRIG)” mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II. Refer to EC-80, 103.
The “Diagnostic Procedure” in EC section contains a description based on open circuit inspection. A short circuit
inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to “Circuit Inspection”
in GI section.
Repair or replace the malfunction parts.
If malfunctioning part cannot be detected, perform EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.

STEP VII

Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer’s initial complaint.
Perform the “DTC Confirmation Procedure” and confirm the normal code [DTC No. P0000] is detected. If the incident is still detected in the final check, perform STEP VI by using a method different from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st trip) DTC in
ECM and TCM (Transmission control module). (Refer to EC-49, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION” and AT section.)

EC-61

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Trouble Diagnosis Introduction (Cont’d)
DIAGNOSTIC WORKSHEET
Description

SEF907L

There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can
make troubleshooting faster and more accurate.
In general, each customer feels differently about an incident. It
is important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one on the next page in
order to organize all the information for troubleshooting.
Some conditions may cause the MI to come on steady or blink
and DTC to be detected. Examples:
+ Vehicle ran out of fuel, which caused the engine to misfire.
+ Fuel filler cap was left off or incorrectly screwed on, allowing
fuel to evaporate into the atmosphere.

EC-62

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Trouble Diagnosis Introduction (Cont’d)
Worksheet sample

MTBL0017

EC-63

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

DTC Inspection Priority Chart
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart.
NOTE:
If DTC U1000 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000. Refer
to EC-121, “DTC U1000 CAN COMMUNICATION LINE”.
Priority

Detected items (DTC)
+
+
+
+
+
+
+
+
+
+
+
+
+
+

U1000 CAN communication line
P0102 P0103 Mass air flow sensor
P0112 P0113 Intake air temperature sensor
P0117 P0118 Engine coolant temperature sensor
P0122 P0123 P0222 P0223 P1225 P1226 P1229 P2135 Throttle position sensor
P0327 P0328 P0332 P0333 Knock sensor
P0335 P1336 Crankshaft position sensor (OBD)
P0340 Camshaft position sensor
P0500 Vehicle speed sensor
P0605 ECM
P0705 Park/Neutral position (PNP) switch
P1610-P1615 NATS
P1706 Park/Neutral position (PNP) switch
P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor

+
+
+
+
+
+
+
+
+
+
+

P0031
P0037
P0132
P0138
P0550
P0740
P1065
P1111
P1122
P1124
P1805

P0032 P0051 P0052 Heated oxygen sensor 1 heater
P0038 P0057 P0058 Heated oxygen sensor 2 heater
P0133 P0134 P0152 P0153 P0154 P1143 P1144 P1163 P1164 Heated oxygen sensor 1
P0139 P0158 P0159 P1146 P1147 P1166 P1167 Heated oxygen sensor 2
Power steering pressure sensor
P0745 A/T solenoid valves
ECM power supply
Intake valve timing control solenoid valve
Electric throttle control function
P1126 P1128 Electric throttle control actuator
Brake switch

+
+
+
+
+
+

P0171
P0300
P0420
P0444
P1121
P1217

P0172 P0174 P0175 Fuel injection system function
— P0306 Misfire
P0430 Three way catalyst function
P0445 EVAP canister purge volume control solenoid valve
Electric throttle control actuator
Engine over temperature (OVERHEAT)

EC-64

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

Fail-safe Chart
+When the DTC listed below is detected, the ECM enters fail-safe mode and the MI lights up.
DTC No.

Detected items

Engine operating condition in fail-safe mode

P0102
P0103

Mass air flow sensor circuit

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

P0117
P0118

Engine coolant temperature sensor circuit

Engine coolant temperature will be determined by ECM based on the time after
turning ignition switch “ON” or “START”.
CONSULT-II displays the engine coolant temperature decided by ECM.
Condition

Engine coolant temperature decided
(CONSULT-II display)

Just as ignition switch is turned
ON or Start

40°C (104°F)

More than approx. 4 minutes
after ignition ON or Start

80°C (176°F)

Except as shown above

40 — 80°C (104 — 176°F)
(Depends on the time)

When the fail-safe system for engine coolant temperature sensor is activated,
the cooling fan operates while engine is running.
P0122
P0123
P0222
P0223
P2135

Throttle position sensor

The ECM controls the electric throttle control actuator in regulating the throttle
opening in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than
the normal condition.
So, the acceleration will be poor.

P1121

Electric throttle control actuator
(ECM detect the throttle valve is
stuck open.)

While the vehicle is driving, it slows down gradually by fuel cut. After the
vehicle stops, the engine stalls.
The engine can restart in “N” or “P” position, and engine speed will not exceed
1,000 rpm or more.

P1122

Electric throttle control function

ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring.

P1124
P1126

Throttle control motor relay

ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring.

P1128

Throttle control motor

ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring

P1229

Sensor power supply

ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring.

P2122
P2123
P2127
P2128
P2138

Accelerator pedal position sensor The ECM controls the electric throttle control actuator in regulating the throttle
opening in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than
the normal condition.
So, the acceleration will be poor.

EC-65

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

Basic Inspection
Preparation
+
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Make sure that the following parts are in
good order.
Battery
Ignition system
Engine oil and coolant levels
Fuses
ECM harness connector
Vacuum hoses
Air intake system
(Oil filler cap, oil level gauge, etc.)
Fuel pressure

(9) Engine compression
(10) Throttle valve
+ On air conditioner equipped models,
checks should be carried out while the air
conditioner is “OFF”.
+ When measuring “CO” percentage, insert
probe more than 40 cm (15.7 in) into tail
pipe.
+ Turn off headlamps, heater blower, rear
window defogger.
+ Keep front wheels pointed straight ahead.

Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
+ Headlamp switch is OFF,
+ Air conditioner switch is OFF,
+ Rear window defogger switch is OFF,
+ Steering wheel is in the straight-ahead position, etc.

SEC297D

BEFORE STARTING
1. Check service records for any recent
repairs that may indicate a related
malfunction, or a current need for
scheduled maintenance.
2. Open engine hood and check the following:
+ Harness connectors for improper connections
+ Wiring harness for improper
connections, pinches, and cuts
+ Vacuum hoses for splits, kinks and
improper connections
+ Hoses and ducts for leaks
+ Air cleaner clogging
+ Gasket

SEF976U
.

1. Start engine and warm it up until
engine coolant temperature indicator
points the middle of gauge.
Ensure engine stays below 1,000 rpm.
2. Run engine at about 2,000 rpm for
about 2 minutes under no-load.
3. Make sure that no DTC is displayed
with CONSULT-II.
.
SEF977U

EC-66

NG
c

Repair or replace components as necessary
according to corresponding “Diagnostic Procedure”.

A
V

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Basic Inspection (Cont’d)
A
V

D
V

CHECK TARGET IDLE SPEED.
With CONSULT-II

SEF978U

1. Run engine at about 2,000 rpm for
about 2 minutes under no-load.
2. Rev engine (2,000 to 3,000 rpm) two or
three times under no-load, then run
engine at idle speed for about 1
minute.
3. Read idle speed in “DATA MONITOR”
mode with CONSULT-II.
675±50 rpm (in “P” or “N” position)

.
c PERFORM THROTTLE
VALVE CLOSED POSITION LEARNING.
1. Stop engine.
2. Perform EC-31,
“Throttle Valve Closed
Position Learning”.

OK
.

PERFORM IDLE AIR
VOLUME LEARNING.
Refer to EC-31, “Idle Air
Volume Learning”.
Is “Idle Air Volume
Learning” carried out
successfully?

Without CONSULT-II
1. Run engine at about 2,000 rpm for
about 2 minutes under no-load.
2. Rev engine (2,000 to 3,000 rpm) two or
three times under no-load, then run
engine at idle speed for about 1
minute.
3. Check idle speed.
675±50 rpm (in “P” or “N” position)

Yes

B
V

C
V

SEF058Y

1. Follow the construction
of “Idle Air Volume
Learning”.
2. Go to V
D .
.

CHECK IGNITION TIMING.
1. Run engine at idle.
2. Check ignition timing with a timing light.
10±5° BTDC (in “P” or “N” position)

NG
c

SEC536DA

ADJUST CAMSHAFT
POSITION SENSOR.
1. Start engine and warm
it up to normal operating temperature.
With CONSULT-II

K
V

OK
D b
V

2. Select “TARGET IGN
TIM ADJ” in “WORK
SUPPORT”.
3. Touch start.
4. Adjust camshaft position
sensor using timing
light.
10°±5° BTDC
Without CONSULT-II
2. Adjust camshaft position
sensor using timing
light.
10°±5° BTDC

SEC537D

NG
.

CHECK TIMING CHAIN
INSTALLATION.
Check timing chain installation.
Refer to “TIMING CHAIN”
in EM section.
.

D b
V

EC-67

Repair the timing chain
installation.

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Basic Inspection (Cont’d)
B
V
.

CHECK TARGET IDLE SPEED AGAIN.

NG
c

With CONSULT-II
1. Start engine and warm it up to normal
operating temperature.
2. Read idle speed in “DATA MONITOR”
mode with CONSULT-II.
675±50 rpm (in “P” or “N” position)
SEC536DA

Check the following.
+ Check camshaft position
sensor and circuit. Refer
to EC-257.
If NG, repair or replace.
Then go to V
D .
.

CHECK ECM FUNCTION.
1. Substitute another
known-good ECM to
check ECM function.
(ECM may be the cause
of an incident, but this
is the rarely the case.)
2. Perform initialization of
NATS (Nissan AntiTheft System) and registration of NATS
(Nissan Anti-Theft System) ignition key IDs.
Refer to EC-50, “NATS
(Nissan Anti-Theft System)”.

Without CONSULT-II
1. Start engine and warm it up to normal
operating temperature.
2. Check idle speed.
675±50 rpm (in “P” or “N” position)
OK

D
V
J
V
.

CHECK IGNITION TIMING.
1. Run engine at idle.
2. Check ignition timing with a timing light.
10°±5° BTDC (in “P” or “N” position)
OK

PERFOR THROTTLE
c
VALVE CLOSED POSITION LEARNING.
1. Stop engine.
2. Perform EC-31,
“Throttle Valve Closed
Position Learning”.

.
.

K
V

PERFORM IDLE AIR
VOLUME LEARNING.
Refer to EC-31, “Idle Air
Volume Learning”.
Is “Idle Air Volume
Learning” carried out
successfully?

Yes
.

.
H

G
V

V
H
V
.

1. Follow the construction
of “Idle Air Volume
Learning”.
2. Go to V
D .

EC-68

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Basic Inspection (Cont’d)
G
V

CHECK TARGET IDLE SPEED AGAIN.

NG
c

With CONSULT-II
1. Start engine and warm it up to normal
operating temperature.
2. Read idle speed in “DATA MONITOR”
mode with CONSULT-II.
675±50 rpm (in “P” or “N” position)
SEC536DA

Check the following.
+ Check camshaft position
sensor and circuit. Refer
to EC-257.
If NG, repair or replace.
Then go to V
D .
.

CHECK ECM FUNCTION.
1. Substitute another
known-good ECM to
check ECM function.
(ECM may be the cause
of a problem, but this is
the rarely the case.)
2. Perform initialization of
NATS (Nissan AntiTheft System) and registration of NATS (Nissan Anti-Theft System)
ignition key IDs. Refer
to EC-50, “NATS (Nissan Anti-Theft System)”.

Without CONSULT-II
1. Start engine and warm it up to normal
operating temperature.
2. Check idle speed.
675±50 rpm (in “P” or “N” position)
OK

SEC537D
.

D
V
.

CHECK IGNITION TIMING AGAIN.
1. Run engine at idle.
2. Check ignition timing with a timing light.
10±5° BTDC (in “P” or “N” position)

NG
c

ADJUST CAMSHAFT
POSITION SENSOR.
1. Start engine and warm
it up to normal operating temperature.
With CONSULT-II
2. Select “TARGET IGN
TIM ADJ” in “WORK
SUPPORT”.
3. Touch start.
4. Adjust camshaft position
sensor using timing
light.
10°±5° BTDC
Without CONSULT-II

K
V

OK
J
V

2. Adjust camshaft position
sensor using timing
light.
10°±5° BTDC
NG
.

CHECK TIMING CHAIN
INSTALLATION.
Check timing chain installation. Refer to EM
section, “TIMING CHAIN”.
If NG, repair the timing
chain installation. Then go
to V
D .
.

EC-69

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Basic Inspection (Cont’d)
K
V

With three way
catalyst
.

Set the diagnostic test mode II (Heated
oxygen sensor 1 monitor). Refer to
EC-52.

.
SAT652J

Run engine at about 2,000 rpm for about
2 minutes under no-load.

CHECK HEATED OXYGEN SENSOR 1
SIGNAL.
With CONSULT-II
1. See “HO2S1 MNTR” in “DATA MONITOR” mode.
2. Maintaining engine at 2,000 rpm under
no-load (engine is warmed up to normal operating temperature), check that
the monitor fluctuates between “LEAN”
and “RICH” more than 5 times during
10 seconds.
1 cycle: RICH → LEAN → RICH
2 cycles: RICH → LEAN → RICH →
LEAN → RICH
—————————————————————— OR ——————————————————————Without CONSULT-II
Make sure that malfunction indicator lamp
goes on and off more than 5 times during
10 seconds at 2,000 rpm.
OK
b
.

ERASE UNNECESSARY DTC.
After this inspection, unnecessary DTC
No. might be displayed.
Erase the stored memory in ECM and
TCM (Transmission control module).
Refer to “HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION,
EC-49.
OK
.

INSPECTION END

EC-70

NG
c

Check oxygen sensor and
the circuit.
OK

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

Symptom Matrix Chart
SYSTEM — BASIC ENGINE CONTROL SYSTEM

Warranty symptom code
Fuel

Fuel pressure regulator system

Injector circuit

Evaporative emission system

Positive crankcase ventilation system

Incorrect idle speed adjustment

Electric throttle control actuator

Incorrect ignition timing adjustment

Ignition circuit

Main power supply and ground circuit

Cooling

Ignition

Cooling fan circuit

Air conditioner circuit

BATTERY DEAD (UNDER CHARGE)

OVERCHARGING

OVERCOOLS

Reference page

AA AB AC AD AE AF AG AH AJ AK AL AM 1P 1X HA

Fuel pump circuit

Air

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

SLOW/NO RETURN TO IDLE

IDLING VIBRATION

ROUGH IDLE/HUNTING

HIGH IDLE/LOW IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

HESITATION/SURGING/FLAT SPOT

ENGINE STALL

SYSTEM
— Basic engine control system

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

1 — 6: The numbers refer to the order of inspection.

EC-71

3
4

EC-459

EC-34

EC-453

2
3

EC-269
1

EC-481
EC-30

EC-299
EC-301
EC-309
EC-315
EC-30
EC-428

2
1

EC-113

EC-361

HA section

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Symptom Matrix Chart (Cont’d)

Warranty symptom code
Engine control

BATTERY DEAD (UNDER CHARGE)

OVERCHARGING

OVERCOOLS

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

SLOW/NO RETURN TO IDLE

IDLING VIBRATION

ROUGH IDLE/HUNTING

HIGH IDLE/LOW IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

HESITATION/SURGING/FLAT SPOT

ENGINE STALL

SYSTEM
— Engine control system

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Reference page

AA AB AC AD AE AF AG AH AJ AK AL AM 1P 1X HA

Camshaft position sensor circuit

Mass air flow sensor circuit

Engine coolant temperature sensor circuit

Throttle position sensor circuit

Accelerator pedal position sensor circuit

Heated oxygen sensor 1 circuit

Start signal circuit

EC-257

EC-140

EC-152

EC-235
EC-372
EC-374
EC-415
EC-401
EC-408
EC-421

Vehicle speed sensor circuit
ECM

Intake valve timing control system
Knock sensor circuit

EC-172
EC-372
EC-320
EC-327

EC-294

EC-276

EC-247

EC-283
EC-450

Park/Neutral position switch circuit

Variable Induction Air Control (VIAS) system

3
2

EC-388
EC-446

Electrical load signal circuit

EC-470

Power steering pressure sensor circuit

EC-278

1 — 6: The numbers refer to the order of inspection.

EC-72

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Symptom Matrix Chart (Cont’d)
SYSTEM — ENGINE MECHANICAL & OTHER

Warranty symptom code
Fuel
Fuel tank
Fuel piping
Vapor lock
Valve deposit
Poor fuel (Heavy weight gasoline, Low
octane)
Air
Air duct
Air cleaner
Air leakage from air duct
(Mass air flow sensor — Electric throttle
control actuator)
Electric throttle control actuator, Throttle
wire
Air leakage from intake manifold/
Collector/Gasket
Cranking
Battery
Alternator circuit
Starter circuit
PNP switch
Drive plate
Engine
Cylinder head
Cylinder head gasket
Cylinder block
Piston
Piston ring
Connecting rod
Bearing
Crankshaft
Valve
Timing chain
mechanism Camshaft
Intake valve
Exhaust valve
Exhaust
Exhaust manifold/Tube/Muffler/Gasket
Three way catalyst*
Oil pan/Oil strainer/Oil pump/Oil filter/Oil
gallery
Oil level (Low)/Filthy oil
Cooling
Radiator/Hose/Radiator filler cap
Thermostat
Water pump
Water gallery
Cooling fan
Coolant level (low)/Contaminated coolant
NATS (Nissan Anti-Theft System)

BATTERY DEAD (UNDER CHARGE)

OVERCHARGING

OVERCOOLS

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEATS/WATER TEMPERATURE HIGH

SLOW/NO RETURN TO IDLE

IDLING VIBRATION

ROUGH IDLE/HUNTING

HIGH IDLE/LOW IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

HESITATION/SURGING/FLAT SPOT

ENGINE STALL

SYSTEM
— Engine mechanical & other

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Reference page

AA AB AC AD AE AF AG AH AJ AK AL AM 1P 1X HA
5
FE section
5
5
5
5
5
5
5
5
5

5
—

5
5

FE section
—

3
4
6

EL section
AT section
EM section

4
6
6

6
EM section

6
5

5
5

6
6

6
EM section &
FE section
FE section

Lubrication

5
LC section
2

5
2

1 — 6: The numbers refer to the order of inspection.

EC-73

EC section
MA section
EC-50 or EL
section

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

Engine Control Component Parts Location

SEC666D

EC-74

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Engine Control Component Parts Location
(Cont’d)

SEC733D

EC-75

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Engine Control Component Parts Location
(Cont’d)

SEC734D

EC-76

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Engine Control Component Parts Location
(Cont’d)

SEC744D

EC-77

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

Circuit Diagram

TEC410M

EC-78

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Circuit Diagram (Cont’d)

TEC329M

EC-79

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

ECM Harness Connector Terminal Layout

PBIB0075E

ECM Terminals and Reference Value
PREPARATION
1. ECM is located behind the center console. For this
inspection, remove instrument lower driver panel.
2. Remove ECM harness protector.

SEC667D

3. Perform all voltage measurements with the connector connected. Extend tester probe as shown to perform tests easily.
+ Open harness securing clip to make testing easily.
+ Use extreme care not to touch 2 pins at one time.
+ Data is for comparison and may not be exact.

MEC486B

ECM INSPECTION TABLE
Specification data are reference values and are measured
between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM’s
transistor. Use a ground other than ECM terminals, such as
the ground.

EC-80

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
ECM Terminals and Reference Value
(Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC voltage)
BATTERY VOLTAGE
(11 — 14V)*1

Engine is running.
Warm-up condition
Idle speed
5
6
7
13
14
15

BR/W
GY/L
BR/Y
GY/R
BR
GY

Injector
Injector
Injector
Injector
Injector
Injector

No.
No.
No.
No.
No.
No.

1
2
3
4
5
6

SEC984C

BATTERY VOLTAGE
(11 — 14V)*1
Engine is running.
Warm-up condition
Engine speed is 2,000 rpm.

SEC985C

Approximately 7.0V*1

Engine is running.

G/Y

Heated oxygen
sensor 1 heater
(bank 2)

Warm-up condition
Engine speed is below 2,800 rpm.

PBIB0519E

Engine is running.
Engine speed is above 2,800 rpm.

BATTERY VOLTAGE
(11 — 14V)
Approximately 7.0V*1

Engine is running.

Y/B

Heated oxygen
sensor 1 heater
(bank 1)

Warm-up condition
Engine speed is below 2,800 rpm.

PBIB0519E

Engine is running.
Engine speed is above 2,800 rpm.

BATTERY VOLTAGE
(11 — 14V)

Engine is running.

Y/R

Heated oxygen
sensor 2 heater
(bank 2)

Warm-up condition
After keeping engine speed between
3,500 and 4,000 rpm for one minute and
at idle for one minute under no load
Engine speed is below 3,200 rpm

0 — 1.0V

Ignition switch “ON”
Engine stopped
Engine is running.
Engine speed is above 3,200 rpm

EC-81

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
ECM Terminals and Reference Value
(Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC voltage)

Engine is running.

R/G

Warm-up condition
After keeping engine speed between
3,500 and 4,000 rpm for one minute and
at idle for one minute under no load
Engine speed is below 3,200 rpm

Heated oxygen
sensor 2 heater
(bank 1)

0 — 1.0V

Ignition switch “ON”
Engine stopped
Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Engine speed is above 3,200 rpm
0 — 0.1V*1

Engine is running.
Warm-up condition
Idle speed
18
19
20
21
29
30

Y/R
G
Y
R/B
R/G
R

Ignition
Ignition
Ignition
Ignition
Ignition
Ignition

signal
signal
signal
signal
signal
signal

No.
No.
No.
No.
No.
No.

1
2
3
4
5
6

SEC986C

0 — 0.2V*1

Engine is running.
Warm-up condition
Engine speed is 2,000 rpm.

SEC987C

P/L

LG/R

Throttle control
motor relay

VIAS control solenoid valve

Ignition switch “OFF”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”

0 — 1.0V

Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Idle speed
Engine is running.

0 — 1.0V
Engine speed is above 5,000 rpm.

Y/G

Ignition switch “ON”

0 — 1.0V

Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Idle speed
Ignition switch “ON”

R/Y

Fuel pump relay

For 5 seconds after turning ignition switch
“ON”
Engine is running.

0 — 1.0V

Ignition switch “ON”
More than 5 seconds after turning ignition
switch “ON”

EC-82

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
ECM Terminals and Reference Value
(Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC voltage)

Engine is running.
Ignition switch “OFF”

B/Y

ECM relay
(Self shut-off)

0 — 1.0V

For 5 seconds after turning ignition switch
“OFF”
Ignition switch “OFF”
5 seconds passed after turning ignition
switch “OFF”

W/G

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “OFF”

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch

BATTERY VOLTAGE
(11 — 14V)*1
Engine is running.
Idle speed

W/B

EVAP canister
purge volume control solenoid valve

SEC990C

BATTERY VOLTAGE
(11 — 14V)*1
Engine is running.
Engine speed is about 2,000 rpm (More
than 100 seconds after starting engine).

SEC991C

Engine is running.
0 — 1.0V
55

L/B

Cooling fan relay
(High)

Cooling fan is operating at high speed.
Engine is running.
Cooling fan is not operating.

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
0 — 1.0V
56

Cooling fan relay
(Low)

Cooling fan is operating.
Engine is running.
Cooling fan is not operating.

R/W

Start signal

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”

Approximately 0V

Ignition switch “START”

9 — 14V

Ignition switch “ON”
Approx. 0V
Snow mode switch is “OFF”
60

Y/G

Snow mode switch
Ignition switch “ON”
Snow mode switch is “ON”

EC-83

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
ECM Terminals and Reference Value
(Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC voltage)
Approx. 2.6 — 2.7V*1

Engine is running.
Warm-up condition
Idle speed

B/W

Camshaft position
sensor (POS signal)

SEC750D

Approx. 2.5 — 2.6V*1

Engine is running.
Engine speed is 2,000 rpm

SEC751D

Ignition switch “ON”
Approximately 0V
Gear position is Neutral.
80

R/PU

PNP switch
Ignition switch “ON”
Approximately 5V
Except the above gear position
Approx. 0.3 — 0.6V*1

Engine is running. (Warm-up condition)
Idle speed

83
84

L
L

SEC746D

Camshaft position
sensor (REF signal)

Approx. 0.3 — 0.6V*1

Engine is running.
Engine speed is 2,000 rpm

SEC747D

Ignition switch “ON”

Accelerator pedal
position sensor 1

Engine stopped
Gear position is “D”
Accelerator pedal fully released

More than 0.36V

Ignition switch “ON”
Engine stopped
Gear position is “D”
Accelerator pedal fully depressed

EC-84

Less than 4.75V

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
ECM Terminals and Reference Value
(Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC voltage)

Engine is running.
88

R/G

Refrigerant pressure sensor

Warm-up condition
Both A/C switch and blower switch are
“ON”
(Compressor operates)

1.0 — 4.0V

Engine is running.
89

Sensors’ ground

Warm-up condition
Idle speed

Approximately 0V

Engine is running.

W/G

Mass air flow sensor

Warm-up condition
Idle speed

0.75 — 1.2V

Engine is running.
Warm-up condition
Engine speed is 2,500 rpm.

1.7 — 2.4V

Accelerator pedal
position sensor 2
power supply

Ignition switch “ON”

Approximately 2.5V

Power supply for
ECM (Buck-up)

Ignition switch “OFF”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”

R/L

Throttle position
sensor 2

Engine stopped
Gear position is “D”
Accelerator pedal fully released

Less than 4.75V

Ignition switch “ON”
Engine stopped
Gear position is “D”
Accelerator pedal fully depressed

More than 0.36V

L/W

Intake air temperature sensor

Engine is running.

Approximately 0 — 4.8V
Output voltage varies with
intake air temperature.

100

Accelerator pedal
position sensor 2
ground

Ignition switch “ON”

Approximately 0V

103

Sensors’ power
supply

Ignition switch “ON”

Approximately 5V

Engine is running.
Approximately 0V
Brake pedal fully released
106

G/Y

Stop lamp switch
Engine is running.
Brake pedal fully depressed

EC-85

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
ECM Terminals and Reference Value
(Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC voltage)

Ignition switch “ON”

108

Throttle position
sensor 1

Engine stopped
Gear position is “D”
Accelerator pedal fully released

More than 0.36V

Ignition switch “ON”
Engine stopped
Gear position is “D”
Accelerator pedal fully depressed

Less than 4.75V

Engine is running.
109

B/W

Mass air flow sensor ground

Warm-up condition
Idle speed

Approximately 0V

1 — 2V
(AC range)
Engine is running.
Warm-up condition
Idle speed

111

SEC748D

Crankshaft position
sensor (OBD)

3 — 4V
(AC range)
Engine is running.
Engine speed is 2,000 rpm.

SEC749D

Engine is running.
114

Heated oxygen
sensor 1 (bank 1)

115

Heated oxygen
sensor 1 (bank 2)

Warm-up condition
Engine speed is 2,000 rpm.

0 — Approximately 1.0V (Periodically change)

Engine is running.
Warm-up condition
Engine speed is 2,000 rpm.

0 — Approximately 1.0V (Periodically change)

Ignition switch “ON”

117

Accelerator pedal
position sensor 2

Engine stopped
Gear position is “D”
Accelerator pedal fully released

More than 0.18V

Ignition switch “ON”
Engine stopped
Gear position is “D”
Accelerator pedal fully depressed

Less than 2.37V

Engine is running.
0.5 — 4.5V
118

BR/W

Power steering
pressure sensor

Steering wheel is being turned
Engine is running.
0.4 — 0.8V
Steering wheel is not being turned

EC-86

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
ECM Terminals and Reference Value
(Cont’d)
TERMINAL
NO.
121

WIRE
COLOR
LG/B

ITEM
Engine coolant temperature sensor

CONDITION

Engine is running.

DATA (DC voltage)
Approximately 0 — 4.8V
Output voltage varies with
engine coolant temperature.

Engine is running.

123

Heated oxygen
sensor 2 (bank 2)

Warm-up condition
Revving engine from idle to 3,000 rpm
quickly after the following conditions are
met
After keeping the engine speed between
3,500 and 4,000 rpm for one minute and
at idle for one minute under no load

0 — Approximately 1.0V

Engine is running.

124

Heated oxygen
sensor 2 (bank 1)

125
126

W
W

Knock sensor
(Bank 1)
Knock sensor
(Bank 2)

0 — Approximately 1.0V

Engine is running.
Approximately 2.5V
Idle speed
0 — 14V*1
Ignition switch “ON”

151

L/W

Throttle control
motor (Open)

Engine stopped
Gear position is “D”
Accelerator pedal is depressing
PBIB1105E

Engine is running.

152

Intake valve timing
control solenoid
valve

Warm-up condition
Engine speed is between 1,000 rpm and
4,200 rpm
During high load condition
Vehicle speed is more than 8 km/h (5
MPH)
Engine is running.
Those other than above

153
156
159
165
168

B
B
B
B
B

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
ECM ground

Engine ground
Idle speed

EC-87

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
ECM Terminals and Reference Value
(Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC voltage)
0 — 14V*1

Ignition switch “ON”
154

L/B

Throttle control
motor (Close)

Engine stopped
Gear position is “D”
Accelerator pedal is releasing
PBIB1105E

157

Throttle control
motor relay power
supply

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

163
166

B/R

Power supply for
ECM

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

164

Data link connector

Ignition switch “ON”
CONSULT-II or GST is disconnected.

BATTERY VOLTAGE
(11 — 14V)

171

W/R

CAN communication line

Ignition switch “ON”

Approximately 1.7 — 2.3V
Output voltage varies with the
communication status.

174

G/B

CAN communication line

Ignition switch “ON”

Approximately 2.6 — 3.2V
Output voltage varies with the
communication status.

*1: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-88

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

CONSULT-II Function
FUNCTION
Diagnostic test mode
Work support

Function
This mode enables a technician to adjust some devices faster and more accurately by following the
indications on the CONSULT-II unit.

Self-diagnostic results

Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame
data can be read and erased quickly.*1

Data monitor

Input/Output data in the ECM can be read.

Data monitor (SPEC)

Input/Output of the specification for Basic fuel schedule, AFM, A/F feedback control value and the
other data monitor items can be read.

Active test

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

Function test

This mode is used to inform customers when their vehicle condition requires periodic maintenance.

DTC & SRT confirmation

The status of system monitoring tests and the self-diagnosis status/result can be confirmed.

ECM part number

ECM part number can be read.

*1: The following emission-related diagnostic information is cleared when the ECM memory is erased.
+ Diagnostic trouble codes
+ 1st trip diagnostic trouble codes
+ Freeze frame data
+ 1st trip freeze frame data
+ System readiness test (SRT) codes
+ Test values
+ Others

EC-89

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE

Item

WORK
SUPPORT

DTC*1

FREEZE
FRAME
DATA

Camshaft position sensor

Mass air flow sensor

Engine coolant temperature sensor

Heated oxygen sensor 1
Heated oxygen sensor 2

INPUT

Crankshaft position sensor
(OBD)

ENGINE CONTROL COMPONENT PARTS

SELF-DIAGNOSTIC
RESULTS

DTC & SRT CONFIRMATION
ACTIVE
TEST

DTC
WORK
SUPPORT

x
x

Vehicle speed signal

Accelerator pedal position sensor

Throttle position sensor

Refrigerant pressure sensor

Closed throttle position switch
(accelerator pedal position sensor signal)

Air conditioner switch

Intake air temperature sensor

Knock sensor

Park/neutral position (PNP)
switch

Stop lamp switch

Power steering pressure sensor

Battery voltage

Electrical load signal

Injectors

x
x

Throttle control motor relay

Throttle control motor

EVAP canister purge volume
control solenoid valve

Air conditioner relay
Fuel pump relay

SRT
STATUS

Power transistor (Ignition timing)

OUTPUT

DATA
MONITOR

DATA
MONITOR
(SPEC)

Cooling fan relay

Heated oxygen sensor 1 heater

Heated oxygen sensor 2 heater

Intake valve timing control solenoid valve

Calculated load value

VIAS control solenoid valve

x: Applicable
*1: This item includes 1st trip DTCs.
*2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame
data mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-41, “FREEZE FRAME DATA AND 1ST TRIP
FREEZE FRAME DATA”.

EC-90

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
CONSULT-II INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to
data link connector, which is located under the drivers side
dash panel.
3. Turn ignition switch ON.

SAT619K

4. Touch “START (NISSAN BASED VHCL)”.

MBIB0233E

5. Touch “ENGINE”.
If “ENGINE” is not indicated, go to GI section, “CONSULT-II
Data Link Connector (DLC) Circuit”.

SEF995X

6. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT-II Operation
Manual.

SEF824Y

EC-91

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
WORK SUPPORT MODE
Work item
WORK ITEM

CONDITION

USAGE

FUEL PRESSURE RELEASE

+ FUEL PUMP WILL STOP BY TOUCHING “START”
DURING IDLING.
CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure from
fuel line

IDLE AIR VOL LEARN

+ THE IDLE AIR VOLUME THAT KEEPS THE
ENGINE WITHIN THE SPECIFIED RANGE IS
MEMORIZED IN ECM.

When learning the idle air volume

SELF-LEARNING CONT

+ THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.

When clearing the coefficient of
self-learning control value

TARGET IDLE RPM ADJ*

+ IDLE CONDITION

When setting target idle speed

TARGET IGN TIM ADJ*

+ IDLE CONDITION

When adjusting target ignition timing

*: This function is not necessary in the usual service procedure.

SELF-DIAG RESULTS MODE
Self diagnostic item
Regarding items of “DTC and 1st trip DTC”, refer to EC-9, “INDEX FOR DTC”.

Freeze frame data and 1st trip freeze frame data
Freeze frame data
item*1

Description

DIAG TROUBLE CODE
[PXXXX]

+ The engine control component part/control system has a trouble code, it is displayed as “PXXXX”.
(Refer to EC-9, “INDEX FOR DTC”.)

FUEL SYS-B1

+ “Fuel injection system status” at the moment a malfunction is detected is displayed.
+ One mode in the following is displayed.
“MODE 2”: Open loop due to detected system malfunction
“MODE 3”: Open loop due to driving conditions (power enrichment, deceleration enrichment)
“MODE 4”: Closed loop — using oxygen sensor(s) as feedback for fuel control
“MODE 5”: Open loop — has not yet satisfied condition to go to closed loop

FUEL SYS-B2

CAL/LD VALUE [%]

+ The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP [°C] or + The engine coolant temperature at the moment a malfunction is detected is displayed.
[°F]
L-FUEL TRIM-B1 [%]

+ “Long-term fuel trim” at the moment a malfunction is detected is displayed.
+ The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim.

S-FUEL TRIM-B1 [%]

+ “Short-term fuel trim” at the moment a malfunction is detected is displayed.
+ The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.

ENGINE SPEED [rpm]

+ The engine speed at the moment a malfunction is detected is displayed.

VHCL SPEED [km/h] or
[mph]

+ The vehicle speed at the moment a malfunction is detected is displayed.

B/FUEL SCHDL [msec]

+ The base fuel schedule at the moment a malfunction is detected is displayed.

INT/A TEMP SE [°C] or
[°F]

+ The intake air temperature at the moment a malfunction is detected is displayed.

*1: The items are the same as those of 1st trip freeze frame data.

EC-92

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
DATA MONITOR MODE
Monitored item
x: Applicable

Monitored item [Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

CAN
DIAG
SUPPORT
MNTR

Description

Remarks

ENG SPEED [rpm]

+ Accuracy becomes poor if engine
+ Indicates the engine speed comspeed drops below the idle rpm.
puted from the POS signal (1° sig+ If the signal is interrupted while
nal) of the camshaft position senthe engine is running, an abnormal
sor.
value may be indicated.

MAS A/F SE-B1 [V]

+ The signal voltage of the mass air
flow sensor is displayed.

B/FUEL SCHDL
[msec]

+ “Base fuel schedule” indicates the
fuel injection pulse width programmed into ECM, prior to any
learned on board correction.

A/F ALPHA-B1 [%]

A/F ALPHA-B2 [%]

COOLAN TEMP/S
[°C] or [°F]

+ When the engine is stopped, a
certain value is indicated.
+ The mean value of the air-fuel
ratio feedback correction factor per + This data also includes the data
for the air-fuel ratio learning concycle is indicated.
trol.
+ The engine coolant temperature
(determined by the signal voltage
of the engine coolant temperature
sensor) is displayed.

HO2S1 (B1) [V]

HO2S1 (B2) [V]

+ The signal voltage of the heated
oxygen sensor 1 is displayed.

+ The signal voltage of the heated
oxygen sensor 2 is displayed.

HO2S2 (B1) [V]

HO2S2 (B2) [V]

HO2S1 MNTR (B1)
[RICH/LEAN]

HO2S1 MNTR (B2)
[RICH/LEAN]

HO2S2 MNTR (B1)
[RICH/LEAN]

HO2S2 MNTR (B2)
[RICH/LEAN]

VHCL SPEED SE
[km/h] or [mph]

+ When the engine is stopped, a
certain value is indicated.

+ When the engine coolant temperature sensor is open or shortcircuited, ECM enters fail-safe
mode. The engine coolant temperature determined by the ECM
is displayed.

+ Display of heated oxygen sensor 1
+ After turning ON the ignition
signal during air-fuel ratio feedswitch, “RICH” is displayed until
back control:
air-fuel mixture ratio feedback conRICH … means the mixture
trol begins.
became “rich”, and control is being
+ When the air-fuel ratio feedback is
affected toward a leaner mixture.
clamped, the value just before the
LEAN … means the mixture
clamping is displayed continubecame “lean”, and control is
ously.
being affected toward a rich mixture.
+ Display of heated oxygen sensor 2
signal:
RICH … means the amount of
oxygen after three way catalyst is + When the engine is stopped, a
certain value is indicated.
relatively small.
LEAN … means the amount of
oxygen after three way catalyst is
relatively large.

+ The vehicle speed computed from
the vehicle speed signal is displayed.

EC-93

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
CAN
DIAG
SUPPORT
MNTR

Monitored item [Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

BATTERY VOLT [V]

ACCEL SEN 1 [V]

ACCEL SEN 2 [V]

+ The accelerator pedal position
sensor signal voltage is displayed.

+ The throttle position sensor signal
voltage is displayed.

THRTL SEN 1 [V]

THRTL SEN 2 [V]

INT/A TEMP SE [°C]
or [°F]

START SIGNAL
[ON/OFF]

CLSD THL POS
[ON/OFF]

Description

+ The power supply voltage of ECM
is displayed.

+ The intake air temperature (determined by the signal voltage of the
intake air temperature sensor) is
indicated.

+ Indicates [ON/OFF] condition of
the starter signal computed from
the signals of the crankshaft position sensor (POS), camshaft position sensor (PHASE) and battery
voltage.

+ Indicates idle position [ON/OFF]
computed by ECM according to
the accelerator pedal position sensor signal.

AIR COND SIG
[ON/OFF]

+ Indicates [ON/OFF] condition of
the air conditioner switch as determined by the air conditioner signal.

P/N POSI SW
[ON/OFF]

+ Indicates [ON/OFF] condition from
the park/neutral position (PNP)
switch signal.

+ [ON/OFF] condition of the power
steering oil pressure switch as
determined by the power steering
oil pressure signal is indicated.

+ Indicates [ON/OFF] condition from
the electrical load signal.
ON … Rear window defogger
switch is ON and/or lighting switch
is in 2nd position.
OFF … Both rear window defogger
switch and lighting switch are
OFF.

PW/ST SIGNAL
[ON/OFF]

LOAD SIGNAL
[ON/OFF]

IGNITION SW
[ON/OFF]

+ Indicates [ON/OFF] condition from
ignition switch.

BRAKE SW
[ON/OFF]

+ Indicates [ON/OFF] condition from
the stop lamp switch signal.

INJ PULSE-B1
[msec]

INJ PULSE-B2
[msec]
IGN TIMING [BTDC]

Remarks

+ After starting the engine, [OFF] is
displayed regardless of the starter
signal.

+ Indicates the actual fuel injection
pulse width compensated by ECM
according to the input signals.

+ When the engine is stopped, a
certain computed value is indicated.

+ Indicates the ignition timing computed by ECM according to the
input signals.

+ When the engine is stopped, a
certain value is indicated.

EC-94

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
Monitored item [Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

CAN
DIAG
SUPPORT
MNTR

Description

CAL/LD VALUE [%]

+ “Calculated load value” indicates
the value of the current airflow
divided by peak airflow.

MASS AIRFLOW
[gzm/s]

+ Indicates the mass airflow computed by ECM according to the
signal voltage of the mass air flow
sensor.

PURG VOL C/V [%]

+ Indicates the EVAP canister purge
volume control solenoid valve control value computed by the ECM
according to the input signals.
+ The opening becomes larger as
the value increases.

VIAS S/V [ON/OFF]

+ The control condition of the VIAS
control solenoid valve (determined
by ECM according to the input signal) is indicated.
+ OFF … VIAS control solenoid
valve is not operating.
+ ON … VIAS control solenoid valve
is operating.

INT/V SOL (B1) [%]

+ The control condition of the intake
valve timing control solenoid valve
(determined by ECM according to
the input signals) is indicated.
ON … intake valve timing control
is operating.
OFF … Intake valve timing control
is not operating.

AIR COND RLY
[ON/OFF]

+ The air conditioner relay control
condition (determined by ECM
according to the input signals) is
indicated.

FUEL PUMP RLY
[ON/OFF]

+ Indicates the fuel pump relay control condition determined by ECM
according to the input signals.

x*2

+ Indicates the throttle control motor
relay control condition determined
by the ECM according to the input
signals.

THRTL RELAY
[ON/OFF]

COOLING FAN
[HI/LOW/OFF]

HO2S1 HTR (B1)
[ON/OFF]
HO2S1 HTR (B2)
[ON/OFF]

+ Indicates the condition of the cooling fan (determined by ECM
according to the input signals).
HI … High speed operation
LOW … Low speed operation
OFF … Stop
+ Indicates [ON/OFF] condition of
heated oxygen sensor 1 heater
determined by ECM according to
the input signals.

EC-95

Remarks

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
Monitored item [Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

CAN
DIAG
SUPPORT
MNTR

HO2S2 HTR (B1)
[ON/OFF]

Description

+ Indicates [ON/OFF] condition of
heated oxygen sensor 2 heater
determined by ECM according to
the input signals.

HO2S2 HTR (B2)
[ON/OFF]

IDL A/V LEARN
[YET/CMPLT]

+ Display the condition of idle air
volume learning
YET … Idle air volume learning
has not been performed yet.
CMPLT … Idle air volume learning
has already been performed successfully.

TRVL AFTER MIL
[km] or [mile]

+ Distance traveled while MI is activated.

O2SEN HTR DTY
[%]

+ Indicates the heated oxygen sensor 1 heater control value computed by the ECM according to
the input signals.

AC PRESS SEN [V]

Remarks

+ The signal voltage from the refrigerant pressure sensor is displayed.

Voltage [V]
Frequency
[msec], [Hz] or [%]
DUTY-HI
DUTY-LOW

+ Voltage, frequency, duty cycle or
pulse width measured by the
probe.

+ Only “#” is displayed if item is
unable to be measured.
+ Figures with “#”s are temporary
ones. They are the same figures
as an actual piece of data which
was just previously measured.

+ Indicates the communication condition of CAN communication line.

+ These items are not displayed in
“SELECTION FROM MENU”
mode.

PLS WIDTH-HI
PLS WIDTH-LOW
CAN COMM
[OK/NG]

CAN CIRC 1
[OK/UNKWN]

CAN CIRC 2
[OK/UNKWN]

CAN CIRC 3
[OK/UNKWN]

CAN CIRC 4
[OK/UNKWN]

CAN CIRC 5
[OK/UNKWN]

CAN CIRC 6
[OK/UNKWN]

CAN CIRC 7
[OK/UNKWN]

NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-96

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
DATA MONITOR (SPEC) MODE
Monitored item
ECM input
signals

Main signals

Description

ENG SPEED [rpm]

+ Indicates the engine speed computed
from the POS signal (1° signal) of the
camshaft position sensor.

MAS A/F SE-B1 [V]

+ The signal voltage of the mass air
flow sensor specification is displayed.

B/FUEL SCHDL
[msec]

+ “Base fuel schedule” indicates the
fuel injection pulse width programmed + When engine is running specification
range is indicated.
into ECM, prior to any learned on
board correction.

A/F ALPHA-B1 [%]

A/F ALPHA-B2 [%]

Monitored item [Unit]

Remarks

+ When engine is running specification
range is indicated.

+ When engine is running specification
+ The mean value of the air-fuel ratio
range is indicated.
feedback correction factor per cycle is
+ This data also includes the data for
indicated.
the air-fuel ratio learning control.

NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

ACTIVE TEST MODE
Test item
TEST ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

+ Engine: Return to the original
trouble condition
FUEL INJECTION
+ Change the amount of fuel injection using CONSULT-II.

If trouble symptom disappears, see
CHECK ITEM.

+ Harness and connectors
+ Fuel injectors
+ Heated oxygen sensor 1

+ Engine: Return to the original
trouble condition
IGNITION TIMING + Timing light: Set
+ Retard the ignition timing using
CONSULT-II.

If trouble symptom disappears, see
CHECK ITEM.

+ Perform “Idle Air Volume Learning”.

Harness and connectors
Compression
Fuel injectors
Power transistor
Spark plugs
Ignition coils

POWER BALANCE

+ Engine: After warming up, idle
the engine.
+ A/C switch “OFF”
Engine runs rough or dies.
+ Shift lever “N”
+ Cut off each injector signal one at
a time using CONSULT-II.

+
+
+
+
+
+

COOLING FAN*

+ Ignition switch: ON
+ Turn the cooling fan “ON” and
“OFF” with CONSULT-II.

Cooling fan moves and stops.

+ Harness and connectors
+ Cooling fan relay
+ Cooling fan motor

ENG COOLANT
TEMP

+ Engine: Return to the original
trouble condition
+ Change the engine coolant temperature using CONSULT-II.

If trouble symptom disappears, see
CHECK ITEM.

+ Harness and connectors
+ Engine coolant temperature sensor
+ Fuel injectors

FUEL PUMP
RELAY

+ Ignition switch: ON (Engine
stopped)
+ Turn the fuel pump relay “ON”
and “OFF” using CONSULT-II
and listen to operating sound.

Fuel pump relay makes the operating sound.

+ Harness and connectors
+ Fuel pump relay

Solenoid valve makes an operating
sound.

+ Harness and connectors
+ Solenoid valve

+ Ignition switch: ON
+ Turn solenoid valve “ON” and
VIAS SOL VALVE
“OFF” with CONSULT-II and listen for operating sound.

EC-97

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
TEST ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

PURG VOL
CONT/V

+ Engine: After warming up, run
engine at 1,500 rpm.
+ Change the EVAP canister purge Engine speed changes according to + Harness and connectors
the opening percent.
+ Solenoid valve
volume control solenoid valve
opening percent using CONSULT-II.

V/T ASSIGN
ANGLE

+ Engine: Return to the original
trouble condition
+ Change intake valve timing using
CONSULT-II.

If trouble symptom disappears, see
CHECK ITEM.

+ Harness and connectors
+ Intake valve timing control solenoid valve

*: Leaving cooling fan “OFF” with CONSULT-II while engine is running may cause the engine to overheat.

DTC & SRT CONFIRMATION MODE
SRT STATUS mode
For details, refer to EC-42, “SYSTEM READINESS TEST (SRT) CODE”.

SRT work support mode
This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.

DTC work support mode
Test mode

Test item

Condition

Reference page

HO2S1 (B1) P0133, P0153

EC-172

HO2S1 (B1) P0134, P0154

EC-185

HO2S1
HO2S1 (B1) P1143, P1163

EC-320
Refer to corresponding
trouble diagnosis for DTC.

HO2S1 (B1) P1144, P1164

H02S2

EC-327

HO2S2 (B1) P0139, P0159

EC-205

HO2S2 (B1) P1146, P1166

EC-335

HO2S2 (B1) P1147, P1167

EC-348

EC-98

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
(RECORDING VEHICLE DATA)
Description

SEF705Y

SEF707X

CONSULT-II has two kinds of triggers and they can be selected
by touching “SETTING” in “DATA MONITOR” mode.
1. “AUTO TRIG” (Automatic trigger):
+ The malfunction will be identified on the CONSULT-II screen
in real time.
In other words, DTC/1st trip DTC and malfunction item will be
displayed if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording
Data … xx%” as shown at right, and the data after the malfunction detection is recorded. Then when the percentage
reached 100%, “REAL-TIME DIAG” screen is displayed. If
“STOP” is touched on the screen during “Recording Data …
xx%”, “REAL-TIME DIAG” screen is also displayed.
The recording time after the malfunction detection and the
recording speed can be changed by “TRIGGER POINT” and
“Recording Speed”. Refer to CONSULT-II OPERATION
MANUAL.
2. “MANU TRIG” (Manual trigger):
+ DTC/1st trip DTC and malfunction item will not be displayed
automatically on CONSULT-II screen even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even
though a malfunction is detected.

Operation
1. “AUTO TRIG”
+ While trying to detect the DTC/1st trip DTC by performing the
“DTC Confirmation Procedure”, be sure to select to “DATA
MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected.
+ While narrowing down the possible causes, CONSULT-II
should be set in “DATA MONITOR (AUTO TRIG)” mode,
especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or
twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a
malfunction is found the DTC/1st trip DTC will be displayed.
(Refer to “Incident Simulation Tests” in GI section.)
2. “MANU TRIG”
+ If the malfunction is displayed as soon as “DATA MONITOR”
is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The
data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

EC-99

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Function (Cont’d)

PBIB0197E

EC-100

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

Generic Scan Tool (GST) Function
DESCRIPTION
Generic Scan Tool (OBDII scan tool) complying with ISO
15031-4 has 8 different functions explained below.
ISO9141 is used as the protocol.
The name “GST” or “Generic Scan Tool” is used in this service
manual.

SEF139P

FUNCTION
Diagnostic test mode

Function

MODE 1

READINESS TESTS

MODE 2

(FREEZE DATA)

MODE 3

DTCs

This mode gains access to current emission-related data values, including analog
inputs and outputs, digital inputs and outputs, and system status information.
This mode gains access to emission-related data value which were stored by ECM during the freeze frame. For details, refer to EC-41, “FREEZE FRAME DATA AND 1ST
TRIP FREEZE FRAME DATA”.
This mode gains access to emission-related power train trouble codes which were
stored by ECM.
This mode can clear all emission-related diagnostic information. This includes:
+ Clear number of diagnostic trouble codes (MODE 1)
+ Clear diagnostic trouble codes (MODE 3)
+ Clear trouble code for freeze frame data (MODE 1)
+ Clear freeze frame data (MODE 2)
+ Reset status of system monitoring test (MODE 1)
+ Clear on board monitoring test results (MODE 6 and 7)

MODE 4

CLEAR DIAG INFO

MODE 6

(ON BOARD TESTS)

This mode accesses the results of on board diagnostic monitoring tests of specific
components/systems that are not continuously monitored.

MODE 7

(ON BOARD TESTS)

This mode enables the off board test drive to obtain test results for emission-related
powertrain components/systems that are continuously monitored during normal driving
conditions.

MODE 8

—

MODE 9

(CALIBRATION ID)

This mode is not applicable on this vehicle.
This mode enables the off-board test device to request specific vehicle information
such as Vehicle Identification Number (VIN) and Calibration IDs.

GST INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Connect “GST” to data link connector, which is located under
the driver side dash panel near the fuse box cover.
3. Turn ignition switch ON.

SAT619K

EC-101

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Generic Scan Tool (GST) Function (Cont’d)
4. Enter the program according to instruction on the screen or
in the operation manual.
(*: Regarding GST screens in this section, sample screens are
shown.)

SEF398S

5. Perform each diagnostic mode according to each service
procedure.
For further information, see the GST Operation Manual of
the tool maker.

SEF416S

EC-102

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

CONSULT-II Reference Value in Data Monitor
Mode
Remarks:
+ Specification data are reference values.
+ Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may
show the specification data in spite of the ignition timing not being adjusted to the specification data. This
IGN TIMING monitors the data calculated by the ECM according to the signals input from the camshaft
position sensor and other ignition timing related sensors.
MONITOR ITEM

CONDITION

SPECIFICATION

ENG SPEED

+ Tachometer: Connect
Almost the same speed as the
+ Run engine and compare CONSULT-II value with the tachometer indica- tachometer indication.
tion.

MAS A/F SE-B1

+
+
+
+

Engine: After warming up
Air conditioner switch: OFF
Shift lever: N
No-load

Idle

Approx. 1.3 — 1.7V

2,500 rpm

Approx. 1.7 — 2.4V

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

5.0 — 5.5 msec

2,000 rpm

5.0 — 5.5 msec

Maintaining engine speed at 2,000
rpm

75% — 125%

B/FUEL SCHDL

A/F ALPHA-B1
A/F ALPHA-B2

+ Engine: After warming up

COOLAN TEMP/S

+ Engine: After warming up

HO2S1 (B1)
HO2S1 (B2)

+ Engine: After warming up

HO2S2 (B1)
HO2S2 (B2)

Revving engine from idle up to 3,000
+ Engine: After warming up
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S1 MNTR (B1)
HO2S1 MNTR (B2)

+ Engine: After warming up

LEAN ←→ RICH
Changes more than 5 times
during 10 seconds.

HO2S2 MNTR (B1)
HO2S2 MNTR (B2)

+ Engine: After warming up
Revving engine from idle up to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

LEAN ←→ RICH

VEH SPEED SE

+ Turn drive wheels and compare CONSULT-II value with the speedometer indication.

Almost the same speed as the
speedometer indication

BATTERY VOLT

+ Ignition switch: ON (Engine stopped)

11 — 14V

ACCEL SEN1
ACCEL SEN2*

+ Ignition switch: ON
(engine stopped)
+ Shift lever: D

Accelerator pedal: Fully released

More than 0.36V

Accelerator pedal: Fully depressed

Less than 4.75V

+ Ignition switch: ON
(Engine stopped)
+ Shift lever: D

Accelerator pedal: Fully released

More than 0.5V

Accelerator pedal: Fully depressed

Less than 1.5V

THRTL SEN1
THRTL SEN2*

More than 70°C (158°F)
Maintaining engine speed at 2,000
rpm

Maintaining engine speed at 2,000
rpm

0 — 0.3V ←→ Approx. 0.6 1.0V

START SIGNAL

+ Ignition switch: ON → START → ON

OFF → ON → OFF

CLSD THL POS

+ Ignition switch: ON

Accelerator pedal: Fully released

Accelerator pedal: Slightly depressed OFF

EC-103

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Reference Value in Data Monitor
Mode (Cont’d)
MONITOR ITEM
AIR COND SIG

P/N POSI SW

PW/ST SIGNAL

LOAD SIGNAL

CONDITION
+ Engine: After warming up, idle
the engine

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

+ Ignition switch: ON

Shift lever: P or N

Shift lever: Except above

OFF

Steering wheel is in neutral position.
(Forward direction)

OFF

Steering wheel is turned.

Rear window defogger switch is ON
and/or lighting switch is in 2nd.

Rear window defogger switch is OFF
and lighting switch is OFF.

OFF

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

+ Engine: After warming up, idle
the engine

+ Ignition switch: ON

IGNITION SW

+ Ignition switch: ON → OFF → ON

BRAKE SW

+ Ignition switch: ON

INJ PULSE-B1
INJ PULSE-B2

IGN TIMING

CAL/LD VALUE

MASS AIRFLOW

PURG VOL C/V

VIAS S/V

INT/V SOL-B1

FUEL PUMP RLY

THRTL RELAY

ON → OFF → ON

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

3.0 — 4.0 msec

2,000 rpm

3.0 — 4.0 msec

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

10°±5° BTDC

2,000 rpm

25° — 45° BTDC

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

10% — 35%

2,500 rpm

10% — 35%

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

3.0 — 9.0 gzm/s

2,500 rpm

10.0 — 25.0 gzm/s

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

2,000 rpm

65 — 85%

Idle

OFF

More than 5,000 rpm

+ Engine: After warming up

+ Engine: Idle
+
+
+
+

AIR COND RLY

SPECIFICATION

OFF

Engine: After warning up
Engine speed is between 1,000 rpm and 4,200 rpm
Vehicle speed is more than 8 km/h (5 MPH).
During high load condition

+ Engine: After warming up, idle
the engine

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates)

+ For 1 seconds after turning ignition switch ON
+ Engine running or cranking

+ Except above conditions

OFF

+ Ignition switch: ON

EC-104

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
CONSULT-II Reference Value in Data Monitor
Mode (Cont’d)
MONITOR ITEM
COOLING FAN

HO2S1 HTR (B1)
HO2S1 HTR (B2)

HO2S2 HTR (B1)
HO2S2 HTR (B2)

CONDITION
+ Engine: After warming up, idle
the engine
+ Air conditioner switch: OFF
+ Vehicle stopped

SPECIFICATION

Engine coolant temperature is 94°C
(201°F) or less

OFF

Engine coolant temperature is
between 95°C (203°F) and 99°C
(210°F)

LOW

Engine coolant temperature is 100°C
(212°F) or more

HIGH

+ Engine: After warming up
+ Engine speed: Below 2,800 rpm

+ Engine speed: Above 2,800 rpm

OFF

+ Engine speed: Below 3,200 rpm after the following conditions are met.
+ Engine: After warming up
+ Keeping the engine speed between 3,500 and 4,000 rpm for one minute
and at idle for one minute under no load

+ Engine speed: Above 3,200 rpm

OFF

TRVL AFTER MIL

+ Ignition switch: ON

Vehicle has traveled after MI has
turned ON.

0 — 65,280 km
(0 — 40,565 mile)

O2SEN HTR DTY

+ Engine coolant temperature when engine started: More than 80° (176°F)
+ Engine speed: Below 2,800 rpm

Approx. 50%

AC PRESS SEN

+ Ignition switch: ON (Engine stopped)

Approx. 1.6V

+ Engine: Idle
+ Air conditioner switch: OFF

1.0 — 2.0V

VEH SPEED SE

+ Turn drive wheels and compare speedometer indication with the CONSULT-II value.

Almost the same speed as the
CONSULT-II value

CAN COMM

+ Ignition switch: ON

CAN CIRC 1

CAN CIRC 2

CAN CIRC 3

UNKWN

CAN CIRC 4

CAN CIRC 5

UNKWN

CAN CIRC 6

UNKWN

CAN CIRC 7

UNKWN

*: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ
from ECM terminals voltage signal.

EC-105

TROUBLE DIAGNOSIS

TB48DE A/T (WITH EURO-OBD)

Major Sensor Reference Graph in Data
Monitor Mode
The following are the major sensor reference graphs in “DATA MONITOR” mode.

CLSD THL POS, ACCEL SEN 1, THRTL SEN 1
Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelerator pedal with the ignition switch “ON” and with selector lever in “D” position.
The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or
rise after “CLSD THL POS” is changed from “ON” to “OFF”.

PBIB0198E

ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1
Below is the data for “ENG SPEED”, “MAS A/F SE-B1”, “THRTL SEN 1”, “HO2S2 (B1)”, “HO2S1 (B1)” and
“INJ PULSE-B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.

SEF241Y

EC-106

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Major Sensor Reference Graph in Data
Monitor Mode (Cont’d)

PBIB0668E

EC-107

TROUBLE DIAGNOSIS — SPECIFICATION
TB48DE A/T (WITH EURO-OBD)
VALUE
Description
The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR
(SPEC)” mode of CONSULT-II during normal operation of the Engine Control System. When the value in
“DATA MONITOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When
the value in “DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may
have one or more malfunctions.
The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the
MIL.
The SP value will be displayed for the following three items:
+ B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board
correction)
+ A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle)
+ MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)

Testing condition
Vehicle driven distance: More than 5,000 km (3,017 miles)
Barometric pressure: 98.3 — 104.3 kPa (0.98 — 1.04 bar, 1.003 — 1.064 kg/cm2, 14.25 — 15.12 psi)
Atmospheric temperature: 20 — 30°C (68 — 86°F)
Engine coolant temperature: 75 — 95°C (167 — 203°F)
Transmission: Warmed-up*1
Electrical load: Not applied*2
Engine speed: Idle
After the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE”
(A/T fluid temperature sensor signal) indicates more than 60°C (140°F).
*2: Rear window defogger switch, air conditioner switch, lighting switch are “OFF”. Steering wheel is straight
ahead.

+
+
+
+
+
+
+
*1:

Inspection Procedure

SEF601Z

NOTE:
Perform “DATA MONITOR (SPEC)” mode in maximum scale
display.
1. Perform EC-66, “Basic Inspection”.
2. Confirm that the testing conditions indicated above are met.
3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1/B2” and “MAS A/F
SE-B1” in “DATA MONITOR (SPEC)” mode with CONSULTII.
4. Make sure that monitor items are within the SP value.
5. If NG, go to EC-109, “Diagnostic Procedure”.

EC-108

TROUBLE DIAGNOSIS — SPECIFICATION
TB48DE A/T (WITH EURO-OBD)
VALUE
Diagnostic Procedure

SEF613ZD

EC-109

TROUBLE DIAGNOSIS — SPECIFICATION
TB48DE A/T (WITH EURO-OBD)
VALUE
Diagnostic Procedure (Cont’d)

SEF768Z

EC-110

TROUBLE DIAGNOSIS — SPECIFICATION
TB48DE A/T (WITH EURO-OBD)
VALUE
Diagnostic Procedure (Cont’d)

SEF615ZA

EC-111

TROUBLE DIAGNOSIS FOR INTERMITTENT
TB48DE A/T (WITH EURO-OBD)
INCIDENT
Description
Intermittent incidents (I/I) may occur. In many cases, the malfunction resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer’s complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of
I/I occurrences is poor electrical connections. Because of this, the conditions under which the incident
occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
not indicate the specific malfunctioning area.
Common I/I Report Situations
STEP in Work Flow

Situation

The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than “0” or “[1t]”.

III

The symptom described by the customer does not recur.

(1st trip) DTC does not appear during the DTC Confirmation Procedure.

The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area.

Diagnostic Procedure
1

INSPECTION START

Erase (1st trip) DTCs. Refer to EC-49, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
c GO TO 2.

CHECK GROUND TERMINALS

Check ground terminals for corroding or loose connection.
Refer to GI section, “Incident Simulation Tests”.
OK or NG
OK

c GO TO 3.

c Repair or replace.

SEARCH FOR ELECTRICAL INCIDENT

Perform GI section, “Incident Simulation Tests”.
OK or NG
OK

c INSPECTION END

c Repair or replace.

EC-112

POWER SUPPLY CIRCUIT
TB48DE A/T (WITH EURO-OBD)
FOR ECM
Wiring Diagram

TEC243M

EC-113

POWER SUPPLY CIRCUIT
TB48DE A/T (WITH EURO-OBD)
FOR ECM
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

DATA
(DC voltage)

CONDITION

Engine is running.
Ignition switch “OFF”

B/Y

ECM relay (Self-shutoff)

0 — 1.0V

For 5 seconds after turning ignition switch
“OFF”
Ignition switch “OFF”
A few seconds passed after turning ignition
switch “OFF”

163
166

W/G

B/R

Ignition switch “OFF”

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch

Power supply for ECM

BATTERY VOLTAGE
(11 — 14V)

EC-114

POWER SUPPLY CIRCUIT
TB48DE A/T (WITH EURO-OBD)
FOR ECM
Wiring Diagram (Cont’d)

TEC144M

EC-115

WIRE
COLOR
B
B
B
B

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
ECM ground

Engine ground
Idle speed

Diagnostic Procedure
1

INSPECTION START

Start engine.
Is engine running?
Yes or No
Yes

c GO TO 11.

c GO TO 2.

CHECK ECM POWER SUPPLY CIRCUIT-I

1. Turn ignition switch “OFF” and then “ON”.
2. Check voltage between ECM terminal 53 and ground with CONSULT-II or tester.

SEC817C

Voltage: Battery voltage
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

EC-116

POWER SUPPLY CIRCUIT
TB48DE A/T (WITH EURO-OBD)
FOR ECM
Diagnostic Procedure (Cont’d)
4

CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminals 156, 159, 165, 168 and engine ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between ECM and ground
c Repair open circuit or short to power in harness or connectors.

CHECK ECM POWER SUPPLY CIRCUIT-II

1. Disconnect ECM relay.

SEC668D

2. Check voltage between ECM relay terminals 2 and 5 and ground with CONSULT-II or tester.

PBIB0071E

Voltage: Battery voltage
OK or NG
OK

c GO TO 8.

c GO TO 7.

EC-117

POWER SUPPLY CIRCUIT
TB48DE A/T (WITH EURO-OBD)
FOR ECM
Diagnostic Procedure (Cont’d)
7

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ 10A fuse
+ 15A fuse
+ Harness for open or short between ECM relay and battery
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 42 and ECM relay terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Harness for open or short between ECM and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ECM RELAY

Refer to EC-120.
OK or NG
OK

c GO TO EC-428.

c Replace ECM relay.

CHECK ECM POWER SUPPLY CIRCUIT-III

1. Stop engine and wait at least 10 seconds.
2. Turn ignition switch “ON” and then “OFF”.
3. Check voltage between ECM terminals 163, 166 and ground with CONSULT-II or tester.

SEC819C

Voltage: After turning ignition switch “OFF”, battery voltage will exist for a few seconds, then drop approximately 0V.
OK or NG
OK

NG (Battery voltage does not
exist.)

GO TO 15.
GO TO 12.

NG (Battery voltage exists for more
than a few seconds.)
c

GO TO 14.

EC-118

POWER SUPPLY CIRCUIT
TB48DE A/T (WITH EURO-OBD)
FOR ECM
Diagnostic Procedure (Cont’d)
12

CHECK ECM POWER SUPPLY CIRCUIT-IV

1. Disconnect ECM relay.

SEC668D

2. Check voltage between ECM relay terminal 7 and ground with CONSULT-II or tester.

PBIB0074E

Voltage: Battery voltage
OK or NG
OK

c GO TO 14.

c GO TO 13.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness for open or short between ECM relay and 10A fuse
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ECM POWER SUPPLY CIRCUIT-V

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminals 163, 166 and ECM relay terminal 6.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 16.

c GO TO 15.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Harness for open or short between ECM and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-119

POWER SUPPLY CIRCUIT
TB48DE A/T (WITH EURO-OBD)
FOR ECM
Diagnostic Procedure (Cont’d)
16

CHECK ECM RELAY

Refer to EC-120, “Component Inspection”.
OK or NG
OK

c GO TO 17.

c Replace ECM relay.

CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II

c GO TO 19.

c GO TO 18.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between ECM and ground
c Repair open circuit or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
OK or NG
OK

c INSPECTION END

Component Inspection
ECM RELAY
1. Apply 12V direct current between ECM relay terminals 1 and
2.
2. Check continuity between relay terminals 3 and 5, 6 and 7.
Condition

PBIB0077E

Continuity

12V direct current supply between
terminals 1 and 2

Yes

OFF

3. If NG, replace ECM relay.

EC-120

DTC U1000 CAN COMMUNICATION
TB48DE A/T (WITH EURO-OBD)
LINE
Description
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle
multiplex communication line with high data communication speed and excellent error detection ability. Many
electronic control units are equipped onto a vehicle, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected
with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with
less wiring. Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic
This self-diagnosis has the one trip detection logic.
DTC No.
U1000
1000

Trouble diagnosis name
CAN communication line

DTC detecting condition

Possible cause

+ ECM can not communicate to other con- + Harness or connectors
(CAN communication line is open or
trol units.
shorted).
+ ECM can not communicate for more
than the specified time.

DTC Confirmation Procedure
1. Turn ignition switch “ON” and wait at least 3 seconds.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. If DTC is detected, go to EC-123, “Diagnostic Procedure”.

EC-121

DTC U1000 CAN COMMUNICATION
TB48DE A/T (WITH EURO-OBD)
LINE
Wiring Diagram

TEC258M

EC-122

DTC U1000 CAN COMMUNICATION
TB48DE A/T (WITH EURO-OBD)
LINE
Diagnostic Procedure
1

INSPECTION START

1. Turn ignition switch “ON”.
2. Select “CAN DIAG SUPPORT MNTR” in “DATA MONITOR” mode with CONSULT-II.
3. Print out the CONSULT-II screen.

SEC575D

c Go to EL section.

EC-123

DTC P0031, P0032, P0051, P0052 HO2S1
TB48DE A/T (WITH EURO-OBD)
HEATER
Description
SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

ECM Function

Camshaft position sensor

Engine speed

Engine coolant temperature
sensor

Engine coolant temperature

Actuator

Heated oxygen sensor 1 heater Heated oxygen sensor 1 heater
control

The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine
speed and engine coolant temperature. The duty percent varies with engine coolant temperature when
engine is started.

OPERATION
Engine speed rpm

Heated oxygen sensor 1 heater

Above 2,800

OFF

Below 2,800

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
HO2S1 HTR (B1)
HO2S1 HTR (B2)

CONDITION

SPECIFICATION

+ Engine: After warming up
+ Engine speed: Below 2,800 rpm

+ Engine speed: Above 2,800 rpm

OFF

On Board Diagnosis Logic
DTC No.
P0031
0031
(Bank 1)

Trouble diagnosis name

P0052
0052
(Bank 2)

Possible cause

Heated oxygen sensor 1
heater control circuit low

+ Harness or connectors
The current amperage in the heated oxy(The heated oxygen sensor 1 heater
gen sensor 1 heater circuit is out of the
circuit is open or shorted.)
normal range.
(An excessively low voltage signal is sent + Heater oxygen sensor 1 heater
to ECM through the heated oxygen sensor
1 heater.)

Heated oxygen sensor 1
heater control circuit high

+ Harness or connectors
The current amperage in the heated oxy(The heated oxygen sensor 1 heater
gen sensor 1 heater circuit is out of the
circuit is shorted.)
normal range.
(An excessively high voltage signal is sent + Heater oxygen sensor 1 heater
to ECM through the heated oxygen sensor
1 heater.)

P0051
0051
(Bank 2)
P0032
0032
(Bank 1)

DTC detecting condition

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V
at idle.

EC-124

DTC P0031, P0032, P0051, P0052 HO2S1
TB48DE A/T (WITH EURO-OBD)
HEATER
DTC Confirmation Procedure (Cont’d)
WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Turn ignition switch “ON” and select “DATA MONITOR”
mode with CONSULT-II.
4. Start engine and run it for at least 6 seconds at idle speed.
5. If 1st trip DTC is detected, go to EC-129, “Diagnostic Procedure”.

SEF058Y

WITH GST
1.
2.
3.
4.
5.
6.
7.
+

Start engine and warm it up to normal operating temperature.
Turn ignition switch “OFF” and wait at least 10 seconds.
Start engine and run it for at least 6 seconds at idle speed.
Turn ignition switch “OFF” and wait at least 10 seconds.
Start engine and run it for at least 6 seconds at idle speed.
Select “MODE 3” with GST.
If DTC is detected, go to EC-129, “Diagnostic Procedure”.
When using GST, “DTC Confirmation Procedure” should
be performed twice as much as when using CONSULT-II
because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is
recommended.

EC-125

DTC P0031, P0032, P0051, P0052 HO2S1
TB48DE A/T (WITH EURO-OBD)
HEATER
Wiring Diagram
BANK 1

TEC409M

EC-126

DTC P0031, P0032, P0051, P0052 HO2S1
TB48DE A/T (WITH EURO-OBD)
HEATER
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERWIRE
MINAL
COLOR
NO.

ITEM

CONDITION

DATA (DC Voltage)

Approximately 7.0V★

Engine is running.
Warm-up condition.
Engine speed is below 2,800 rpm.
9

Y/B

Heated oxygen sensor 1
heater (bank 1)

PBIB0519E

Ignition switch “ON”
Engine stopped.
Engine is running.
Engine speed is above 2,800 rpm.

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-127

BATTERY VOLTAGE
(11 — 14V)

DTC P0031, P0032, P0051, P0052 HO2S1
TB48DE A/T (WITH EURO-OBD)
HEATER
Wiring Diagram (Cont’d)
BANK 2

TEC414M

EC-128

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 7.0V★

Engine is running.
Warm-up condition.
Engine speed is below 2,800 rpm.
8

G/Y

Heated oxygen sensor 1
heater (bank 2)

PBIB0519E

Ignition switch “ON”
Engine stopped.
Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Engine speed is above 2,800 rpm.

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure
1

CHECK HO2S1 POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect heated oxygen sensor 1 harness connector.

SEC671D

3. Turn ignition switch “ON”.
4. Check voltage between HO2S1 terminal 3 and ground with CONSULT-II or tester.

PBIB0112E

Voltage: Battery voltage
OK or NG
OK

c GO TO 3.

c GO TO 2.

EC-129

DTC P0031, P0032, P0051, P0052 HO2S1
TB48DE A/T (WITH EURO-OBD)
HEATER
Diagnostic Procedure (Cont’d)
2

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M55, F35
+ Fuse block (J/B) connector E112
+ 15A fuse
+ Harness for open or short between heated oxygen sensor 1 and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal and HO2S1 terminal as follows.
Refer to Wiring Diagram.

MTBL1566

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 1 HEATER

Refer to EC-131, “Component Inspection”.
OK or NG
OK

c GO TO 5.

c Replace malfunctioning heated oxygen sensor 1.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-130

DTC P0031, P0032, P0051, P0052 HO2S1
TB48DE A/T (WITH EURO-OBD)
HEATER
Component Inspection
HEATED OXYGEN SENSOR 1 HEATER
1. Check resistance between HO2S1 terminals as follows.
Terminal No.

Resistance

2 and 3

3.3 — 4.0Ω at 20°C (68°F)

1 and 2, 3, 4

Ω
(Continuity should not exist.)

4 and 1, 2, 3

2. If NG, replace heated oxygen sensor 1.
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

SEF249Y

EC-131

DTC P0037, P0038, P0057, P0058 HO2S2
TB48DE A/T (WITH EURO-OBD)
HEATER
Description
SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

ECM Function

Camshaft position sensor

Engine speed

Engine coolant temperature
sensor

Engine coolant temperature

Mass air flow sensor

Amount of intake air

Actuator

Heated oxygen sensor 2 heater
Heated oxygen sensor 2 heater
control

The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine
speed, amount of intake air and engine coolant temperature.

OPERATION
Engine speed rpm

Heated oxygen sensor 2 heater

Above 3,200

OFF

+ Below 3,200 rpm after the following conditions are met.
+ Engine: After warming up
+ Keeping the engine speed between 3,500 and 4,000 rpm for
one minute and at idle for one minute under no load

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
HO2S2 HTR (B1)
HO2S2 HTR (B2)

CONDITION

SPECIFICATION

+ Engine speed: Below 3,200 rpm after the following conditions are met. ON
+ Engine: After warming up
+ Keeping the engine speed between 3,500 and 4,000 rpm for one
minute and at idle for one minute under no load
+ Engine speed: Above 3,200 rpm

OFF

On Board Diagnosis Logic
DTC No.
P0037
0037
(Bank 1)

Trouble diagnosis name

P0058
0058
(Bank 2)

Possible cause

Heated oxygen sensor 2
heater control circuit low

+ Harness or connectors
The current amperage in the heated oxy(The heated oxygen sensor 2 heater
gen sensor 2 heater circuit is out of the
circuit is open or shorted.)
normal range.
(An excessively low voltage signal is sent + Heater oxygen sensor 2 heater
to ECM through the heated oxygen sensor
2 heater.)

Heated oxygen sensor 2
heater control circuit high

+ Harness or connectors
The current amperage in the heated oxy(The heated oxygen sensor 2 heater
gen sensor 2 heater circuit is out of the
circuit is shorted.)
normal range.
(An excessively high voltage signal is sent + Heater oxygen sensor 2 heater
to ECM through the heated oxygen sensor
2 heater.)

P0057
0057
(Bank 2)
P0038
0038
(Bank 1)

DTC detecting condition

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V
at idle.

EC-132

DTC P0037, P0038, P0057, P0058 HO2S2
TB48DE A/T (WITH EURO-OBD)
HEATER
DTC Confirmation Procedure (Cont’d)
WITH CONSULT-II

SEF174Y

1. Turn ignition switch “ON” and select “DATA MONITOR”
mode with CONSULT-II.
2. Start engine and warm it up to the normal operating temperature.
3. Turn ignition switch “OFF” and wait at least 10 seconds.
4. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
5. Let engine idle for one minute.
6. If 1st trip DTC is detected, go to EC-137, “Diagnostic Procedure”.

WITH GST
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
4. Let engine idle for one minute.
5. Turn ignition switch “OFF” and wait at least 10 seconds.
6. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
7. Let engine idle for one minute.
8. Select “MODE 3” with GST.
9. If DTC is detected, go to EC-137, “Diagnostic Procedure”.
+ When using GST, “DTC Confirmation Procedure” should
be performed twice as much as when using CONSULT-II
because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is
recommended.

EC-133

DTC P0037, P0038, P0057, P0058 HO2S2
TB48DE A/T (WITH EURO-OBD)
HEATER
Wiring Diagram
BANK 1

TEC413M

EC-134

DTC P0037, P0038, P0057, P0058 HO2S2
TB48DE A/T (WITH EURO-OBD)
HEATER
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

R/G

Heated oxygen sensor 2
heater (bank 1)

Warm-up condition
Engine speed: Below 3,200 rpm after the following conditions are met.
Keeping the engine speed between 3,500 and
4,000 rpm for one minute and at idle for one
minute under no load

0 — 1.0V

Ignition switch “ON”
Engine stopped.
Engine is running.
Engine speed is above 3,200 rpm.

EC-135

BATTERY VOLTAGE
(11 — 14V)

DTC P0037, P0038, P0057, P0058 HO2S2
TB48DE A/T (WITH EURO-OBD)
HEATER
Wiring Diagram (Cont’d)
BANK 2

TEC340M

EC-136

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

Y/R

Warm-up condition
Engine speed: Below 3,200 rpm after the following conditions are met.
Keeping the engine speed between 3,500 and
4,000 rpm for one minute and at idle for one
minute under no load

Heated oxygen sensor 2
heater (bank 2)

0 — 1.0V

Ignition switch “ON”
Engine stopped.
Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Engine speed is above 3,200 rpm.

Diagnostic Procedure
1

CHECK HO2S2 POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect heated oxygen sensor 2 harness connector.

SEC669D

3. Turn ignition switch “ON”.
4. Check voltage between HO2S2 terminal 3 and ground with CONSULT-II or tester.

PBIB0112E

Voltage: Battery voltage
OK or NG
OK

c GO TO 3.

c GO TO 2.

EC-137

DTC P0037, P0038, P0057, P0058 HO2S2
TB48DE A/T (WITH EURO-OBD)
HEATER
Diagnostic Procedure (Cont’d)
2

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M55, F35
+ Fuse block (J/B) connector E112
+ 15A fuse
+ Harness for open or short between heated oxygen sensor 2 and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal and HO2S2 terminal as follows.
Refer to Wiring Diagram.

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 2 HEATER

Refer to EC-139, “Component Inspection”.
OK or NG
OK

c GO TO 5.

c Replace malfunctioning heated oxygen sensor 2.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-138

MTBL1567

DTC P0037, P0038, P0057, P0058 HO2S2
TB48DE A/T (WITH EURO-OBD)
HEATER
Component Inspection
HEATED OXYGEN SENSOR 2 HEATER
1. Check resistance between HO2S2 terminals as follows.
Terminal No.

Resistance

2 and 3

5.0 — 7.0Ω at 25°C (77°F)

1 and 2, 3, 4

Ω
(Continuity should not exist)

4 and 1, 2, 3

2. If NG, replace heated oxygen sensor 2.
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

SEF249Y

EC-139

DTC P0102, P0103 MAF
TB48DE A/T (WITH EURO-OBD)
SENSOR
Component Description

SEC266C

The mass air flow sensor is placed in the stream of intake air. It
measures the intake flow rate by measuring a part of the entire
intake flow. It consists of a hot film that is supplied with electric
current from the ECM. The temperature of the hot film is controlled by the ECM a certain amount. The heat generated by the
hot film is reduced as the intake air flows around it. The more air,
the greater the heat loss.
Therefore, the ECM must supply more electric current to maintain the temperature of the hot film as air flow increases. The
ECM detects the air flow by means of this current change.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
MAS A/F SE-B1

CAL/LD VALUE

MASS AIRFLOW

CONDITION

SPECIFICATION

+
+
+
+

Engine: After warming up
Air conditioner switch: OFF
Shift lever: N
No-load

Idle

Approx. 1.3 — 1.7V

2,500 rpm

Approx. 1.7 — 2.4V

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

10% — 35%

2,500 rpm

10% — 35%

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

3.0 — 9.0 gzm/s

2,500 rpm

10.0 — 25.0 gzm/s

On Board Diagnosis Logic
These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P0102
0102

Mass air flow sensor circuit low input

An excessively low voltage from the sensor is sent to ECM when engine is running.

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Intake air leaks
+ Mass air flow sensor

P0103
0103

Mass air flow sensor circuit high input

An excessively high voltage from the sensor is sent to ECM.

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Mass air flow sensor

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items
Mass air flow sensor circuit

Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,400 rpm due to the fuel
cut.

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.

EC-140

DTC P0102, P0103 MAF
TB48DE A/T (WITH EURO-OBD)
SENSOR
DTC Confirmation Procedure (Cont’d)
PROCEDURE FOR DTC P0102
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and wait at least 5 seconds.
If DTC is detected, go to EC-143, “Diagnostic Procedure”.

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

PROCEDURE FOR DTC P0103
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If DTC is detected, go to EC-143, “Diagnostic Procedure”.
If DTC is not detected, go to next step.
5. Start engine and wait at least 5 seconds.
6. If DTC is detected, go to EC-143, “Diagnostic Procedure”.
SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-141

DTC P0102, P0103 MAF
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram

TEC146M

EC-142

DTC P0102, P0103 MAF
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
Warm-up condition
Idle speed
91

W/G

1.3 — 1.7V

Mass air flow sensor
Engine is running.
Warm-up condition
Engine speed is 2,500 rpm.

103

Sensor power supply
(Mass air flow sensor)

109

B/W

Sensor ground
(Mass air flow sensor)

Ignition switch “ON”

1.7 — 2.4V

Approximately 5V

Engine is running.
Warm-up condition
Idle speed

Diagnostic Procedure
1

INSPECTION START

Which malfunction (P0102 or P0103) is duplicated?
P0102 or P0103
P0102

c GO TO 2.

P0103

c GO TO 3.

CHECK INTAKE SYSTEM

Check the following for connection.
+ Air duct
+ Vacuum hoses
+ Intake air passage between air duct to intake manifold
OK or NG
OK

c GO TO 3.

c Reconnect the parts.

EC-143

Approximately 0V

DTC P0102, P0103 MAF
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
3

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 4.

CHECK MAF SENSOR POWER SUPPLY CIRCUIT

1. Disconnect MAF sensor harness connector.

SEC688C

2. Turn ignition switch “ON”.
3. Check voltage between MAF sensor terminals 2, 4 and ground with CONSULT-II or tester.

PBIB0076E

MTBL1568

OK or NG
OK

c GO TO 6.

c GO TO 5.

EC-144

DTC P0102, P0103 MAF
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
5

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Harness for open or short between mass air flow sensor and ECM
+ Harness for open or short between mass air flow sensor and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between MAF sensor terminal 3 and ECM terminal 109.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between MAF sensor terminal 1 and ECM terminal 91.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK MASS AIR FLOW SENSOR

Refer to EC-146, “Component Inspection”.
OK or NG
OK

c GO TO 9.

c Replace mass air flow sensor.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-145

DTC P0102, P0103 MAF
TB48DE A/T (WITH EURO-OBD)
SENSOR
Component Inspection
MASS AIR FLOW SENSOR
1. Reconnect harness connectors disconnected.
2. Start engine and warm it up to normal operating temperature.
3. Check voltage between ECM terminal 91 (Mass air flow sensor signal) and ground.

PBIB0078E

Condition

Voltage V

Ignition switch “ON” (Engine stopped.)

Approx. 1.0

Idle (Engine is warmed-up to normal
operating temperature.)

1.3 — 1.7

2,500 rpm (Engine is warmed-up to
normal operating temperature.)

1.7 — 2.4

Idle to about 4,000 rpm*

1.3 — 1.7 to Approx. 4.0

*: Check for liner voltage rise in response to engine being increased to about
4,000 rpm.

4. If the voltage is out of specification, proceed the following.
a. Turn ignition switch “OFF”.
b. Disconnect mass air flow sensor harness connector and
reconnect it again.
c. Perform steps 2 and 3 again.
5. If NG, remove mass air flow sensor from air duct. Check hot
film for damage or dust.
6. If NG, clean or replace mass air flow sensor.

EC-146

DTC P0112, P0113 IAT
SENSOR

TB48DE A/T (WITH EURO-OBD)

Component Description
The intake air temperature sensor is built into mass air flow sensor. The sensor detects intake air temperature and transmits a
signal to the ECM.
The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the
thermistor decreases in response to the temperature rise.

SEC266C

Intake air temperature
°C (°F)

Voltage* V

Resistance kΩ

−10 (14)

4.43

7.9 — 9.3

25 (77)

3.32

1.9 — 2.1

80 (176)

1.23

0.31 — 0.37

*: These data are reference values and are measured between ECM terminal 99 (Intake air temperature sensor) and ground.
SEF012P

CAUTION:
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM’s
transistor. Use a ground other than ECM terminals, such as
the ground.

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

DTC detecting condition

P0112
0112

Intake air temperature
sensor circuit low input

An excessively low voltage from the sensor is sent to ECM.

P0113
0113

Intake air temperature
sensor circuit high input

An excessively high voltage from the sensor is sent to ECM.

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Intake air temperature sensor

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-150, “Diagnostic Procedure”.

SEF058Y

EC-147

DTC P0112, P0113 IAT
TB48DE A/T (WITH EURO-OBD)
SENSOR
DTC Confirmation Procedure (Cont’d)
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-148

DTC P0112, P0113 IAT
SENSOR

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC343M

EC-149

DTC P0112, P0113 IAT
SENSOR

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
1

CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect mass air flow sensor (intake air temperature sensor is built-into) harness connector.

SEC688C

3. Turn ignition switch “ON”.
4. Check voltage between MAF sensor terminal 5 and ground.

PBIB0066E

Voltage: Approximately 5V
OK or NG
OK

c GO TO 2.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

c GO TO 3.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTAKE AIR TEMPERATURE SENSOR

Refer to EC-151, “Component Inspection”.
OK or NG
OK

c GO TO 4.

c Replace mass air flow sensor (with intake air temperature sensor).

EC-150

DTC P0112, P0113 IAT
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
4

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
INTAKE AIR TEMPERATURE SENSOR
1. Check resistance between mass air flow sensor terminals 3
and 5 under the following conditions.
Intake air temperature °C (°F)

Resistance kΩ

25 (77)

1.9 — 2.1

2. If NG, replace mass air flow sensor (with intake air temperature sensor).
SEC266C

SEF012P

EC-151

DTC P0117, P0118 ECT
TB48DE A/T (WITH EURO-OBD)
SENSOR
Component Description
The engine coolant temperature sensor is used to detect the
engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the
engine coolant temperature input. The sensor uses a thermistor
which is sensitive to the change in temperature. The electrical
resistance of the thermistor decreases as temperature
increases.
SEF594K

SEF012P

Engine coolant temperature °C (°F)

Voltage* V

Resistance kΩ

−10 (14)

4.4

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.2

0.68 — 1.00

90 (194)

0.9

0.236 — 0.260

*: These data are reference values and are measured between ECM terminal
121 (Engine coolant temperature sensor) and ground.

CAUTION:
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM’s
transistor. Use a ground other than ECM terminals, such as
the ground.

On Board Diagnosis Logic
These self-diagnoses have the one trip detection logic.
DTC No.
P0117
0117

P0118
0118

Trouble Diagnosis Name
Engine coolant temperature sensor circuit low
input
Engine coolant temperature sensor circuit high
input

DTC Detecting Condition
An excessively low voltage from the sensor is sent to ECM.

An excessively high voltage from the sensor is sent to ECM.

EC-152

Possible Cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Engine coolant temperature sensor

DTC P0117, P0118 ECT
TB48DE A/T (WITH EURO-OBD)
SENSOR
On Board Diagnosis Logic (Cont’d)
FAIL-SAFE MODE
When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items
Engine coolant temperature sensor circuit

Engine operating condition in fail-safe mode
Engine coolant temperature will be determined by ECM based on the time after turning ignition switch
“ON” or “START”. CONSULT-II displays the engine coolant temperature decided by ECM.
Condition

Engine coolant temperature decided
(CONSULT-II display)

Just as ignition switch is turned ON or Start

40°C (104°F)

More than approx. 4 minutes after ignition ON or
Start

80°C (176°F)

Except as shown above

40 — 80°C (104 — 176°F)
(Depends on the time)

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates
while engine is running.

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If DTC is detected, go to EC-155, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-153

DTC P0117, P0118 ECT
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram

TEC147M

EC-154

DTC P0117, P0118 ECT
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure
1

CHECK ECT SENSOR POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect engine coolant temperature (ECT) sensor harness connector.

SEC689C

3. Turn ignition switch “ON”.
4. Check voltage between ECT sensor terminal 2 and ground with CONSULT-II or tester.

SEF645R

Voltage: Approximately 5V
OK or NG
OK

c GO TO 2.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Check harness continuity between ECT sensor terminal 1 and engine ground.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between engine coolant temperature sensor and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-155

DTC P0117, P0118 ECT
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
4

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Refer to EC-156, “Component Inspection”.
OK or NG
OK

c GO TO 5.

c Replace engine coolant temperature sensor.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
ENGINE COOLANT TEMPERATURE SENSOR
1. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure.

PBIB0353E

SEF012P

Engine coolant temperature °C (°F)

Voltage* V

Resistance kΩ

−10 (14)

4.4

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.2

0.68 — 1.00

90 (194)

0.9

0.236 — 0.260

*: These data are reference values and are measured between ECM terminal
121 (Engine coolant temperature sensor) and ground.

2. If NG, replace engine coolant temperature sensor.

EC-156

DTC P0122, P0123 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Component Description

PBIB0145E

Electric Throttle Control Actuator consists of throttle control
motor, throttle position sensor, etc. The throttle position sensor
responds to the throttle valve movement.
The throttle position sensor has the two sensors. These sensors
are a kind of potentiometers which transform the throttle valve
position into output voltage, and emit the voltage signal to the
ECM. In addition, these sensors detect the opening and closing
speed of the throttle valve and feed the voltage signals to the
ECM. The ECM judges the current opening angle of the throttle
valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
THRTL SEN1
THRTL SEN2*

CONDITION
+ Ignition switch: ON
(Engine stopped)
+ Shift lever: D

SPECIFICATION

Accelerator pedal: Fully released

More than 0.5V

Accelerator pedal: Fully depressed

Less than 1.5V

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs for ECM terminal voltage signal.

On Board Diagnosis Logic
These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

P0122
0122

Throttle position sensor 2
circuit low input

An excessively low voltage from the TP
sensor 2 is sent to ECM.

P0123
0123

Throttle position sensor 2
circuit high input

An excessively high voltage from the TP
sensor 2 is sent to ECM.

Possible cause
+ Harness or connectors
(The TP sensor 2 circuit is open or
shorted.)
+ Electric throttle control actuator
(TP sensor 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-157

DTC P0122, P0123 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-160, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-158

DTC P0122, P0123 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC399M

EC-159

DTC P0122, P0123 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
89

Sensor ground

Warm-up condition
Idle speed

Approximately 0V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully released
98

R/L

Less than 4.75V

Throttle position sensor 2
Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

103

Sensor power supply

Ignition switch “ON”

More than 0.36V

Approximately 5V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully released
108

More than 0.36V

Throttle position sensor 1
Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

Less than 4.75V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-160

DTC P0122, P0123 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
2

CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT

1. Disconnect electric throttle control actuator harness connector.

SEC182D

2. Turn ignition switch “ON”.
3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester.

PBIB0082E

Voltage: Approximately 5V
OK or NG
OK

c GO TO 3.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between electric throttle control actuator terminal 5 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 98 and electric throttle control actuator terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-161

DTC P0122, P0123 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
5

CHECK THROTTLE POSITION SENSOR

Refer to EC-162, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c GO TO 6.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

Replace the electric throttle control actuator.
Perform EC-31, “Accelerator Pedal Released Position Learning”.
Perform EC-31, “Throttle Valve Closed Position Learning”.
Perform EC-31, “Idle Air Volume Learning”.
c INSPECTION END

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

PBIB0179E

Reconnect all harness connectors disconnected.
Perform EC-31, “Throttle Valve Closed Position Learning”.
Turn ignition switch “ON”.
Set selector lever to “D” position.
Check voltage between ECM terminals 108 (TP sensor 1
signal), 98 (TP sensor 2 signal) and engine ground under the
following conditions.
Terminal

Accelerator pedal

Voltage

108
(Throttle position sensor
1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

98
(Throttle position sensor
2)

6. If NG, replace electric throttle control actuator and go to the
next step.
7. Perform EC-31, “Accelerator Pedal Released Position Learning”.
8. Perform EC-31, “Throttle Valve Closed Position Learning”.
9. Perform EC-31, “Idle Air Volume Learning”.

EC-162

DTC P0132, P0152
HO2S1

TB48DE A/T (WITH EURO-OBD)

Component Description
The heated oxygen sensor 1 is placed into the exhaust manifold.
It detects the amount of oxygen in the exhaust gas compared to
the outside air. The heated oxygen sensor 1 has a closed-end
tube made of ceramic zirconia. The zirconia generates voltage
from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM.
The ECM adjusts the injection pulse duration to achieve the ideal
air-fuel ratio. The ideal air-fuel ratio occurs near the radical
change from 1V to 0V.
SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1)
HO2S1 (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S1 MNTR (B1)
HO2S1 MNTR (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times
during 10 seconds.

On Board Diagnosis Logic
To judge the malfunction, the diagnosis checks that the heated
oxygen sensor 1 output is not inordinately high.

SEF301UA

DTC No.
P0132
0132
(Bank 1)

Trouble diagnosis name
Heated oxygen sensor 1
circuit high voltage

DTC detecting condition
An excessively high voltage from the sensor is sent to ECM.

P0152
0152
(Bank 2)

EC-163

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted).
+ Heated oxygen sensor 1

DTC P0132, P0152
HO2S1

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to normal operating temperature.
Turn ignition switch “OFF” and wait at least 10 seconds.
Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Restart engine and let it idle for 2 minutes.
If 1st trip DTC is detected, go to EC-168, “Diagnostic Procedure”.

SEF174Y

WITH GST
1.
2.
3.
4.
5.
6.
7.
+

Start engine and warm it up to normal operating temperature.
Turn ignition switch “OFF” and wait at least 10 seconds.
Restart engine and let it idle for 2 minutes.
Turn ignition switch “OFF” and wait at least 10 seconds.
Restart engine and let it idle for 2 minutes.
Select “MODE 3” with GST.
If DTC is detected, go to EC-168, “Diagnostic Procedure”.
When using GST, “DTC Confirmation Procedure” should
be performed twice as much as when using CONSULT-II
because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is
recommended.

EC-164

DTC P0132, P0152
HO2S1

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram
BANK 1

TEC408M

EC-165

DTC P0132, P0152
TB48DE A/T (WITH EURO-OBD)
HO2S1
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
115

Heated oxygen sensor 1
(bank 1)

Warm-up condition
Engine speed is 2,000 rpm.

EC-166

0 — Approximately 1.0V
(Periodically change)

DTC P0132, P0152
TB48DE A/T (WITH EURO-OBD)
HO2S1
Wiring Diagram (Cont’d)
BANK 2

TEC412M

EC-167

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
114

Heated oxygen sensor 1
(bank 2)

Warm-up condition
Engine speed is 2,000 rpm.

0 — Approximately 1.0V
(Periodically change)

Diagnostic Procedure
1

RETIGHTEN HEATED OXYGEN SENSOR 1

1. Turn ignition switch “OFF”.
2. Loosen and retighten corresponding heated oxygen sensor 1.

SEC888C

Tightening torque: 40 — 60 Nzm (4.1 — 6.2 kg-m, 30 — 44 ft-lb)
c GO TO 2.

CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT

1. Disconnect heated oxygen sensor 1 harness connector.

SEC671D

2. Disconnect ECM harness connector.
3. Check harness continuity between HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 3.

EC-168

DTC P0132, P0152
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
3

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between HO2S1 and ground
c Repair open circuit or short to power in harness or connectors.

CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S1 terminal as follows.
Refer to Wiring Diagram.

MTBL1569

Continuity should exist.
2. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1570

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HO2S1 CONNECTOR FOR WATER

Check heated oxygen sensor 1 connectors for water.
Water should not exist.
OK or NG
OK

c GO TO 6.

c Repair or replace harness or connectors.

CHECK HEATED OXYGEN SENSOR 1

Refer to EC-170, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c Replace malfunctioning heated oxygen sensor 1.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-169

DTC P0132, P0152
HO2S1

TB48DE A/T (WITH EURO-OBD)

Component Inspection
HEATED OXYGEN SENSOR 1
With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100%
in “DATA MONITOR” mode with CONSULT-II.
3. Select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”.
4. Hold engine speed at 2,000 rpm under no load during the
following steps.
5. Touch “RECORD” on CONSULT-II screen.

SEF646Y

6. Check the following.
+ “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode
changes from “RICH” to “LEAN” to “RICH” 5 times in 10
seconds.
5 times (cycles) are counted as shown at right.
+ “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once.
+ “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once.
+ “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V.

SEF647Y

SEF648Y

CAUTION:
+ Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m
(19.7 in) onto a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-170

DTC P0132, P0152
TB48DE A/T (WITH EURO-OBD)
HO2S1
Component Inspection (Cont’d)
Without CONSULT-II

SEC184DA

1. Start engine and warm it up to normal operating temperature.
2. Set voltmeter probes between ECM terminal 115 [HO2S1
(B1) signal] or 114 [HO2S1 (B2) signal] and engine ground.
3. Check the following with engine speed held at 2,000 rpm
constant under no load.
+ The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
+ The maximum voltage is over 0.6V at least one time.
+ The minimum voltage is below 0.3V at least one time.
+ The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-171

DTC P0133, P0153
HO2S1

TB48DE A/T (WITH EURO-OBD)

SEF288D

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1)
HO2S1 (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S1 MNTR (B1)
HO2S1 MNTR (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times
during 10 seconds.

On Board Diagnosis Logic
To judge the malfunction of heated oxygen sensor 1, this diagnosis measures response time of heated oxygen sensor 1 signal. The time is compensated by engine operating (speed and
load), fuel feedback control constant, and heated oxygen sensor
1 temperature index. Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is
inordinately long or not.
SEF010V

DTC No.
P0133
0133
(Bank 1)

Trouble diagnosis name
Heated oxygen sensor 1
circuit slow response

DTC detecting condition
The response of the voltage signal from
the sensor takes more than the specified
time.

P0153
0153
(Bank 2)

EC-172

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Heated oxygen sensor 1
+ Heated oxygen sensor 1 heater
+ Fuel pressure
+ Injectors
+ Intake air leaks
+ Exhaust gas leaks
+ PCV valve
+ Mass air flow sensor

DTC P0133, P0153
HO2S1

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
+ Always perform at a temperature above −10°C (14°F).
+ Before performing the following procedure, confirm that
battery voltage is more than 11V at idle.

WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Stop engine and wait at least 10 seconds.
3. Turn ignition switch “ON” and select “HO2S1 (B1) P0133” or
“HO2S1 (B2) P0153” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II.

4. Touch “START”.
5. Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 2,800 rpm after this step. If
the engine speed limit is exceeded, return to step 5.

SEF338Z

6. When the following conditions are met, “TESTING” will be
displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 20 to 50 seconds.)
ENG SPEED

SEF339Z

1,550 — 2,500 rpm

Vehicle speed

More than 80 km/h (50 MPH)

B/FUEL SCHDL

5 — 16.7 msec

Selector lever

Suitable position

If “TESTING” is not displayed after 5 minutes, retry from
step 2.

EC-173

DTC P0133, P0153
HO2S1

TB48DE A/T (WITH EURO-OBD)

7. Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-178, “Diagnostic Procedure”.

SEF658Y

Overall Function Check
Use this procedure to check the overall function of the heated
oxygen sensor 1 circuit. During this check, a DTC might not be
confirmed.

WITH GST
1. Start engine and warm it up to normal operating temperature.
2. Set voltmeter probes between ECM terminal 115
[HO2S1(B1) signal] or 114 [HO2S1(B2) signal] and engine
ground.
3. Check the following with engine speed held at 2,000 rpm
constant under no load.
— The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V
4. If NG, go to EC-178, “Diagnostic Procedure”.

SEC184DA

EC-174

DTC P0133, P0153
HO2S1

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram
BANK 1

TEC408M

EC-175

DTC P0133, P0153
TB48DE A/T (WITH EURO-OBD)
HO2S1
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
115

Heated oxygen sensor 1
(bank 1)

Warm-up condition
Engine speed is 2,000 rpm.

EC-176

0 — Approximately 1.0V
(Periodically change)

DTC P0133, P0153
TB48DE A/T (WITH EURO-OBD)
HO2S1
Wiring Diagram (Cont’d)
BANK 2

TEC412M

EC-177

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
114

Heated oxygen sensor 1
(bank 2)

Warm-up condition
Engine speed is 2,000 rpm.

0 — Approximately 1.0V
(Periodically change)

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1

Loosen and retighten heated oxygen sensor 1.
Tightening torque: 40 — 60 Nzm (4.1 — 6.2 kg-m, 30 — 44 ft-lb)

SEC888C

c GO TO 3.

EC-178

DTC P0133, P0153
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
3

CHECK FOR EXHAUST GAS LEAK

1. Start engine and run it at idle.
2. Listen for an exhaust gas leak before three way catalyst (Manifold).

SEC502D

OK or NG
OK

c GO TO 4.

c Repair or replace.

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK

c GO TO 5.

c Repair or replace.

EC-179

DTC P0133, P0153
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
5

CLEAR THE SELF-LEARNING DATA

With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF215Z

4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected?
Is it difficult to start engine?
Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch “OFF”.
3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed.

SEC688C

4.
5.
6.
7.
8.

Stop engine and reconnect mass air flow sensor harness connector.
Make sure that DTC P0102 is displayed.
Erase the DTC memory. Refer to EC-49, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
Make sure that DTC P0000 is displayed.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected?
Is it difficult to start engine?
Yes or No

Yes

c Perform trouble diagnosis for DTC P0171, P0174 or DTC P0172, P0175 (Refer to EC-218
or EC-227).

c GO TO 6.

EC-180

DTC P0133, P0153
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
6

CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect heated oxygen sensor 1 harness connector.

SEC671D

3. Disconnect ECM harness connector.
4. Check harness continuity between HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between HO2S1 and ground
c Repair open circuit or short to power in harness or connectors.

EC-181

DTC P0133, P0153
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
8

CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S1 terminal as follows.
Refer to Wiring Diagram.

MTBL1571

Continuity should exist.
2. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1572

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 9.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 1 HEATER

Refer to EC-131, “Component Inspection”.
OK or NG
OK

c GO TO 9.

c Replace malfunctioning heated oxygen sensor 1.

CHECK MASS AIR FLOW SENSOR

Refer to EC-146, “Component Inspection”.
OK or NG
OK

c GO TO 11.

c Replace mass air flow sensor.

CHECK PCV VALVE

Refer to EC-482, “Component Inspection”.
OK or NG
OK

c GO TO 12.

c Replace PCV valve.

CHECK HEATED OXYGEN SENSOR 1

Refer to EC-183, “Component Inspection”.
OK or NG
OK

c GO TO 13.

c Replace malfunctioning heated oxygen sensor 1.

EC-182

DTC P0133, P0153
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
13

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

SEF646Y

SEF647Y

SEF648Y

EC-183

DTC P0133, P0153
TB48DE A/T (WITH EURO-OBD)
HO2S1
Component Inspection (Cont’d)
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

Without CONSULT-II

SEC184DA

EC-184

DTC P0134, P0154
HO2S1

TB48DE A/T (WITH EURO-OBD)

SEF288D

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1)
HO2S1 (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S1 MNTR (B1)
HO2S1 MNTR (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times
during 10 seconds.

On Board Diagnosis Logic
Under the condition in which the heated oxygen sensor 1 signal
is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output
voltage is within 200 to 400 mV range is monitored, and the
diagnosis checks that this time is not inordinately long.

SEF237U

DTC No.
P0134
0134
(Bank 1)

Trouble diagnosis name

DTC detecting condition

Heated oxygen sensor 1 The voltage from the sensor is constantly
circuit no activity detected approx. 0.3V.

P0154
0154
(Bank 2)

EC-185

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Heated oxygen sensor 1

DTC P0134, P0154
HO2S1

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 11V at idle.

WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Select “HO2S1 (B1) P0134” or “HO2S1 (B2) P0154” of
“HO2S1” in “DTC WORK SUPPORT” mode with CONSULTII.
3. Touch “START”.
4. Let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 2,800 rpm after this step. If
the engine speed limit is exceeded, return to step 4.
PBIB0544E

5. When the following conditions are met, “TESTING” will be
displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 10 to 60 seconds.)

PBIB0545E

ENG SPEED

1,550 — 2,500 rpm

Vehicle speed

More than 64 km/h (40 MPH)

B/FUEL SCHDL

5 — 16.7 msec

Selector lever

Suitable position

If “TESTING” is not displayed after 5 minutes, retry from
step 2.

6. Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-191, “Diagnostic Procedure”.

SEC750C

EC-186

DTC P0134, P0154
HO2S1

TB48DE A/T (WITH EURO-OBD)

Overall Function Check
Use this procedure to check the overall function of the heated
oxygen sensor 1 circuit. During this check, a DTC might not be
confirmed.

SEC184DA

EC-187

DTC P0134, P0154
HO2S1

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram
BANK 1

TEC408M

EC-188

DTC P0134, P0154
TB48DE A/T (WITH EURO-OBD)
HO2S1
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
115

Heated oxygen sensor 1
(bank 1)

Warm-up condition
Engine speed is 2,000 rpm.

EC-189

0 — Approximately 1.0V
(Periodically change)

DTC P0134, P0154
TB48DE A/T (WITH EURO-OBD)
HO2S1
Wiring Diagram (Cont’d)
BANK 2

TEC412M

EC-190

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
114

Heated oxygen sensor 1
(bank 2)

Warm-up condition
Engine speed is 2,000 rpm.

0 — Approximately 1.0V
(Periodically change)

Diagnostic Procedure
1

INSPECTION START

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT

1. Disconnect heated oxygen sensor 1 harness connector.

SEC888C

c GO TO 4.

c GO TO 3.

EC-191

DTC P0134, P0154
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
3

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between HO2S1 and ground
c Repair open circuit or short to power in harness or connectors.

CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S1 terminal as follows.
Refer to Wiring Diagram.

MTBL1573

Continuity should exist.
2. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1574

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 1

Refer to EC-193, “Component Inspection”.
OK or NG
OK

c GO TO 6.

c Replace malfunctioning heated oxygen sensor 1.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-192

DTC P0134, P0154
HO2S1

TB48DE A/T (WITH EURO-OBD)

SEF646Y

SEF647Y

SEF648Y

CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-193

DTC P0134, P0154
TB48DE A/T (WITH EURO-OBD)
HO2S1
Component Inspection (Cont’d)
Without CONSULT-II

SEC184DA

EC-194

DTC P0138, P0158
HO2S2

TB48DE A/T (WITH EURO-OBD)

Component Description

SEF327R

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas on each bank.
Even if switching characteristics of the heated oxygen sensor 1
are shifted, the air-fuel ratio is controlled to stoichiometric, by the
signal from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates
voltage from approximately 1V in richer conditions to 0V in leaner
conditions.
Under normal conditions the heated oxygen sensor 2 is not used
for engine control operation.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1)
HO2S2 (B2)

+ Engine: After warming up
Revving engine from idle to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S2 MNTR (B1)
HO2S2 MNTR (B2)

+ Engine: After warming up
Revving engine from idle to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

LEAN ←→ RICH

On Board Diagnosis Logic
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The
oxygen storage capacity before the three way catalyst (manifold)
causes the longer switching time. To judge the malfunctions of
heated oxygen sensor 2, ECM monitors whether the voltage is
unusually high during the various driving condition such as fuelcut.
SEF305UA

DTC No.
P0138
0138
(Bank 1)

Trouble diagnosis name
Heated oxygen sensor 2
circuit high voltage

DTC detecting condition
An excessively high voltage from the sensor is sent to ECM.

P0158
0158
(Bank 2)

EC-195

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Heated oxygen sensor 2

DTC P0138, P0158
HO2S2

TB48DE A/T (WITH EURO-OBD)

WITH CONSULT-II
1. Turn ignition switch “ON” and select “DATA MONITOR”
mode with CONSULT-II.
2. Start engine and warm it up to the normal operating temperature.
3. Turn ignition switch “OFF” and wait at least 10 seconds.

4. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
5. Let engine idle for two minutes.
6. If 1st trip DTC is detected, go to EC-200, “Diagnostic Procedure”.

SEF174Y

WITH GST
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
4. Let engine idle for two minutes.
5. Turn ignition switch “OFF” and wait at least 10 seconds.
6. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
7. Let engine idle for two minutes.
8. Select “Mode 3” with GST.
9. If NG, go to EC-200, “Diagnostic Procedure”.
+ When using GST, “DTC Confirmation Procedure” should
be performed twice as much as when using CONSULT-II
because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is
recommended.

EC-196

DTC P0138, P0158
HO2S2

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram
BANK 1

TEC411M

EC-197

DTC P0138, P0158
TB48DE A/T (WITH EURO-OBD)
HO2S2
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

124

Heated oxygen sensor 2
(bank 1)

Warm-up condition
Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.
Keeping the engine speed between 3,500 and
4,000 rpm for one minute and at idle for one
minute under no load

EC-198

0 — Approximately 1.0V

DTC P0138, P0158
TB48DE A/T (WITH EURO-OBD)
HO2S2
Wiring Diagram (Cont’d)
BANK 2

TEC336M

EC-199

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

123

Heated oxygen sensor 2
(bank 2)

0 — Approximately 1.0V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-200

DTC P0138, P0158
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
2

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect heated oxygen sensor 2 harness connector.

SEC669D

3. Disconnect ECM harness connector.
4. Check harness continuity between HO2S2 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between HO2S2 and ground
c Repair open circuit or short to power in harness or connectors.

EC-201

DTC P0138, P0158
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
4

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S2 terminal as follows.
Refer to Wiring Diagram.

MTBL1575

Continuity should exist.
2. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1576

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 2

Refer to EC-203, “Component Inspection”.
OK or NG
OK

c GO TO 6.

c Replace heated oxygen sensor 2.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-202

DTC P0138, P0158
HO2S2

TB48DE A/T (WITH EURO-OBD)

Component Inspection
HEATED OXYGEN SENSOR 2
With CONSULT-II
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
4. Let engine idle for one minute.
5. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and
select “HO2S2 (B1)/(B2)” as the monitor item with CONSULT-II.

SEF662Y

6. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting
“FUEL INJECTION” to ±25%.

SEF972YA

“HO2S2 (B1)/(B2)” should be
when the “FUEL INJECTION”
“HO2S2 (B1)/(B2)” should be
when the “FUEL INJECTION”

above 0.68V at least once
is +25%.
below 0.48V at least once
is −25%.

CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

Without CONSULT-II
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
4. Let engine idle for one minute.

EC-203

DTC P0138, P0158
TB48DE A/T (WITH EURO-OBD)
HO2S2
Component Inspection (Cont’d)
5. Set voltmeter probes between ECM terminal 124 [HO2S2
(B1) signal] or 123 [HO2S2 (B2) signal] and engine ground.

SEC774D

6. Check the voltage when revving up to 4,000 rpm under no
load at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during
this procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in
“D” position with “OD” OFF.
The voltage should be below 0.48V at least once during
this procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-204

DTC P0139, P0159
HO2S2

TB48DE A/T (WITH EURO-OBD)

Component Description

SEF327R

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1)
HO2S2 (B2)

+ Engine: After warming up
Revving engine from idle to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S2 MNTR (B1)
HO2S2 MNTR (B2)

+ Engine: After warming up
Revving engine from idle to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

LEAN ←→ RICH

On Board Diagnosis Logic
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The
oxygen storage capacity before the three way catalyst (manifold)
causes the longer switching time. To judge the malfunctions of
heated oxygen sensor 2, ECM monitors whether the switching
response of the sensor’s voltage is faster than specified during
the various driving condition such as fuel-cut.
SEF302U

DTC No.
P0139
0139
(Bank 1)

Trouble diagnosis name
Heated oxygen sensor 2
circuit slow response

DTC detecting condition
It takes more time for the sensor to
respond between rich and lean than the
specified time.

P0159
0159
(Bank 2)

EC-205

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Heated oxygen sensor 2
+ Fuel pressure
+ Injectors
+ Intake air leaks

DTC P0139, P0159
HO2S2

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
+ “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and
“COND3” are completed.
+ If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch
“OFF” and wait at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2
in “Procedure for COND1”.

WITH CONSULT-II
Procedure for COND1
For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C (32 to 86°F)
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no
load.
4. Let engine idle one minute.
5. Select “HO2S2 (B1) P0139” or “HO2S2 (B2) P0159” of “HO2S2” in “DTC WORK SUPPORT” mode with
CONSULT-II.
6. Touch “START”.
7. Let engine idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in “Procedure for COND3”.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
ENG SPEED

More than 1,000 rpm

B/FUEL SCHDL

More than 1.0 msec

COOLANT TEMP/S

70 — 100°C

Selector level

Suitable position

PBIB0552E

NOTE:
+ If “TESTING” is not displayed after 5 minutes, retry from step 2 in “Procedure for COND1”.
+ If “COMPLETED” already appears at “COND2” on CONSULT-II screen before “Procedure for
COND2” is conducted, it is unnecessary to conduct step 1 in “Procedure for COND2”.

EC-206

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
DTC Confirmation Procedure (Cont’d)
Procedure for COND2
1. While driving, release accelerator pedal completely with “OD”
OFF from the above condition [step 9] until “INCOMPLETE”
at “COND2” on CONSULT-II screen has turned to “COMPLETED”. (It will take approximately 4 seconds.)
NOTE:
If “COMPLETED” already appears at “COND3” on CONSULT-II screen before “Procedure for COND3” is conducted,
it is unnecessary to conduct step 1 in “Procedure for
COND3”.
PBIB0553E

Procedure for COND3

SEF668Y

1. Stop vehicle and let it idle until “INCOMPLETE” of “COND3”
on CONSULT-II screen has turned to “COMPLETED”. (It will
take a maximum of approximately 6 minutes.)
2. Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-212, “Diagnostic Procedure”.
If “CAN NOT BE DIAGNOSED” is displayed, perform the following.
a. Turn ignition switch “OFF” and leave the vehicle in a cool
place (soak the vehicle).
b. Turn ignition switch “ON” and select “COOLANTEMP/S” in
“DATA MONITOR” mode with CONSULT-II.
c. Start engine and warm it up while monitoring
“COOLANTEMP/S” indication on CONSULT-II.
d. When “COOLANTEMP/S” indication reaches to 70°C
(158°F), go to “Procedure for COND 1” step 3.

Overall Function Check
Use this procedure to check the overall function of the heated
oxygen sensor 2 circuit. During this check, a DTC might not be
confirmed.

WITH GST
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
4. Let engine idle for one minute.
5. Set voltmeter probes between ECM terminal 124 [HO2S2
(B1) signal] or 123 [HO2S2 (B2) signal] and engine ground.
6. Check the voltage when revving up to 4,000 rpm under no
load at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
A change of voltage should be more than 0.06V for 1
second during this procedure.
If the voltage can be confirmed in step 6, step 7 is not
necessary.
7. Keep vehicle at idling for 10 minutes, then check the voltage.
Or check the voltage when coasting from 80 km/h (50 MPH)
SEC774D

EC-207

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
Overall Function Check (Cont’d)
in “D” position with “OD” OFF.
A change of voltage should be more than 0.06V for 1
second during this procedure.
8. If NG, go to EC-212, “Diagnostic Procedure”.

EC-208

DTC P0139, P0159
HO2S2

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram
BANK 1

TEC411M

EC-209

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

124

Heated oxygen sensor 2
(bank 1)

EC-210

0 — Approximately 1.0V

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
Wiring Diagram (Cont’d)
BANK 2

TEC336M

EC-211

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

123

Heated oxygen sensor 2
(bank 2)

0 — Approximately 1.0V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-212

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
2

CLEAR THE SELF-LEARNING DATA

SEF215Z

4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected?
Is it difficult to start engine?
1.
2.
3.
4.

Without CONSULT-II
Start engine and warm it up to normal operating temperature.
Turn ignition switch “OFF”.
Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed.
Stop engine and reconnect mass air flow sensor harness connector.

SEC688C

5.
6.
7.
8.

Make sure that DTC P0102 is displayed.
Erase the DTC memory. Refer to EC-49, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
Make sure that DTC P0000 is displayed.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected?
Is it difficult to start engine?
Yes or No

Yes

c Perform trouble diagnosis for DTC P0171, P0174 or P0172, P0175. Refer to EC-218 or
EC-227.

c GO TO 3.

EC-213

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
3

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect heated oxygen sensor 2 harness connector.

SEC669D

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between HO2S2 and ground
c Repair open circuit or short to power in harness or connectors.

EC-214

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
5

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S2 terminal as follows.
Refer to Wiring Diagram.

MTBL1577

Continuity should exist.
2. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1578

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 6.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 2

Refer to EC-215, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c Replace heated oxygen sensor 2.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-215

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
Component Inspection (Cont’d)
5. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and
select “HO2S2 (B1)/(B2)” as the monitor item with CONSULT-II.

SEF662Y

6. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting
“FUEL INJECTION” to ±25%.

SEF972YA

“HO2S2 (B1)/(B2)” should be
when the “FUEL INJECTION”
“HO2S2 (B1)/(B2)” should be
when the “FUEL INJECTION”

above 0.68V at least once
is +25%.
below 0.48V at least once
is −25%.

CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-216

DTC P0139, P0159
TB48DE A/T (WITH EURO-OBD)
HO2S2
Component Inspection (Cont’d)

SEC774D

EC-217

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
On Board Diagnosis Logic
With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the
theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The
ECM calculates the necessary compensation to correct the offset between the actual and the theoretical
ratios.
In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the
ECM judges the condition as the fuel injection system malfunction and light up the MI (2 trip detection logic).
Sensor
Heated oxygen sensors 1

DTC No.
P0171
0171
(Bank 1)

P0174
0174
(Bank 2)

Input Signal to ECM
Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

ECM function
Fuel injection control

Trouble diagnosis name

DTC detecting condition

Fuel injection system too
lean

+ Fuel injection system does not operate
properly.
+ The amount of mixture ratio compensation is too large.
(The mixture ratio is too lean.)

Actuator
Fuel injectors

Possible cause
+
+
+
+
+
+
+
+

Intake air leaks
Heated oxygen sensor 1
Injectors
Exhaust gas leaks
Incorrect fuel pressure
Lack of fuel
Mass air flow sensor
Incorrect PCV hose connection

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Turn ignition switch “ON” and select “SELF-LEARNING
CONT” in “WORK SUPPORT” mode with CONSULT-II.

SEF215Z

4. Clear the self-learning control coefficient by touching
“CLEAR”.
5. Select “DATA MONITOR” mode with CONSULT-II.
6. Start engine again and let it idle for at least 10 minutes.
The 1st trip DTC P0171 or P0174 should be detected at this
stage, if a malfunction exists. If so, go to EC-222, “Diagnostic Procedure”.
7. If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too.
8. Crank engine while depressing accelerator pedal. If engine
starts, go to EC-222, “Diagnostic Procedure”. If engine does
not start, check exhaust and intake air leak visually.

EC-218

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
DTC Confirmation Procedure (Cont’d)
WITH GST
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.

SEC688C

3. Disconnect mass air flow sensor harness connector. Then
restart and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness
connector.
5. Select “MODE 3” with GST. Make sure DTC P0102 is
detected.
6. Select “MODE 4” with GST and erase the DTC P0102.
7. Start engine again and let it idle for at least 10 minutes.
8. Select “MODE 7” with GST. The 1st trip DTC P0171 or
P0174 should be detected at this stage, if a malfunction
exists. If so, go to EC-222, “Diagnostic Procedure”.
9. If it is difficult to start engine at step 7, the fuel injection system has a malfunction.
10. Crank engine while depressing accelerator pedal. If engine
starts, go to EC-222, “Diagnostic Procedure”. If engine does
not start, check exhaust and intake air leak visually.

EC-219

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
Wiring Diagram
BANK 1

TEC424M

EC-220

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
Wiring Diagram (Cont’d)
BANK 2

TEC425M

EC-221

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure
1

CHECK EXHAUST GAS LEAK

1. Start engine and run it at idle.
2. Listen for an exhaust gas leak before three way catalyst (manifold).

SEC502D

OK or NG
OK

c GO TO 2.

c Repair or replace.

CHECK FOR INTAKE AIR LEAK

1. Listen for an intake air leak after the mass air flow sensor.
2. Check PCV hose connection.
OK or NG
OK

c GO TO 3.

c Repair or replace.

EC-222

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
3

CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect corresponding heated oxygen sensor 1 (HO2S1) harness connector.

SEC671D

3. Disconnect ECM harness connector.
4. Check harness continuity between ECM terminal and HO2S1 terminal as follows.
Refer to Wiring Diagram.

MTBL1579

Continuity should exist.
5. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1580

Continuity should not exist.
6. Also check harness for short to power.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-34, “FUEL PRESSURE RELEASE”.
2. Install fuel pressure gauge and check fuel pressure. Refer to EC-34, “FUEL PRESSURE CHECK”.
At idling: 245 kPa (2.45 bar, 2.5 kg/cm2, 36 psi)
OK or NG
OK

c GO TO 6.

c GO TO 5.

EC-223

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
5

DETECT MALFUNCTIONING PART

Check the following.
+ Fuel pump and circuit (Refer to EC-459, “FUEL PUMP CIRCUIT”.)
+ Fuel pressure regulator (Refer to EC-34, “FUEL PRESSURE CHECK”.)
+ Fuel lines (Refer to MA section.)
+ Fuel filter for clogging
c Repair or replace.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II
1. Install all removed parts.
2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II.
3.0 — 9.0 gzm/sec: at idling
10.0 — 25.0 gzm/sec: at 2,500 rpm
With GST
1. Install all removed parts.
2. Check mass air flow sensor signal in MODE 1 with GST.
3.0 — 9.0 gzm/sec: at idling
10.0 — 25.0 gzm/sec: at 2,500 rpm
OK or NG
OK

c GO TO 7.

c Check connectors for rusted terminals or loose connections in the mass air flow sensor
circuit or engine grounds. Refer to EC-140, “DTC P0102, P0103 MAF SENSOR”.

EC-224

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
7

CHECK FUNCTION OF INJECTORS

With CONSULT-II
1. Start engine.
2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

PBIB0133E

3. Make sure that each circuit produces a momentary engine speed drop.
Without CONSULT-II
1. Start engine.

MEC703B

2. Listen to each injector operating sound.
Clicking noise should be heard.
OK or NG
OK

c GO TO 8.

c Perform trouble diagnosis for EC-453, “INJECTOR CIRCUIT”.

EC-225

DTC P0171, P0174 FUEL INJECTION
SYSTEM FUNCTION TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
8

CHECK INJECTOR

1.
2.
3.
4.

Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
Turn ignition switch “OFF”.
Disconnect injector harness connectors on bank 2 (for DTC P0171), bank 1 (for DTC P0174).
Remove injector gallery assembly. Refer to EM section.
Keep fuel hose and all injectors connected to injector gallery.
The injector harness connectors on bank 1 (for DTC P0171), bank 2 (for DTC P0174) should remain connected.
5. Disconnect all ignition coil harness connectors.
6. Prepare pans or saucers under each injector.
7. Crank engine for about 3 seconds. Make sure that fuel sprays out from injectors.

SEF595Q

Fuel should be sprayed evenly for each injector.
OK or NG
OK

c GO TO 9.

c Replace injectors from which fuel does not spray out. Always replace O-ring with new
ones.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-226

DTC P0172, P0175 FUEL INJECTION SYSTEM
TB48DE A/T (WITH EURO-OBD)
FUNCTION
On Board Diagnosis Logic
With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the
theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The
ECM calculates the necessary compensation to correct the offset between the actual and the theoretical
ratios.
In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the
ECM judges the condition as the fuel injection system malfunction and light up the MI (2 trip detection logic).
Sensor
Heated oxygen sensors 1

DTC No.
P0172
0172
(Bank 1)
P0175
0175
(Bank 2)

Input Signal to ECM
Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

ECM function
Fuel injection control

Trouble diagnosis name

DTC detecting condition

Fuel injection system too
rich

+ Fuel injection system does not operate
properly.
+ The amount of mixture ratio compensation is too large.
(The mixture ratio is too rich.)

Actuator
Fuel injectors

Possible cause
+
+
+
+
+

Heated oxygen sensor 1
Injectors
Exhaust gas leaks
Incorrect fuel pressure
Mass air flow sensor

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

SEF215Z

4. Clear the self-learning control coefficient by touching
“CLEAR”.
5. Select “DATA MONITOR” mode with CONSULT-II.
6. Start engine again and let it idle for at least 10 minutes.
The 1st trip DTC P0172, P0175 should be detected at this
stage, if a malfunction exists. If so, go to EC-231, “Diagnostic Procedure”.
7. If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too.
8. Crank engine while depressing accelerator pedal.
If engine starts, go to EC-231, “Diagnostic Procedure”. If
engine does not start, remove ignition plugs and check for
fouling, etc.

EC-227

DTC P0172, P0175 FUEL INJECTION SYSTEM
TB48DE A/T (WITH EURO-OBD)
FUNCTION
DTC Confirmation Procedure (Cont’d)
WITH GST

SEC688C

1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Disconnect mass air flow sensor harness connector. Then
restart and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness
connector.
5. Select “MODE 3” with GST. Make sure DTC P0102 is
detected.
6. Select “MODE 4” with GST and erase the DTC P0102.
7. Start engine again and let it idle for at least 10 minutes.
8. Select “MODE 7” with GST. The 1st trip DTC P0172 or
P0175 should be detected at this stage, if a malfunction
exists. If so, go to EC-231, “Diagnostic Procedure”.
9. If it is difficult to start engine at step 7, the fuel injection system has a malfunction.
10. Crank engine while depressing accelerator pedal.
If engine starts, go to EC-231, “Diagnostic Procedure”. If
engine does not start, check exhaust and intake air leak
visually.

EC-228

DTC P0172, P0175 FUEL INJECTION SYSTEM
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Wiring Diagram
BANK 1

TEC424M

EC-229

DTC P0172, P0175 FUEL INJECTION SYSTEM
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Wiring Diagram (Cont’d)
BANK 2

TEC425M

EC-230

DTC P0172, P0175 FUEL INJECTION SYSTEM
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure
1

CHECK EXHAUST GAS LEAK

1. Start engine and run it at idle.
2. Listen for an exhaust gas leak before three way catalyst (manifold).

SEC502D

OK or NG
OK

c GO TO 2.

c Repair or replace.

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK

c GO TO 3.

c Repair or replace.

EC-231

DTC P0172, P0175 FUEL INJECTION SYSTEM
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
3

CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect corresponding heated oxygen sensor 1 (HO2S1) harness connector.

SEC671D

3. Disconnect ECM harness connector.
4. Check harness continuity between ECM terminal and HO2S1 terminal as follows.
Refer to Wiring Diagram.

MTBL1581

Continuity should exist.
5. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1582

Continuity should not exist.
6. Also check harness for short to power.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK FUEL PRESSURE

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Fuel pump and circuit (Refer to EC-459, “FUEL PUMP CIRCUIT”.)
+ Fuel pressure regulator (Refer to EC-34, “FUEL PRESSURE CHECK”.)
c Repair or replace.

EC-232

DTC P0172, P0175 FUEL INJECTION SYSTEM
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
6

CHECK MASS AIR FLOW SENSOR

c GO TO 7.

c Check connectors for rusted terminals or loose connections in the mass air flow sensor
circuit or engine grounds. Refer to EC-140, “DTC P0102, P0103 MAF SENSOR”.

CHECK FUNCTION OF INJECTORS

With CONSULT-II
1. Start engine.
2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

PBIB0133E

3. Make sure that each circuit produces a momentary engine speed drop.
Without CONSULT-II
1. Start engine.
2. Listen to each injector operating sound.

MEC703B

Clicking noise should be heard.
OK or NG
OK

c GO TO 8.

c Perform trouble diagnosis for EC-453, “INJECTOR CIRCUIT”.

EC-233

DTC P0172, P0175 FUEL INJECTION SYSTEM
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
8

CHECK INJECTOR

1. Remove injector assembly. Refer to EM section.
Keep fuel hose and all injectors connected to injector gallery.
2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
3. Disconnect injector harness connectors bank 2 (for DTC P0172), bank 1 (for P0175).
The injector harness connectors on bank 1 (for P0172), bank 2 (for P0175) should remain connected.
4. Disconnect all ignition coil harness connectors.
5. Prepare pans or saucers under each injectors.
6. Crank engine for about 3 seconds.
Make sure fuel does not drip from injector.
OK or NG
OK (Does not drip.)

c GO TO 9.

NG (Drips.)

c Replace the injectors from which fuel is dripping. Always replace O-ring with new one.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-234

DTC P0222, P0223 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Component Description

PBIB0145E

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
THRTL SEN1
THRTL SEN2*

CONDITION
+ Ignition switch: ON
(Engine stopped)
+ Shift lever: D

SPECIFICATION

Accelerator pedal: Fully released

More than 0.5V

Accelerator pedal: Fully depressed

Less than 1.5V

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic
These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

P0222
0222

Throttle position sensor 1
circuit low input

An excessively low voltage from the TP
sensor 1 is sent to ECM.

P0223
0223

Throttle position sensor 1
circuit high input

An excessively high voltage from the TP
sensor 1 is sent to ECM.

Possible cause
+ Harness or connectors
(The TP sensor 1 circuit is open or
shorted.)
+ Electric throttle control actuator
(TP sensor 1)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

EC-235

DTC P0222, P0223 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
DTC Confirmation Procedure (Cont’d)
WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-238, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-236

DTC P0222, P0223 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC398M

EC-237

DTC P0222, P0223 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
89

Sensor ground
(Throttle position sensor)

Warm-up condition
Idle speed

Approximately 0V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully released
98

R/L

Less than 4.75V

Throttle position sensor 2
Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

103

Sensor power supply
(Throttle position sensor)

Ignition switch “ON”

More than 0.36V

Approximately 5V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully released
108

More than 0.36V

Throttle position sensor 1
Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

Less than 4.75V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-238

DTC P0222, P0223 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
2

CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT

1. Disconnect electric throttle control actuator harness connector.

SEC182D

2. Turn ignition switch “ON”.
3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester.

PBIB0082E

Voltage: Approximately 5V
OK or NG
OK

c GO TO 3.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between electric throttle control actuator terminal 5 and engine ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 108 and electric throttle control actuator terminal 4.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-239

DTC P0222, P0223 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
5

CHECK THROTTLE POSITION SENSOR

Refer to EC-240, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c GO TO 6.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
THROTTLE POSITION SENSOR
1.
2.
3.
4.

Reconnect all harness connectors disconnected.
Perform EC-31, “Throttle Valve Closed Position Learning”.
Turn ignition switch “ON”.
Set selector lever to “D” position.

5. Check voltage between ECM terminals 108 (TP sensor 1
signal), 98 (TP sensor 2 signal) and engine ground under the
following conditions.

PBIB0179E

Terminal

Accelerator pedal

Voltage

108
(Throttle position sensor
1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

98
(Throttle position sensor
2)

EC-240

DTC P0300 — P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 — 6
CYLINDER MISFIRE TB48DE A/T (WITH EURO-OBD)
On Board Diagnosis Logic
When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the
crankshaft position (CKP) sensor (OBD) signal to vary, ECM can determine that a misfire is occurring.
Sensor
Crankshaft position sensor (OBD)

Input Signal to ECM
Engine speed

ECM function
On board diagnosis of misfire

The misfire detection logic consists of the following two conditions.
1. One Trip Detection Logic (Three Way Catalyst Damage)
On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to
overheating, the MI will blink.
When a misfire condition occurs, the ECM monitors the CKP sensor (OBD) signal every 200 engine
revolutions for a change.
When the misfire condition decreases to a level that will not damage the TWC, the MI will turn off.
If another misfire condition occurs that can damage the TWC on a second trip, the MI will blink.
When the misfire condition decreases to a level that will not damage the TWC, the MI will remain on.
If another misfire condition occurs that can damage the TWC, the MI will begin to blink again.
2. Two Trip Detection Logic (Exhaust quality deterioration)
For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MI will only
light when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP
sensor signal every 1,000 engine revolutions.
A misfire malfunction can be detected on any one cylinder or on multiple cylinders.
DTC No.

Trouble diagnosis name

DTC detecting condition

P0300
0300

Multiple cylinder misfire
detected

Multiple cylinder misfire.

P0301
0301

No.1 cylinder misfire
detected

No. 1 cylinder misfires.

P0302
0302

No. 2 cylinder misfire
detected

No. 2 cylinder misfires.

P0303
0303

No. 3 cylinder misfire
detected

No. 3 cylinder misfires.

P0304
0304

No. 4 cylinder misfire
detected

No. 4 cylinder misfires.

P0305
0305

No. 5 cylinder misfire
detected

No. 5 cylinder misfires.

P0306
0306

No. 6 cylinder misfire
detected

No. 6 cylinder misfires.

Possible cause
+
+
+
+
+
+
+
+
+
+
+

Improper spark plug
Insufficient compression
Incorrect fuel pressure
The injector circuit is open or shorted
Fuel injectors
Intake air leak
The ignition signal circuit is open or
shorted
Lack of fuel
Drive plate or flywheel
Heated oxygen sensor 1
Incorrect PCV hose connection

EC-241

DTC P0300 — P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 — 6
CYLINDER MISFIRE TB48DE A/T (WITH EURO-OBD)
DTC Confirmation Procedure (Cont’d)
WITH CONSULT-II

PBIB0164E

1. Turn ignition switch “ON”, and select “DATA MONITOR”
mode with CONSULT-II.
2. Start engine and warm it up to normal operating temperature.
3. Turn ignition switch “OFF” and wait at least 10 seconds.
4. Start engine again and drive at 1,500 to 3,000 rpm for at least
3 minutes.
Hold the accelerator pedal as steady as possible.
NOTE:
Refer to the freeze frame data for the test driving conditions.
5. If 1st trip DTC is detected, go to EC-242, “Diagnostic Procedure”.

WITH GST
Follow the procedure “WITH CONSULT-II” above.

Diagnostic Procedure
1

CHECK FOR INTAKE AIR LEAK AND PCV HOSE

1. Start engine and run it at idle speed.
2. Listen for the sound of the intake air leak.
3. Check PCV hose connection.
OK or NG
OK

c GO TO 2.

c Repair or replace.

CHECK FOR EXHAUST SYSTEM CLOGGING

Stop engine and visually check exhaust tube, three way catalyst and muffler for dents.
OK or NG
OK

c GO TO 3.

c Repair or replace.

EC-242

DTC P0300 — P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 — 6
CYLINDER MISFIRE TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
3

PERFORM POWER BALANCE TEST

With CONSULT-II
1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.

PBIB0133E

2. Is there any cylinder which does not produce a momentary engine speed drop?
Without CONSULT-II
When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary
engine speed drop?

SEC793C

Yes or No
Yes

c GO TO 4.

c GO TO 7.

CHECK INJECTOR

Does each injector make an operating sound at idle?

MEC703B

Yes or No
Yes

c GO TO 5.

c Check injector(s) and circuit(s). Refer to EC-453, “INJECTOR CIRCUIT”.

EC-243

DTC P0300 — P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 — 6
CYLINDER MISFIRE TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
5
1.
2.
3.
4.

CHECK IGNITION SPARK
Disconnect ignition coil assembly from rocker cover.
Connect a known good spark plug to the ignition coil assembly.
Place end of spark plug against a suitable ground and crank engine.
Check for spark.

SEF575Q

OK or NG
OK

c GO TO 6.

c Check ignition coil, power transistor and their circuits. Refer to EC-428, “IGNITION SIGNAL”.

CHECK SPARK PLUGS

Remove the spark plugs and check for fouling, etc.

SEF156I

OK or NG
OK

c GO TO 7.

c Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to MA
section.

CHECK COMPRESSION PRESSURE

Check compression pressure. Refer to EM section.
Standard: 1,226 kPa (12.26 bar, 12.5 kg/cm2, 178 psi)/200 rpm
Minimum: 1,030 kPa (10.30 bar, 10.5 kg/cm2, 149 psi)/200 rpm
Difference between each cylinder: 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)/200 rpm
OK or NG
OK

c GO TO 8.

c Check pistons, piston rings, valves, valve seats and cylinder head gaskets.

EC-244

DTC P0300 — P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 — 6
CYLINDER MISFIRE TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
8

CHECK FUEL PRESSURE

1. Install all removed parts.
2. Release fuel pressure to zero. Refer to EC-34, “FUEL PRESSURE RELEASE”.
3. Install fuel pressure gauge and check fuel pressure. Refer to EC-34, “FUEL PRESSURE CHECK”.
At idle: Approx. 245 kPa (2.45 bar, 2.5 kg/cm2, 36 psi)
OK or NG
OK

c GO TO 9.

c Follow the construction of “FUEL PRESSURE CHECK”.

CHECK IGNITION TIMING

Check the following items. Refer to EC-66, “Basic Inspection”.

MTBL1583

OK or NG
OK

c GO TO 10.

c Follow the “Basic Inspection”.

CHECK HEATED OXYGEN SENSOR 1

Refer to EC-170, “Component Inspection”.
OK or NG
OK

c GO TO 12.

c GO TO 11.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II
Check mass air flow sensor signal in “DATA MONITOR” mode with CONSULT-II.
3.0 — 9.0 gzm/sec: at idling
10.0 — 25.0 gzm/sec: at 2,500 rpm
With GST
Check mass air flow sensor signal in MODE 1 with GST.
3.0 — 9.0 gzm/sec: at idling
10.0 — 25.0 gzm/sec: at 2,500 rpm
OK or NG
OK

c GO TO 12.

c Check connectors for rusted terminals or loose connections in the mass air flow sensor
circuit or engine grounds. Refer to EC-140, “DTC P0102, P0103 MAF SENSOR”.

CHECK SYMPTOM MATRIX CHART

Check items on the rough idle symptom in EC-71, “Symptom Matrix Chart”.
OK or NG
OK

c GO TO 13.

c Repair or replace.

EC-245

DTC P0300 — P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 — 6
CYLINDER MISFIRE TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
13

ERASE THE 1ST TRIP DTC

Some tests may cause a 1st trip DTC to be set.
Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-49, “HOW TO ERASE EMISSION-RELATED
DIAGNOSTIC INFORMATION”.
c GO TO 14.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-246

DTC P0327, P0328, P0332,
TB48DE A/T (WITH EURO-OBD)
P0333 KS
Component Description
The knock sensor is attached to the cylinder block. It senses
engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure.
This pressure is converted into a voltage signal and sent to the
ECM.

SEF598K

On Board Diagnosis Logic
The MI will not light up for these self-diagnoses.
DTC No.
P0327
0327 (bank 1)
P0332
0332 (bank 2)
P0328
0328 (bank 1)
P0333
0333 (bank 2)

Trouble Diagnosis Name

DTC Detecting Condition

Knock sensor circuit low
input

An excessively low voltage from the sensor is sent to ECM.

Knock sensor circuit high
input

An excessively high voltage from the sensor is sent to ECM.

Possible Cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Knock sensor

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

WITH CONSULT-II
1. Turn ignition switch “ON” and select “DATA MONITOR”
mode with CONSULT-II.
2. Start engine and run it for at least 5 seconds at idle speed.
3. If 1st trip DTC is detected, go to EC-249, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-247

DTC P0327, P0328, P0332,
TB48DE A/T (WITH EURO-OBD)
P0333 KS
Wiring Diagram

TEC153M

EC-248

DTC P0327, P0328, P0332,
TB48DE A/T (WITH EURO-OBD)
P0333 KS
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
125

Knock sensor (bank 1)

Approximately 2.5V
Idle speed
Engine is running.

126

Knock sensor (bank 2)

Approximately 2.5V
Idle speed

Diagnostic Procedure
1

CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check resistance between ECM terminal 125 (bank 1) or 126 (bank 2) and engine ground. Refer to Wiring Diagram.
NOTE:
It is necessary to use an ohmmeter which can measure more than 10 MΩ. Resistance: Approximately 530 — 590 kΩ [at
20°C (68°F)]
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 2.

CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II

1. Disconnect knock sensor harness connector.

SEC889C

2. Check harness continuity between ECM terminal 125 (bank 1) or 126 (bank 2) and knock sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 3.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-249

DTC P0327, P0328, P0332,
TB48DE A/T (WITH EURO-OBD)
P0333 KS
Diagnostic Procedure (Cont’d)
3

CHECK KNOCK SENSOR

Refer to EC-250, “Component Inspection”.
OK or NG
OK

c GO TO 5.

c Replace knock sensor.

RETIGHTEN GROUND SCREWS

Loosen and retighten engine ground screws.

SEC690C

c GO TO 5.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
KNOCK SENSOR
Check resistance between knock sensor terminal 1 and ground.
NOTE:
It is necessary to use an ohmmeter which can measure
more than 10 MΩ.
Resistance: Approximately 530 — 590 kΩ [at 20°C
(68°F)]
SEF478Y

CAUTION:
Do not use any knock sensors that have been dropped or
physically damaged. Use only new ones.

EC-250

DTC P0335 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Component Description

SEF804Z

The crankshaft position sensor (OBD) is located on the cylinder
block rear housing facing the gear teeth (cogs) of the signal plate
at the end of the crankshaft. It detects the fluctuation of the
engine revolution.
The sensor consists of a permanent magnet, core and coil.
When the engine is running, the high and low parts of the teeth
cause the gap with the sensor change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation
of the engine revolution.
This sensor is not used to control the engine system. It is used
only for the on board diagnosis.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
ENG SPEED

CONDITION

SPECIFICATION

+ Tachometer: Connect
Almost the same speed as the
+ Run engine and compare CONSULT-II value with the tachometer indica- tachometer indication.
tion.

On Board Diagnosis Logic
DTC No.
P0335
0335

Trouble diagnosis name
Crankshaft position sensor (OBD) circuit

DTC detecting condition
+ The proper pulse signal from the crankshaft position sensor (OBD) is not sent
to ECM while the engine is running at
the specified engine speed.

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Crankshaft position sensor (OBD)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10.5V with ignition switch ON”.

WITH CONSULT-II
1. Turn ignition switch “ON” and select “DATA MONITOR”
mode with CONSULT-II.
2. Start engine and run it for at least 15 seconds at idle speed.
3. If 1st trip DTC is detected, go to EC-254, “Diagnostic Procedure”.

SEF058Y

EC-251

DTC P0335 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
DTC Confirmation Procedure (Cont’d)
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-252

DTC P0335 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Wiring Diagram

TEC344M

EC-253

DTC P0335 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
89

WIRE
COLOR

ITEM

CONDITION

Crankshaft position sensor (OBD) ground

DATA (DC Voltage)

Engine is running.
Approximately 0V
Idle speed
Approximately 1 — 2V★

Engine is running.
Warm-up condition.
Idle speed

111

SEC748D

Crankshaft position sensor (OBD)

Approximately 3 — 4V★

Engine is running.
Engine speed is 2,000 rpm

SEC749D

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-254

DTC P0335 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Diagnostic Procedure (Cont’d)
2

CHECK CKP SENSOR (OBD) POWER SUPPLY CIRCUIT

1. Disconnect crankshaft position (CKP) sensor (OBD) harness connector and ECM harness connector.

SEC732D

2. Check harness continuity between CKP sensor (OBD) terminal 1 and ECM terminal 111.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E201, E70
+ Harness connectors E127, M21
+ Harness connectors M51, F6
+ Harness for open or short between crankshaft position sensor (OBD) and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK CKP SENSOR (OBD) GROUND CIRCUIT FOR OPEN AND SHORT

1. Reconnect ECM harness connector.
2. Check harness continuity between CKP sensor (OBD) terminal 2 and ground.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for and short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E202, E69
+ Harness connectors E127, M21
+ Harness connectors M51, F6
+ Harness for open or short between crankshaft position sensor (OBD) and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-255

DTC P0335 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Diagnostic Procedure (Cont’d)
6

CHECK SHIELD CIRCUIT

1. Disconnect harness connectors E201, E70.
2. Check harness continuity between harness connector E70 terminal 10 and ground.
Continuity should exist.
3. Also check harness for short to power.
4. Then reconnect harness connectors.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M51, F6
+ Joint connector-7
+ Harness for open or short between harness connector E70 and ground
c Repair open circuit or short to power in harness or connectors.

CHECK CRANKSHAFT POSITION SENSOR (OBD)

Refer to EC-256, “Component Inspection”.
OK or NG
OK

c GO TO 9.

c Replace crankshaft position sensor (OBD).

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
CRANKSHAFT POSITION SENSOR (OBD)
1. Loosen the fixing bolt of the sensor.
2. Disconnect crankshaft position sensor (OBD) harness connector.
3. Remove the sensor.
4. Visually check the sensor for chipping.

SEF960N

5. Check resistance as shown in the figure.
Resistance: Approximately 512 — 632Ω [at 20°C (68°F)]
6. If NG, replace crankshaft position sensor (OBD).

SEF231W

EC-256

DTC P0340 CAMSHAFT POSITION
TB48DE A/T (WITH EURO-OBD)
(CMP) SENSOR
Component Description

SEC695C

The camshaft position sensor (CMPS) is a basic component of
the ECM. It monitors engine speed and piston position. It sends
signals to the ECM to control fuel injection, ignition timing and
other functions.
The camshaft position sensor has a rotor plate and a waveforming circuit. The rotor plate has 360 slits for 1° signal and 6
slits for 120° signal. Light Emitting Diodes (LED) and photo
diodes are built into the wave-forming circuit.
When the rotor plate passes between the LED and the photo
diode, the following happens:
Slits in the rotor plate continually cut the transmitted light to the
photo diode from the LED. This generates rough-shaped pulses
converted into on-off pulses by the wave forming circuit sent to
the ECM.

SEF614B

ECM Terminals and Reference Value
Specification data are reference values, and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring voltage. Doing so may result in damage to the
ECM’s transistor. Use a ground other than ECM terminals such as the body ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC voltage)
1.0 — 4.0V*1

Engine is running. (Warmed-up condition)
Idle speed

B/W

SEC750D

Camshaft position sensor
(POS signal)

1.0 — 4.0V*1

Engine is running. (Warmed-up condition)
Engine speed is 2,000 rpm.

SEC751D

EC-257

TERMINAL
NO.

DTC P0340 CAMSHAFT POSITION
TB48DE A/T (WITH EURO-OBD)
(CMP) SENSOR
ECM Terminals and Reference Value
(Cont’d)
WIRE
COLOR

ITEM

DATA
(DC voltage)

CONDITION

Approximately 0.3 0.6V*1

Engine is running. (Warmed-up condition)
Idle speed

83
84

SEC746D

Camshaft position sensor
(REF signal)

Approximately 0.3 0.6V*1

Engine is running. (Warmed-up condition)
Engine speed is 2,000 rpm.

SEC747D

*1: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

On Board Diagnosis Logic
Diagnostic
Trouble Code
No.
P0340
0340

Malfunction is detected when ….
A) Either 1° or 120° signal is not sent to ECM for the
first few seconds during engine cranking.
……………………………………………………………………………
B) Either 1° or 120° signal is not sent to ECM during
engine running.
……………………………………………………………………………

Check Items
(Possible Cause)
+ Harness or connectors
(The camshaft position sensor circuit is open or
shorted.)
+ Camshaft position sensor
+ Starter motor (Refer to EL section.)
+ Starting system circuit (Refer to EL section.)
+ Dead (Weak) battery

C) Either 1° or 120° signal is not in the normal pattern
during engine running.

DTC Confirmation Procedure
Perform “Procedure for malfunction A” first. If DTC cannot
be confirmed, perform “Procedure for malfunction B and C”.
NOTE:
If “DTC CONFIRMATION PROCEDURE” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 5 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10.5V at idle.

EC-258

DTC P0340 CAMSHAFT POSITION
TB48DE A/T (WITH EURO-OBD)
(CMP) SENSOR
DTC Confirmation Procedure (Cont’d)
PROCEDURE FOR MALFUNCTION A
With CONSULT-II
1) Turn ignition switch “ON” and select “DATA MONITOR”
mode with CONSULT-II.
2) Crank engine at least 2 seconds.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
3) If DTC is detected, go to “Diagnostic Procedure”, EC-261.

Without CONSULT-II

SEF013Y

1) Crank engine for at least 2 seconds.
(If engine does not run, turn ignition switch to “START” for at
least 2 seconds.)
2) Turn ignition switch “OFF”, wait at least 10 seconds and then
turn “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
4) If DTC is detected, go to “Diagnostic Procedure”, EC-261.

PROCEDURE FOR MALFUNCTION B AND C
With CONSULT-II
1)
2)
3)
4)

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and run it for at least 2 seconds at idle speed.
If DTC is detected, go to “DIAGNOSTIC PROCEDURE”,
EC-261.

Without CONSULT-II
1) Start engine and run it for at least 2 seconds at idle speed.
2) Turn ignition switch “OFF”, wait at least 10 seconds and then
turn “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic results)”
with ECM.
4) If DTC is detected, go to “Diagnostic Procedure”, EC-261.

EC-259

DTC P0340 CAMSHAFT POSITION
TB48DE A/T (WITH EURO-OBD)
(CMP) SENSOR
Wiring Diagram

TEC145M

EC-260

DTC P0340 CAMSHAFT POSITION
TB48DE A/T (WITH EURO-OBD)
(CMP) SENSOR
Diagnostic Procedure
INSPECTION START
.

CHECK STARTING SYSTEM.
Does the engine turn over?
(Does the starter motor operate?)

Check starting system.
(Refer to EL section.)

Yes
.

SEC690C

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground
screws.
OK
.

SEC696C

NG
Check the following.
CHECK POWER SUPPLY.
c
+ Harness connectors
1. Disconnect camshaft position sensor
M52 , F7
harness connector.
2. Turn ignition switch “ON”.
+ Harness for open or
3. Check voltage between terminal V
short between camshaft
3 and
position sensor and ECM
ground with CONSULT-II or tester.
Voltage: Battery voltage
+ Harness for open or
short between camshaft
OK
position sensor and ECM
relay
If NG, repair harness or
connectors.
.

CHECK GROUND CIRCUIT.
1. Turn ignition switch “OFF”.
2. Check harness continuity between terminal V
4 and engine ground.
Refer to Wiring Diagram.
Continuity should exist.
If OK, check harness for short to power.

NG
c

Repair open circuit, short to
power in harness or connectors.

OK
.

SEC697C

CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between
CMPS terminals V
1 ,V
2 and ECM terminals.
CMPS
terminal

ECM terminal

Continuity

120° signal
(REF signal)

1
V

83 , V
84
V

Yes

1° signal
(POS signal)

2
V

63
V

Yes

Refer to Wiring Diagram.
If OK, check harness for short to ground
and short to power.
.

A
V

EC-261

NG
c

Repair open circuit, short to
ground or short to power in
harness or connectors.

DTC P0340 CAMSHAFT POSITION
TB48DE A/T (WITH EURO-OBD)
(CMP) SENSOR
Diagnostic Procedure (Cont’d)
A
V
.

CHECK COMPONENT.
(Camshaft position sensor).
Refer to “COMPONENT INSPECTION”,
EC-262.

NG
c

Replace camshaft position
sensor.

OK
.

CHECK INTERMITTENT INCIDENT.
Refer to “TROUBLE DIAGNOSIS FOR
INTERMITTENT INCIDENT”, EC-112.
.

INSPECTION END

Component Inspection
CAMSHAFT POSITION SENSOR
1. Start engine and warm it up to the normal operating temperature.
2. Check voltage between the following ECM terminals and
ground with DC range.

SEC827C

ECM terminal

Reference illustration

1° signal
(POS signal)

63
V

A
V

120° signal
(REF signal)

83 , V
84
V

B
V

CAUTION:
Do not use ECM ground terminals when measuring voltage.
Doing so may result in damage to the ECM’s transistor. Use
a ground other than ECM terminals such as the body
ground.

EC-262

DTC P0340 CAMSHAFT POSITION
TB48DE A/T (WITH EURO-OBD)
(CMP) SENSOR
Component Inspection (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC voltage)
1.0 — 4.0V*1

Engine is running. (Warmed-up condition)
Idle speed

B/W

SEC750D

Camshaft position sensor
(POS signal)

1.0 — 4.0V*1

Engine is running. (Warmed-up condition)
Engine speed is 2,000 rpm.

SEC751D

Approximately 0.3 0.6V*1

Engine is running. (Warmed-up condition)
Idle speed

83
84

SEC746D

Camshaft position sensor
(REF signal)

Approximately 0.3 0.6V*1

Engine is running. (Warmed-up condition)
Engine speed is 2,000 rpm.

SEC747D

*1: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

If NG, replace camshaft position sensor.

EC-263

DTC P0420, P0430 THREE WAY CATALYST
TB48DE A/T (WITH EURO-OBD)
FUNCTION
On Board Diagnosis Logic
The ECM monitors the switching frequency ratio of heated oxygen sensors 1 and 2.
A three way catalyst (manifold) with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2. As oxygen storage capacity decreases, the heated oxygen
sensor 2 switching frequency will increase.
When the frequency ratio of heated oxygen sensors 1 and 2
approaches a specified limit value, the three way catalyst (manifold) malfunction is diagnosed.
SEF484YF

DTC No.
P0420
0420
(Bank 1)

Trouble diagnosis name

DTC detecting condition

Catalyst system efficiency + Three way catalyst (manifold) does not
below threshold
operate properly.
+ Three way catalyst (manifold) does not
have enough oxygen storage capacity.

P0430
0430
(Bank 2)

Possible cause
+
+
+
+
+
+
+

Three way catalyst (manifold)
Exhaust tube
Intake air leaks
Fuel injectors
Fuel injector leaks
Spark plug
Improper ignition timing

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
TESTING CONDITION:
+ Open engine hood before conducting the following procedure.
+ Do not hold engine speed for more than the specified
minutes below.
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
4. Let engine idle for one minute.

5. Select “DTC & SRT CONFIRMATION” then “SRT WORK
SUPPORT” mode with CONSULT-II.
6. Rev engine up to 2,500 to 3,500 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely.
If “INCMP” of “CATALYST” changed to “COMPLT”, go to
step 9
7. Wait 5 seconds at idle.

PBIB0566E

EC-264

DTC P0420, P0430 THREE WAY CATALYST
TB48DE A/T (WITH EURO-OBD)
FUNCTION
DTC Confirmation Procedure (Cont’d)
8. Rev engine up to 2,000 to 3,000 rpm and maintain it
“INCMP” of “CATALYST” changes to “CMPLT” (It will
approximately 5 minutes).
If not “CMPLT”, stop engine and cool it down to less
70°C (158°F) and then retest from step 1.
a. Turn ignition switch “OFF” and leave the vehicle in a
place (soak the vehicle).

until
take
than
cool

PBIB0567E

b. Turn ignition switch “ON” and select “COOLANTEMP/S” in
“DATA MONITOR” mode with CONSULT-II.
c. Start engine and warm it up while monitoring
“COOLANTEMP/S” indication on CONSULT-II.
d. When “COOLANTEMP/S” indication reaches to 70°C
(158°F), go to step 3.

SEF013Y

9. Select “SELF-DIAG RESULTS” mode with CONSULT-II.
10. Confirm that the 1st trip DTC is not detected.
If the 1st trip DTC is detected, go to EC-266, “Diagnostic
Procedure”.

SEF535Z

Overall Function Check
Use this procedure to check the overall function of the three way
catalyst (Manifold). During this check, a DTC might not be confirmed.
CAUTION:
Always drive vehicle at a safe speed.

EC-265

DTC P0420, P0430 THREE WAY CATALYST
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Overall Function Check (Cont’d)
5. Set voltmeters probes between ECM terminals 115 [HO2S1
(B 1) signal], 114 [HO2S1 (B 2) signal] and engine ground,
and ECM terminals 124 [HO2S2 (B 1) signal], 123 [HO2S2
(B 2) signal] and engine ground.
6. Keep engine speed at 2,000 rpm constant under no load.

SEC184DA

SEC672D

7. Make sure that the voltage switching frequency (high & low)
between ECM terminals 124 and engine ground, or 123 and
engine ground is very less than that of ECM terminals 115
and engine ground, or 114 and engine ground.
Switching frequency ratio = A/B
A: Heated oxygen sensor 2 voltage switching frequency
B: Heated oxygen sensor 1 voltage switching frequency
This ratio should be less than 0.75.
If the ratio is greater than above, it means three way catalyst does not operate properly. Go to EC-266, “Diagnostic
Procedure”.
NOTE:
If the voltage at terminal 35 or 36 does not switch periodically more than 5 times within 10 seconds at step 7, perform
trouble diagnosis for “DTC P0133, P0153” first. (See
EC-172.)

Diagnostic Procedure
1

CHECK EXHAUST SYSTEM

Visually check exhaust tubes and muffler for dent.
OK or NG
OK

c GO TO 2.

c Repair or replace.

CHECK EXHAUST GAS LEAK

1. Start engine and run it at idle.
2. Listen for an exhaust gas leak before the three way catalyst (manifold).

SEC502D

OK or NG
OK

c GO TO 3.

c Repair or replace.

EC-266

DTC P0420, P0430 THREE WAY CATALYST
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
3

CHECK INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK

c GO TO 4.

c Repair or replace.

CHECK IGNITION TIMING

Check the following items. Refer to EC-66, “Basic Inspection”.

MTBL1584

OK or NG
OK

c GO TO 5.

c Follow the EC-66, “Basic Inspection”.

CHECK INJECTORS

1. Stop engine and then turn ignition switch “ON”.
2. Check voltage between ECM terminals 5, 6, 7, 13, 14, 15 and ground with CONSULT-II or tester.

SEC743D

Battery voltage should exist.
3. Refer to Wiring Diagram for Injectors, EC-454.
OK or NG
OK

c GO TO 6.

c Perform EC-455, “Diagnostic Procedure”.

EC-267

DTC P0420, P0430 THREE WAY CATALYST
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
6
1.
2.
3.
4.
5.

CHECK IGNITION SPARK
Turn ignition switch “OFF”.
Disconnect ignition coil assembly from rocker cover.
Connect a known good spark plug to the ignition coil assembly.
Place end of spark plug against a suitable ground and crank engine.
Check for spark.

SEF575Q

OK or NG
OK

c GO TO 7.

c Check ignition coil with power transistor and their circuit. Refer to EC-428, “IGNITION SIGNAL”.

CHECK INJECTOR

1. Turn ignition switch “OFF”.
2. Remove injector assembly.
Refer to EM section.
Keep fuel hose and all injectors connected to injector gallery.
3. Disconnect all ignition coil harness connectors.
4. Turn ignition switch “ON”.
Make sure fuel does not drip from injector.
OK or NG
OK (Does not drip.)

c GO TO 8.

NG (Drips.)

c Replace the injector(s) from which fuel is dripping.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
Trouble is fixed.

c INSPECTION END

Trouble is not fixed.

c Replace three way catalyst (Manifold).

EC-268

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Description
SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Closed throttle position

Heated oxygen sensors 1

Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Vehicle speed sensor

Vehicle speed

ECM Function

Actuator

EVAP canister purge
flow control

EVAP canister purge volume control solenoid
valve

*: This signal is sent to the ECM through CAN communication line.

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP
canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from
the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM
is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel
vapor from the EVAP canister is regulated as the air flow changes.

COMPONENT DESCRIPTION
The EVAP canister purge volume control solenoid valve uses a
ON/OFF duty to control the flow rate of fuel vapor from the EVAP
canister. The EVAP canister purge volume control solenoid valve
is moved by ON/OFF pulses from the ECM. The longer the ON
pulse, the greater the amount of fuel vapor that will flow through
the valve.

SEF337U

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
PURG VOL C/V

CONDITION
+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

SPECIFICATION

Idle

2,000 rpm

65 — 85%

On Board Diagnosis Logic
DTC No.
P0444
0444

P0445
0445

Trouble diagnosis name
EVAP canister purge volume control solenoid
valve circuit open

EVAP canister purge volume control solenoid
valve circuit shorted

DTC detecting condition
An excessively low voltage signal
is sent to ECM through the valve

An excessively high voltage signal
is sent to ECM through the valve

EC-269

Possible cause
+ Harness or connectors
(The solenoid valve circuit is open or shorted.)
+ EVAP canister purge volume control solenoid
valve
+ Harness or connectors
(The solenoid valve circuit is shorted.)
+ EVAP canister purge volume control solenoid
valve

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm battery
voltage is more than 11V at idle.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 30 seconds.
If 1st trip DTC is detected, go to EC-273, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-270

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Wiring Diagram

TEC418M

EC-271

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

BATTERY VOLTAGE
(11 — 14V)
Engine is running.
Idle speed

W/B

EVAP canister purge volume control solenoid
valve

PBIB0050E

Approximately 10V★
Engine is running.
Engine speed is about 2,000 rpm (More than
100 seconds after starting engine)

PBIB0520E

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-272

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Diagnostic Procedure
1

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect EVAP canister purge volume control solenoid valve harness connector.

SEC785C

3. Turn ignition switch “ON”.
4. Check voltage between EVAP canister purge volume control solenoid valve terminal 1 and ground with CONSULT-II or tester.

SEC815C

Voltage: Battery voltage
OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ 10A fuse
+ Fuse block (J/B) connector M2
+ Harness connectors M52, F7
+ Harness for open or short between EVAP canister purge volume control solenoid valve and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-273

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Diagnostic Procedure (Cont’d)
3

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND
SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 54 and EVAP canister purge volume control solenoid valve terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK (With CONSULT-II)

c GO TO 4.

OK (Without CONSULT-II)

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

With CONSULT-II
1. Reconnect all harness connectors disconnected.
2. Start engine.
3. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the
valve opening.

PBIB0147E

OK or NG
OK

c GO TO 6.

c GO TO 5.

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Refer to EC-275, “Component Inspection”.
OK or NG
OK

c GO TO 6.

c Replace EVAP canister purge volume control solenoid valve.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-274

DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Component Inspection
EVAP CANISTER PURGE VOLUME CONTROL
SOLENOID VALVE
With CONSULT-II
Check air passage continuity of EVAP canister purge volume
control solenoid valve under the following conditions.
Condition
(PURG VOL CONT/V value)
PBIB0149E

Air passage continuity between A and
B

100.0%

Yes

0.0%

Without CONSULT-II
Check air passage continuity of EVAP canister purge volume
control solenoid valve under the following conditions.
Condition

Air passage continuity between A and
B

12V direct current supply between
terminals 1 and 2

Yes

No supply

PBIB0150E

EC-275

DTC P0500 VSS

TB48DE A/T (WITH EURO-OBD)

Description
NOTE:
If DTC P0500 is displayed with DTC U1000, first perform the trouble diagnosis for DTC U1000. Refer
to EC-121, “DTC U1000 CAN COMMUNICATION LINE”.
The vehicle speed sensor is installed in the transaxle. It contains a pulse generator which provides a vehicle
speed signal to the combination meter. The combination meter then sends a signal to the ECM through CAN
communication line.

On Board Diagnosis Logic
DTC No.
P0500
0500

Trouble diagnosis name
Vehicle speed sensor

DTC detecting condition
The almost 0 km/h (0 MPH)
signal from vehicle speed
sensor is sent to ECM even
when vehicle is being driven.

Possible cause
+ Harness or connectors
(The CAN communication line is open or shorted.)
+ Harness or connectors
(The vehicle speed signal circuit is open or shorted.)
+ Combination meter
+ Vehicle speed signal

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Steps 1 and 2 may be conducted with the drive wheels lifted
in the shop or by driving the vehicle. If a road test is
expected to be easier, it is unnecessary to lift the vehicle.

WITH CONSULT-II
1. Start engine.
2. Read “VHCL SPEED SE” in “DATA MONITOR” mode with
CONSULT-II. The vehicle speed on CONSULT-II should
exceed 10 km/h (6 MPH) when rotating wheels with suitable
gear position.
If NG, go to EC-277, “Diagnostic Procedure”.
If OK, go to following step.
3. Select “DATA MONITOR” mode with CONSULT-II.
4. Warm engine up to normal operating temperature.

5. Maintain the following conditions for at least 60 consecutive
seconds.

SEF196Y

ENG SPEED

More than 1,350 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

More than 6.5 msec

Selector lever

Suitable position

PW/ST SIGNAL

OFF

6. If 1st trip DTC is detected, go to EC-277, “Diagnostic Procedure”.

EC-276

DTC P0500 VSS

TB48DE A/T (WITH EURO-OBD)

Overall Function Check
Use this procedure to check the overall function of the vehicle
speed signal circuit. During this check, a 1st trip DTC might not
be confirmed.

WITH GST
1. Lift up drive wheels.
2. Start engine.
3. Read vehicle speed signal in “MODE 1” with GST.
The vehicle speed signal on GST should be able to exceed
10 km/h (6 MPH) when rotating wheels with suitable gear
position.
4. If NG, go to EC-277, “Diagnostic Procedure”.

Diagnostic Procedure
1

CHECK VEHICLE SPEED SENSOR CIRCUIT

Refer to EL section.
OK or NG
OK

c GO TO 2.

c Repair or replace.

CHECK COMBINATION METER

Check combination meter function.
Refer to EL section.
c INSPECTION END

EC-277

DTC P0550 PSP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Component Description
Power steering pressure (PSP) sensor is installed to the power
steering high-pressure tube and detects a power steering load.
This sensor is a potentiometer which transforms the power steering load into output voltage, and emits the voltage signal to the
ECM. The ECM controls the electric throttle control actuator and
adjusts the throttle valve opening angle to increase the engine
speed and adjusts the idle speed for the increased load.
SEC735D

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
PW/ST SIGNAL

CONDITION
+ Engine: After warming up, idle
the engine

SPECIFICATION

Steering wheel is in neutral position.
(Forward direction)

OFF

Steering wheel is turned.

On Board Diagnosis Logic
The MI will not light up for this diagnosis.
DTC No.
P0550
0550

Trouble diagnosis name
Power steering pressure
sensor circuit

DTC detecting condition
An excessively low or high voltage from
the sensor is sent to ECM.

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Power steering pressure sensor

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 5 seconds.
If 1st trip DTC is detected, go to EC-280, “Diagnostic Procedure”.

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-278

DTC P0550 PSP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC342M

EC-279

DTC P0550 PSP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

103

ITEM

CONDITION

Sensor ground
(Power steering pressure
sensor)
Sensor power supply
(Power steering pressure
sensor)

DATA (DC Voltage)

Engine is running.
Approximately 0V
Idle speed

Ignition switch “ON”

Approximately 5V

Engine is running.
0.5 — 4.0V
118

BR/W

Power steering pressure
sensor

Steering wheel is being turned.
Engine is running.
0.4 — 0.8V
Steering wheel is not being turned.

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-280

DTC P0550 PSP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
2

CHECK PSP SENSOR POWER SUPPLY CIRCUIT

1. Disconnect PSP sensor harness connector.

SEC735D

2. Turn ignition switch “ON”.
3. Check voltage between PSP sensor terminal 1 and ground with CONSULT-II or tester.

PBIB0085E

Voltage: Approximately 5V
OK or NG
OK

c GO TO 3.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK PSP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between PSP sensor terminal 3 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK PSP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 118 and PSP sensor terminal 2.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-281

DTC P0550 PSP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
5

CHECK PSP SENSOR

Refer to EC-282, “Component Inspection”.
OK or NG
OK

c GO TO 6.

c Replace PSP sensor.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
POWER STEERING PRESSURE SENSOR
1. Reconnect all harness connectors disconnected.
2. Start engine and let it idle.
3. Check voltage between ECM terminal 118 and ground under
the following conditions.
Condition

SEC736D

Voltage

Steering wheel is being turned fully.

0.5 — 4.0V

Steering wheel is not being turned.

0.4 — 0.8V

EC-282

DTC P0605 ECM

TB48DE A/T (WITH EURO-OBD)

Component Description
The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The ECM controls the
engine.

SEF093X

On Board Diagnosis Logic
This self-diagnosis has one or two trip detection logic.
DTC No.
P0605
0605

Trouble diagnosis name
Engine control module

DTC detecting condition
A)

ECM calculation function is malfunctioning.

ECM EEP-ROM system is malfunctioning.

ECM self shut-off function is malfunctioning.

Possible cause
+ ECM

FAIL-SAFE MODE
ECM enters fail-safe mode when malfunction A is detected.
Detected items
Malfunction A

Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening
(approx. 5 degrees) by the return spring.

DTC Confirmation Procedure
Perform “PROCEDURE FOR MALFUNCTION A” first. If the DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. If there is no malfunction on “PROCEDURE FOR MALFUNCTION
B”, perform “PROCEDURE FOR MALFUNCTION C”.
NOTE:
If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF”
and wait at least 10 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A
With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. If 1st DTC is detected, go to EC-285, “Diagnostic Procedure”.

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-283

TB48DE A/T (WITH EURO-OBD)
DTC P0605 ECM
DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION B
With CONSULT-II
1. Turn ignition switch “ON” and wait at least 1 second.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Turn ignition switch “OFF”, wait at least 10 seconds, and then
turn “ON”.
4. If 1st trip DTC is detected, go to EC-285, “Diagnostic Procedure”.
SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1. Turn ignition switch “ON” and wait at least 1 second.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Turn ignition switch “OFF”, wait at least 10 seconds, and then
turn “ON”.
4. Repeat step 3 for 32 times.
5. If 1st trip DTC is detected, go to EC-285, “Diagnostic Procedure”.
SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-284

DTC P0605 ECM

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
1

INSPECTION START

With CONSULT-II
Turn ignition switch “ON”.
Select “SELF DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform “DTC Confirmation Procedure”.
See EC-283.
5. Is the 1st trip DTC P0605 displayed again?
1.
2.
3.
4.

With GST
Turn ignition switch “ON”.
Select MODE 4 with GST.
Touch “ERASE”.
Perform “DTC Confirmation Procedure”.
See EC-283.
5. Is the 1st trip DTC P0605 displayed again?
1.
2.
3.
4.

Yes or No
Yes

c GO TO 2.

c INSPECTION END

REPLACE ECM

1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EC-50, “NATS (Nissan Anti-theft
System)”.
3. Perform EC-31, “Accelerator Pedal Released Position Learning”.
4. Perform EC-31, “Throttle Valve Closed Position Learning”.
5. Perform EC-31, “Idle Air Volume Learning”.
c INSPECTION END

EC-285

DTC P0650 MI

TB48DE A/T (WITH EURO-OBD)

Component Description
Malfunction Indicator (MI) is located on the instrument panel. When the ignition switch is turned ON without
engine running, MI will light up. This is a bulb check. When the engine is started, MI should go off. If MI
remains on, the on board diagnostic system has detected an engine system malfunction.

On Board Diagnosis Logic
The MI will not light up for this self-diagnosis.
DTC No.
P0650
0650

Trouble diagnosis name
Malfunction indicator (MI)
control circuit

DTC detecting condition

Possible cause

+ Harness or connectors
+ An excessively high voltage is sent to
(MI circuit is open or shorted.)
ECM through the MI circuit under the
+ MI
condition that calls for MI light up.
+ An excessively low voltage is sent to
ECM through the MI circuit under the
condition that calls for MI not to light up.

FAIL-SAFE MODE
ECM enters fail-safe mode when both DTC P0650 and another DTC, which calls for MI to light up, are
detected at the same time.
Detected items
MI circuit

Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,500 rpm due to the fuel cut.

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON” and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If 1st trip DTC is detected, go to “Diagnostic Procedure”,
EC-288.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-286

DTC P0650 MI

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC422M

EC-287

TB48DE A/T (WITH EURO-OBD)
DTC P0650 MI
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and body ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

Y/G

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”

0 — 1.0V

Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Idle speed

Diagnostic Procedure
1
1.
2.
3.
4.

CHECK MIL POWER SUPPLY CIRCUIT
Turn ignition switch “OFF”.
Disconnect combination meter harness connector.
Turn ignition switch “ON”.
Check voltage between combination meter terminal 46 and ground with CONSULT-II or tester.

SEC737D

Voltage: Battery voltage
OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ Fuse block (J/B) connector M3
+ 10A fuse
+ Harness for open or short between fuse block (J/B) and combination meter
c Repair harness or connectors.

CHECK MIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 35 and combination meter terminal 3.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

EC-288

TB48DE A/T (WITH EURO-OBD)
DTC P0650 MI
Diagnostic Procedure (Cont’d)
4

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Harness for open or short between ECM and combination meter
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK COMBINATION METER

Check continuity between combination meter terminals 46 and 3 under the following conditions.

SEC777D

MTBL1599

OK or NG
OK

c GO TO 6.

c Replace combination meter.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-112.
OK or NG
OK

c Replace combination meter. Refer to EL section.

c Repair or replace.

EC-289

DTC P1065 ECM POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
Component Description
Battery voltage is supplied to the ECM even when the ignition
switch is turned OFF for the ECM memory function of the DTC
memory, the air fuel ratio feedback compensation value memory,
the idle air volume learning value memory, etc.

SEF093X

On Board Diagnosis Logic
DTC No.
P1065
1065

Trouble diagnosis name

DTC detecting condition

ECM power supply circuit ECM back up RAM system does not function properly.

Possible cause
+ Harness or connectors
[ECM power supply (back-up) circuit is
open or shorted.]
+ ECM

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON” and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
Turn ignition switch “OFF”, wait at least 10 seconds, and then
turn “ON”.
5. Repeat steps 3 and 4 four times.
6. If 1st trip DTC is detected, go to EC-292, “Diagnostic Procedure”.
SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-290

DTC P1065 ECM POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
Wiring Diagram

TEC244M

EC-291

DTC P1065 ECM POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
95

WIRE
COLOR

ITEM

CONDITION

Power supply for ECM
(Buck-up)

Ignition switch “ON”

DATA (DC Voltage)

BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure
1

CHECK ECM POWER SUPPLY

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check voltage between ECM terminal 95 and ground with CONSULT-II or tester.

PBIB0087E

Voltage: Battery voltage
OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M52, F7
+ 10A fuse
+ Harness for open or short between ECM and battery
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-292

DTC P1065 ECM POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
Diagnostic Procedure (Cont’d)
4

PERFORM DTC CONFIRMATION PROCEDURE

With CONSULT-II
Turn ignition switch “ON”.
Select “SELF DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform “DTC Confirmation Procedure”.
See EC-290.
5. Is the 1st trip DTC P1065 displayed again?
1.
2.
3.
4.

With GST
Turn ignition switch “ON”.
Select MODE 4 with GST.
Touch “ERASE”.
Perform “DTC Confirmation Procedure”.
See EC-290.
5. Is the 1st trip DTC P1065 displayed again?
1.
2.
3.
4.

Yes or No
Yes

c GO TO 5.

c INSPECTION END

REPLACE ECM

EC-293

DTC P1111 IVT CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Description
SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

Vehicle speed sensor

Vehicle speed

The intake valve timing control system is utilized to
control intake valve opening and closing timing.
Engine coolant temperature signals, engine speed,
amount of intake air, vehicle speed and throttle
position are used to determine intake valve timing.
The intake camshaft sprocket position is regulated
by oil pressure controlled by the intake valve timing control.

ECM Function
Intake valve timing control

Actuator
Intake valve timing control solenoid valve

When ECM sends ON signal to intake valve timing
control solenoid valve, oil pressure is transmitted to
camshaft sprocket. Then, intake side camshaft is
advanced.

SEC776D

Operation
Engine operating condition

Intake valve timing control solenoid valve

Intake valve opening
and closing time

Valve overlap

Engine valve timing

+ Engine coolant temperature is
between 70°C (158°F) to 119°C
(246°F) and engine speed is
between 1,000 rpm and 4,200 rpm.
+ During high load condition
+ Vehicle speed is more than 8 km/h
(5 MPH).

Advance

Increased

II
V

Those other than above

OFF

Normal

EC-294

DTC P1111 IVT CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

+ Engine: Idle
INT/V SOL-B1

+
+
+
+

OFF

Engine: After warning up
Engine speed is between 1,000 rpm and 4,200 rpm
Vehicle speed is more than 8 km/h (5 MPH).
During high load condition

On Board Diagnosis Logic
DTC No.
P1111
1111

Trouble diagnosis name
Intake valve timing control solenoid valve circuit

DTC detecting condition
An improper voltage is sent to the ECM
through intake valve timing control solenoid valve.

Possible cause
+ Harness or connectors
(Solenoid valve circuit is open or
shorted.)
+ Intake valve timing control solenoid
valve

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If 1st trip DTC is detected, go to EC-297, “Diagnostic Procedure”.

SEF058Y

WITH GST
Following the procedure “WITH CONSULT-II” above.

EC-295

DTC P1111 IVT CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Wiring Diagram

TEC419M

EC-296

DTC P1111 IVT CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

152

Intake valve timing control
solenoid valve

Intake valve timing control solenoid is operating.

Approximately 0V

Engine is running.
Intake valve timing control solenoid is not
operating.

BATTERY VOLTAGE
(11 — 14V)

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure
1

CHECK IVT CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect intake valve timing control solenoid valve harness connector.

SEC793C

3. Turn ignition switch “ON”.
4. Check voltage between intake valve timing control solenoid valve terminal 2 and ground with CONSULT-II or tester.

SEC794C

Voltage: Battery voltage
OK or NG
OK

c GO TO 3.

c GO TO 2.

EC-297

DTC P1111 IVT CONTROL SOLENOID
TB48DE A/T (WITH EURO-OBD)
VALVE
Diagnostic Procedure (Cont’d)
2

DETECT MALFUNCTION PART

Check the following.
+ Harness connectors M52, F7
+ 10A fuse
+ Fuse block (J/B) connector M2
+ Harness for open or short between intake valve timing control solenoid valve and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK IVT CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 152 and intake valve timing control solenoid valve terminal 1. Refer to Wiring
Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE

Refer to EC-298, “Component Inspection”.
OK or NG
OK

c GO TO 5.

c Replace intake valve timing control solenoid valve.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.
c INSPECTION END

Component Inspection
INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1. Check oil passage visually for any metal debris.
2. Supply intake valve timing control solenoid valve terminals
with battery voltage.
3. Make sure that inside plunger protrudes.
If NG, replace intake valve timing control solenoid valve.

SEC795C

EC-298

DTC P1121 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
ACTUATOR
Component Description
Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The throttle position sensor detects the throttle valve position, and the opening and closing speed of the
throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the
throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve
opening angle properly in response to driving condition.

On Board Diagnosis Logic
DTC No.
P1121
1121

Trouble diagnosis name
Electric throttle control
actuator

DTC detecting condition
A)

Electric throttle control actuator does not function
properly due to the return spring malfunction.

Throttle valve opening angle in fail-safe mode is not
in specified range.

ECM detect the throttle valve is stuck open.
This self-diagnosis has the one trip detection
logic.

Possible cause
+ Electric throttle control
actuator

FAIL-SAFE MODE
When the malfunction A or B is detected in the two consecutive trips, the ECM enters fail-safe mode and
the MI lights up.
When the malfunction C is detected even in the 1st trip, the ECM enters fail-safe mode and the MI lights
up.
Detected items

Engine operating condition in fail-safe mode

Malfunction A

The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position.
The engine speed will not rise more than 2,000 rpm.

Malfunction B

ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less.

Malfunction C

While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls.
The engine can restart in “N” or “P” position, and engine speed will not exceed 1,000 rpm or more.

DTC Confirmation Procedure
NOTE:
+ Perform “PROCEDURE FOR MALFUNCTION A AND B”
first. If the 1st trip DTC cannot be confirmed, perform
“PROCEDURE FOR MALFUNCTION C”.
If there is no malfunction on “PROCEDURE FOR MALFUNCTION A AND B”, perform “PROCEDURE FOR MALFUNCTION C”.
+ If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at least
10 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A AND B
With CONSULT-II

SEF058Y

1. Turn ignition witch “ON” and wait at least 1 second.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Shift selector lever to “D” position and wait at least 2 seconds.
4. Turn ignition switch “OFF”, wait at least 10 seconds, and then
turn “ON”.
5. If 1st trip DTC is detected, go to EC-300, “Diagnostic Procedure”.

EC-299

DTC P1121 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
ACTUATOR
DTC Confirmation Procedure (Cont’d)
With GST
Follow the procedure “With CONSULT-II” above.

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1. Turn ignition switch “ON” and wait at least 1 second.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Shift selector lever to “D” position and wait at least 2 seconds.
4. Shift selector lever to “N” or “P” position.
5. Start engine and let it idle for 3 seconds.
6. If DTC is detected, go to EC-300, “Diagnostic Procedure”.
SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

Diagnostic Procedure
1

CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY

1. Remove the intake air duct.
2. Perform 31, “Accelerator Pedal Released Position Learning”.
3. Check if a foreign matter is caught between the throttle valve and the housing.

SEC183D

OK or NG
OK

c GO TO 2.

c Remove the foreign matter and clean the electric throttle control actuator inside.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

EC-300

DTC P1122 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Description
NOTE:
If DTC P1122 is displayed with DTC P1121 or 1126, first perform the trouble diagnosis for DTC P1121
or P1126. Refer to EC-299 or EC-309.
Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides
feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly
in response to driving condition.

On Board Diagnosis Logic
This self-diagnosis has the one trip detection logic.
DTC No.
P1122
1122

Trouble diagnosis name
Electric throttle control
performance problem

DTC detecting condition
Electric throttle control function does not
operate properly.

Possible cause
+ Harness or connectors
(Throttle control motor circuit is open or
shorted.)
+ Harness or connectors
(Throttle control motor relay circuit is
open or shorted.)
+ Electric throttle control actuator
+ Throttle control motor relay

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the
return spring.

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II

SEF058Y

1.
2.
3.
4.

Turn ignition switch “ON” and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-303, “Diagnostic Procedure”.

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-301

DTC P1122 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Wiring Diagram

TEC404M

EC-302

DTC P1122 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

P/L

ITEM

CONDITION

Throttle control motor
relay

DATA (DC Voltage)

Ignition switch “OFF”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”

0 — 1.0V
0 — 14V★

Ignition switch “ON”
151

L/W

Throttle control motor
(Open)

Engine stopped
Shift lever position is “D”
Accelerator pedal is depressed
PBIB0534E

153

Throttle control motor
ground

Engine is running.

Approximately 0V
0 — 14V★

Ignition switch “ON”
154

L/B

Throttle control motor
(Close)

Engine stopped
Shift lever position is “D”
Accelerator pedal is released
PBIB0533E

157

Throttle control motor
power supply

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-303

DTC P1122 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
2

CHECK THROTTLE CONTROL MOTOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 153 and engine ground.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 3.

c Repair open circuit or short to power in harness or connectors.

CHECK THROTTLE CONTROL MOTOR RELAY SIGNAL CIRCUIT

1. Reconnect harness connectors disconnected.
2. Check voltage between ECM terminal 157 and ground under the following conditions with CONSULT-II or tester.

SEC740D

MTBL1585

OK or NG
OK

c GO TO 11.

c GO TO 4.

EC-304

DTC P1122 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
4

CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect throttle control motor relay.

SEC185D

3. Check voltage between throttle control motor relay terminals 2, 3 and ground.

PBIB0097E

Voltage: Battery voltage
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ 15A fuse
+ Harness for open or short between throttle control motor relay and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 157 and throttle control motor relay terminal 5.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

EC-305

DTC P1122 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
7

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M55, F35
+ Harness for open or short between ECM and throttle control motor relay
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE CONTROL MOTOR RELAY OUTPUT SIGNAL CIRCUIT

1. Check continuity between ECM terminal 26 and throttle control motor relay terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

CHECK THROTTLE CONTROL MOTOR RELAY

Refer to EC-308, “Component Inspection”.
OK or NG
OK

c GO TO 14.

c Replace throttle control motor relay.

EC-306

DTC P1122 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
11

CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1. Turn ignition switch “OFF”.
2. Disconnect electric throttle control actuator harness connector.

SEC182D

3. Disconnect ECM harness connector.
4. Check harness continuity between the following terminals.
Refer to Wiring Diagram.

MTBL1586

5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 12.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY

1. Remove the intake air duct.
2. Check if foreign matter is caught between the throttle valve and the housing.

SEC183D

OK or NG
OK

c GO TO 13.

c Remove the foreign matter and clean the electric throttle control actuator inside.

EC-307

DTC P1122 ELECTRIC THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
FUNCTION
Diagnostic Procedure (Cont’d)
13

CHECK THROTTLE CONTROL MOTOR

Refer to EC-308, “Component Inspection”.
OK or NG
OK

c GO TO 14.

c GO TO 15.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.
OK or NG
OK

c GO TO 15.

c Repair or replace harness or connectors.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

Component Inspection
THROTTLE CONTROL MOTOR RELAY
1. Apply 12V direct current between relay terminals 1 and 2.
2. Check continuity between relay terminals 3 and 5.
Conditions

PBIB0098E

Continuity

12V direct current supply between
terminals 1 and 2

Yes

No current supply

3. If NG, replace throttle control motor relay.

THROTTLE CONTROL MOTOR

PBIB0095E

1. Disconnect electric throttle control actuator harness connector.
2. Check resistance between terminals 3 and 6.
Resistance: Approximately 1 — 15 Ω [at 25°C (77°F)]
3. If NG, replace electric throttle control actuator and go to next
step.
4. Perform EC-31, “Accelerator Pedal Released Position Learning”.
5. Perform EC-31, “Throttle Valve Closed Position Learning”.
6. Perform EC-31, “Idle Air Volume Learning”.

EC-308

DTC P1124, P1126 THROTTLE CONTROL MOTOR
TB48DE A/T (WITH EURO-OBD)
RELAY
Component Description
Power supply for the Throttle Control motor is provided to the ECM via throttle control motor relay. The
throttle control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the
ECM sends an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When
the ignition switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery
voltage is not provided to the ECM.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
THRTL RELAY

CONDITION

SPECIFICATION

+ Ignition switch: ON

On Board Diagnosis Logic
These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P1124
1124

Throttle control motor
relay circuit short

ECM detect the throttle control motor relay + Harness or connectors
is stuck ON.
(Throttle control motor relay circuit is
shorted.)
+ Throttle control motor relay

P1126
1126

Throttle control motor
relay circuit open

ECM detects a voltage of power source for
throttle control motor is excessively low.

+ Harness or connectors
(Throttle control motor relay circuit is
open.)
+ Throttle control motor relay

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the
return spring.

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR DTC P1124
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

EC-309

DTC P1124, P1126 THROTTLE CONTROL MOTOR
TB48DE A/T (WITH EURO-OBD)
RELAY
DTC Confirmation Procedure (Cont’d)
With CONSULT-II
1. Turn ignition switch “ON” and wait at least 1 second.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. If DTC is detected, go to EC-312, “Diagnostic Procedure”.

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

PROCEDURE FOR DTC P1126
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON” and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-312, “Diagnostic Procedure”.

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-310

DTC P1124, P1126 THROTTLE CONTROL MOTOR
TB48DE A/T (WITH EURO-OBD)
RELAY
Wiring Diagram

TEC405M

EC-311

DTC P1124, P1126 THROTTLE CONTROL MOTOR
TB48DE A/T (WITH EURO-OBD)
RELAY
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

P/L

157

ITEM

CONDITION

Throttle control motor
relay
Throttle control motor
power supply

DATA (DC Voltage)

Ignition switch “OFF”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”

0 — 1.0V

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure
1

CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect throttle control motor relay.

SEC185D

3. Check voltage between throttle control motor relay terminals 2, 3 and ground.

PBIB0097E

Voltage: Battery voltage
OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

Check the following.
+ 15A fuse
+ Harness for open or short between throttle control motor relay and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-312

DTC P1124, P1126 THROTTLE CONTROL MOTOR
TB48DE A/T (WITH EURO-OBD)
RELAY
Diagnostic Procedure (Cont’d)
3

CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M51, F35
+ Harness for open or short between ECM and throttle control motor relay
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE CONTROL MOTOR RELAY OUTPUT SIGNAL CIRCUIT

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

CHECK THROTTLE CONTROL MOTOR RELAY

Refer to EC-314, “Component Inspection”.
OK or NG
OK

c GO TO 8.

c Replace throttle control motor relay.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-313

DTC P1124, P1126 THROTTLE CONTROL MOTOR
TB48DE A/T (WITH EURO-OBD)
RELAY
Component Inspection
THROTTLE CONTROL MOTOR RELAY
1. Apply 12V direct current between relay terminals 1 and 2.
2. Check continuity between relay terminals 3 and 5.
Conditions

PBIB0098E

Continuity

12V direct current supply between
terminals 1 and 2

Yes

No current supply

3. If NG, replace throttle control motor relay.

EC-314

DTC P1128 THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
MOTOR
Component Description
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides
feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly
in response to driving condition.

On Board Diagnosis Logic
This self-diagnosis has the one trip detection logic.
DTC No.
P1128
1128

Trouble diagnosis name
Throttle control motor circuit short

DTC detecting condition
ECM detects short both circuits between
ECM and throttle control motor.

Possible cause
+ Harness or connectors
(Throttle control motor circuit is shorted.)
+ Electric throttle control actuator
(Throttle control motor)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON” and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-317, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-315

DTC P1128 THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
MOTOR
Wiring Diagram

TEC406M

EC-316

DTC P1128 THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
MOTOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

0 — 14V★
Ignition switch “ON”
151

L/W

Throttle control motor
(Open)

Engine stopped
Shift lever position is “D”
Accelerator pedal is depressed
PBIB0534E

0 — 14V★
Ignition switch “ON”
154

L/B

Throttle control motor
(Close)

Engine stopped
Shift lever position is “D”
Accelerator pedal is released
PBIB0533E

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-317

DTC P1128 THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
MOTOR
Diagnostic Procedure (Cont’d)
2

CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1. Turn ignition switch “OFF”.
2. Disconnect electric throttle control actuator harness connector.

SEC182D

3. Disconnect ECM harness connector.
4. Check harness continuity between the following terminals.
Refer to Wiring Diagram.

MTBL1587

5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 3.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE CONTROL MOTOR

Refer to EC-319, “Component Inspection”.
OK or NG
OK

c GO TO 4.

c GO TO 5.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
OK or NG
OK

c GO TO 5.

c Repair or replace harness or connectors.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

EC-318

DTC P1128 THROTTLE CONTROL
TB48DE A/T (WITH EURO-OBD)
MOTOR
Component Inspection
THROTTLE CONTROL MOTOR

PBIB0095E

1. Disconnect electric throttle control actuator harness connector.
2. Check resistance between terminals 3 and 6.
Resistance: Approximately 1 — 15Ω [at 25°C (77°F)]
3. If NG, replace electric throttle control actuator and go to next
step.
4. Perform EC-31, “Accelerator Pedal Released Position Learning”.
5. Perform EC-31, “Throttle Valve Closed Position Learning”.
6. Perform EC-31, “Idle Air Volume Learning”.

EC-319

DTC P1143, P1163
HO2S1

TB48DE A/T (WITH EURO-OBD)

SEF288D

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1)
HO2S1 (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S1 MNTR (B1)
HO2S1 MNTR (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times
during 10 seconds.

On Board Diagnosis Logic
To judge the malfunction, the output from the heated oxygen
sensor 1 is monitored to determine whether the “rich” output is
sufficiently high and whether the “lean” output is sufficiently low.
When both the outputs are shifting to the lean side, the malfunction will be detected.

SEF300U

DTC No.
P1143
1143
(Bank 1)
P1163
1163
(Bank 2)

Trouble diagnosis name
Heated oxygen sensor 1
lean shift monitoring

DTC detecting condition

Possible cause

The maximum and minimum voltage from + Heated oxygen sensor 1
the sensor are not reached to the specified + Heated oxygen sensor 1 heater
+ Fuel pressure
voltages.
+ Injectors
+ Intake air leaks

EC-320

DTC P1143, P1163
HO2S1

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
+ Always perform at a temperature above −10°C (14°F).
+ Before performing following procedure, confirm that battery voltage is more than 11V at idle.

WITH CONSULT-II

PBIB0546E

1. Start engine and warm it up to normal operating temperature.
2. Stop engine and wait at least 10 seconds.
3. Turn ignition switch “ON” and select “HO2S1 (B1) P1143” of
“HO2S1” or “HO2S1 (B2) P1163” of “HO2S1” in “DTC WORK
SUPPORT” mode with CONSULT-II.
4. Touch “START”.
5. Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 2,800 rpm after this step. If
the engine speed limit is exceeded, return to step 5.
6. When the following conditions are met, “TESTING” will be
displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.)

PBIB0547E

ENG SPEED

1,050 — 2,500 rpm

Vehicle speed

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

5 — 16.7 msec

Selector lever

Suitable position

If “TESTING” is not displayed after 5 minutes, retry from
step 2.

7. Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-322, “Diagnostic Procedure”.

SEC769C

EC-321

DTC P1143, P1163
HO2S1

TB48DE A/T (WITH EURO-OBD)

Overall Function Check
Use this procedure to check the overall function of the heated
oxygen sensor 1 circuit. During this check, a DTC might not be
confirmed.

WITH GST
1. Start engine and warm it up to normal operating temperature.
2. Set voltmeter probes between ECM terminal 115 [HO2S1
(B1) signal] or 114 [HO2S1 (B2) signal] and engine ground.
3. Check one of the following with engine speed held at 2,000
rpm constant under no load.
+ The maximum voltage is over 0.6V at least one time.
+ The minimum voltage is over 0.1V at least one time.
4. If NG, go to EC-322, “Diagnostic Procedure”.
SEC184DA

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-322

DTC P1143, P1163
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
2

RETIGHTEN HEATED OXYGEN SENSOR 1

Loosen and retighten corresponding heated oxygen sensor 1.

SEC888C

Tightening torque: 40 — 60 Nzm (4.1 — 6.2 kg-m, 30 — 44 ft-lb)
c GO TO 3.

EC-323

DTC P1143, P1163
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
3

CLEAR THE SELF-LEARNING DATA

SEF215Z

4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0174 detected?
Is it difficult to start engine?
Without CONSULT-II
1.
2.
3.
4.

Start engine and warm it up to normal operating temperature.
Turn ignition switch “OFF”.
Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed.
Stop engine and reconnect mass air flow sensor harness connector.

5.
6.
7.
8.

Make sure that DTC P0102 is displayed.
Erase the DTC memory. Refer to EC-49, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
Make sure that DTC P0000 is displayed.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0174 detected?
Is it difficult to start engine?
Yes or No

SEC688C

Yes

c Perform trouble diagnosis for DTC P0171, P0174. Refer to EC-218.

c GO TO 4.

CHECK HEATED OXYGEN SENSOR 1 HEATER

Refer to EC-131, “Component Inspection”.
OK or NG
OK

c GO TO 5.

c Replace malfunctioning heated oxygen sensor 1.

EC-324

DTC P1143, P1163
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
5

CHECK HEATED OXYGEN SENSOR 1

Refer to EC-325, “Component Inspection”.
OK or NG
OK

c GO TO 6.

c Replace malfunctioning heated oxygen sensor 1.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.
For circuit, refer to EC-165, “Wiring Diagram”.
c INSPECTION END

SEF646Y

SEF647Y

EC-325

DTC P1143, P1163
TB48DE A/T (WITH EURO-OBD)
HO2S1
Component Inspection (Cont’d)

SEF648Y

Without CONSULT-II

SEC184DA

EC-326

DTC P1144, P1164
HO2S1

TB48DE A/T (WITH EURO-OBD)

SEF288D

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S1 (B1)
HO2S1 (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S1 MNTR (B1)
HO2S1 MNTR (B2)

+ Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times
during 10 seconds.

On Board Diagnosis Logic
To judge the malfunction, the output from the heated oxygen
sensor 1 is monitored to determine whether the “rich” output is
sufficiently high. The “lean” output is sufficiently low. When both
the outputs are shifting to the rich side, the malfunction will be
detected.

SEF299U

DTC No.
P1144
1144
(Bank 1)
P1164
1164
(Bank 2)

Trouble diagnosis name
Heated oxygen sensor 1
rich shift monitoring

DTC detecting condition

Possible cause

The maximum and minimum voltages from + Heated oxygen sensor 1
+ Heated oxygen sensor 1 heater
the sensor are beyond the specified volt+ Fuel pressure
ages.
+ Injectors

EC-327

DTC P1144, P1164
HO2S1

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
+ Always perform at a temperature above −10°C (14°F).
+ Before performing the following procedure, confirm that
battery voltage is more than 11V at idle.

WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Stop engine and wait at least 5 seconds.
3. Turn ignition switch “ON” and select “HO2S1 (B1) P1144” or
“HO2S1 (B2) P1164” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II.

4. Touch “START”.
5. Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 2,800 rpm after this step. If
the engine speed limit is exceeded, return to step 5.

PBIB0548E

PBIB0549E

1,500 — 2,500 rpm

Vehicle speed

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

5 — 16.7 msec

Selector lever

Suitable position

If “TESTING” is not displayed after 5 minutes, retry from
step 2.

EC-328

DTC P1144, P1164
HO2S1

TB48DE A/T (WITH EURO-OBD)

7. Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-329, “Diagnostic Procedure”.

SEC772C

Overall Function Check
Use this procedure to check the overall function of the heated
oxygen sensor 1 circuit. During this check, a DTC might not be
confirmed.

WITH GST
1. Start engine and warm it up to normal operating temperature.
2. Set voltmeter probes between ECM terminal 115 [HO2S1
(B1) signal] or 114 [HO2S1 (B2) signal] and engine ground.
3. Check one of the following with engine speed held at 2,000
rpm constant under no load.
— The maximum voltage is below 0.8V at least one time.
— The minimum voltage is below 0.32V at least one time.
4. If NG, go to EC-329, “Diagnostic Procedure”.

SEC184DA

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-329

DTC P1144, P1164
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
2

RETIGHTEN HEATED OXYGEN SENSOR 1

Loosen and retighten heated oxygen sensor 1.

SEC888C

Tightening torque: 40 — 60 Nzm (4.1 — 6.2 kg-m, 30 — 44 ft-lb)
c GO TO 3.

EC-330

DTC P1144, P1164
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
3

CLEAR THE SELF-LEARNING DATA

SEF215Z

4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 or P0175 detected?
Is it difficult to start engine?
Without CONSULT-II
1.
2.
3.
4.

5.
6.
7.
8.

Make sure that DTC P0102 is displayed.
Erase the DTC memory. Refer to EC-49, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
Make sure that DTC P0000 is displayed.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 or P0175 detected?
Is it difficult to start engine?

SEC688C

Yes or No
Yes

c Perform trouble diagnosis for DTC P0172, P0175. Refer to EC-227.

c GO TO 4.

EC-331

DTC P1144, P1164
TB48DE A/T (WITH EURO-OBD)
HO2S1
Diagnostic Procedure (Cont’d)
4

CHECK HO2S1 CONNECTOR FOR WATER

1. Turn ignition switch “OFF”.
2. Disconnect heated oxygen sensor 1 harness connector.
3. Check connectors for water.

SEC671D

Water should not exist.
OK or NG
OK

c GO TO 5.

c Repair or replace harness or connectors.

CHECK HEATED OXYGEN SENSOR 1 HEATER

Refer to EC-131, “Component Inspection”.
OK or NG
OK

c GO TO 6.

c Replace malfunctioning heated oxygen sensor 1.

CHECK HEATED OXYGEN SENSOR 1

Refer to EC-332, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c Replace malfunctioning heated oxygen sensor 1.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
For circuit, refer to EC-165, “Wiring Diagram”.
c INSPECTION END

Component Inspection
HEATED OXYGEN SENSOR 1
With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100%
in “DATA MONITOR” mode with CONSULT-II.
3. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
4. Hold engine speed at 2,000 rpm under no load during the
following steps.

EC-332

DTC P1144, P1164
TB48DE A/T (WITH EURO-OBD)
HO2S1
Component Inspection (Cont’d)
5. Touch “RECORD” on CONSULT-II screen.

SEF646Y

SEF647Y

SEF648Y

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Set voltmeter probes between ECM terminal 115 [HO2S1
(B1) signal] or 114 [HO2S1 (B2) signal] and engine ground.
3. Check the following with engine speed held at 2,000 rpm
constant under no load.
+ The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
+ The maximum voltage is over 0.6V at least one time.
+ The minimum voltage is below 0.3V at least one time.
SEC184DA

EC-333

DTC P1144, P1164
TB48DE A/T (WITH EURO-OBD)
HO2S1
Component Inspection (Cont’d)
+ The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-334

DTC P1146, P1166
HO2S2

TB48DE A/T (WITH EURO-OBD)

Component Description

SEF327R

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1)
HO2S2 (B2)

+ Engine: After warming up
Revving engine from idle to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S2 MNTR (B1)
HO2S2 MNTR (B2)

+ Engine: After warming up
Revving engine from idle to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

LEAN ←→ RICH

On Board Diagnosis Logic
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The
oxygen storage capacity before the three way catalyst (manifold)
causes the longer switching time. To judge the malfunctions of
heated oxygen sensor 2, ECM monitors whether the minimum
voltage of sensor is sufficiently low during the various driving
condition such as fuel-cut.
SEF972Z

DTC No.
P1146
1146
(Bank 1)

Trouble diagnosis name

DTC detecting condition

Heated oxygen sensor 2 The minimum voltage from the sensor is
minimum voltage monitor- not reached to the specified voltage.
ing

P1166
1166
(Bank 2)

EC-335

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Heated oxygen sensor 2
+ Fuel pressure
+ Injectors

DTC P1146, P1166
HO2S2

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
+ “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and
“COND3” are completed.
+ If “DTC confirmation Procedure” has been previously conducted, always turn ignition switch
“OFF” and wait at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in
“Procedure for COND1”

WITH CONSULT-II
Procedure for COND1
For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C (32 to 86°F).
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no
load.
4. Let engine idle for one minute.
5. Select “HO2S2 (B1) P1146” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II.
6. Touch START”.
7. Let engine idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3”.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
ENG SPEED

More than 1,000 rpm

B/FUEL SCHDL

More than 1.0 msec

COOLANT TEMP/S

70 — 100°C

Selector lever

Suitable position

PBIB0555E

EC-336

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
DTC Confirmation Procedure (Cont’d)
Procedure for COND2
1. While driving, release accelerator pedal completed with “OD”
OFF from the above condition [step 9] until “INCOMPLETE”
at “COND2” on CONSULT-II screen has turned to “COMPLETED” (It will take approximately 4 seconds.)
NOTE:
If “COMPLETE” already appears at “COND3” on CONSULT-II screen before “Procedure for COND3” is conducted,
it is unnecessary to conduct step 1 in “Procedure for
COND3”.
PBIB0556E

Procedure for COND3

SEC775C

1. Stop vehicle and let it idle until “INCOMPLETE” of “COND3”
on CONSULT-II screen has turned to COMPLETED”. (It will
take a maximum of approximately 6 minutes.)
2. Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-342, “Diagnostic Procedure”.
If “CAN NOT BE DIAGNOSED” is displayed, perform the following.
a. Turn ignition switch “OFF” and leave the vehicle in a cool
place (soak the vehicle).
b. Turn ignition switch “ON” and select “COOLANTEMP/S” in
“DATA MONITOR” mode with CONSULT-II
c. Start engine and warm it up while monitoring
“COOLANTEMP/S” indication on CONSULT-II.
d. When “COOLANTEMP/S” indication reaches to 70°C
(158°F), go to “Procedure for COND 1” step 3.

Overall Function Check
Use this procedure to check the overall function of the heated
oxygen sensor 2 circuit. During this check, a DTC might not be
confirmed.

WITH GST
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
4. Let engine idle for one minute.
5. Set voltmeter probes between ECM terminal 124 [HO2S2
(B1) signal] or 123 [HO2S2 (B2) signal] and engine ground.
6. Check the voltage when revving up to 4,000 rpm under no
load at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be below 0.48V at least once during
this procedure.
If the voltage can be confirmed in step 6, step 7 is not
necessary.

SEC774D

EC-337

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
Overall Function Check (Cont’d)
7. Keep vehicle at idling for 10 minutes, then check the voltage.
Or check the voltage when coasting from 80 km/h (50 MPH)
in “D” position with “OD” OFF.
The voltage should be below 0.48V at least once during
this procedure.
8. If NG, go to EC-342, “Diagnostic Procedure”.

EC-338

DTC P1146, P1166
HO2S2

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram
BANK 1

TEC411M

EC-339

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

124

Heated oxygen sensor 2
(bank 1)

Warm-up condition.
Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.
Keeping the engine speed between 3,500 and
4,000 rpm for one minute and at idle for one
minute under no load

EC-340

0 — Approximately 1.0V

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
Wiring Diagram (Cont’d)
BANK 2

TEC336M

EC-341

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

123

Heated oxygen sensor 2
(bank 2)

0 — Approximately 1.0V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-342

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
2

CLEAR THE SELF-LEARNING DATA

SEF215Z

4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 or P0175 detected?
Is it difficult to start engine?
Without CONSULT-II
1.
2.
3.
4.

5.
6.
7.
8.

Make sure that DTC P0102 is displayed.
Erase the DTC memory. Refer to EC-49, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
Make sure that DTC P0000 is displayed.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 or P0175 detected?
Is it difficult to start engine?

SEC688C

Yes or No
Yes

c Perform trouble diagnosis for DTC P0172, P0175. Refer to EC-227.

c GO TO 3.

EC-343

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
3

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect heated oxygen sensor 2 harness connector.

SEC669D

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between heated oxygen sensor 2 and ground
c Repair open circuit or short to power in harness or connectors.

EC-344

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
5

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S2 terminal as follows.
Refer to Wiring Diagram.

MTBL1588

Continuity should exist.
2. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1589

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 6.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 2

Refer to EC-345, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c Replace heated oxygen sensor 2.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-345

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
Component Inspection (Cont’d)
5. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and
select “HO2S2 (B1)/(B2)” as the monitor item with CONSULT-II.

SEF662Y

6. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting
“FUEL INJECTION” to ±25%.

SEF972YA

“HO2S2 (B1)/(B2)” should be above 0.68V at least once
when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)/(B2)” should be below 0.48V at least once
when the “FUEL INJECTION” is −25%.
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-346

DTC P1146, P1166
TB48DE A/T (WITH EURO-OBD)
HO2S2
Component Inspection (Cont’d)

SEC774D

6. Check the voltage when revving up to 4,000 rpm under no
load at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during
this procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle at idling for 10 minutes, then check voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in
“D” position with “OD” OFF.
The voltage should be below 0.48V at least once during
this procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-347

DTC P1147, P1167
HO2S2

TB48DE A/T (WITH EURO-OBD)

Component Description

SEF327R

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

HO2S2 (B1)
HO2S2 (B2)

+ Engine: After warming up
Revving engine from idle to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

0 — 0.3V ←→ Approx. 0.6 1.0V

HO2S2 MNTR (B1)
HO2S2 MNTR (B2)

+ Engine: After warming up
Revving engine from idle to 3,000
+ Keeping the engine speed
rpm quickly.
between 3,500 and 4,000 rpm for
one minute and at idle for one
minute under no load

LEAN ←→ RICH

On Board Diagnosis Logic
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The
oxygen storage capacity before the three way catalyst (manifold)
causes the longer switching time. To judge the malfunctions of
heated oxygen sensor 2, ECM monitors whether the maximum
voltage of the sensor is sufficiently high during the various driving condition such as fuel-cut.
SEF259VA

DTC No.
P1147
1147
(Bank 1)

Trouble diagnosis name
Heated oxygen sensor 2
maximum voltage monitoring

DTC detecting condition
The maximum voltage from the sensor is
not reached to the specified voltage.

P1167
1167
(Bank 2)

EC-348

Possible cause
+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Heated oxygen sensor 2
+ Fuel pressure
+ Injectors
+ Intake air leaks

DTC P1147, P1167
HO2S2

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
+ “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and
“COND3” are completed.
+ If “DTC confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and
wait at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in
“Procedure for COND1”

WITH CONSULT-II
Procedure for COND1
For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C (32 to 86°F).
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no
load.
4. Let engine idle for one minute.
5. Select “HO2S2 (B1) P1147” or “HO2S2 (B2) P1167” of “HO2S2” in “DTC WORK SUPPORT” mode with
CONSULT-II.
6. Touch “START”.
7. Let engine idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in “Procedure for COND3”.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
ENG SPEED

More than 1,000 rpm

B/FUEL SCHDL

More than 1.0 msec

COOLANT TEMP/S

70 — 100°C

Selector lever

Suitable position

PBIB0557E

NOTE:
+ If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1”.
+ If “COMPLETED” already appears at “COND2” on CONSULT-II screen before “Procedure for
COND2” is conducted, it is unnecessary to conduct step 1 in “Procedure for COND2”.

EC-349

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
DTC Confirmation Procedure (Cont’d)
Procedure for COND2
1. While driving, release accelerator pedal completed with “OD”
OFF from the above condition [step 9] until “INCOMPLETE”
at “COND2” on CONSULT-II screen has turned to “COMPLETED” (It will take approximately 4 seconds.)
NOTE:
If “COMPLETE” already appears at “COND3” on CONSULT-II screen before “Procedure for COND3” is conducted,
it is unnecessary to conduct step 1 in “Procedure for
COND3”.
PBIB0558E

Procedure for COND3

SEC778C

1. Stop vehicle and let it idle until “INCOMPLETE” of “COND3”
on CONSULT-II screen has turned to “COMPLETED”. (It will
take a maximum of approximately 6 minutes.)
2. Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-355, “Diagnostic Procedure”.
If “CAN NOT BE DIAGNOSED” is displayed, perform the following.
a. Turn ignition switch “OFF” and leave the vehicle in a cool
place (soak the vehicle).
b. Turn ignition switch “ON” and select “COOLANTEMP/S” in
“DATA MONITOR” mode with CONSULT-II
c. Start engine and warm it up while monitoring
“COOLANTEMP/S” indication on CONSULT-II.
d. When “COOLANTEMP/S” indication reaches to 70°C
(158°F), go to “Procedure for COND 1” step 3.

Overall Function Check
Use this procedure to check the overall function of the heated
oxygen sensor 2 circuit. During this check, a DTC might not be
confirmed.

WITH GST
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch “OFF” and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least one minute under no load.
4. Let engine idle for one minute.
5. Set voltmeter probes between ECM terminal 124 [HO2S2
(B1) signal] or 123 [HO2S2 (B2) signal] and engine ground.
6. Check the voltage when revving up to 4,000 rpm under no
load at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during
this procedure.
If the voltage can be confirmed in step 6, step 7 is not
necessary.

SEC774D

EC-350

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
Overall Function Check (Cont’d)
7. Keep vehicle idling for 10 minutes, then check the voltage.
Or check the voltage when coasting from 80 km/h (50 MPH)
in “D” position with “OD” OFF.
The voltage should be above 0.68V at least once during
this procedure.
8. If NG, go to EC-355, “Diagnostic Procedure”.

EC-351

DTC P1147, P1167
HO2S2

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram
BANK 1

TEC411M

EC-352

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

124

Heated oxygen sensor 2
(bank 1)

EC-353

0 — Approximately 1.0V

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
Wiring Diagram (Cont’d)
BANK 2

TEC336M

EC-354

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.

123

Heated oxygen sensor 2
(bank 2)

0 — Approximately 1.0V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-355

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
2

CLEAR THE SELF-LEARNING DATA

SEF215Z

4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0174 detected?
Is it difficult to start engine?
Without CONSULT-II
1.
2.
3.
4.

5.
6.
7.
8.

Make sure that DTC P0102 is displayed.
Erase the DTC memory. Refer to EC-49, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
Make sure that DTC P0000 is displayed.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0174 detected?
Is it difficult to start engine?

SEC688C

Yes or No
Yes

c Perform trouble diagnosis for DTC P0171, P0174. Refer to EC-218.

c GO TO 3.

EC-356

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
3

CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect heated oxygen sensor 2 harness connector.

SEC669D

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-7
+ Harness for open or short between heated oxygen sensor 2 and ground
c Repair open circuit or short to power in harness or connectors.

EC-357

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
Diagnostic Procedure (Cont’d)
5

CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal and HO2S2 terminal as follows.
Refer to Wiring Diagram.

MTBL1590

Continuity should exist.
2. Check harness continuity between the following terminals and ground.
Refer to Wiring Diagram.

MTBL1591

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 6.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK HEATED OXYGEN SENSOR 2

Refer to EC-358, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c Replace heated oxygen sensor 2.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-358

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
Component Inspection (Cont’d)
5. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and
select “HO2S2 (B1)/(B2)” as the monitor item with CONSULT-II.

SEF662Y

6. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting
“FUEL INJECTION” to ±25%.

SEF972YA

“HO2S2 (B1)/(B2)” should be above 0.68V at least once
when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)/(B2)” should be below 0.48V at least once
when the “FUEL INJECTION” is -25%.
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-359

DTC P1147, P1167
TB48DE A/T (WITH EURO-OBD)
HO2S2
Component Inspection (Cont’d)

SEC774D

6. Check the voltage when revving up to 4,000 rpm under no
load at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during
this procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in
“D” position with “OD” OFF.
The voltage should be below 0.56V at least once during
this procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.
+ Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool
J-43897-18 or J-43897-12 and approved anti-seize lubricant.

EC-360

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
System Description
Vehicle speed sensor

Engine coolant temperature sensor

Air conditioner switch

Vehicle speed
c

Engine coolant temperature
c

ECM

Cooling fan relays

Air conditioner “ON” signal
c

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and air
conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF].

Operation

SEC775D

CONSULT-II Reference Value In Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

COOLING FAN

AIR COND SIG

CONDITION

+ After warming up engine, idle the
engine.
+ Air conditioner switch “OFF”
+ Vehicle stopped

+ Engine: After warming up, idle the
engine

SPECIFICATION

Engine coolant temperature is 94°C
(201°F) or less.

OFF

Engine coolant temperature is between
95°C (203°F) and 99°C (210°F)

LOW

Engine coolant temperature is 100°C
(212°F) or more.

HIGH

Air conditioner switch: “OFF”

OFF

Air conditioner switch: “ON”
(Compressor operates.)

EC-361

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

DATA
(DC voltage)

CONDITION
Engine is running.

Cooling fan relay (Low
speed)

BATTERY VOLTAGE
(11 — 14V)

Cooling fan is not operating.
Engine is running.

Approximately 0V
Cooling fan is operating.
Engine is running.

L/B

Cooling fan relay
(High speed)

Cooling fan is not operating.
Cooling fan is operating at low speed.

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Approximately 0V
Cooling fan is operating at high speed.

On Board Diagnosis Logic
This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, the engine coolant temperature
will rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
detected by the ECM and the MIL lights on.
Diagnostic trouble
code No.
P1217
1217

Check Items
(Possible Cause)
+ Harness or connectors
(The cooling fan circuit is open or shorted)
+ Cooling fan
+ Thermostat
+ Improper ignition timing
+ Engine coolant temperature sensor
+ Blocked radiator
+ Blocked front end (Improper fitting of nose
mask)
+ Crushed vehicle frontal area (Vehicle frontal
is collided but not repaired)
+ Blocked air passage by improper installation
of front fog lamp or fog lamps.
+ Improper mixture ratio of coolant
+ Damaged bumper
For more information, refer to “MAIN 12
CAUSES OF OVERHEATING”, EC-370.

CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the engine oil.
a. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to MA section
(“Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED LUBRICANTS AND FLUIDS”).
b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.

EC-362

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Overall Function Check
Use this procedure to check the overall function of the cooling
fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping
from the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by
turning it a quarter turn to allow built-up pressure to escape.
Then turn the cap all the way off.
AEC640

With CONSULT-II

SEF646X

1) Check the coolant level and mixture ratio (using coolant
tester) in the reservoir tank and radiator.
Allow engine to cool before checking coolant level and
mixture ratio.
+ If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
“Diagnostic Procedure”, EC-365.
+ If the coolant mixture ratio is out of the range of 45 to 55%
(varies depending on destinations), replace the coolant in the
following procedure LC section, “Changing Engine Coolant”.
2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to
“Diagnostic Procedure”, EC-365.
3) Turn ignition switch “ON”.
4) Perform “COOLING FAN” in “ACTIVE TEST” mode with
CONSULT-II.
5) If the results are NG, go to “Diagnostic Procedure”, EC-365.

Without CONSULT-II
SEC163BA

1) Check the coolant level and mixture ratio (using coolant
tester) in the reservoir tank and radiator.
Allow engine to cool before checking coolant level and
mixture ratio.
If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
“Diagnostic Procedure”, EC-365.
+ If the coolant mixture ratio is out of the range of 45 to 55%
(varies depending on destinations), replace the coolant in the
following procedure LC section, “Changing Engine Coolant”.
2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to
“Diagnostic Procedure”, EC-365.
3) Start engine.
Be careful not to overheat engine.
4) Set temperature control lever to full cold position.
5) Turn air conditioner switch “ON”.
6) Turn blower fan switch “ON”.
7) Run engine at idle for a few minutes with air conditioner
operating.
Be careful not to overheat engine.
Make sure that cooling fan operates. Refer to “OPERATION”
table of Cooling fan, EC-361.
If NG, go to “Diagnostic Procedure”, EC-365.

EC-363

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Wiring Diagram

TEC151M

EC-364

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Diagnostic Procedure
INSPECTION START
.

Do you have CONSULT-II?

No
c

Yes

GO TO V
A Without CONSULT-II.

CHECK COOLING FAN LOW SPEED
OPERATION.
SEC698C

NG
c

With CONSULT-II
1. Disconnect cooling fan relay-2 and -3.
2. Turn ignition switch “ON”.
3. Perform “COOLING FAN” in “ACTIVE
TEST” mode with CONSULT-II.
4. Make sure that cooling fans-1 and -2
operate at low speed.

GO TO V
C . Check cooling
fan low speed control circuit.

OK
.

CHECK COOLING FAN HIGH SPEED
OPERATION.
SEF646X

With CONSULT-II
1. Turn ignition switch “OFF”.
2. Reconnect cooling fan relay-2 and -3.
3. Turn ignition switch “ON”.
4. Perform “COOLING FAN” in “ACTIVE
TEST” mode with CONSULT-II.
5. Make sure that cooling fans-1 and -2
operate at high speed.
OK
.

GO TO V
B .
SEF111X

EC-365

NG
c

GO TO V
D . Check cooling
fan high speed control circuit.

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Diagnostic Procedure (Cont’d)
A
V

CHECK COOLING FAN LOW SPEED
OPERATION.

SEC698C

NG
c

Without CONSULT-II
1. Disconnect cooling fan relays-2 and -3.
2. Start engine and let it idle.
3. Set temperature lever at full cold position.
4. Turn air conditioner switch “ON”.
5. Turn blower fan switch “ON”.
6. Make sure that cooling fans-1 and -2
operate at low speed.

C . Check cooling
GO TO V
fan low speed control circuit.

OK
.

CHECK COOLING FAN HIGH SPEED
OPERATION.

SEC163BA

Without CONSULT-II
1. Turn ignitions witch “OFF”.
2. Reconnect cooling fan relays-2 and -3.
3. Turn air conditioner switch and blower
fan switch “OFF”.
4. Disconnect engine coolant temperature
sensor harness connector.
5. Connect 150Ω resistor to engine coolant
temperature sensor harness connector.
6. Restart engine and make sure that cooling fans-1 and -2 operate at high speed.
OK
.

GO TO V
B .
SEC322D

EC-366

NG
c

GO TO V
D . Check cooling
fan high speed control circuit.

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Diagnostic Procedure (Cont’d)
B
V

SLC754A

CHECK COOLING SYSTEM FOR LEAK.
Apply pressure to the cooling system with
a tester, and check if the pressure drops.
Testing pressure:
157 kPa (1.6 kg/cm2, 23 psi)
CAUTION:
Higher than the specified pressure may
cause radiator damage.
Pressure should not drop.

NG
c

Check the following for
leak.
+ Hose
+ Radiator
+ Water pump (Refer to
LC section, “Water
Pump”.)
If NG, repair or replace.

OK
.

SLC755A

CHECK RADIATOR CAP.
Apply pressure to cap with a tester and
check radiator cap relief pressure.
Radiator cap relief pressure:
For the Middle East:
78 — 98 kPa (0.78 — 0.98 bar, 0.8 1.0 kg/cm2, 11 — 14 psi)
Except above:
108 — 127 kPa (1.08 — 1.27 bar,
1.1 — 1.3 kg/cm2, 16 — 18 psi)

NG
c

Replace radiator cap.

OK
.

SLC343

NG
CHECK THERMOSTAT.
Replace thermostat.
c
1. Remove thermostat.
2. Check valve seating condition at normal
room temperatures.
It should seat tightly.
3. Check valve opening temperature and
valve lift.
Valve opening temperature:
76.5°C (170°F) [standard]
Valve lift:
More than 10 mm/90°C (0.39
in/194°F)
4. Check if valve is closed at 5°C (9°F)
below valve opening temperature. For
details, refer to LC section, “Thermostat”.
OK
.

CHECK ENGINE COOLANT TEMPERATURE SENSOR.
Refer to “COMPONENT INSPECTION”,
EC-156.
OK
.

CHECK MAIN 12 CAUSES.
If the cause cannot be isolated, go to
“MAIN 12 CAUSES OF OVERHEATING”,
EC-370.
.

CHECK INSPECTION END

EC-367

NG
c

Replace engine coolant
temperature sensor.

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Diagnostic Procedure (Cont’d)
C
V
.

CHECK COOLING FAN POWER SUPPLY CIRCUIT.
1. Turn ignition switch “OFF”.
2. Disconnect cooling fan relay-1.
3. Turn ignition switch “ON”.
4. Check voltage between cooling fan
relay-1 terminals V
1 ,V
3 ,V
6 and
ground with CONSULT-II or tester.
Battery voltage

SEC699C

SEC700C

CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch “OFF”.
2. Disconnect cooling fan motor-1 harness
connector and cooling fan motor-2 harness connector.
3. Check harness continuity between cooling fan relay-1 terminal V
5 and cooling
fan motor-1 terminal V
1 , cooling fan
motor-1 terminal V
4 and body ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground
and short to power.
5. Check harness continuity between cooling fan relay-1 terminal V
7 and cooling
fan motor-2 terminal V
1 , cooling fan
motor-2 terminal V
4 and body ground.
Refer to Wiring Diagram.
Continuity should exist.
6. Also check harness for short to ground
and short to power.
.

NG
c

OK
.

CHECK COOLING FAN RELAY-1.
Refer to “Component Inspection”, EC-371

CHECK INTERMITTENT INCIDENT.
Perform “TROUBLE DIAGNOSIS FOR
INTERMITTENT INCIDENT”, EC-112.
.

INSPECTION END

EC-368

NG
c

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M52 , F7
+ Harness for open or
short between cooling
fan relay-1 and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.
Replace cooling fan relay.

CHECK COOLING FAN MOTORS-1 AND
-2.
Refer to “Component Inspection”, EC-371.
.

Repair open circuit or short
to ground or short to power
in harness or connectors.

CHECK COOLING FAN OUTPUT SIGNAL
CIRCUIT FOR OPEN AND SHORT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal V
56 and cooling fan relay-1 terminal V
2 . Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground
and short to power.

Check the following.
+ 10A fuse
+ 40A fusible links
+ Harness for open or
short between cooling
fan relay-1 and fuse
+ Harness for open or
short between cooling
fan relay-1 and battery
If NG, repair open circuit or
short to ground to short to
power in harness or connectors.

NG
c

Replace cooling fan
motors.

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Diagnostic Procedure (Cont’d)
D
V

SEC780C

CHECK COOLING FAN POWER SUPPLY CIRCUIT.
1. Turn ignition switch “OFF”.
2. Disconnect cooling fan relays-2 and -3.
3. Turn ignition switch “ON”.
4. Check voltage between cooling fan relays-2
and -3 terminals V
1 ,V
6 and ground with
CONSULT-II or tester.
Battery voltage

NG
c

Check the following.
+ Harness for open or short
between cooling fan relays-2
and -3 and 10A fuse
+ Harness for open or short
between cooling fan relays-2
and fusible link
If NG, repair harness or connectors.

OK
.

SEC698C

CHECK COOLING FAN GROUND CIRCUIT
FOR OPEN AND SHORT
1. Turn ignition switch “OFF”.
2. Disconnect cooling fan motor-1 harness connector and cooling fan motor-2 harness connector.
3. Check harness continuity between cooling fan
relay-2 terminal V
7 and cooling fan motor-1
terminal V
2 , cooling fan relay-2 terminal V
3
and cooling fan motor-1 terminal V
3 , cooling
fan relay-2 terminal V
5 and body ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and
short to power.
5. Check harness continuity between cooling fan
relay-3 terminal V
7 and cooling fan motor-2
terminal V
2 , cooling fan relay-3 terminal V
3 ,
cooling fan relay-2 terminal V
5 .
Refer to Wiring Diagram.
Continuity should exist.
6. Also check harness for short to ground and
short to power.

NG
c

Repair open circuit or short to
ground or short to power in
harness or connectors.

Check the following.
+ Harness connectors E127 ,

OK
.
SEC700C

CHECK COOLING FAN OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal V
55 and cooling fan relay-2 terminal V
2 ,
cooling fan relay-3 terminal V
2 .
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and
short power.

M21

+ Harness connectors M52 ,
F7

+ Harness for open or short
between cooling fan relay-2
and -3 and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

OK
.

CHECK COOLING FAN RELAYS-2 AND -3.
Refer to “Component Inspection”, EC-371.

NG
c

Replace cooling fan relays.

OK
.

CHECK COOLING FAN MOTORS.
Refer to “Component Inspection”, EC-371.
OK
.

CHECK INTERMITTENT INCIDENT.
Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-112.
OK
.

INSPECTION END

EC-369

NG
c

Replace cooling fan motors.

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Main 12 Causes of Overheating
Engine

Step

Inspection item

OFF

+
+
+
+

Equipment

Standard

Reference page

+ Visual

No blocking

+ Coolant mixture

+ Coolant tester

30 — 50% coolant mixture

See “RECOMMENDED
FLUIDS AND LUBRICANTS” in MA section.

+ Coolant level

+ Visual

Coolant up to MAX level
in reservoir tank and
radiator filler neck

See “Changing Engine
Coolant”, “ENGINE MAINTENANCE” in MA section.

+ Radiator cap

+ Pressure tester

108 — 127 kPa
(1.08 — 1.27 bar, 1.1 — 1.3
kg/cm2, 16 — 18 psi)
59 — 98 kPa (0.59 — 0.98
bar, 0.6 — 1.0 kg/cm2,
9 — 14 psi) (Limit)

See “System Check”,
“ENGINE COOLING SYSTEM” in LC section.

ON*2

+ Coolant leaks

+ Visual

No leaks

See “System Check”,
“ENGINE COOLING SYSTEM” in LC section.

ON*2

+ Thermostat

+ Touch the upper and
lower radiator hoses

Both hoses should be hot. See “Thermostat” and
“Radiator”, “ENGINE
COOLING SYSTEM” in
LC section.

ON*1

+ Cooling fan

+ Visual (Coupling)
+ CONSULT-II

Operating

OFF

+ Combustion gas leak

+ Color checker chemical Negative
tester 4 gas analyzer

—

ON*3

+ Coolant temperature
gauge

+ Visual

—

Blocked
Blocked
Blocked
Blocked

radiator
condenser
radiator grille
bumper

Gauge less than 3/4
when driving

—

See “TROUBLE DIAGNOSIS FOR DTC P1217”,
EC-361.

+ Coolant overflow to res- + Visual
ervoir tank

No overflow during driving See “Changing Engine
and idling
Coolant”, “ENGINE MAINTENANCE” in MA section.

OFF*4

+ Coolant return from res- + Visual
ervoir tank to radiator

Should be initial level in
reservoir tank

See “ENGINE MAINTENANCE” in MA section.

OFF

+ Cylinder head

+ Straight gauge feeler
gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD” in EM section.

+ Cylinder block and pistons

+ Visual

No scuffing on cylinder
walls or piston

See “Inspection”, “CYLINDER BLOCK” in EM section.

*1: Engine running at idle for coupling type. Turn ignition switch ON for electrical cooling fan.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.

EC-370

DTC P1217 ENGINE OVER TEMPERATURE
TB48DE A/T (WITH EURO-OBD)
(OVERHEAT)
Component Inspection
COOLING FAN RELAYS-1, -2 AND -3
Check continuity between terminals V
3 and V
5 ,V
6 and V
7 .
Conditions

SEF745U

Continuity

12V direct current supply between terminals 1 and
2

Yes

No current supply

If NG, replace relay.

COOLING FAN MOTORS-1 AND -2
1. Disconnect cooling fan motor harness connectors.
2. Supply cooling fan motor terminals with battery voltage and
check operation.
Terminals

Cooling fan motor

SEF734W

Speed

(+)

(−)

Low

High

1, 2

3, 4

Cooling fan motor should operate.
If NG, replace cooling fan motor.

EC-371

DTC P1225 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Component Description

PBIB0145E

On Board Diagnosis Logic
The MI will not light up for this self-diagnosis.
DTC No.
P1225
1225

Trouble diagnosis name
Closed throttle position
learning performance
problem

DTC detecting condition
Closed throttle position learning value is
excessively low.

Possible cause
+ Electric throttle control actuator
(TP sensor 1 and 2)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch “OFF”, wait at least 10 seconds.
Turn ignition switch “ON”.
If 1st trip DTC is detected, go to EC-373, “Diagnostic Procedure”.

WITH GST
SEF058Y

Follow the procedure “With CONSULT-II” above.

EC-372

DTC P1225 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
1

CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY

1. Turn ignition switch “OFF”.
2. Remove the intake air duct.
3. Check if foreign matter is caught between the throttle valve and the housing.

SEC183D

OK or NG
OK

c GO TO 2.

c Remove the foreign matter and clean the electric throttle control actuator inside.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

EC-373

DTC P1226 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Component Description

PBIB0145E

On Board Diagnosis Logic
The MI will not light up for this self-diagnosis.
DTC No.
P1226
1226

Trouble diagnosis name
Closed throttle position
learning performance
problem

DTC detecting condition

Possible cause

Closed throttle position learning is not per- + Electric throttle control actuator
formed successfully, repeatedly.
(TP sensor 1 and 2)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch “OFF”, wait at least 10 seconds.
Turn ignition switch “ON”.
Repeat steps 3 and 4, 32 times.
If 1st trip DTC is detected, go to EC-375, “Diagnostic Procedure”.

WITH GST
SEF058Y

Follow the procedure “With CONSULT-II” above.

EC-374

DTC P1226 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
1

CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY

1. Turn ignition switch “OFF”.
2. Remove the intake air duct.
3. Check if foreign matter is caught between the throttle valve and the housing.

SEC183D

OK or NG
OK

c GO TO 2.

c Remove the foreign matter and clean the electric throttle control actuator inside.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

EC-375

DTC P1229 SENSOR POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
On Board Diagnosis Logic
This self-diagnosis has the one trip detection logic.
DTC No.
P1229
1229

Trouble diagnosis name
Sensor power supply circuit short

DTC detecting condition

Possible cause

ECM detects a voltage of power source for + Harness or connectors
sensor is excessively low or high.
(The TP sensor 1 and 2 circuit is
shorted.)
(APP sensor circuit is shorted.)
(MAF sensor circuit is shorted.)
(Power steering pressure sensor circuit
is shorted.)
(Refrigerant pressure sensor circuit is
shorted.)
+ Electric throttle control actuator
(TP sensor 1 and 2)
+ Accelerator pedal position sensor (APP
sensor 1)
+ MAF sensor
+ Power steering pressure sensor
+ Refrigerant pressure sensor
+ ECM pin terminal

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the
return spring.

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-378, “Diagnostic Procedure”.

WITH GST
Follow the procedure “WITH CONSULT-II” above.
SEF058Y

EC-376

DTC P1229 SENSOR POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
Wiring Diagram

TEC407M

EC-377

DTC P1229 SENSOR POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
103

WIRE
COLOR
Y

ITEM

CONDITION

Sensors’ power supply

Ignition switch “ON”

DATA (DC Voltage)

Approximately 5V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-378

DTC P1229 SENSOR POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
Diagnostic Procedure (Cont’d)
2

CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT

1. Disconnect electric throttle control actuator harness connector.

SEC182D

2. Turn ignition switch “ON”.
3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester.

PBIB0082E

Voltage: Approximately 5V
OK or NG
OK

c GO TO 4.

c GO TO 3.

CHECK SENSOR POWER SUPPLY CIRCUITS FOR SHORT

Check the following.
+ Harness for short to power and short to ground, between the following terminals.

MTBL1592

+ ECM pin terminal.
OK or NG
OK

c GO TO 4.

c Repair short to ground or short to power in harness or connectors.

EC-379

DTC P1229 SENSOR POWER
TB48DE A/T (WITH EURO-OBD)
SUPPLY
Diagnostic Procedure (Cont’d)
4

CHECK COMPONENTS

Check the following.
+ Accelerator pedal position sensor (Refer to EC-427, “Component Inspection”.)
+ Mass air flow sensor (Refer to EC-146, “Component Inspection”.)
+ Power steering pressure sensor (Refer to EC-282, “Component Inspection”.)
OK or NG
OK

c GO TO 7.

c Replace malfunctioning component.

CHECK THROTTLE POSITION SENSOR

Refer to EC-420, “Component Inspection”.
OK or NG
OK

c GO TO 6.

c GO TO 5.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

Replace electric throttle control actuator.
Perform EC-31, “Accelerator Pedal Released Position Learning”.
Perform EC-31, “Throttle Valve Closed Position Learning”.
Perform EC-31, “Idle Air Volume Learning”.
c INSPECTION END

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-380

DTC P1336 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Component Description

SEF804Z

The crankshaft position sensor (OBD) is located on the transmission housing facing the gear teeth (cogs) of the flywheel or drive
plate. It detects the fluctuation of the engine revolution.
The sensor consists of a permanent magnet, core and coil.
When the engine is running, the high and low parts of the teeth
cause the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation
of the engine revolution.
This sensor is not used to control the engine system.
It is used only for the on board diagnosis.

SEC732D

ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than the ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (AC Voltage)

Approximately 1 — 2V★

Engine is running.
Warm-up condition.
Idle speed

SEC748D

111

Crankshaft position sensor (OBD)

3 — 4V★
(AC range)
Engine is running.
Engine speed is 2,000 rpm

SEC749D

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-381

DTC P1336 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
On Board Diagnosis Logic
Malfunction is detected when a chipping of the flywheel or drive
plate gear tooth (cog) is detected by the ECM.

POSSIBLE CAUSE
+ Harness or connectors
+ Crankshaft position sensor (OBD)
+ Drive plate/Flywheel

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch OFF and wait at least
5 seconds before conducting the next test.

With CONSULT-II
1. Turn ignition switch ON and select “DATA MONITOR” mode
with CONSULT-II.
2. Start engine and run it for at least 2 minutes at idle speed.
3. If 1st trip DTC is detected, go to “Diagnostic Procedure”,
EC-384.

With GST
Follow the procedure “With CONSULT-II”.
SEF058Y

EC-382

DTC P1336 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Wiring Diagram

TEC344M

EC-383

DTC P1336 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch OFF.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

CHECK CKPS (OBD) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

SEC732D

2. Check continuity between ECM terminal 111 and sensor terminal 1.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E201, E70
+ Harness connectors E127, M21
+ Harness connectors M51, F6
+ Harness for open or short between ECM and crankshaft position sensor (OBD)
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-384

DTC P1336 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Diagnostic Procedure (Cont’d)
4

CHECK CKPS (OBD) GROUND CIRCUIT FOR OPEN AND SHORT

1. Reconnect ECM harness connectors.
2. Check harness continuity between CKPS (OBD) terminal 2 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E202, E69
+ Harness connectors E127, M21
+ Harness connectors M51, F6
+ Harness for open between crankshaft position sensor (OBD) and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK IMPROPER INSTALLATION

1. Loosen and retighten the fixing bolt of the crankshaft position sensor (OBD).
2. Perform “DTC Confirmation Procedure”, again.
Is a 1st trip DTC P1336 detected?
Yes or No
Yes

c GO TO 7.

c INSPECTION END

EC-385

DTC P1336 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Diagnostic Procedure (Cont’d)
7
1.
2.
3.
4.

CHECK CRANKSHAFT POSITION SENSOR (OBD)
Disconnect crankshaft position sensor (OBD) harness connector.
Loosen the fixing bolt of the sensor.
Remove the sensor.
Visually check the sensor for chipping.

SEF960N

5. Check resistance as shown in the figure.

SEF504V

Resistance: Approximately 512 — 632Ω [at 20°C (68°F)]
OK or NG
OK

c GO TO 8.

c Replace crankshaft position sensor (OBD).

CHECK CKPS (OBD) SHIELD CIRCUIT FOR OPEN AND SHORT

1. Disconnect harness connectors E201, E70.
2. Check harness continuity between harness connector E70 terminal 10 and engine ground.
Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E201, E70
+ Harness connectors E127, M21
+ Harness connectors M51, F6
+ Joint connector-7
+ Harness for open between harness connector F38 and engine ground
c Repair open circuit or short to power in harness or connectors.

EC-386

DTC P1336 CKP SENSOR
TB48DE A/T (WITH EURO-OBD)
(OBD)
Diagnostic Procedure (Cont’d)
10

CHECK GEAR TOOTH

Visually check for chipping flywheel or drive plate gear tooth (cog).
OK or NG
OK

c GO TO 11.

c Replace the flywheel or drive plate.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-112.
c INSPECTION END

EC-387

DTC P1706 PNP
SWITCH

TB48DE A/T (WITH EURO-OBD)

Component Description
When the shift lever position is “P” or “N”, park/neutral position (PNP) switch is “ON”.
ECM detects the position because the continuity of the line (the “ON” signal) exists.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
P/N POSI SW

CONDITION
+ Ignition switch: ON

SPECIFICATION

Shift lever: P or N

Shift lever: Except above

OFF

On Board Diagnosis Logic
DTC No.
P1706
1706

Trouble diagnosis name
Park/neutral position
switch

DTC detecting condition
The signal of the park/neutral position
(PNP) switch is not changed in the process of engine starting and driving.

Possible cause
+ Harness or connectors
(PNP switch circuit is open or shorted.)
+ Park/neutral position (PNP) switch

WITH CONSULT-II
1. Turn ignition switch “ON”.
2. Select “P/N POSI SW” in “DATA MONITOR” mode with
CONSULT-II. Then check the “P/N POSI SW” signal under
the following conditions.
Position (Selector lever)

SEF212Y

Known-good signal

“N” and “P” position

Except the above position

OFF

If NG, go to EC-392, “Diagnostic Procedure”.
If OK, go to following step.
3. Select “DATA MONITOR” mode with CONSULT-II.
4. Start engine and warm it up to normal operating temperature.
5. Maintain the following conditions for at least 60 consecutive
seconds.
ENG SPEED

1,250 — 6,375 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

More than 5 msec

VHCL SPEED SE

More than 64 km/h (40 MPH)

Selector lever

Suitable position

SEF213Y

EC-388

DTC P1706 PNP
TB48DE A/T (WITH EURO-OBD)
SWITCH
DTC Confirmation Procedure (Cont’d)
6. If 1st trip DTC is detected, go to EC-392, “Diagnostic Procedure”.

Overall Function Check
Use this procedure to check the overall function of the park/
neutral position (PNP) switch circuit. During this check, a 1st trip
DTC might not be confirmed.

WITH GST
1. Turn ignition switch “ON”.
2. Check voltage between ECM terminal 80 (PNP switch signal)
and body ground under the following conditions.
Condition (Gear position)

Voltage V (Known-good data)

“P” and “N” position

Approximately 0

Except the above position

Battery voltage

3. If NG, go to EC-392, “Diagnostic Procedure”.
PBIB0169E

EC-389

DTC P1706 PNP
SWITCH

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC420M

EC-390

DTC P1706 PNP
TB48DE A/T (WITH EURO-OBD)
SWITCH
Wiring Diagram (Cont’d)

TEC421M

EC-391

DTC P1706 PNP
TB48DE A/T (WITH EURO-OBD)
SWITCH
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”
Approximately 0V
Shift lever position is “P” or “N”.
80

R/PU

PNP switch
Ignition switch “ON”
Except the above gear position

BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure
1

INSPECTION START

Do you have CONSULT-II?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

CHECK PNP SWITCH SIGNAL

1. Turn ignition switch “ON”.
2. Select “A/T”, then “DATA MONITOR” mode while CONSULT-II.
3. Select “P/N POSI SW” signal and check its indication under the following conditions.

PBIB0102E

MTBL1597

OK or NG
OK

c GO TO 5.

c GO TO 4.

EC-392

DTC P1706 PNP
TB48DE A/T (WITH EURO-OBD)
SWITCH
Diagnostic Procedure (Cont’d)
3

CHECK PNP SWITCH SIGNAL

Confirm that the PNP switch signal is sent to TCM correctly.
Refer to AT section.
OK or NG
OK

c GO TO 5.

c GO TO 4.

CHECK PNP SWITCH CIRCUIT

Check the PNP switch circuit.
Refer to AT section.
c INSPECTION END

CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-I

1. Turn ignition switch “OFF”.
2. Disconnect TCM harness connector.

SEC298D

3. Disconnect park/neutral position relay-3 harness connector.

SEC185D

4. Check harness continuity between TCM terminal 48 and park/neutral position relay-3 terminal 2. Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-393

DTC P1706 PNP
TB48DE A/T (WITH EURO-OBD)
SWITCH
Diagnostic Procedure (Cont’d)
6

CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-II

1. Check harness continuity between park/neutral position relay-3 terminal 1, 6 and ground.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to power.
OK or NG
OK

c GO TO 7.

c Repair open circuit or short to power in harness or connectors.

CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-III

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 80 and park/neutral position relay-3 terminal 7.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 9.

c GO TO 8.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F7, M52
+ Harness connectors M21, E127
+ Harness for open between ECM and park/neutral position relay-3
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK PARK/NEUTRAL POSITION RELAY-3

Refer to AT section.
OK or NG
OK

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-394

DTC P1805 BRAKE
SWITCH

TB48DE A/T (WITH EURO-OBD)

Description
Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed.
This signal is used mainly to decrease the engine speed when the vehicle is driving.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
BRAKE SW

CONDITION
+ Ignition switch: ON

SPECIFICATION

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

On Board Diagnosis Logic
The MI will not light up for this self-diagnosis.
DTC No.
P1805
1805

Trouble diagnosis name
Brake switch

DTC detecting condition
A brake switch signal is not sent to ECM
for an extremely long time while the
vehicle is driving.

Possible cause
+ Harness or connectors
(Stop lamp switch circuit is open or
shorted.)
+ Stop lamp switch

FALI-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM controls the electric throttle control actuator by regulating the throttle opening to a small range.
Therefore, acceleration will be poor.
Vehicle condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

DTC Confirmation Procedure
WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch “ON”.
Fully depress the brake pedal for at least 5 seconds.
Erase the DTC with CONSULT-II.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-397, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-395

DTC P1805 BRAKE
SWITCH

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC249M

EC-396

DTC P1805 BRAKE
TB48DE A/T (WITH EURO-OBD)
SWITCH
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
Approximately 0V
Brake pedal fully released
106

G/Y

Stop lamp switch
Engine is running.
Brake pedal depressed

BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure
1

CHECK STOP LAMP SWITCH CIRCUIT

1. Turn ignition switch “OFF”.
2. Check the stop lamp when depressing and releasing the brake pedal.

MTBL1593

OK or NG
OK

c GO TO 4.

c GO TO 2.

EC-397

DTC P1805 BRAKE
TB48DE A/T (WITH EURO-OBD)
SWITCH
Diagnostic Procedure (Cont’d)
2

CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT

1. Disconnect stop lamp switch harness connector.

SEC194D

2. Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester.

PBIB0117E

Voltage: Battery voltage
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ 10A fuse
+ Fuse block (J/B) connector M3
+ Harness for open and short between stop lamp switch and battery
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-398

DTC P1805 BRAKE
TB48DE A/T (WITH EURO-OBD)
SWITCH
Diagnostic Procedure (Cont’d)
4

CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Disconnect stop lamp switch harness connector.

SEC194D

4. Check harness continuity between ECM terminal 106 and stop lamp switch terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M52, F7
+ Harness for open or short between ECM and stop lamp switch
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK STOP LAMP SWITCH

Refer to EC-399, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c Replace stop lamp switch.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
STOP LAMP SWITCH
1. Disconnect stop lamp switch harness connector.

SEC194D

EC-399

DTC P1805 BRAKE
TB48DE A/T (WITH EURO-OBD)
SWITCH
Component Inspection (Cont’d)
2. Check continuity between stop lamp switch terminals 1 and
2 under the following conditions.
Conditions

Continuity

Brake pedal fully released

Should not exist.

Brake pedal depressed

Should exist.

If NG, adjust brake pedal installation, refer to BR section, and
perform step 2 again.
PBIB0118E

EC-400

DTC P2122, P2123 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Component Description

PBIB0146E

The accelerator pedal position sensor is installed on the upper
end of the accelerator pedal assembly. The sensor detects the
accelerator position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening
and closing speed of the accelerator pedal and feed the voltage
signals to the ECM. The ECM judges the current opening angle
of the accelerator pedal from these signals and controls the
throttle control motor based on these signals.
Idle position of the accelerator pedal is determined by the ECM
receiving the signal from the accelerator pedal position sensor.
The ECM uses this signal for the engine operation such as fuel
cut.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
ACCEL SEN1
ACCEL SEN2*
CLSD THL POS

CONDITION

SPECIFICATION

+ Ignition switch: ON
(engine stopped)
+ Shift lever position is “D”

Accelerator pedal: Fully released

More than 0.36V

Accelerator pedal: Fully depressed

Less than 4.75V

+ Ignition switch: ON
(engine stopped)
+ Shift lever position is “D”

Accelerator pedal: Fully released

Accelerator pedal: Slightly depressed OFF

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic
These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

P2122
2122

Accelerator pedal position An excessively low voltage from the APP
sensor 1 circuit low input sensor 1 is sent to ECM.

P2123
2123

Accelerator pedal position An excessively high voltage from the APP
sensor 1 circuit high input sensor 1 is sent to ECM.

Possible cause
+ Harness or connectors
(The APP sensor 1 circuit is open or
shorted.)
+ Accelerator pedal position sensor
(Accelerator pedal position sensor 1)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-401

DTC P2122, P2123 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-405, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-402

DTC P2122, P2123 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram

TEC401M

EC-403

DTC P2122, P2123 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”

Accelerator pedal position
sensor 1

Engine stopped
Shift lever position is “D”
Accelerator pedal fully released

More than 0.36V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

Less than 4.75V

Engine is running.

Sensor ground
(Accelerator pedal position sensor 1)

Sensor power supply
(Accelerator pedal position sensor 2)

Ignition switch “ON”

Approximately 2.5V

100

Sensor ground
(Accelerator pedal position sensor 2)

Ignition switch “ON”

Approximately 0V

103

Sensor power supply
(Accelerator pedal position sensor 1)

Ignition switch “ON”

Approximately 5V

Warm-up condition.
Idle speed

Approximately 0V

Ignition switch “ON”

117

Accelerator pedal position
sensor 2

Engine stopped
Shift lever position is “D”
Accelerator pedal fully released

More than 0.18V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

EC-404

Less than 2.37V

DTC P2122, P2123 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT

1. Disconnect accelerator pedal position (APP) sensor harness connector.

SEC182D

2. Turn ignition switch “ON”.
3. Check voltage between APP sensor terminal 7 and ground with CONSULT-II or tester.

SEC673D

Voltage: Approximately 5V
OK or NG
OK

c GO TO 4.

c GO TO 3.

EC-405

DTC P2122, P2123 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
3

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between APP sensor terminal 9 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 87 and APP sensor terminal 8.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR

Refer to EC-407, “Component Inspection”.
OK or NG
OK

c GO TO 10.

c GO TO 9.

9
1.
2.
3.
4.

REPLACE APP SENSOR
Replace the accelerator pedal position sensor.
Perform EC-31, “Accelerator Pedal Released Position Learning”.
Perform EC-31, “Throttle Valve Closed Position Learning”.
Perform EC-31, “Idle Air Volume Learning”.
c INSPECTION END

EC-406

DTC P2122, P2123 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
10

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
ACCELERATOR PEDAL POSITION SENSOR
1. Reconnect all harness connectors disconnected.
2. Turn ignition switch “ON”.
3. Check voltage between ECM terminals 87 (APP sensor 1
signal), 117 (APP sensor 2 signal) and engine ground under
the following conditions.
Terminal
PBIB0184E

Accelerator pedal

Voltage

87
(Accelerator pedal position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

117
(Accelerator pedal position sensor 2)

Fully released

More than 0.18V

Fully depressed

Less than 2.37V

4. If NG, replace accelerator pedal assembly and go to the next
step.
5. Perform EC-31, “Accelerator Pedal Released Position Learning”.
6. Perform EC-31, “Throttle Valve Closed Position Learning”.
7. Perform EC-31, “Idle Air Volume Learning”.

EC-407

DTC P2127, P2128 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Component Description

PBIB0146E

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
ACCEL SEN1
ACCEL SEN2*
CLSD THL POS

CONDITION

SPECIFICATION

+ Ignition switch: ON
(engine stopped)
+ Shift lever position is “D”

Accelerator pedal: Fully released

More than 0.36

Accelerator pedal: Fully depressed

Less than 4.75V

+ Ignition switch: ON
(engine stopped)
+ Shift lever position is “D”

Accelerator pedal: Fully released

Accelerator pedal: Slightly depressed OFF

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic
These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

P2127
2127

Accelerator pedal position An excessively low voltage from the APP
sensor 2 circuit low input sensor 2 is sent to ECM.

P2128
2128

Accelerator pedal position An excessively high voltage from the APP
sensor 2 circuit high input sensor 2 is sent to ECM.

Possible cause
+ Harness or connectors
(The APP sensor 2 circuit is open or
shorted.)
+ Accelerator pedal position sensor
(Accelerator pedal position sensor 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-408

DTC P2127, P2128 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-411, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-409

DTC P2127, P2128 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram

TEC402M

EC-410

DTC P2127, P2128 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”

Accelerator pedal position
sensor 1

Engine stopped
Shift lever position is “D”
Accelerator pedal fully released

More than 0.36V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

Less than 4.75V

Engine is running.
89

Sensors’ ground

Sensor power supply
(Accelerator pedal position sensor 2)

Ignition switch “ON”

Approximately 2.5V

100

Sensor ground
(Accelerator pedal position sensor 2)

Ignition switch “ON”

Approximately 0V

103

Sensors’ power supply

Ignition switch “ON”

Approximately 5V

Warm-up condition.
Idle speed

Approximately 0V

Ignition switch “ON”

117

Accelerator pedal position
sensor 2

Engine stopped
Shift lever position is “D”
Accelerator pedal fully released

More than 0.18V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

Less than 2.37V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-411

DTC P2127, P2128 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
2

CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT

1. Disconnect accelerator pedal position (APP) sensor harness connector.

SEC182D

2. Turn ignition switch “ON”.
3. Check voltage between APP sensor terminal 10 and ground with CONSULT-II or tester.

SEC674D

Voltage: Approximately 2.5V
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between APP sensor terminal 12 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

EC-412

DTC P2127, P2128 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
5

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 117 and APP sensor terminal 11.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR

Refer to EC-414, “Component Inspection”.
OK or NG
OK

c GO TO 10.

c GO TO 9.

9
1.
2.
3.
4.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-413

DTC P2127, P2128 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Component Inspection
ACCELERATOR PEDAL POSITION SENSOR
1. Reconnect all harness connectors disconnected.
2. Turn ignition switch “ON”.
3. Check voltage between ECM terminals 87 (APP sensor 1
signal), 117 (APP sensor 2 signal) and engine ground under
the following conditions.
Terminal
PBIB0184E

Accelerator pedal

Voltage

87
(Accelerator pedal position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

117
(Accelerator pedal position sensor 2)

Fully released

More than 0.18V

Fully depressed

Less than 2.37V

EC-414

DTC P2135 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Component Description

PBIB0145E

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
THRTL SEN1
THRTL SEN2*

CONDITION
+ Ignition switch: ON
(Engine stopped)
+ Shift lever: D

SPECIFICATION

Accelerator pedal: Fully released

More than 0.5V

Accelerator pedal: Fully depressed

Less than 1.5V

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic
This self-diagnosis has the one trip detection logic.
DTC No.
P2135
2135

Trouble diagnosis name
Throttle position sensor
circuit range/performance
problem

DTC detecting condition

Possible cause

Rationally incorrect voltage is sent to ECM + Harness or connector
(The TP sensor 1 and 2 circuit is open
compared with the signals from TP sensor
or shorted.)
1 and TP sensor 2.
+ Electric throttle control actuator
(TP sensor 1 and 2)

EC-415

DTC P2135 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-418, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-416

DTC P2135 TP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC400M

EC-417

DTC P2135 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
89

Sensor ground
(Throttle position sensor)

Warm-up condition.
Idle speed

Approximately 0V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully released
98

R/L

Less than 4.75V

Throttle position sensor 2
Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

103

Sensor power supply
(Throttle position sensor)

Ignition switch “ON”

More than 0.36V

Approximately 5V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully released
108

More than 0.36V

Throttle position sensor 1
Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

Less than 4.75V

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

EC-418

DTC P2135 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
2

CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT

1. Disconnect electric throttle control actuator harness connector.

SEC182D

2. Turn ignition switch “ON”.
3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester.

PBIB0082E

Voltage: Approximately 5V
OK or NG
OK

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

c GO TO 4.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 108 and electric throttle control actuator terminal 4, ECM terminal 98 and electric throttle control actuator terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c Repair open circuit or short to ground or short to power in harness or connectors.

EC-419

DTC P2135 TP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
5

CHECK THROTTLE POSITION SENSOR

Refer to EC-420, “Component Inspection”.
OK or NG
OK

c GO TO 7.

c GO TO 6.

REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

1.
2.
3.
4.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

PBIB0179E

Accelerator pedal

Voltage

108
(Throttle position sensor
1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

98
(Throttle position sensor
2)

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

EC-420

DTC P2138 APP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Component Description

PBIB0146E

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
ACCEL SEN1
ACCEL SEN2*
CLSD THL POS

CONDITION

SPECIFICATION

+ Ignition switch: ON
(engine stopped)
+ Shift lever position is “D”

Accelerator pedal: Fully released

More than 0.36V

Accelerator pedal: Fully depressed

Less than 4.75V

+ Ignition switch: ON
(engine stopped)
+ Shift lever position is “D”

Accelerator pedal: Fully released

Accelerator pedal: Slightly depressed OFF

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic
This self-diagnosis has the one trip detection logic.
DTC No.
P2138
2138

Trouble diagnosis name

DTC detecting condition

Possible cause

Accelerator pedal position Rationally incorrect voltage is sent to ECM + Harness or connector
(The APP sensor 1 and 2 circuit is open
compared with the signals from APP sensensor circuit range/
or shorted.)
sor 1 and APP sensor 2.
performance problem
+ Accelerator pedal position sensor 1 and
2

EC-421

DTC P2138 APP
SENSOR

TB48DE A/T (WITH EURO-OBD)

DTC Confirmation Procedure
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that
battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.

Turn ignition switch “ON”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-425, “Diagnostic Procedure”.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-422

DTC P2138 APP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC403M

EC-423

DTC P2138 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”

Accelerator pedal position
sensor 1

Engine stopped
Shift lever position is “D”
Accelerator pedal fully released

More than 0.36V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

Less than 4.75V

Engine is running.

Sensor ground
(Accelerator pedal position sensor 1)

Sensor power supply
(Accelerator pedal position sensor 2)

Ignition switch “ON”

Approximately 2.5V

100

Sensor ground
(Accelerator pedal position sensor 2)

Ignition switch “ON”

Approximately 0V

103

Sensor power supply
(Accelerator pedal position sensor 1)

Ignition switch “ON”

Approximately 5V

Warm-up condition.
Idle speed

Approximately 0V

Ignition switch “ON”

117

Accelerator pedal position
sensor 2

Engine stopped
Shift lever position is “D”
Accelerator pedal fully released

More than 0.18V

Ignition switch “ON”
Engine stopped
Shift lever position is “D”
Accelerator pedal fully depressed

EC-424

Less than 2.37V

DTC P2138 APP
SENSOR

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
1

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEC690C

c GO TO 2.

CHECK APP SENSOR POWER SUPPLY CIRCUIT

1. Disconnect accelerator pedal position (APP) sensor harness connector.

SEC182D

2. Turn ignition switch “ON”.
3. Check voltage between APP sensor terminals 7, 10 and ground with CONSULT-II or tester.

PBIB0084E

Voltage: Approximately 5V
OK or NG
OK

c GO TO 4.

c GO TO 3.

EC-425

DTC P2138 APP
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
3

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between APP sensor terminals 9, 12 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 87 and APP sensor terminal 8, ECM terminal 117 and APP sensor terminal
11.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness for open or short between ECM and accelerator pedal position sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK APP SENSOR

Refer to EC-427, “Component Inspection”.
OK or NG
OK

c GO TO 10.

c GO TO 9.

9
1.
2.
3.
4.

EC-426

DTC P2138 APP
SENSOR
10

TB48DE A/T (WITH EURO-OBD)

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.

Accelerator pedal

Voltage

87
(Accelerator pedal position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

117
(Accelerator pedal position sensor 2)

Fully released

More than 0.18V

Fully depressed

Less than 2.37V

EC-427

IGNITION SIGNAL

TB48DE A/T (WITH EURO-OBD)

Component Description
IGNITION COIL & POWER TRANSISTOR
The ignition signal from the ECM is sent to and amplified by the
power transistor. The power transistor turns on and off the ignition coil primary circuit. This on-off operation induces the proper
high voltage in the coil secondary circuit.

SEC781C

EC-428

IGNITION SIGNAL

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC415M

EC-429

TB48DE A/T (WITH EURO-OBD)
IGNITION SIGNAL
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
Ignition switch “OFF”
42

B/Y

ECM relay
(Self shut-off)

0 — 1.0V

For a few seconds after turning ignition switch
“OFF”
Ignition switch “OFF”
More than a few seconds passed after turning
ignition switch “OFF”

163
166

B/R
B/R

Power supply for ECM

Ignition switch “OFF”

EC-430

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

TB48DE A/T (WITH EURO-OBD)
IGNITION SIGNAL
Wiring Diagram (Cont’d)

TEC416M

EC-431

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

0 — 0.1V★

Engine is running.
Warm-up condition.
Idle speed
18
19
20

Y/R
G
Y

Ignition signal No. 1
Ignition signal No. 2
Ignition signal No. 3

PBIB0521E

0 — 0.2V★

Engine is running.
Warm-up condition.
Engine speed is 2,000 rpm

PBIB0522E

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-432

TB48DE A/T (WITH EURO-OBD)
IGNITION SIGNAL
Wiring Diagram (Cont’d)

TEC417M

EC-433

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

0 — 0.1V★

Engine is running.
Warm-up condition.
Idle speed
21
29
30

R/B
R/G
R

Ignition signal No. 4
Ignition signal No. 5
Ignition signal No. 6

PBIB0521E

0 — 0.2V★

Engine is running.
Warm-up condition.
Engine speed is 2,000 rpm

PBIB0522E

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-434

IGNITION SIGNAL

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
1

CHECK ENGINE START

Turn ignition switch “OFF”, and restart engine.
Is engine running?
Yes or No
Yes (With CONSULT-II)

c GO TO 2.

Yes (Without CONSULT-II)

c GO TO 3.

c GO TO 4.

CHECK OVERALL FUNCTION

With CONSULT-II
1. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
2. Make sure that each circuit produces a momentary engine speed drop.

PBIB0133E

OK or NG
OK

c INSPECTION END

c GO TO 13.

EC-435

TB48DE A/T (WITH EURO-OBD)
IGNITION SIGNAL
Diagnostic Procedure (Cont’d)
3

CHECK OVERALL FUNCTION

Without CONSULT-II
1. Let engine idle.
2. Read the voltage signal between ECM terminals 18, 19, 20, 21, 29, 30 and ground with an oscilloscope.

SEC828C

3. Verify that the oscilloscope screen shows the signal wave as shown below.

PBIB0521E

OK or NG
OK

c INSPECTION END

c GO TO 13.

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I

1. Turn ignition switch “ON”.
2. Check voltage between ECM terminals 163, 166 and ground with CONSULT-II or tester.

PBIB0135E

Voltage: Battery voltage
OK or NG
OK

c GO TO 5.

c Go to EC-113, “POWER SUPPLY CIRCUIT FOR ECM”.

EC-436

TB48DE A/T (WITH EURO-OBD)
IGNITION SIGNAL
Diagnostic Procedure (Cont’d)
5
1.
2.
3.
4.

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II
Turn ignition switch “OFF”.
Disconnect condenser harness connector.
Turn ignition switch “ON”.
Check voltage between condenser terminal 1 and ground with CONSULT-II or tester.

PBIB0624E

Voltage: Battery voltage
OK or NG
OK

c GO TO 11.

c GO TO 6.

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III

1. Turn ignition switch “OFF”.
2. Disconnect ECM relay.

SEC668D

3. Check harness continuity between ECM relay terminal 3 and condenser terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M55, F35
+ Harness for open or short between ECM relay and condenser
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-437

TB48DE A/T (WITH EURO-OBD)
IGNITION SIGNAL
Diagnostic Procedure (Cont’d)
8

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV

Check voltage between ECM relay terminal 5 and ground with CONSULT-II or tester.

SEC741D

Voltage: Battery voltage
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ 15A fuse
+ Harness for open or short between ECM relay and battery
c Repair or replace harness or connectors.

CHECK ECM RELAY

Refer to EC-112, “Component Inspection”.
OK or NG
OK

c GO TO 20.

c Replace ECM relay.

CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect condenser harness connector.
3. Check harness continuity between condenser terminal 2 and ground.
Refer to Wiring diagram.
Continuity should exist.
4. Also check harness for short to power.
OK or NG
OK

c GO TO 12.

c Repair open circuit or short to power in harness or connector.

CHECK CONDENSER

Refer to EC-441, “Component Inspection”.
OK or NG
OK

c GO TO 13.

c Replace condenser.

EC-438

TB48DE A/T (WITH EURO-OBD)
IGNITION SIGNAL
Diagnostic Procedure (Cont’d)
13

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V

1. Turn ignition switch “OFF”.
2. Reconnect all harness connectors disconnected.
3. Disconnect ignition coil harness connector.

SEC783C

SEC784C

4. Turn ignition switch “ON”.
5. Check voltage between ignition coil terminal 1 and ground with CONSULT-II or tester.

SEF107S

Voltage: Battery voltage
OK or NG
OK

c GO TO 15.

c GO TO 14.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F25, F121
+ Harness for open or short between ignition coil and ECM relay
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-439

TB48DE A/T (WITH EURO-OBD)
IGNITION SIGNAL
Diagnostic Procedure (Cont’d)
15

CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Check harness continuity between ignition coil terminal 2 and engine ground.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 17.

c GO TO 16.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F25, F121
+ Harness for open or short between ignition coil and ground
c Repair open circuit or short to power in harness or connectors.

CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminals 18, 19, 20, 21, 29, 30 and ignition coil terminal 3.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 19.

c GO TO 18.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F25, F121
+ Harness for open or short between ECM and ignition coil
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK IGNITION COIL WITH POWER TRANSISTOR

Refer to EC-441, “Component Inspection”.
OK or NG
OK

c GO TO 20.

c Replace ignition coil with power transistor.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-440

IGNITION SIGNAL

TB48DE A/T (WITH EURO-OBD)

Component Inspection
ECM RELAY
1. Apply 12V direct current between ECM relay terminals 1 and
2.
2. Check continuity between relay terminals 3 and 5, 6 and 7.
Condition

PBIB0077E

Continuity

12V direct current supply between
terminals 1 and 2

Yes

OFF

3. If NG, replace ECM relay.

CONDENSER
1. Turn ignition switch “OFF”.
2. Disconnect condenser harness connector.
3. Check resistance between condenser terminals 1 and 2.
Resistance: Above 1 MΩ at 25°C (77°F)

MBIB0031E

IGNITION COIL WITH POWER TRANSISTOR
1. Turn ignition switch “OFF”.
2. Disconnect ignition coil harness connector.
3. Check resistance between ignition coil terminals as follows.
Terminal No.
3 and 1

Resistance Ω [at 25°C (77°F)]
Except 0 or

3 and 2
Except 0
1 and 2
MBIB0032E

EC-441

SNOW MODE SWITCH

TB48DE A/T (WITH EURO-OBD)

Component Description
To turn on the switch, push the lower side of it. The indicator light
of the switch will illuminate and the transmission shifts into the
snow driving mode.
+ This mode is used for standing starts on slippery (snowy,
sandy) roads.
+ When the selector lever is in the D position, the transmission
shifts from 1st to 5th gear automatically from standing starts
or when accelerating from low speed.
SEC222D

ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC voltage)

Ignition switch “ON”

Y/G

Snow mode switch

Snow mode switch is snow position.
Snow switch is “ON”.

Battery voltage (11 — 14V)

Ignition switch “ON”
Approximately 0V
Except above switch position

EC-442

SNOW MODE SWITCH

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC332M

EC-443

SNOW MODE SWITCH

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
INSPECTION START
.

CHECK OVERALL FUNCTION.
1. Turn ignition switch “ON”.
2. Check voltage as follows.
Snow mode switch

SEC188D

ECM terminal V
60 voltage

AUTO

SNOW

11 — 14 V (Battery voltage)

Snow mode
switch

NG
Ab
V

CHECK SNOW INDICATOR LAMP.
1. Turn ignition switch
“ON”.
2. Check snow indicator
lamp as follows.

Snow indicator lamp

AUTO

OFF

SNOW

INSPECTION END
.

CHECK POWER SUPPLY FOR SNOW
MODE SWITCH.
1. Turn ignition switch “OFF”.
2. Disconnect snow mode switch harness
connector.
3. Turn ignition switch “ON”.
4. Check voltage between snow mode
switch terminal V
2 and ground.
Battery voltage

NG
c

OK
.

CHECK INPUT SIGNAL CIRCUIT-I.
1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between snow
mode switch terminal V
1 and ECM terminal V
60 .
Refer to Wiring Diagram.
Continuity should exist.
4. Check harness continuity between ECM
terminal V
60 and snow mode switch terminal V
6 . Refer to wiring diagram.
Continuity should exist.
5. Also check harness for short to ground
and short to power.
If OK, reconnect ECM harness connector.
.

NG
c

Check the following.
+ 7.5A fuse
+ Harness connectors
M20 , B19
+ Harness for open or
short between snow
mode switch and fuse.
If NG, repair open circuit,
short to ground or short to
power in harness or connectors.
Check the following.
+ Harness connector B19 ,
M20

+ Harness connector M52 ,
F7

+ Harness for open or
short between snow
mode switch and ECM
If NG, repair open circuit,
short to ground or short to
power in harness or connectors.

NG
Check the following.
CHECK GROUND CIRCUIT.
c
+ Harness connector B19 ,
1. Check harness continuity between snow
M20
mode switch harness connector terminal
7 and ground.
+ Harness for open or
V
Refer to Wiring Diagram.
short between snow
Continuity should exist.
mode switch and ground.
If OK, check harness for short to power.
If NG, repair open circuit,
short to power in harness
OK
or connectors.
.

CHECK INTERMITTENT INCIDENT.
Refer to “TROUBLE DIAGNOSIS FOR
INTERMITTENT INCIDENT”, EC-112.
.

INSPECTION END

EC-444

SNOW MODE SWITCH TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
A
V
.

CHECK SNOW INDICATOR LAMP
INPUT SIGNAL CIRCUIT.
1. Check continuity between snow mode
switch terminal V
1 and V
6 . Refer to
wiring diagram.
Continuity should exist.
2. Also check harness for short to ground
and short to power.

NG
c

Repair open circuit, short
to ground or short to
power in harness or connectors.

OK
.

CHECK SNOW INDICATOR LAMP
GROUND.
1. Check harness continuity between
snow mode switch terminal V
7 and
ground. Refer to wiring diagram.
Continuity should exist.

NG
c

CHECK SNOW INDICATOR LAMP.
Refer to EL or AT section.
OK
.

INSPECTION END

EC-445

NG
c

Check the following.
+ Harness connectors
B19 , M20
+ Harness for open or
short between snow
mode switch and ground
If NG, repair open circuit,
short to power in harness
or connectors.

Replace snow indicator
lamp or snow mode switch
assembly.

VARIABLE INDUCTION AIR CONTROL
TB48DE A/T (WITH EURO-OBD)
SYSTEM (VIAS)
Description
SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Mass air flow sensor

Amount of intake air

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Ignition switch

Start signal

Camshaft position sensor

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

ECM function

VIAS control

Actuator

VIAS control solenoid valve

SEC802C

When the engine is running at low or medium speed, the ECM
sends the signal to the VIAS control solenoid valve then power
valve is fully closed. Under this condition, the effective suction
port length is equivalent to the total length of the intake manifold
collector’s suction port including the intake valve. This long suction port provides increased air intake which results in improved
suction efficiency and higher torque generation.
The surge tank and one-way valve are provided. When engine
is running at high speed, the ECM does not send the signal to
the VIAS control solenoid valve, thus enabling power valve to be
fully opened. This signal introduces the intake manifold vacuum
into the power valve actuator and therefore opens the power
valve to two suction passages together in the collector.
Under this condition, the effective port length is equivalent to the

EC-446

VARIABLE INDUCTION AIR CONTROL
TB48DE A/T (WITH EURO-OBD)
SYSTEM (VIAS)
Description (Cont’d)
length of the suction port provided independently for each cylinder. This shortened port length results in enhanced engine output with reduced suction resistance under high speeds.

COMPONENT DESCRIPTION
Power valve
The power valve is installed in intake manifold collector and used
to control the suction passage of the variable induction air control system. It is set in the fully closed or fully opened position by
the power valve actuator operated by the vacuum stored in the
surge tank. The vacuum in the surge tank is controlled by the
VIAS control solenoid valve.
SEC803C

VIAS control solenoid valve
The VIAS control solenoid valve cuts the intake manifold vacuum
signal for power valve control. It responds to ON/OFF signals
from the ECM. When the solenoid is off, the vacuum signal from
the intake manifold is for high speed. When the ECM sends an
ON signal the coil pulls the plunger downward and feeds the
vacuum signal to the power valve actuator.

SEC804C

ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
Engine is running.

LG/R

VIAS control solenoid
valve

Idle speed

DATA (DC Voltage)

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
0 — 1.0V
Engine speed is above 5,000 rpm.

EC-447

VARIABLE INDUCTION AIR CONTROL
TB48DE A/T (WITH EURO-OBD)
SYSTEM (VIAS)
Wiring Diagram

TEC161M

EC-448

VARIABLE INDUCTION AIR CONTROL
TB48DE A/T (WITH EURO-OBD)
SYSTEM (VIAS)
Diagnostic Procedure
INSPECTION START

CHECK OVERALL FUNCTION.

SEC805C

OK
c

INSPECTION END

With CONSULT-II
1. Start engine and warm it up to normal
operating temperature.
2. Perform “VIAS SOL VALVE” in “ACTIVE
TEST” mode with CONSULT-II.
3. Turn VIAS control solenoid valve “ON”
and “OFF”, and make sure that power
valve actuator rod moves.
Without CONSULT-II
1. Start engine and warm it up to normal
operating temperature.
2. Rev engine quickly up to above 5,000
rpm and make sure that power valve
actuator rod moves.
NG
.

SEC806C

NG
Check the following.
CHECK VIAS CONTROL SOLENOID
c
+ Harness connectors
VALVE POWER SUPPLY CIRCUIT.
M52 , F7
1. Stop engine.
2. Disconnect VIAS control solenoid valve
+ 10A fuse
harness connector.
+ Harness continuity
3. Turn ignition switch “ON”.
between fuse and VIAS
4. Check voltage between terminal V
control solenoid valve
1 and
If NG, repair harness or
ground with CONSULT-II or tester.
connectors.
Voltage: Battery voltage
.

SEC804C

CHECK VIAS CONTROL SOLENOID
VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT.
1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM
terminal V
27 and terminal V
2 . Refer to
Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground
and short to power.
.

Replace VIAS control solenoid valve as
intake manifold collector assembly.

EC-449

Repair open circuit or short
to ground or short to power
in harness or connectors.

OK
c

INSPECTION END

CHECK INTERMITTENT INCIDENT.
Refer to “TROUBLE DIAGNOSIS FOR
INTERMITTENT INCIDENT”, EC-112.
.

RETEST OVERALL FUNCTION.
1. Reconnect harness connectors disconnected.
2. Perform CHECK OVERALL FUNCTION
again.
SEC807C

NG
c

Repair or replace harness
or connectors.

START SIGNAL

TB48DE A/T (WITH EURO-OBD)

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
START SIGNAL

CONDITION

SPECIFICATION

+ Ignition switch: ON → START → ON

OFF → ON → OFF

ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
59

WIRE
COLOR

R/W

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”

Approximately 0V

Ignition switch “START”

9 — 12V

Start signal

EC-450

START SIGNAL

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC163M

EC-451

START SIGNAL

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
INSPECTION START

CHECK OVERALL FUNCTION.

OK
c

INSPECTION END

With CONSULT-II

PBIB0182E

1. Turn ignition switch “ON”.
2. Check “START SIGNAL” in “DATA
MONITOR” mode with CONSULT-II.
IGN “ON”
IGN “START”

OFF
ON

—————————————————————— OR ——————————————————————Without CONSULT-II

SEC824C

1. Turn ignition switch to “START”.
2. Check voltage between ECM terminal
59 and ground.
V
Voltage:
Ignition switch “START”
Battery voltage (9 — 12V)
Except above
Approximately 0V
NG
.

Check if 7.5A fuse is OK.

NG
c

Replace 7.5A fuse.

OK
.

NG
Check the following.
CHECK INPUT SIGNAL CIRCUIT.
c
+ Harness connectors
1. Turn ignition switch “OFF”.
M52 , F7
2. Disconnect ECM harness connector and
+ Harness for open or
7.5A fuse.
short between ECM and
3. Check harness continuity between ECM
fuse block
terminal V
59 and fuse block.
If NG, repair open circuit,
Refer to Wiring Diagram.
short to ground or short to
Continuity should exist.
power in harness or conIf OK, check harness for short to ground
nectors.
and short to power.
OK
.

CHECK INTERMITTENT INCIDENT.
Refer to “TROUBLE DIAGNOSIS FOR
INTERMITTENT INCIDENT”, EC-112.
.

INSPECTION END

EC-452

INJECTOR CIRCUIT

TB48DE A/T (WITH EURO-OBD)

Component Description
The fuel injector is a small, precise solenoid valve. When the
ECM supplies a ground to the injector circuit, the coil in the
injector is energized. The energized coil pulls the needle valve
back and allows fuel to flow through the injector into the intake
manifold. The amount of fuel injected depends upon the injection
pulse duration. Pulse duration is the length of time the injector
remains open. The ECM controls the injection pulse duration
based on engine fuel needs.
SEF375Z

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
B/FUEL SCHDL

INJ PULSE-B1
INJ PULSE-B2

CONDITION

SPECIFICATION

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

5.0 — 5.5 msec

2,000 rpm

5.0 — 5.5 msec

+
+
+
+

Engine: After warming up
Shift lever: N
Air conditioner switch: OFF
No-load

Idle

3.0 — 4.0 msec

2,000 rpm

3.0 — 4.0 msec

EC-453

INJECTOR CIRCUIT

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC162M

EC-454

INJECTOR CIRCUIT TB48DE A/T (WITH EURO-OBD)
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

BATTERY VOLTAGE
(11 — 14V)★
Engine is running.
Warm-up condition.
Idle speed
5
6
7
13
14
15

BR/W
GY/L
BR/Y
GY/R
BR
GY

Injector
Injector
Injector
Injector
Injector
Injector

No.
No.
No.
No.
No.
No.

1
2
3
4
5
6

PBIB0529E

BATTERY VOLTAGE
(11 — 14V)★
Engine is running.
Warm-up condition.
Engine speed is 2,000 rpm

PBIB0530E

★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure
1

INSPECTION START

Turn ignition switch to “START”.
Is any cylinder ignited?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

EC-455

INJECTOR CIRCUIT TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
2

CHECK OVERALL FUNCTION

With CONSULT-II
1. Start engine.
2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

PBIB0133E

3. Make sure that each circuit produces a momentary engine speed drop.
Without CONSULT-II
1. Start engine.
2. Listen to each injector operating sound.

MEC703B

Clicking noise should be heard.
OK or NG
OK

c INSPECTION END

c GO TO 3.

EC-456

INJECTOR CIRCUIT TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
3

CHECK INJECTOR POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect injector harness connector.

SEC793C

3. Turn ignition switch “ON”.
4. Check voltage between injector terminal 2 and ground with CONSULT-II or tester.

PBIB0289E

Voltage: Battery voltage
OK or NG
OK

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F12, F101
+ Harness connectors M52, F7
+ Fuse block (J/B) connector M2
+ 10A fuse
+ Harness for open or short between injector and fuse
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between injector terminal 1 and ECM terminals 5, 6, 7, 13, 14, 15.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

EC-457

INJECTOR CIRCUIT TB48DE A/T (WITH EURO-OBD)
Diagnostic Procedure (Cont’d)
6

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors F101, F12
+ Harness for open or short between ECM and injector
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INJECTOR

Refer to EC-458, “Component Inspection”.
OK or NG
OK

c GO TO 8.

c Replace injector.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

Component Inspection
INJECTOR
1. Disconnect injector harness connector.
2. Check resistance between terminals as shown in the figure.
Resistance: 13.5 — 17.5Ω [at 20°C (68°F)]

SEC809C

EC-458

FUEL PUMP

TB48DE A/T (WITH EURO-OBD)

System Description
Engine speed

Camshaft position sensor

ECM

Start signal

Ignition switch

Fuel
pump
relay

The ECM activates the fuel pump for several seconds after the ignition switch is turned on to
improve engine storability. If the ECM receives a
120° signal from the camshaft position sensor, it
knows that the engine is rotating, and causes the
pump to operate. If the 120° signal is not received
when the ignition switch is on, the engine stalls.
The ECM stops pump operation and prevents battery discharging, thereby improving safety. The
ECM does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn
controls the fuel pump.

Condition

Fuel pump operation

Ignition switch is turned to ON.
Engine running and cranking

Operates for
5 seconds.
Operates.

When engine is stopped

Stops in 1 second.

Except as shown above

Stops.

Component Description
The fuel pump with a fuel damper is an in-tank type (the pump
and damper are located in the fuel tank).

SEF609V

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM

FUEL PUMP RLY

CONDITION

SPECIFICATION

+ Ignition switch is turned to ON (Operates for 5 seconds).
+ Engine running and cranking
+ When engine is stopped (Stops in 1 second)

Except as shown above

OFF

EC-459

FUEL PUMP

TB48DE A/T (WITH EURO-OBD)

ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC voltage)

Ignition switch “ON”

R/Y

Fuel pump relay

For 5 seconds after turning ignition switch
“ON”
Engine is running.

0 — 1.0V

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

5 seconds after turning ignition switch “ON”

EC-460

FUEL PUMP

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC164M

EC-461

FUEL PUMP

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
INSPECTION START

SEC810C

CHECK OVERALL FUNCTION.
1. Turn ignition switch “ON”.
2. Pinch fuel feed hose with fingers.
Fuel pressure pulsation should be
felt on the fuel feed hose for 5 seconds after ignition switch is turned
“ON”.

OK
c

INSPECTION END

NG
.

CHECK POWER SUPPLY.
1. Turn ignition switch “OFF”.
2. Disconnect fuel pump relay.
3. Turn ignition switch “ON”.
1 ,
4. Check voltage between terminals V
3 and ground with CONSULT-II or
V
tester.
Voltage: Battery voltage

NG
c

Check the following.
+ 15A fuse
+ Harness for open or
short between fuse and
fuel pump relay
If NG, repair harness or
connectors.

SEC684CA
.

CHECK GROUND CIRCUIT-I.
1. Turn ignition switch “OFF”.
2. Disconnect fuel tank gauge unit (fuel
pump) harness connector.
3. Check harness continuity between terminal V
6 and body ground.

NG
c

Refer to Wiring Diagram.
Continuity should exist.
If OK, check harness for short to
power.

Check the following.
+ Harness connectors
C2 , B37
+ Harness for open or
short between fuel pump
and body ground
If NG, repair open circuit,
short to power in harness
or connectors.

SEF479P
.

CHECK GROUND CIRCUIT-II.
1. Turn ignition switch “OFF”.
2. Check harness continuity between relay
terminal V
5 and fuel pump terminal V
4 .
Refer to Wiring Diagram.

Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
SEF608V
.

A
V

(Go to next page.)

EC-462

NG
c

Check the following.
+ Harness connectors
M20 , B19
+ Harness connectors
B137 , C2
+ Harness for open or
short between fuel pump
and fuel pump relay
If NG, repair open circuit,
short to ground or short to
power in harness or connectors.

TB48DE A/T (WITH EURO-OBD)
FUEL PUMP
Diagnostic Procedure (Cont’d)
A
V

CHECK OUTPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
41 and fuel pump relay termiterminal V
nal V
2 .
Refer to Wiring Diagram.
SEF073Y

NG
c

Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK

Check the following.
+ Harness connectors
M52 , F7
+ Harness for open or
short between ECM and
fuel pump relay
If NG, repair open circuit,
short to ground or short to
power in harness or connectors.

CHECK COMPONENT
(Fuel pump relay).

NG
c

Replace fuel pump relay.

With CONSULT-II
1. Reconnect fuel pump relay, fuel pump
harness connector and ECM harness
connector.
2. Turn ignition switch “ON”.
3. Turn fuel pump relay “ON” and “OFF” in
“ACTIVE TEST” mode with CONSULT-II
and check operating sound.
—————————————————————— OR ——————————————————————Without CONSULT-II
Refer to “COMPONENT INSPECTION”,
EC-464.
OK
.

CHECK COMPONENT
(Fuel pump).
Refer to “COMPONENT INSPECTION”,
EC-464.
OK
.

CHECK INTERMITTENT INCIDENT.
Refer to “TROUBLE DIAGNOSIS FOR
INTERMITTENT INCIDENT”, EC-112.
.

INSPECTION END

EC-463

NG
c

Replace fuel pump.

FUEL PUMP

TB48DE A/T (WITH EURO-OBD)

Component Inspection
FUEL PUMP RELAY
Check continuity between terminals V
3 and V
5 .
Conditions

SEF511P

Continuity

12V direct current supply
between terminals V
1 and V
2

Yes

No current supply

If NG, replace relay.

FUEL PUMP
1. Disconnect fuel pump harness connector.
4 and V
6 .
2. Check resistance between terminals V
Resistance: 0.2 — 5.0Ω at 25°C (77°F)
If NG, replace fuel pump.

SEF607V

EC-464

REFRIGERANT PRESSURE
TB48DE A/T (WITH EURO-OBD)
SENSOR
Component Description
The refrigerant pressure sensor is installed at the liquid tank of
the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The voltage signal is sent to ECM, and ECM controls cooling fan system.

SEC742D

SEF099X

EC-465

REFRIGERANT PRESSURE
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram

TEC341M

EC-466

REFRIGERANT PRESSURE
TB48DE A/T (WITH EURO-OBD)
SENSOR
Wiring Diagram (Cont’d)
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Engine is running.
88

R/G

Refrigerant pressure sensor

Sensor ground
(Refrigerant pressure sensor)

Engine is running.

103

Sensors’ power supply

Ignition switch “ON”

Warm-up condition.
Both A/C switch and blower switch are “ON”.
(Compressor operates.)

Warm-up condition.
Idle speed

1.0 — 4.0V

Approximately 0V

Approximately 5V

Diagnostic Procedure
1

CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION

1. Start engine and warm it up to normal operating temperature.
2. Turn A/C switch and blower switch “ON”.
3. Check voltage between ECM terminal 88 and ground with CONSULT-II or tester.

PBIB0187E

Voltage: 1.0 — 4.0V
OK or NG
OK

c INSPECTION END

c GO TO 2.

EC-467

REFRIGERANT PRESSURE
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
2

CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT

1. Turn A/C switch and blower switch “OFF”.
2. Stop engine.
3. Disconnect refrigerant pressure sensor harness connector.

SEC742D

4. Turn ignition switch “ON”.
5. Check voltage between refrigerant pressure sensor terminal 1 and ground with CONSULT-II or tester.

PBIB0085E

Voltage: Approximately 5V
OK or NG
OK

c GO TO 4.

c GO TO 3.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness connectors M51, F6
+ Harness for open or short between ECM and refrigerant pressure sensor
c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between refrigerant pressure sensor terminal 3 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

EC-468

REFRIGERANT PRESSURE
TB48DE A/T (WITH EURO-OBD)
SENSOR
Diagnostic Procedure (Cont’d)
5

DETECT MALFUNCTIONING PART

CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN ANDSHORT

1. Check harness continuity between ECM terminal 88 and refrigerant pressure sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
OK or NG
OK

c Replace refrigerant pressure sensor.

c Repair or replace.

EC-469

ELECTRICAL LOAD
SIGNAL

TB48DE A/T (WITH EURO-OBD)

Description
The electrical load signal (Headlamp switch signal, rear window defogger switch signal, etc.) is transferred
through the CAN communication line from combination meter to ECM.

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM
LOAD SIGNAL

CONDITION
+ Ignition switch: ON

SPECIFICATION

Rear window defogger switch is ON
and/or lighting switch is 2nd.

Rear window defogger switch is OFF
and lighting switch is OFF.

OFF

EC-470

ELECTRICAL LOAD
SIGNAL

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC426M

EC-471

ELECTRICAL LOAD
TB48DE A/T (WITH EURO-OBD)
SIGNAL
Wiring Diagram (Cont’d)

TEC371M

EC-472

ELECTRICAL LOAD
SIGNAL

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
1

CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I
With CONSULT-II

With GST
1. Turn ignition switch “ON”.
2. Connect CONSULT-II or GST and select “DATA MONITOR” mode.
3. Select “LOAD SIGNAL” and check indication under the following conditions.

PBIB0103E

MTBL1594

OK or NG
OK (With CONSULT-II)

c GO TO 2.

OK (Without CONSULT-II)

c GO TO 3.

c GO TO 4.

EC-473

ELECTRICAL LOAD
TB48DE A/T (WITH EURO-OBD)
SIGNAL
Diagnostic Procedure (Cont’d)
2

CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II

With CONSULT-II
Check “LOAD SIGNAL” indication under the following conditions.

PBIB0103E

MTBL1595

OK or NG
OK

c INSPECTION END

c GO TO 5.

CHECK REAR WINDOW DEFOGGER FUNCTION

1. Start engine.
2. Turn “ON” the rear window defogger switch.
3. Check the rear windshield. Is the rear windshield heated up?
Yes or No
Yes

c GO TO 4.

c Check rear window defogger circuit. Refer to xx.

CHECK REAR WINDOW DEFOGGER INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1.
2.
3.
4.

Stop engine.
Disconnect rear window defogger relay.
Disconnect combination meter harness connector.
Check harness continuity between rear window defogger relay terminal 5 and combination meter terminal 27.
Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Harness for open or short between rear window defogger relay and combination meter
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-474

ELECTRICAL LOAD
TB48DE A/T (WITH EURO-OBD)
SIGNAL
Diagnostic Procedure (Cont’d)
6

CHECK COMBINATION METER

Refer to EL section.
OK or NG
OK

c GO TO 10.

c Replace combination meter.

CHECK HEADLAMP FUNCTION

1. Start engine.
2. Lighting switch “ON” at 2nd position.
3. Check that headlamp high beams are illuminated.
OK or NG
OK

c GO TO 8.

c Check headlamp circuit. Refer to EL section.

8
1.
2.
3.
4.

CHECK HEADLAMP INPUT SIGNAL CIRCUIT
Stop engine.
Disconnect combination meter harness connector.
Disconnect combination switch harness connector.
Check harness continuity between combination switch terminals 6, 7 and combination meter terminal 26.

SEC761D

MTBL1596

5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors E127, M21
+ Diode E108
+ Harness for open or short between combination switch and combination meter
c Repair open circuit or short to ground or short to power.

EC-475

ELECTRICAL LOAD
TB48DE A/T (WITH EURO-OBD)
SIGNAL
Diagnostic Procedure (Cont’d)
10

CHECK COMBINATION METER

Refer to EL section.
OK or NG
OK

c GO TO 11.

c Replace combination meter.

CHECK INTERMITTENT INCIDENT

Refer to EC-112, “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END

EC-476

DATA LINK
CONNECTORS

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC423M

EC-477

EVAPORATIVE EMISSION
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Description
SYSTEM DESCRIPTION

PBIB0491E

The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel
system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister.
The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the
vapor is stored there when the engine is not operating or when refueling to the fuel tank.
The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the
engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the
engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is
proportionally regulated as the air flow increases.
EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating
and idling.

EC-478

EVAPORATIVE EMISSION
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Description (Cont’d)
EVAPORATIVE EMISSION LINE DRAWING

SEC665D

EC-479

EVAPORATIVE EMISSION
TB48DE A/T (WITH EURO-OBD)
SYSTEM
Component Inspection
EVAP CANISTER
Check EVAP canister as follows:
1. Block port C. Orally blow air through port A.
Check that air flows freely through port B.
2. Block port A. Orally blow air through port C.
Check that air flows freely through port B.

SEF917W

FUEL CHECK VALVE
1. Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air
flow should be directed toward the EVAP canister side.
2. Blow air through connector on EVAP canister side.
Air flow should be smoothly directed toward fuel tank side.
3. If fuel check valve is suspected of not properly functioning in
steps 1 and 2 above, replace it.

SEF631V

FUEL TANK VACUUM RELIEF VALVE (BUILT INTO
FUEL FILLER CAP)
1. Wipe clean valve housing.

SEF989X

2. Check valve opening pressure and vacuum.
Pressure:
16.0 — 20.0 kPa (0.16 — 0.200 bar, 0.163 — 0.204
kg/cm2, 2.32 — 2.90 psi)
Vacuum:
−6.0 to −3.5 kPa (−0.060 to −0.035 bar, −0.061 to
−0.036 kg/cm2, −0.87 to −0.51 psi)
3. If out of specification, replace fuel filler cap as an assembly.

SEF943S

EVAP CANISTER PURGE VOLUME CONTROL
SOLENOID VALVE
Refer to EC-275, “Component Inspection”.

EC-480

POSITIVE CRANKCASE
TB48DE A/T (WITH EURO-OBD)
VENTILATION
Description
SYSTEM DESCRIPTION

PBIB0492E

This system returns blow-by gas to the intake manifold.
The positive crankcase ventilation (PCV) valve is provided to
conduct crankcase blow-by gas to the intake manifold. During
partial throttle operation of the engine, the intake manifold sucks
the blow-by gas through the PCV valve. Normally, the capacity
of the valve is sufficient to handle any blow-by and a small
amount of ventilating air. The ventilating air is then drawn from
the air inlet tubes into the crankcase. In this process the air
passes through the hose connecting air inlet tubes to rocker
cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes
through the hose connection in the reverse direction.

On vehicles with an excessively high blow-by, the valve does not
meet the requirement. This is because some of the flow will go
through the hose connection to the air inlet tubes under all conditions.

SEC481D

EC-481

POSITIVE CRANKCASE
TB48DE A/T (WITH EURO-OBD)
VENTILATION
Component Inspection
PCV (POSITIVE CRANKCASE VENTILATION) VALVE
With engine running at idle, remove PCV valve from rocker
cover. A properly working valve makes a hissing noise as air
passes through it. A strong vacuum should be felt immediately
when a finger is placed over valve inlet.

SEC137A

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

ET277

EC-482

SERVICE DATA AND SPECIFICATIONS
TB48DE A/T (WITH EURO-OBD)
(SDS)
Fuel Pressure Regulator
Fuel pressure
kPa (bar, kg/cm2, psi)
At idle

Approximately
245 (2.45, 2.5, 36)

A few seconds after ignition
switch is turned OFF to ON

Approximately
294 (2.94, 3.0, 43)

Idle Speed and Ignition Timing
Idle speed

rpm

No-load*1
(in “N” position)

Target idle speed

Air conditioner: ON
(in “N” position)

675±50

750 rpm or more

Ignition timing

10°±5° BTDC

*1: Under the following conditions:
+ Air conditioner switch: OFF
+ Steering wheel: Kept in straight-ahead position
+ Electrical load: OFF (Lights, heater fan & rear window defogger)

Mass Air Flow Sensor
Supply voltage

Battery voltage (11 — 14)

Output voltage at idle

0.75 — 1.5 at idle*
1.7 — 2.4 at 2,500 rpm*

*: Engine is warmed up to normal operating temperature and running
under no-load.

Engine Coolant Temperature Sensor
Temperature °C (°F)

Resistance

20 (68)

2.1 — 2.9 kΩ

50 (122)

0.68 — 1.00 kΩ

90 (194)

0.236 — 0.260 kΩ

Heated Oxygen Sensor 1
Resistance [at 25°C (77°F)]

3.3 — 4.0Ω

Heated Oxygen Sensor 2
Resistance [at 25°C (77°F)]

5.0 — 7.0Ω

Fuel Pump
Resistance [at 25°C (77°F)]

Ω

0.2 — 5.0

EC-483

SERVICE DATA AND SPECIFICATIONS
TB48DE A/T (WITH EURO-OBD)
(SDS)
EVAP Canister Purge Volume Control
Solenoid Valve
Ω

Resistance [at 20°C (68°F)]

31 — 35

Injector
Ω

Resistance [at 20°C (77°F)]

14.0 — 15.0

Ignition Coil with Power Transistor
Resistance Ω [at 25°C (77°F)]

Terminal No. (Polarity)
3 (+) — 2 (−)

Except 0 or

1 (+) — 3 (−)
Except 0
1 (+) — 2 (−)

Condenser
Resistance [at 25°C (77°F)]

MΩ

Above 1

Throttle Control Motor
Resistance [at 25°C (77°F)]

Approximately 1 — 15 Ω

EC-484

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram

ZD30DDTi

SMA for models with 2nd oil
pressure switch. Engine serial
number > ZD-089395A

TEC395M

EC-485

TROUBLE DIAGNOSIS FOR POWER SUPPLY

ZD30DDTi

Main Power Supply and Ground Circuit

TEC352M

EC-486

DTC 0102 MASS AIR FLOW SEN

ZD30DDTi

Wiring Diagram

TEC353M

EC-487

DTC 0104 VEHICLE SPEED SEN

ZD30DDTi

Wiring Diagram

TEC354M

EC-488

DTC 0208 OVER HEAT

ZD30DDTi

Wiring Diagram

TEC355M

EC-489

DTC 0208 OVER HEAT

ZD30DDTi

Diagnostic Procedure
1

INSPECTION START

Do you have CONSULT-II?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

CHECK COOLING FAN OPERATION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II.

SEF646X

3. Make sure that cooling fan-1 operates.
OK or NG
OK

c GO TO 12.

c GO TO 4.

3
1.
2.
3.
4.

CHECK COOLING FAN OPERATION
Without CONSULT-II
Turn ignition switch “OFF”.
Disconnect engine coolant temperature sensor harness connector.
Connect 150Ω resistor to engine coolant temperature sensor harness connector.
Restart engine and make sure that cooling fan operates.

MEC475B

OK or NG
OK

c GO TO 12.

c GO TO 4.

EC-490

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
4

ZD30DDTi

CHECK COOLING FAN POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect cooling fan relay-1.

SEF690V

3. Turn ignition switch “ON”.
4. Check voltage between cooling fan relay-1 terminals 1, 3, 6 and ground with CONSULT-II or tester.

SEC533D

OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

Check the following.
+ Fuse block (J/B) connector E112
+ 10A fuse or 20A fuse
+ 40A fusible links
+ Harness for open or short between cooling fan relay-1 and fuse
+ Harness for open or short between cooling fan relay-1 and battery
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-491

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
6

ZD30DDTi

CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Disconnect cooling fan motor-1 harness connector.

SEF691V

3. Check harness continuity between cooling fan relay-1 terminal 5 and cooling fan motor-1 terminal 1, cooling fan relay-1 terminal
7 and cooling fan motor-1 terminal 3, cooling fan motor-1 terminals 2, 4 and body ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c Repair open circuit or short to ground or short to power in harness or connectors.

CHECK COOLING FAN OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 14 and cooling fan relay-1 terminal 2. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 9.

c GO TO 8.

DETECT MALFUNCTIONING PART

CHECK COOLING FAN RELAY-1

Refer to “Component Inspection”, EC-495.
OK or NG
OK

c GO TO 10.

c Replace cooling fan relay.

EC-492

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
10

ZD30DDTi

CHECK COOLING FAN MOTOR-1

Supply battery voltage between the following terminals and check operation.

SEF645V

MTBL1304

OK or NG
OK

c GO TO 11.

c Replace cooling fan motor.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END
12

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops.
Testing pressure: 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
CAUTION:
Higher than the specified pressure may cause radiator damage.

SLC754A

Pressure should not drop.
OK or NG
OK

c GO TO 14.

c GO TO 13.

EC-493

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
13

ZD30DDTi

DETECT MALFUNCTIONING PART

Check the following for leak.
+ Hose
+ Radiator
+ Water pump (Refer to LC section, “Water Pump”.)
c Repair or replace.
14

CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief pressure.

SLC755A

Radiator cap relief pressure:
59 — 98 kPa (0.59 — 0.98 bar, 0.6 — 1.0 kg/cm2, 9 — 14 psi)
OK or NG
OK

c GO TO 15.

c Replace radiator cap.

CHECK THERMOSTAT

1. Remove thermostat.
2. Check valve seating condition at normal room temperatures.
It should seat tightly.
3. Check valve opening temperature and valve lift.

SLC343

c GO TO 16.

c Replace thermostat.

EC-494

ZD30DDTi

DTC 0208 OVER HEAT
Diagnostic Procedure (Cont’d)
16

CHECK ENGINE COOLANT TEMPERATURE SENSOR

1. Remove engine coolant temperature sensor.
2. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure.

SEF304X

OK or NG
OK

c GO TO 17.

c Replace engine coolant temperature sensor.

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-496.
c INSPECTION END

Component Inspection
COOLING FAN RELAY-1
Check continuity between terminals V
3 and V
5 ,V
6 and V
7 .
Conditions

SEC202B

Continuity

12V direct current supply between
terminals 1 and 2

Yes

No current supply

If NG, replace relay.

EC-495

ZD30DDTi

DTC 0208 OVER HEAT
Main 12 Causes of Overheating
Engine

Step

Inspection item

OFF

+
+
+
+

Equipment

Standard

Reference page

+ Visual

No blocking

+ Coolant mixture

+ Coolant tester

30 — 50% coolant mixture

See “RECOMMENDED
FLUIDS AND LUBRICANTS” in MA section.

+ Coolant level

+ Visual

Coolant up to MAX level
in reservoir tank and
radiator filler neck

See “Changing Engine
Coolant”, “ENGINE MAINTENANCE” in MA section.

+ Radiator cap

+ Pressure tester

59 — 98 kPa (0.59 — 0.98
bar, 0.6 — 1.0 kg/cm2,
9 — 14 psi) (Limit)

See “System Check”,
“ENGINE COOLING SYSTEM” in LC section.

ON*2

+ Coolant leaks

+ Visual

No leaks

See “System Check”,
“ENGINE COOLING SYSTEM” in LC section.

ON*2

+ Thermostat

+ Touch the upper and
lower radiator hoses

Both hoses should be hot. See “Thermostat” and
“Radiator”, “ENGINE
COOLING SYSTEM” in
LC section.

ON*1

+ Cooling fan

+ Visual

Operating

OFF

+ Combustion gas leak

+ Color checker chemical Negative
tester 4 gas analyzer

—

ON*3

+ Coolant temperature
gauge

+ Visual

—

Blocked
Blocked
Blocked
Blocked

radiator
condenser
radiator grille
bumper

Gauge less than 3/4
when driving

—

See “DTC 0208 OVER
HEAT”.

+ Coolant overflow to res- + Visual
ervoir tank

No overflow during driving See “Changing Engine
and idling
Coolant”, “ENGINE MAINTENANCE” in MA section.

OFF*4

+ Coolant return from res- + Visual
ervoir tank to radiator

Should be initial level in
reservoir tank

See “ENGINE MAINTENANCE” in MA section.

OFF

+ Cylinder head

+ Straight gauge feeler
gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD” in EM section.

+ Cylinder block and pistons

+ Visual

No scuffing on cylinder
walls or piston

See “Inspection”, “CYLINDER BLOCK” in EM section.

EC-496

DTC 0402 P9zFUEL TEMP SEN

ZD30DDTi

Wiring Diagram

TEC356M

EC-497

DTC 0403 ACCEL POS SENSOR

ZD30DDTi

Wiring Diagram

TEC357M

EC-498

DTC 0902 ECM RLY

ZD30DDTi

Wiring Diagram

TEC358M

EC-499

DTC 1003 EGR VOLUME CONT/V

ZD30DDTi

Wiring Diagram

TEC359M

EC-500

MI (MIL) & DATA LINK CONNECTORS

ZD30DDTi

Wiring Diagram

TEC396M

EC-501

ELECTRICAL SYSTEM
SECTION

MODIFICATION NOTICE:
+
+

Combination meter has been changed.
Wiring Diagram has been changed.

CONTENTS
PRECAUTIONS AND PREPARATION ……………………. 4
Supplemental Restraint System (SRS) ‘‘AIR
BAG’’ and ‘‘SEAT BELT PRE-TENSIONER’’………… 4
Precautions for Trouble Diagnoses ……………………… 4
Precautions for Harness Repair ………………………….. 4
POWER SUPPLY ROUTING………………………………….. 6
Schematic ………………………………………………………… 6
Wiring Diagram — POWER — ……………………………….. 7
GROUND DISTRIBUTION……………………………………. 17
Engine Room Harness/LHD Models ………………….. 17
Engine Room Harness/RHD Models………………….. 19
Engine Control Harness/LHD Models ………………… 21
Engine Room Harness/RHD Models………………….. 23
Main Harness/LHD Models……………………………….. 25
Main Harness/RHD Models ………………………………. 28
Body Harness/LHD Models ………………………………. 31
Body Harness/RHD Models………………………………. 33
Body No. 2 Harness/LHD Models ……………………… 34
Body No. 2 Harness/RHD Models……………………… 35
Back Door and Rear Window Defogger Harness/
LHD Models ……………………………………………………. 36
Back Door and Rear Window Defogger Harness/
RHD Models …………………………………………………… 37
COMBINATION SWITCH …………………………………….. 38
Check…………………………………………………………….. 38
STEERING SWITCH……………………………………………. 39
Check…………………………………………………………….. 39

BATTERY…………………………………………………………… 40
Service Data and Specifications (SDS)………………. 40
STARTING SYSTEM …………………………………………… 41
Wiring Diagram — START -/A/T Models with TB48
Engine……………………………………………………………. 41
Service Data and Specifications (SDS)………………. 42
CHARGING SYSTEM ………………………………………….. 43
Wiring Diagram — CHARGE -…………………………….. 43
Construction……………………………………………………. 44
Service Data and Specifications (SDS)………………. 45
HEADLAMP — CONVENTIONAL TYPE -……………….. 46
Wiring Diagram — H/LAMP -………………………………. 46
HEADLAMP — HEADLAMP AIMING CONTROL -…… 47
Wiring Diagram — H/AIM — …………………………………. 47
HEADLAMP — DAYTIME LIGHT SYSTEM — …………… 49
Wiring Diagram — DTRL -………………………………….. 49
PARKING, LICENSE AND TAIL LAMPS ………………. 51
Wiring Diagram — TAIL/L -/Type A……………………… 51
Wiring Diagram — TAIL/L -/Type B……………………… 53
Wiring Diagram — TAIL/L -/Type C……………………… 55
BACK-UP LAMP…………………………………………………. 57
Wiring Diagram — BACK/L -/LHD Models for
TB48 Engine with A/T………………………………………. 57
Wiring Diagram — F/FOG -/RHD Models for
Europe and China……………………………………………. 58
Wiring Diagram — F/FOG -/LHD Models for
Europe …………………………………………………………… 59

ELECTRICAL SYSTEM
REAR FOG LAMP ………………………………………………. 60
Wiring Diagram — R/FOG -/For Europe and China.. 60
TURN SIGNAL AND HAZARD WARNING LAMPS… 63
Wiring Diagram — TURN -/Type A ……………………… 63
Wiring Diagram — TURN -/Type C ……………………… 65
ILLUMINATION…………………………………………………… 69
Schematic ………………………………………………………. 69
Wiring Diagram — ILL — ……………………………………… 70
Wiring Diagram — ROOM/L -/LHD Models for
Europe …………………………………………………………… 76
Wiring Diagram — ROOM/L -/RHD Models for
Europe …………………………………………………………… 78
INTERIOR ROOM LAMP — WITHOUT TIMER — ……… 80
Wiring Diagram — ROOM/L -/LHD Models…………… 80
Wiring Diagram — ROOM/L -/RHD Models ………….. 81
METER AND GAUGES ……………………………………….. 82
Combination Meter ………………………………………….. 82
Schematic ………………………………………………………. 83
Wiring Diagram — METER — ………………………………. 84
Wiring Diagram — LOAD/S -/TB48 Engine Models
with A/T………………………………………………………….. 86
ı́CAN Communication/TB48 Engine Models With
A/T ………………………………………………………………… 88
COMPASS AND THERMOMETER ……………………….. 89
Wiring Diagram — COMPAS — ……………………………. 89
WARNING LAMPS ……………………………………………… 90
Schematic ………………………………………………………. 90
Wiring Diagram — WARN — ………………………………… 92
A/T INDICATOR………………………………………………… 104
Wiring Diagram — AT/IND -/TB48 Engine Models
with A/T………………………………………………………… 104
Wiring Diagram — CHIME -/LHD Models for
Europe …………………………………………………………. 105
HEADLAMP WASHER ………………………………………. 106
Wiring Diagram — HLC -………………………………….. 106
Washer Tube Layout ……………………………………… 108
CIGARETTE LIGHTER………………………………………. 109
Wiring Diagram — CIGAR -/LHD Models……………. 109
Wiring Diagram — CIGAR -/RHD Models …………… 110
WIPER DEICER ………………………………………………… 111
Wiring Diagram — DEICER — ……………………………. 111
REAR WINDOW DEFOGGER…………………………….. 112
Wiring Diagram — DEF -/LHD Models for Europe.. 112
Wiring Diagram — DEF -/RHD Models Except for
Europe …………………………………………………………. 114
AUDIO ……………………………………………………………… 115
Schematic/For Europe ……………………………………. 115
Wiring Diagram — AUDIO -/LHD Models for
Europe …………………………………………………………. 116
Wiring Diagram — CD/CHG -/With IDIN Type CD
Auto Changer………………………………………………… 119
Wiring Diagram — REMOTE -…………………………… 120
CLOCK…………………………………………………………….. 121
Wiring Diagram — CLOCK -……………………………… 121
AUTOMATIC SPEED CONTROL DEVICE (ASCD) . 122
Schematic/TB48 and TD42Ti Engine Models ……. 122

Wiring Diagram — ASCD -/TB48 and TD42Ti
Engine Models ………………………………………………. 123
Fail-safe System/TB48 Engine Models …………….. 127
Trouble Diagnoses/TB48 Engine Models………….. 128
Electrical Component Inspection/TB48 Engine
Models …………………………………………………………. 137
ASCD Wire Adjustment/TB48 Engine Models …… 138
POWER DOOR LOCK……………………………………….. 139
Schematic/Without Theft Warning System
Models …………………………………………………………. 139
Wiring Diagram — D/LOCK -/Without Theft
Warning System Models…………………………………. 140
Schematic/With Theft Warning System Models …. 143
Wiring Diagram — D/LOCK -/With Theft Warning
System Models ……………………………………………… 144
POWER DOOR LOCK — SUPER LOCK -…………….. 152
Schematic …………………………………………………….. 152
Wiring Diagram — S/LOCK -/LHD Models………….. 153
Wiring Diagram — S/LOCK -/RHD Models …………. 158
Trouble Diagnoses/With Theft Warning System
Models …………………………………………………………. 163
MULTI-REMOTE CONTROL SYSTEM ………………… 169
Schematic/With Theft Warning System Models …. 169
Wiring Diagram — MULTI -/LHD Models with
Theft Warning System ……………………………………. 170
Wiring Diagram — MULTI -/RHD Models with
Theft Warning System ……………………………………. 174
Trouble Diagnoses/With Theft Warning System
Models …………………………………………………………. 177
ID Code Entry Procedure/With Theft Warning
System Models ……………………………………………… 183
Remote Controller Battery Replacement/With
Theft Warning System Models ………………………… 187
THEFT WARNING SYSTEM ………………………………. 188
Schematic …………………………………………………….. 188
Wiring Diagram — THEFT -/LHD Models …………… 189
Wiring Diagram — THEFT -/RHD Models…………… 194
UNIFIED METER CONTROL UNIT (TIME
CONTROL SYSTEM)…………………………………………. 199
Schematic/Except for Europe and With Theft
Warning System Models…………………………………. 199
NATS (NISSAN ANTI-THEFT SYSTEM)/TB48DE
ENGINE MODELS FOR EUROPE ………………………. 200
System Description………………………………………… 200
System Composition………………………………………. 200
Wiring Diagram — NATS — ……………………………….. 201
CONSULT-II………………………………………………….. 203
Trouble Diagnoses…………………………………………. 205
How to Replace NATS IMMU………………………….. 214
NATS (NISSAN ANTI-THEFT SYSTEM)/ZD
ENGINE MODELS …………………………………………….. 215
Wiring Diagram — NATS -/For Europe ………………. 215
Wiring Diagram — NATS -/LHD Models for
Europe …………………………………………………………. 216
Wiring Diagram — NATS -/RHD Models for
Europe …………………………………………………………. 217

EL-2

ELECTRICAL SYSTEM
Wiring Diagram — NATS -/Except for Europe …….. 218
CAN SYSTEM/TB48 ENGINE MODELS WITH A/T . 219
Wiring Diagram — CAN — …………………………………. 219
Trouble Diagnoses…………………………………………. 220
Component Inspection……………………………………. 228
LOCATION OF ELECTRICAL UNITS………………….. 229
Engine Compartment……………………………………… 229
Passenger Compartment — LHD Models …………… 231
Passenger Compartment — RHD Models…………… 233
HARNESS LAYOUT ………………………………………….. 236
How to Read Harness Layout …………………………. 236
Main Harness/LHD Models……………………………… 237
Main Harness/RHD Models …………………………….. 241

Engine Room Harness/LHD Models ………………… 245
Engine Room Harness/RHD Models………………… 253
Engine Harness …………………………………………….. 259
Engine Control Harness …………………………………. 263
Body Harness/LHD Models …………………………….. 265
Body Harness/RHD Models…………………………….. 269
Body No. 2 Harness/LHD Models ……………………. 271
Body No. 2 Harness/RHD Models……………………. 273
Chassis Harness……………………………………………. 275
Back Door Harness and Rear Window Defogger
Harness………………………………………………………… 276
WIRING DIAGRAM CODES (CELL CODES)……….. 277
Wiring Diagram Codes (Cell Codes) ………………… 277

EL-3

PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The
composition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision),
wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
+ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and
Air Bag Module, see the RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.

Precautions for Trouble Diagnoses
CAN SYSTEM
+ Do not apply voltage of 7.0V or higher to the measurement terminals.
+ Use the tester with its open terminal voltage being 7.0V
or less.

Precautions for Harness Repair
CAN SYSTEM
+ Solder the repaired parts, and wrap with tape. [Frays of
twisted line must be within 110 mm (4.33 in)]

PKIA0306E

EL-4

PRECAUTIONS AND PREPARATION
Precautions for Harness Repair (Cont’d)
+ Do not perform bypass wire connections for the repair parts.
(The spliced wire will become separated and the characteristics of twisted line will be lost.)

PKIA0307E

EL-5

POWER SUPPLY ROUTING
Schematic

TEL745M

EL-6

POWER SUPPLY ROUTING
Wiring Diagram — POWER —
BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

TEL809M

EL-7

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL810M

EL-8

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL746M

EL-9

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL747M

EL-10

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL748M

EL-11

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)
ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON”

TEL647M

EL-12

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)
IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START”

TEL749M

EL-13

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL811M

EL-14

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL750M

EL-15

POWER SUPPLY ROUTING
Wiring Diagram — POWER — (Cont’d)

TEL812M

EL-16

GROUND DISTRIBUTION
Engine Room Harness/LHD Models

CEL430M

EL-17

GROUND DISTRIBUTION
Engine Room Harness/LHD Models (Cont’d)

CEL431M

EL-18

GROUND DISTRIBUTION
Engine Room Harness/RHD Models

CEL437M

EL-19

GROUND DISTRIBUTION
Engine Room Harness/RHD Models (Cont’d)

CEL438M

EL-20

GROUND DISTRIBUTION
Engine Control Harness/LHD Models
TB48DE ENGINE

CEL432M

EL-21

GROUND DISTRIBUTION
Engine Control Harness/LHD Models
(Cont’d)

CEL433M

EL-22

GROUND DISTRIBUTION
Engine Room Harness/RHD Models
TB48DE ENGINE

CEL301M

EL-23

GROUND DISTRIBUTION
Engine Room Harness/RHD Models (Cont’d)
TB48DE ENGINE

CEL302M

EL-24

GROUND DISTRIBUTION
Main Harness/LHD Models

CEL490M

EL-25

GROUND DISTRIBUTION
Main Harness/LHD Models (Cont’d)

CEL434M

EL-26

GROUND DISTRIBUTION
Main Harness/LHD Models (Cont’d)

CEL435M

EL-27

GROUND DISTRIBUTION
Main Harness/RHD Models

CEL440M

EL-28

GROUND DISTRIBUTION
Main Harness/RHD Models (Cont’d)

CEL441M

EL-29

GROUND DISTRIBUTION
Main Harness/RHD Models (Cont’d)

CEL442M

EL-30

GROUND DISTRIBUTION
Body Harness/LHD Models

CEL400M

EL-31

GROUND DISTRIBUTION
Body Harness/LHD Models (Cont’d)

CEL436M

EL-32

GROUND DISTRIBUTION
Body Harness/RHD Models

CEL443M

EL-33

GROUND DISTRIBUTION
Body No. 2 Harness/LHD Models

CEL402M

EL-34

GROUND DISTRIBUTION
Body No. 2 Harness/RHD Models

CEL444M

EL-35

GROUND DISTRIBUTION
Back Door and Rear Window Defogger
Harness/LHD Models

CEL296M

EL-36

GROUND DISTRIBUTION
Back Door and Rear Window Defogger
Harness/RHD Models

CEL445M

EL-37

COMBINATION SWITCH
Check
RHD MODELS FOR EUROPE AND LHD MODELS

CEL446M

EL-38

STEERING SWITCH
Check
WITH ASCD AND AUDIO SWITCH

CEL310M

EL-39

BATTERY
Service Data and Specifications (SDS)
ZD30DDTi
Applied model

TB48DE

Except for North Europe
Standard

Type
Capacity

V-AH

EL-40

Option

For North
Europe

115D31L

110D26L x 2

12-70

12-128 (64 + 64)

STARTING SYSTEM
Wiring Diagram — START —/A/T Models with
TB48 Engine

TEL652M

EL-41

STARTING SYSTEM
Service Data and Specifications (SDS)
STARTER
S114-878A
Type

S13-551A

S14-607

HITACHI make
Reduction gear type
ZD30DDTi

Applied model

TB48DE
Standard

System voltage

Option

No-load
Terminal voltage
Current
Revolution

Less than 90

rpm

2,300

11
Less than 160

3,300

3,400

Minimum diameter of commutator
mm (in)

28 (1.102)

Minimum length of brush mm (in)

10.5 (0.413)

11 (0.43)

10.5 (0.413)

16.2 (1.65, 3.64)

28.4 — 34.3
(2.9 — 3.5,
6.4 — 7.7)

24.5 — 34.3
(2.5 — 3.5,
5.5 — 7.7)

Clearance between bearing metal
and armature shaft
mm (in)

Less than 0.2
(0.008)

—

Clearance “!” between pinion
front edge and pinion stopper
mm (in)

0.3 — 2.5
(0.012 — 0.098)

—

Movement “!” in height of pinion
assembly
mm (in)

—

Brush spring tension
N (kg, lb)

EL-42

35.5 (1.398)

0.3 — 2.0
(0.012 — 0.079)

CHARGING SYSTEM
Wiring Diagram — CHARGE —

TEL653M

EL-43

CHARGING SYSTEM
Construction

MEL206O

SEL544V

EL-44

SMA for disassembly of LR190-752

CHARGING SYSTEM
Service Data and Specifications (SDS)
ALTERNATOR
LR1110-718

LR190-752

Type
HITACHI
Applied model
Nominal rating

V-A

TB48DE

ZD30DDTi

12-110

12-90

Ground polarity

Negative

Minimum revolution under noload
(When 13.5V is applied)
rpm
Hot output current
(When 13.5V is applied)
A/rpm
Regulated output voltage

Less than 950

Less than 1,000

More than 35/1,300
More than 85/2,500
More than 110/5,000

More than 23/1,300
More than 65/2,500
More than 87/5,000

14.1 — 14.7

Minimum length of brush mm (in)

6.0 (0.236)

Brush spring pressure
N (g, oz)

1.0 — 3.43 (102 — 350, 3.60 — 12.34)

Slip ring minimum outer diameter
mm (in)
Rotor (Field coil) resistance

EL-45

Ω

26.0 (1.024)
2.31

2.67

HEADLAMP — Conventional Type —
Wiring Diagram — H/LAMP —

TEL654M

EL-46

HEADLAMP — Headlamp Aiming Control —
Wiring Diagram — H/AIM —

TEL736M

EL-47

HEADLAMP — Headlamp Aiming Control —
Wiring Diagram — H/AIM — (Cont’d)

TEL751M

EL-48

HEADLAMP — Daytime Light System —
Wiring Diagram — DTRL —

TEL655M

EL-49

HEADLAMP — Daytime Light System —
Wiring Diagram — DTRL — (Cont’d)

TEL656M

EL-50

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type A
Rear combination lamps are not located on rear bumper.

TEL752M

EL-51

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type A (Cont’d)

TEL212M

EL-52

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type B
LHD MODELS FOR EUROPE

Rear combination lamps are located on rear bumper.

TEL658M

EL-53

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type B (Cont’d)

TEL213M

EL-54

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type C
RHD MODELS FOR EUROPE, CHINA, AUSTRALIA AND SOUTH AFRICA
Rear combination lamps are located on rear bumper.

TEL753M

EL-55

PARKING, LICENSE AND TAIL LAMPS
Wiring Diagram — TAIL/L —/Type C (Cont’d)

TEL394M

EL-56

BACK-UP LAMP
Wiring Diagram — BACK/L —/LHD Models
for TB48 Engine with A/T

TEL660M

EL-57

BACK-UP LAMP
Wiring Diagram — F/FOG —/RHD Models for
Europe and China

TEL755M

EL-58

BACK-UP LAMP
Wiring Diagram — F/FOG —/LHD Models for
Europe

TEL813M

EL-59

REAR FOG LAMP
Wiring Diagram — R/FOG —/For Europe and
China
WITH FRONT FOG LAMP

TEL814M

EL-60

REAR FOG LAMP
Wiring Diagram — R/FOG —/For Europe and
China (Cont’d)

TEL756M

EL-61

REAR FOG LAMP
Wiring Diagram — R/FOG —/For Europe and
China (Cont’d)
WITHOUT FRONT FOG LAMP

TEL757M

EL-62

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type A
RHD MODELS EXCEPT FOR EUROPE, AUSTRALIA AND SOUTH AFRICA
Rear combination lamps are not located on rear bumper.

TEL817M

EL-63

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type A (Cont’d)

TEL818M

EL-64

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type C
FOR EUROPE

Rear combination lamps are located on rear bumper.

TEL758M

EL-65

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type C (Cont’d)

TEL838M

EL-66

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type C (Cont’d)
FOR SOUTH AFRICA

Rear combination lamps are located on rear bumper.

TEL815M

EL-67

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —/Type C (Cont’d)

TEL816M

EL-68

ILLUMINATION
Schematic

TEL667M

EL-69

ILLUMINATION
Wiring Diagram — ILL —

TEL668M

EL-70

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL669M

EL-71

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL759M

EL-72

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL671M

EL-73

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL672M

EL-74

ILLUMINATION
Wiring Diagram — ILL — (Cont’d)

TEL673M

EL-75

ILLUMINATION
Wiring Diagram — ROOM/L —/LHD Models
for Europe

TEL676M

EL-76

ILLUMINATION
Wiring Diagram — ROOM/L —/LHD Models
for Europe (Cont’d)

TEL677M

EL-77

ILLUMINATION
Wiring Diagram — ROOM/L —/RHD Models
for Europe

TEL760M

EL-78

ILLUMINATION
Wiring Diagram — ROOM/L —/RHD Models
for Europe (Cont’d)

TEL761M

EL-79

INTERIOR ROOM LAMP — Without Timer —
Wiring Diagram — ROOM/L —/LHD Models

TEL762M

EL-80

INTERIOR ROOM LAMP — Without Timer —
Wiring Diagram — ROOM/L —/RHD Models

TEL763M

EL-81

METER AND GAUGES
Combination Meter

SEL738Y

EL-82

METER AND GAUGES
Schematic

TEL837M

EL-83

METER AND GAUGES
Wiring Diagram — METER —

TEL764M

EL-84

METER AND GAUGES
Wiring Diagram — METER — (Cont’d)

TEL765M

EL-85

METER AND GAUGES
Wiring Diagram — LOAD/S —/TB48 Engine
Models with A/T

TEL622M

EL-86

METER AND GAUGES
Wiring Diagram — LOAD/S —/TB48 Engine
Models with A/T (Cont’d)

TEL623M

EL-87

METER AND GAUGES
CAN Communication/TB48 Engine Models
With A/T
SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle
multiplex communication line with high data communication speed and excellent error detection ability. Many
electronic control units are equipped onto a vehicle, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected
with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with
less wiring. Each control unit transmits/receives data but selectively reads required data only.

System diagram

SEL599Y

Input/Output signal chart
T: Transmit
Signals

R: Receive

Combination meter

TCM

ECM

Engine speed signal

Engine coolant temperature signal

Accelerator pedal position signal

Closed throttle position signal

Wide open throttle position signal

A/T fluid temperature warning lamp signal

Current gear position signal

Shift change signal
Air conditioner switch signal

Headlamp switch signal

Rear window defogger switch signal

Brake switch signal

Vehicle speed signal

A/T self diagnosis signal
Manual mode signal

EL-88

COMPASS AND THERMOMETER
Wiring Diagram — COMPAS —

TEL486M

EL-89

WARNING LAMPS
Schematic

TEL766M

EL-90

WARNING LAMPS
Schematic (Cont’d)

TEL807M

EL-91

WARNING LAMPS
Wiring Diagram — WARN —

TEL819M

EL-92

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL820M

EL-93

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL821M

EL-94

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL841M

EL-95

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL822M

EL-96

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL767M

EL-97

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL823M

EL-98

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL808M

EL-99

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL824M

EL-100

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)

TEL825M

EL-101

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)
LHD MODELS

TEL826M

EL-102

WARNING LAMPS
Wiring Diagram — WARN — (Cont’d)
RHD MODELS

TEL768M

EL-103

A/T INDICATOR
Wiring Diagram — AT/IND —/TB48 Engine
Models with A/T

TEL735M

EL-104

A/T INDICATOR
Wiring Diagram — CHIME —/LHD Models for
Europe

TEL827M

EL-105

HEADLAMP WASHER
Wiring Diagram — HLC —

TEL772M

EL-106

HEADLAMP WASHER
Wiring Diagram — HLC — (Cont’d)

TEL773M

EL-107

HEADLAMP WASHER
Washer Tube Layout

CEL448M

EL-108

CIGARETTE LIGHTER
Wiring Diagram — CIGAR —/LHD Models

TEL699M

EL-109

CIGARETTE LIGHTER
Wiring Diagram — CIGAR —/RHD Models

TEL774M

EL-110

WIPER DEICER
Wiring Diagram — DEICER —

TEL775M

EL-111

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/LHD Models for
Europe

TEL701M

EL-112

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/LHD Models for
Europe (Cont’d)

TEL702M

EL-113

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —/RHD Models
Except for Europe

TEL776M

EL-114

AUDIO
Schematic/For Europe

TEL777M

EL-115

AUDIO
Wiring Diagram — AUDIO —/LHD Models for
Europe

TEL784M

EL-116

AUDIO
Wiring Diagram — AUDIO —/LHD Models for
Europe (Cont’d)

TEL785M

EL-117

AUDIO
Wiring Diagram — AUDIO —/LHD Models for
Europe (Cont’d)

TEL786M

EL-118

AUDIO
Wiring Diagram — CD/CHG —/With IDIN Type
CD Auto Changer

TEL713M

EL-119

AUDIO
Wiring Diagram — REMOTE —
FM-AM TUNER RADIO WITH SUB-HARNESS

TEL840M

EL-120

CLOCK
Wiring Diagram — CLOCK —

TEL828M

EL-121

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Schematic/TB48 and TD42Ti Engine Models

TEL737M

EL-122

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram — ASCD —/TB48 and TD42Ti
Engine Models

TEL569M

EL-123

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram — ASCD —/TB48 and
TD42Ti Engine Models (Cont’d)

TEL570M

EL-124

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram — ASCD —/TB48 and
TD42Ti Engine Models (Cont’d)

TEL714M

EL-125

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram — ASCD —/TB48 and
TD42Ti Engine Models (Cont’d)

TEL738M

EL-126

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Fail-safe System/TB48 Engine Models
DESCRIPTION
When the fail-safe system senses a malfunction, it deactivates
ASCD operation. The SET indicator in the combination meter will
then flash.

SEL255W

MALFUNCTION DETECTION CONDITIONS
Detection conditions
+
+
+
+
+
+

ASCD operation during malfunction detection

ASCD steering (RESUME/ACCEL, CANCEL, SET/COAST) switch is stuck.
Vacuum motor ground circuit or power circuit is open or shorted.
Air valve ground circuit or power circuit is open or shorted.
Release valve ground circuit or power circuit is open or shorted.
Vehicle speed sensor is faulty.
ASCD control unit internal circuit is malfunctioning.

+ ASCD is deactivated.
+ Vehicle speed memory is canceled.

+ ASCD is deactivated.
+ Vehicle speed memory is not canceled.

+ ASCD brake switch or stop lamp switch is faulty.

EL-127

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
SYMPTOM CHART

ASCD cannot be set. (“CRUISE” indicator lamp does not ON.)

ASCD cannot be set. (“SET” indicator
lamp does not blink.)
ASCD cannot be set. (“SET” indicator
lamp blinks.★1)

132

133

135

ASCD PUMP CIRCUIT CHECK

ASCD ACTUATOR/PUMP CHECK

131

VEHICLE SPEED SENSOR CHECK

130

ASCD STEERING SWITCH CHECK

SYMPTOM

129

ASCD BRAKE/STOP LAMP SWITCH CHECK

)

POWER SUPPLY AND GROUND CIRCUIT CHECK

REFERENCE PAGE (EL-

Diagnostic procedure

FAIL-SAFE SYSTEM CHECK

PROEDURE

X★3
X

Vehicle speed does not decrease after
SET/COAST switch has been pressed.

Vehicle speed does not return to the set
speed after RESUME/ACCEL switch has
been pressed.★2

Vehicle speed does not increase after
RESUME/ACCEL switch has been
pressed.

System is not released after CANCEL
switch (steering) has been pressed.

Large difference between set speed and
actual vehicle speed.

Deceleration is greatest immediately
after ASCD has been set.

★1: It indicates that system is in fail-safe. After completing diagnostic procedures, perform “FAIL-SAFE SYSTEM CHECK” (EL-129) to verify repairs.
★2: If vehicle speed is greater than 48 km/h (30 MPH) after system has been released, pressing RESUME/ACCEL switch returns vehicle speed to the
set speed previously achieved. However, doing so when the ASCD main switch is turned to “OFF”, vehicle speed will not return to the set speed since
the memory is canceled.
★3: Check only main switch built-in steering switch.

EL-128

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
(Cont’d)
FAIL-SAFE SYSTEM CHECK
1. Turn ignition switch to ON position.
2. Turn ASCD main switch to ON and check if the “set indicator” blinks.
If the indicator lamp blinks, check the following.
+ ASCD steering switch. Refer to EL-132.

SEL417V

3. Drive the vehicle at more than 48 km/h (30 MPH) and push
SET/COAST switch.
If the indicator lamp blinks, check the following.
+ Vehicle speed sensor. Refer to EL-133.
+ ASCD pump circuit. Refer to EL-133.
+ Replace control unit.

SEL767P

4. Depress brake pedal slowly (brake pedal should be
depressed more than 5 seconds).
If the indicator lamp blinks, check the following.
+ ASCD brake/stop lamp switch. Refer to EL-131.

SAT797A

5. END. (System is OK.)

EL-129

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
(Cont’d)
POWER SUPPLY AND GROUND CIRCUIT CHECK
1

CHECK POWER SUPPLY CIRCUIT FOR ASCD CONTROL UNIT

1. Disconnect ASCD control unit harness connector.
2. Turn ignition switch ON.
3. Check voltage between ASCD control unit harness connector M17 terminal 5 (G) and ground.

SEL256WD

Yes or No
Yes

c GO TO 2.

c Check the following.

7.5A fuse (No. 14 located in the fuse block)

Harness for open or short

CHECK GROUND CIRCUIT FOR ASCD CONTROL UNIT

Check continuity between ASCD control unit harness connector M17 terminal 17 (B) and body ground.

SEL257WD

Yes or No
Yes

c Power supply and ground circuit is OK.

c Repair harness.

EL-130

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
(Cont’d)
ASCD BRAKE/STOP LAMP SWITCH CHECK
1

CHECK ASCD BRAKE SWITCH CIRCUIT

1. Disconnect ASCD control unit harness connector.
2. Turn ignition switch ON.
3. Check voltage between ASCD control unit harness connector M17 terminal 8 (BR/Y) and ground.

SEL258WG

OK or NG
OK

c GO TO 2.

c Check the following.
+ ASCD brake switch
Refer to “Electrical Component Inspection”
+ Park/neutral position relay-2 (A/T models)
Refer to “Electrical Component Inspection”
+ Manual mode position relay (A/T models)
Refer to “Electrical Component Inspection”
+ ASCD clutch switch (M/T models)
Refer to “Electrical Component Inspection”
+ Harness for open or short

(EL-137).
(EL-137).
(EL-137).
(EL-137).

CHECK STOP LAMP SWITCH CIRCUIT

1. Disconnect ASCD control unit harness connector.
2. Check voltage between ASCD control unit harness connector M17 terminal 23 (G/Y) and ground.

SEL259WD

OK or NG
OK

c ASCD brake/stop lamp switch is OK.

c Check the following.
+ 10A fuse [No. 14, located in the fuse block (J/B)]
+ Harness for open or short between ASCD control unit and stop lamp switch
+ Harness for open or short between fuse and stop lamp switch
+ Stop lamp switch
Refer to “Electrical Component Inspection” (EL-137).

EL-131

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
(Cont’d)
ASCD STEERING SWITCH CHECK
1

CHECK ASCD STEERING SWITCH CIRCUIT FOR ASCD CONTROL UNIT

Check voltage between ASCD control unit harness connector M17 terminal 11 (GY/R) and ground.

SEL005Y

OK or NG
OK

c ASCD steering switch is OK.

c GO TO 2.

CHECK ASCD STEERING SWITCH

1. Disconnect ASCD steering switch.
2. Check continuity between RS3 terminals 1 and 2 by pushing each switch.

SEL196Y

OK or NG
OK

c Check harness for open or short between ASCD steering switch and ASCD control unit.

c Replace ASCD steering switch.

EL-132

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
(Cont’d)
VEHICLE SPEED SENSOR CHECK
1

CHECK SPEEDOMETER OPERATION
Does speedometer operate normally?

Yes

c GO TO 2.

c Check speedometer and vehicle speed sensor circuit.

CHECK VEHICLE SPEED INPUT

1. Apply wheel chocks and jack up drive wheel.
2. Disconnect ASCD control unit harness connector.
3. Check voltage between control unit M17 terminal 22 (L/OR) and ground with turning drive wheel slowly by hand.

SEL263WD

Yes or No
Yes

c Vehicle speed sensor is OK.

c Check harness for open or short between ASCD control unit terminal 22 and combination meter
terminal 65.

ASCD PUMP CIRCUIT CHECK
1

CHECK ASCD PUMP

1. Disconnect ASCD pump connector.
2. Measure resistance between ASCD pump terminals 1 and 2, 3, 4.

SEL262WC

OK or NG
OK

c GO TO 2.

c Replace ASCD pump.

EL-133

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
f
(Cont’d)
2

CHECK ASCD PUMP CIRCUIT

1. Disconnect ASCD control unit harness connector.
2. Check harness for open or short between ASCD control unit and ASCD pump.

SEL269WD

OK or NG
OK

c GO TO 3.

c Repair harness.

CHECK ASCD PUMP POWER SUPPLY

1. Jack-up the drive wheels.
2 Maintain the conditions below.
+ Vehicle speed is more than 48 km/h (30 MPH).
+ Main switch (CRUISE lamp) is ON.
+ Set/coast switch (SET lamp) is ON.
Check voltage between ASCD control unit harness connector M17 terminal 12 (W) and ground.

SEL381WD

OK or NG
OK

c ASCD pump power supply is OK.

c Replace ASCD control unit.

EL-134

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
(Cont’d)
ASCD ACTUATOR/PUMP CHECK
1

CHECK VACUUM HOSE

Check vacuum hose (between ASCD actuator and ASCD pump) for breakage, cracks or fracture.

MEL402G

OK or NG
OK

c GO TO 2.

c Repair or replace hose.

CHECK ASCD WIRE

Check wire for improper installation, rust formation or breaks.
OK or NG
OK

c GOTO 3.

c Repair or replace wire. Refer to “ASCD Wire Adjustment” (EL-138).

CHECK ASCD ACTUATOR

1. Disconnect vacuum hose from ASCD actuator.
2. Connect the hose of hand vacuum pump to ASCD actuator.

SEL264WE

OK or NG
OK

c GO TO 4.

c Replace ASCD actuator.

EL-135

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses/TB48 Engine Models
(Cont’d)
4
1.
2.
3.
4.

CHECK ASCD PUMP
Disconnect vacuum hose from ASCD pump and ASCD pump connector.
If necessary remove ASCD pump.
Connect vacuum gauge to ASCD pump.
Apply 12V direct current to ASCD pump and check operation.

SEL265WE

OK or NG
OK

c INSPECTION END

c Replace ASCD pump.

EL-136

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Electrical Component Inspection/TB48
Engine Models
ASCD BRAKE SWITCH AND STOP LAMP SWITCH
Continuity
Condition

CEL488-A

ASCD brake switch

Stop lamp switch

When brake pedal is
depressed

Yes

When brake pedal is
released

Yes

Check each switch after adjusting brake pedal — refer to BR
section.

ASCD CLUTCH SWITCH (FOR M/T MODELS)
Condition

Continuity

When clutch pedal is depressed

When clutch pedal is released

Yes

MEL381K

PARK/NEUTRAL POSITION RELAY-2 (FOR A/T
MODELS)
Continuity
A/T selector lever position
Between terminals 3 and 4
“P”

“N”

Except “P” and “N”

Yes

CEL364A

MANUAL MODE POSITION RELAY (FOR A/T
MODELS)
Continuity
A/T selector lever position
Between terminals 3 and 5
Manual mode

Except manual mode

Yes

CEL365A

EL-137

AUTOMATIC SPEED CONTROL DEVICE (ASCD)
ASCD Wire Adjustment/TB48 Engine Models

CEL749

CAUTION:
+ Be careful not to twist ASCD wire when removing it.
+ Do not tense ASCD wire excessively during adjustment.
Adjust the tension of ASCD wire in the following manner.
1. Loosen lock nut and adjusting nut.
2. Make sure that accelerator wire is properly adjusted. Refer
to FE section, “ACCELERATOR CONTROL SYSTEM”.
4. Tighten adjusting nut just until throttle drum starts to move.
5. Loosen adjusting nut again 1/2 to 1 turn.
6. Tighten lock nut.

EL-138

POWER DOOR LOCK
Schematic/Without Theft Warning System
Models

TEL471M

EL-139

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/Without Theft
Warning System Models

TEL839M

EL-140

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/Without Theft
Warning System Models (Cont’d)

TEL473M

EL-141

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/Without Theft
Warning System Models (Cont’d)

TEL474M

EL-142

POWER DOOR LOCK
Schematic/With Theft Warning System
Models

TEL573M

EL-143

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/With Theft
Warning System Models
LHD MODELS

TEL790M

EL-144

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/With Theft
Warning System Models (Cont’d)

TEL791M

EL-145

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/With Theft
Warning System Models (Cont’d)

TEL792M

EL-146

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/With Theft
Warning System Models (Cont’d)

TEL793M

EL-147

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/With Theft
Warning System Models (Cont’d)
RHD MODELS

TEL578M

EL-148

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/With Theft
Warning System Models (Cont’d)

TEL794M

EL-149

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/With Theft
Warning System Models (Cont’d)

TEL580M

EL-150

POWER DOOR LOCK
Wiring Diagram — D/LOCK —/With Theft
Warning System Models (Cont’d)

TEL581M

EL-151

POWER DOOR LOCK — Super Lock —
Schematic

TEL261M

EL-152

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models

TEL719M

EL-153

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL263M

EL-154

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL264M

EL-155

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL720M

EL-156

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/LHD Models
(Cont’d)

TEL266M

EL-157

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models

TEL796M

EL-158

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL268M

EL-159

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL269M

EL-160

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL270M

EL-161

POWER DOOR LOCK — Super Lock —
Wiring Diagram — S/LOCK —/RHD Models
(Cont’d)

TEL271M

EL-162

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Trouble Diagnoses/With Theft Warning
System Models

EL-165

EL-166

EL-167

EL-168

DIAGNOSTIC PROCEDURE 3
(Door key cylinder switch check)

DIAGNOSTIC PROCEDURE 4
(Door switch check)

DIAGNOSTIC PROCEDURE 5
[Key switch (insert) check]

None of the doors lock/unlock when operating any switch.

EL-164

DIAGNOSTIC PROCEDURE 2
(Door lock actuator check)

SYMPTOM

EL-163

DIAGNOSTIC PROCEDURE 1
(Door lock/unlock switch check)

REFERENCE PAGE

POWER SUPPLY AND GROUND CIRCUIT CHECK

SYMPTOM CHART

One or more doors are not locked and/or
unlocked.

Door lock/unlock switch does not operate.

Door key cylinder does not operate.

Key reminder door system does not operate
properly.

POWER SUPPLY AND GROUND CIRCUIT CHECK
Power supply circuit check
Terminal

Ignition switch

⊕

OFF

ACC

10
V
11
V

Ground

Battery
voltage

Ground

SEL883W

Ground circuit check
Terminals

Continuity

16 — Ground
V

Yes

SEL881VB

EL-163

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
DIAGNOSTIC PROCEDURE 1
(Door lock and unlock switch check)
CHECK DOOR LOCK AND UNLOCK
SWITCH INPUT SIGNAL.
Check voltage between control unit terminal V
23 or V
35 and ground.
SEL028WA

Terminals

23 — Ground
V

Door lock and
unlock switch
condition
Lock
N and Unlock
Unlock

35 — Ground
V

N and Lock

OK
c

Door lock and unlock
switch is OK.

Voltage
(V)
0
Battery
voltage
0
Battery
voltage

SEL873W

SEL628X

Unlock
N
Lock

Terminals
18

17
j

No continuity
j

19
j
j

Door lock and unlock switch (without
power window)
Condition
Lock
N
Unlock

Terminals
2
j
No continuity

3
j
j

OK
.

EL-164

NG
c

Replace power window
main switch (with power
window) or door lock and
unlock switch (without
power window).

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
DIAGNOSTIC PROCEDURE 2
(Door lock actuator check)
CHECK DOOR LOCK ACTUATOR CIRCUIT.
Check voltage for door lock actuator.
Door lock actuator front LH

NG
c

SEL031WA

Terminals

Door lock/unlock
switch condition

⊕

Voltage
(V)

Lock
Unlock

15
V
13
V

Ground
Ground

Battery
voltage

Replace smart entrance
control unit. (Before
replacing control unit, perform DIAGNOSTIC PROCEDURE 1.)

Door lock actuator front RH, rear and
back

SEL032WA

Terminals

Door lock/unlock
switch condition

⊕

Voltage
(V)

Lock
Unlock

15
V
14
V

Ground
Ground

Battery
voltage

OK
.

CHECK DOOR LOCK ACTUATOR.
1. Disconnect door lock actuator connector.
2. Apply 12V direct current to door lock
actuator and check operation.

SEL874W

Terminals

Door lock actuator
operation

⊕

Unlocked → Locked
Locked → Unlocked

3
V
1
V

1
V
3
V

OK
.

Repair harness between smart entrance
control unit connector and door lock
actuator.

EL-165

NG
c

Replace door lock actuator.

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
DIAGNOSTIC PROCEDURE 3
(Door key cylinder switch check)
CHECK DOOR KEY CYLINDER SWITCH
INPUT SIGNAL (LOCK/UNLOCK SIGNAL).
Check voltage between smart entrance
control unit terminal V
30 or V
41 and
ground.
Terminals

⊕

Ground

30
V

Ground

Key position

Voltage
[V]

Between neutral
and lock

Other positions

Approx.
5

Between neutral
and unlock

Other positions

Approx.
5

OK
c

Door key cylinder switch is
OK.

Replace door key cylinder
switch.

SEL038WA

NG
.

Key position

Continuity

Neutral

Between neutral
and lock

Yes

Neutral

Between neutral
and unlock

Yes

OK
.

SEL875WB

Check the following.
+ Door key cylinder switch ground circuit
+ Harness for open or short between
smart entrance control unit and door
key cylinder switch

EL-166

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
DIAGNOSTIC PROCEDURE 4
(Door switch check)
CHECK DOOR SWITCH INPUT SIGNAL.
Check voltage between smart entrance
control unit terminal V
28 or V
29 and
ground.
SEL876W

Terminals

OK
c

Door switch is OK.

Condi- Voltage
tion
[V]

⊕

Front LH
door switch

29
V

Ground

Front door,
Rear and
back door
switch

Ground

Open

0
Approx.
Closed
5
Open

Closed

Approx.
5

NG
.

CHECK DOOR SWITCH.
1. Disconnect door switch connector.
2. Check continuity between door switch
terminals.
Terminals
Front LH
door
switch

1 -V
3
V

Back door
switch RH
Other door
switches

1 -V
2
V
1 V

Ground

Condition

Continuity

Closed

Open

Yes

Closed
Open
Closed
Open

No
Yes
No
Yes

OK
.

Check the following.
+ Door switch ground circuit (Front LH,
back door RH) or door switch ground
condition
+ Harness for open or short between
smart entrance control unit and door
switch
SEL877W

EL-167

NG
c

Replace door switch.

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
DIAGNOSTIC PROCEDURE 5
[Key switch (insert) check]
CHECK KEY SWITCH INPUT SIGNAL
CHECK.
Check voltage between smart entrance
control unit terminal V
32 and ground.
SEL010WA

Condition of key
switch

Voltage [V]

Key is inserted.

Approx. 12

Key is removed.

OK
c

Key switch is OK.

NG
.

CEL363A

CHECK KEY SWITCH.
1. Disconnect key switch connector.
2. Check continuity between key switch
terminals.
Terminals

1 -V
2
V

Condition

Continuity

Key is
inserted.

Yes

Key is
removed.

OK
.

Check the following.
+ 7.5A fuse [No. 24 , located in fuse block
(J/B)]
+ Harness for open or short between key
switch and fuse
+ Harness for open or short between
smart entrance control unit and key
switch

EL-168

NG
c

Replace key switch.

MULTI-REMOTE CONTROL SYSTEM
Schematic/With Theft Warning System
Models

TEL584M

EL-169

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/LHD Models
with Theft Warning System

TEL586M

EL-170

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/LHD Models
with Theft Warning System (Cont’d)

TEL588M

EL-171

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/LHD Models
with Theft Warning System (Cont’d)

TEL589M

EL-172

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/LHD Models
with Theft Warning System (Cont’d)

TEL799M

EL-173

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/RHD Models
with Theft Warning System

TEL591M

EL-174

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/RHD Models
with Theft Warning System (Cont’d)

TEL592M

EL-175

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —/RHD Models
with Theft Warning System (Cont’d)

TEL800M

EL-176

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses/With Theft Warning
System Models
TROUBLE SYMPTOM
+

All functions of remote control system do not operate.
NG

CHECK REMOTE CONTROLLER BATTERY.
Refer to DIAGNOSTIC PROCEDURE 1.
.

Replace battery.

Enter the Identity (ID) code of different or new remote controller.
.

Can the new ID code be entered?

c
.

Go to DIAGNOSTIC PROCEDURE 2.

Yes

Replace with the originally used multi-remote controller.

Some functions of multi-remote controller do not operate.
1 DOOR LOCK OR UNLOCK DOES NOT FUNCTION.
V

(Pressing lock or unlock button of remote controller normally locks or
unlocks all doors.)
No
+ Check if power door lock system functions with door lock & unlock switch.
———————————————————————————————————————————— OR ———————————————————————————————————————————-2 HAZARD INDICATOR DOES NOT FLASH PROPERLY WHEN PRESSING
V
No
LOCK OR UNLOCK BUTTON OF REMOTE CONTROLLER.
+ Check if hazard indicator flashes with hazard switch.
If check is OK, Go to DIAGNOSTIC PROCEDURE 3.
———————————————————————————————————————————— OR ———————————————————————————————————————————-3 FRONT INTERIOR ROOM LAMP DOES NOT TURN ON FOR 30 SECV
ONDS WHEN PRESSING UNLOCK BUTTON OF REMOTE CONTROLLER.
+ Check if the front interior room lamp switch is in the “door” position, the lamp
illuminates when a door is open.
No
If check is OK, Go to DIAGNOSTIC PROCEDURE 4.
———————————————————————————————————————————— OR ———————————————————————————————————————————-4 PANIC ALARM (HORN AND HEADLAMP) DOES NOT ACTIVATE WHEN
V
PANIC ALARM BUTTON IS CONTINUOUSLY PRESSED FOR MORE
THAN 1.5 SECONDS. (With theft warning system)
+ Check if horn and headlamps activate when test is conducted as follows:
1. Open the driver’s window.
2. Close all doors.
3. Lock doors with the key.
4. Wait for about 30 seconds to make sure that the lighted “SECURITY” warnNo
ing lamp begins to blink.
5. Manually unlock with driver’s door lock knob, then panic alarm should activate. (The alarm will stop when door is locked and unlocked with the key.)

Check “POWER DOOR LOCK” system.

Check “Hazard indicator lamp” circuit.

Check “Front interior room lamp” circuit.

Check “THEFT WARNING” system.

Yes
.

Enter the identity (ID) code of different or new remote controller and recheck
operation to see if the same trouble as indicated above occurs.
No

Yes
c

Check multi-remote controller operation again.
If necessary, replace Smart Entrance
Control Unit.

Replace the multi-remote controller.

NOTE:
+ Always check remote controller battery before replacing remote controller.

EL-177

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
DIAGNOSTIC PROCEDURE 1
Check remote controller battery.
CHECK REMOTE CONTROLLER BATTERY.
Remove battery and measure voltage
between battery positive and negative
terminals ⊕ and @.
SEL672U

Measuring terminal

⊕

Battery positive terminal

⊕

Battery negative terminal
@

Standard
value

2.5 — 3.0V

Note:
Remote controller does not function if battery is not set
correctly.

DIAGNOSTIC PROCEDURE 2
All remote controls do not function even if remote controller is operated properly.

SEL883W

CHECK MAIN POWER SUPPLY AND
GROUND CIRCUIT.
1) Remove key from ignition.
2) Disconnect connector from smart
entrance control unit. Check voltage
between smart entrance control unit
terminal V
10 or V
11 and GND.
Battery voltage should exist.

NG
c

+ 7.5A fuse [No. 24 ,
located in fuse block
(J/B)]
+ M92 circuit breaker
+ Harness for open or
short between smart
entrance control unit
and circuit breaker
+ Harness for open or
short between circuit
breaker and fusible link

Refer to EL-MULTI-05 or 09.
OK

.
SEL013WA

Check continuity between terminal V
16
and GND.
Continuity should exist.
Refer to EL-MULTI-05 or 09.
.

A
V

(Go to next page.)

EL-178

Check the following.
+ 40A fusible link (Letter
e , located in fuse and
fusible link box)

NG
c

Check GND harness.

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
A
V

CHECK DOOR SWITCH CIRCUIT.
Check continuity between smart entrance
control unit terminal V
29 and GND, V
28
and GND.
Terminals

⊕

Front door
switch LH

29
V

GND

Other
door
switches

28
V

GND

SEL876W

NG
c

Voltage
[V]

Condition
Open

Approx. 5

Open

Approx. 5

Check the following.
+ Door switch
+ Door switch ground circuit (Front LH side and
back door RH) or door
switch case ground condition (Front RH side,
rear and back door LH)
+ Harness for open or
short

Refer to EL-MULTI-08 or 11.
OK
.

SEL056WA

CHECK IGNITION SWITCH “ACC” CIRCUIT.
Check voltage between smart entrance
control unit terminal V
21 and GND while
ignition switch is “ACC”.
Does battery voltage exist?

No
c

Check the following.
+ 7.5A fuse [No. 9 ,
located in fuse block
(J/B)]
+ Harness for open or
short

Refer to EL-MULTI-05 or 09.
Yes
.

KEY SWITCH INPUT SIGNAL CHECK.
Check voltage between smart entrance
control unit terminal V
32 and GND.
SEL010WA

Condition

Voltage [V]

Key is inserted

Approx. 12

Key is pulled

Refer to EL-MULTI-05 or 09.
OK

B
V

EL-179

NG
c

Check the following.
+ 7.5A fuse [No. 24 ,
located in fuse block
(J/B)]
+ Key switch
+ Harness for open or
short between smart
entrance control unit
and key switch
+ Harness for open or
short between key
switch and fuse

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
B
V

CHECK DOOR LOCK/UNLOCK SWITCH.
1. Disconnect door lock/unlock switch
connector.
2. Check continuity between each door
lock/unlock switch terminals.
SEL873W

Power window main switch
[Door lock/unlock switch (with power
window)]
Condition
Unlock
N
Lock

Terminals
17
j
No continuity

19
j
j

Door lock and unlock switch (without
power window)
SEL628X

Condition
Lock
N
Unlock

Terminals
2
j
No continuity

3
j
j

OK
.

Check operation parts in multi-remote
control system for function.

EL-180

NG
c

Replace door lock/unlock
switch.

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
DIAGNOSTIC PROCEDURE 3
Hazard indicator does not flash properly when pressing lock
or unlock button of remote controller. Everything else functions.

SEL059WA

CHECK HAZARD INDICATOR OPERATION.
1. Disconnect smart entrance control unit
connector.
2. Apply ground to smart entrance control
unit terminal V
7 .
Does hazard indicator illuminate?

Yes
c

Replace smart entrance
control unit.

Refer to EL-MULTI-07 or 10.
No
.

Check multi-remote control relay.

NG
c

Replace.

OK
SEL878W

CHECK POWER SUPPLY FOR MULTIREMOTE CONTROL RELAY.
1. Disconnect multi-remote control relay
connector.
2. Measure voltage between terminal V
2
and body ground.
Battery voltage should exist.

NG
c

Check the following.
+ 10A fuse (No. 48 ,
located in fuse and fusible link box)
+ Harness for open or
short

OK
.

SEL879W

CHECK MULTI-REMOTE CONTROL
RELAY CIRCUIT.
1. Disconnect multi-remote control relay
connector.
2. Measure voltage between terminals V
3
and V
5 .
Battery voltage should exist.
3. Measure voltage between terminals V
6
and V
7 .
Battery voltage should exist.
OK
.

Check harness for open or short between
smart entrance control unit and multi-remote control relay.

EL-181

NG
c

Check harness for open or
short.

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnoses/With Theft Warning
System Models (Cont’d)
DIAGNOSTIC PROCEDURE 4
Front interior room lamp does not turn on for 30 seconds
when pressing unlock button of remote controller. Everything else functions.

SEL061WA

CHECK INTERIOR LAMP CIRCUIT.
When front interior room lamp switch is
“DOOR” position, check voltage across
smart entrance control unit terminal V
8
and GND.
Does battery voltage exist?

No
c

Repair harness between
smart entrance control unit
connector and front interior
room lamp connector.

Refer to EL-MULTI-07.
Yes
.

When all doors are closed and driver’s
door is locked, push unlock button of
remote controller and check voltage
across smart entrance control unit terminal V
8 and GND.
Is voltage approx. 0V?
Yes
.

Check system again.

EL-182

No
c

Replace smart entrance
control unit.

MULTI-REMOTE CONTROL SYSTEM
ID Code Entry Procedure/With Theft Warning
System Models
REMOTE CONTROLLER ID SET UP WITH CONSULT-II
NOTE:
If a remote controller is lost, the ID code of the lost remote
controller must be erased to prevent unauthorized use.
When the ID code of a lost remote controller is not known,
all controller ID codes should be erased. After all ID codes
are erased, the ID codes of all remaining and/or new remote
controllers must be re-registered.
1. Turn ignition switch “OFF”.
2. Connect CONSULT-II to the data link connector.

SEF532VA

3. Turn ignition switch “ON”.
4. Touch “START”.

PBR455D

5. Touch “SMART ENTRANCE”.

SEL845W

6. Touch “MULTI REMOTE ENT”.

SEL846W

EL-183

MULTI-REMOTE CONTROL SYSTEM
ID Code Entry Procedure/With Theft Warning
System Models (Cont’d)
7. Touch “WORK SUPPORT”.

SEL274W

SEL277W

8. The items are shown on the figure at left can be set up.
+ “REMO CONT ID CONFIR”
Use this mode to confirm if a remote controller ID code is
registered or not.
+ “REMO CONT ID REGIST”
Use this mode to register a remote controller ID code.
NOTE:
Register the ID code when remote controller or smart
entrance control unit is replaced, or when additional remote
controller is required.
+ “REMO CONT ID ERASUR”
Use this mode to erase a remote controller ID code.
+ “HZRD REM SET”
Use this mode to activate or deactivate the hazard reminder.

EL-184

MULTI-REMOTE CONTROL SYSTEM
ID Code Entry Procedure/With Theft Warning
System Models (Cont’d)
REMOTE CONTROLLER ID SETUP WITHOUT CONSULT-II
Close all doors.
.

Insert key into and remove it from the ignition key cylinder more than six times
within 10 seconds. (The hazard warning lamp will then flash twice.)
NOTE
+ Withdraw key completely from ignition key cylinder each time.
+ If procedure is performed too fast, system will not enter registration mode.
.

Insert key into ignition key cylinder and turn ignition key switch to “ACC” position.
.

Push any button on remote controller once. (The hazard warning lamp will then
flash twice.)
At this time, the oldest ID code is erased (pushed out). Then, the new ID code
is entered.
.

Do you want to enter any additional remote controller ID codes?
A maximum four ID codes can be entered. If more than four ID codes are
entered, the oldest ID code will be erased.
No

Yes
.

ADDITIONAL ID CODE ENTRY
Lock the door with driver’s lock/unlock
switch (power window main switch).
.

Push any button on the new remote
controller once.
(The hazard warning lamp will then flash
twice.)
b
At this time, the oldest ID code is
erased (pushed out). Then, the new
ID code is entered.
.

Do you want to enter an additional
remote controller ID code?
A maximum four ID codes can be
entered. If more than four ID codes
are entered, the oldest ID code will
be erased.
Yes
.

ADDITIONAL ID CODE ENTRY
Unlock the door, then lock again with
driver’s lock/unlock switch (power window main switch).
.

A
V

(Go to next page.)

EL-185

MULTI-REMOTE CONTROL SYSTEM
ID Code Entry Procedure/With Theft Warning
System Models (Cont’d)
A
V
.

Open driver side door.
.

END.
After entering the identity (ID) code, check the operation of multi-remote control system.

NOTE
+ If a remote controller is lost, the ID code of the lost remote controller must be erased to prevent unauthorized use. When the ID code of a lost remote controller is not known, all controller ID codes should
be erased. After all ID codes are erased, the ID codes of all remaining and/or new remote controllers
must be re-registered.
To erase all ID codes in memory, register one ID code (remote controller) four times. After all ID codes
are erased, the ID codes of all remaining and/or new remote controllers must be re-registered.
+ When registering an additional remote controller, the existing ID codes in memory may or may not be
erased. If four ID codes are stored in memory, when an additional code is registered, only the oldest
code is erased. If less than four ID codes are stored in memory, when an additional ID code is registered,
the new ID code is added and no ID codes are erased.
+ If you need to activate more than two additional new remote controllers, repeat the procedure “Additional
ID code entry” for each new remote controller.
+ Entry of maximum four ID codes is allowed. When more than four ID codes are entered, the oldest ID
code will be erased.
+ Even if same ID code that is already in the memory is input, the same ID code can be entered. The code
is counted as an additional code.

EL-186

MULTI-REMOTE CONTROL SYSTEM
Remote Controller Battery Replacement/With
Theft Warning System Models

SEL042X

EL-187

THEFT WARNING SYSTEM
Schematic

TEL595M

EL-188

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/LHD Models

TEL596M

EL-189

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/LHD Models
(Cont’d)

TEL597M

EL-190

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/LHD Models
(Cont’d)

TEL726M

EL-191

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/LHD Models
(Cont’d)

TEL599M

EL-192

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/LHD Models
(Cont’d)

TEL332M

EL-193

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/RHD Models

TEL600M

EL-194

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/RHD Models
(Cont’d)

TEL601M

EL-195

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/RHD Models
(Cont’d)

TEL801M

EL-196

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/RHD Models
(Cont’d)

TEL603M

EL-197

THEFT WARNING SYSTEM
Wiring Diagram — THEFT —/RHD Models
(Cont’d)

TEL834M

EL-198

UNIFIED METER CONTROL UNIT (TIME CONTROL SYSTEM)
Schematic/Except for Europe and With Theft
Warning System Models

TEL835M

EL-199

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
System Description
NATS (Nissan Anti-Theft System) has the following immobilizer functions:
+ Since only NATS ignition keys, whose ID nos. have been registered into the ECM and IMMU of NATS,
allow the engine to run, operation of a stolen vehicle without a NATS registered key is prevented by
NATS.
That is to say, NATS will immobilize the engine if someone tries to start it without the registered key of
NATS.
+ Both of the originally supplied ignition key IDs have been NATS registered.
If requested by the vehicle owner, a maximum of five key IDs can be registered into the NATS components.
+ The security indicator blinks when the ignition switch is in “OFF” or “ACC” position. Therefore, NATS
warns outsiders that the vehicle is equipped with the anti-theft system.
+ When NATS detects trouble, the security indicator lamp lights up while ignition key is in the “ON” position.
+ NATS trouble diagnoses, system initialization and additional registration of other NATS ignition key IDs
must be carried out using CONSULT-II hardware and CONSULT-II NATS software.
When NATS initialization has been completed, the ID of the inserted ignition key is automatically NATS
registered. Then, if necessary, additional registration of other NATS ignition key IDs can be carried out.
Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.
+ When servicing a malfunction of the NATS (indicated by lighting up of Security Indicator Lamp)
or registering another NATS ignition key ID no., it is necessary to re-register original key identification. Therefore, be sure to receive ALL KEYS from vehicle owner.

System Composition
The immobilizer function of the NATS consists of the following:
+ NATS ignition key
+ NATS immobilizer control unit NATS (IMMU), located in the ignition key cylinder
+ Engine control module (ECM)
+ NATS security indicator

SEL085W

EL-200

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Wiring Diagram — NATS —

TEL728M

EL-201

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Wiring Diagram — NATS — (Cont’d)

TEL729M

EL-202

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
CONSULT-II
CONSULT-II INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Insert NATS program card into CONSULT-II.
Program card
AEN00A/B
3. Connect CONSULT-II to Data link connector which is located
behind the fuse box cover.
SEF532VA

4. Turn ignition switch ON.
5. Touch “START”.

PBR455D

6. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT-II Operation
Manual, NATS.

SEL150X

EL-203

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
CONSULT-II (Cont’d)
CONSULT-II DIAGNOSTIC TEST MODE FUNCTION
CONSULT-II DIAGNOSTIC TEST
MODE

Description

C/U INITIALIZATION

When replacing any of the following components, C/U initialization is necessary.
[NATS ignition key/IMMU/ECM/Dongle unit]

SELF-DIAG RESULTS

Detected items (screen terms) are as shown in the chart below.

HOW TO READ SELF-DIAGNOSTIC RESULTS

SEL151X

SELF-DIAGNOSTIC RESULTS ITEM CHART
Detected items (Screen terms)

Description

Reference page

ECM INT CIRC-IMMU

The malfunction of ECM internal circuit of IMMU communication line is
detected.

EL-207

CHAIN OF ECM-IMMU

Communication impossible between ECM and IMMU.
(In rare case, “CHAIN OF ECM-IMMU” might be stored during key registration procedure, even if the system is not malfunctioning.)

EL-208

DIFFERENCE OF KEY

IMMU can receive the key ID signal but the result of ID verification
between key ID and IMMU is NG.

EL-210

CHAIN OF IMMU-KEY

IMMU cannot receive the key ID signal. Otherwise, the registered ID signal from dongle unit cannot be received when the IMMU requests the
ID.

EL-210

ID DISCORD, IMM-ECM

The result of ID verification between IMMU and ECM is NG. System initialization is required.

EL-211

DON’T ERASE BEFORE CHECKING ENG DIAG

Engine trouble data and NATS trouble data have been detected in ECM.

EL-205

LOCK MODE

EL-212

EL-204

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses
WORK FLOW
*NOTE: In rare case, “CHAIN OF ECM-IMMU” might be stored as a selfdiagnostic result during key registration procedure, even if the system is not malfunctioning.

CHECK IN
.

TROUBLE
.

Verify the security indicator.

INITIALIZATION
(Refer to CONSULT-II operation
manual NATS.)

Using the CONSULT-II program card for NATS check the

c “SELF-DIAG RESULTS” with CONSULT-II.

Self-diagnostic results referring to NATS, but no information
about engine self-diagnostic results is displayed on CONSULTII.

Self-diagnostic results referring to NATS and “DON’T ERASE
BEFORE CHECKING ENG DIAG” are displayed on CONSULT-II.
(This means that engine trouble data has been detected in ECM.)

Turn ignition switch “OFF”.
.

Repair NATS.
(If necessary, carry out “C/U INITIALIZATION” with CONSULTII.*)

Turn ignition switch “OFF”.

Turn ignition switch “ON”.

Repair NATS according to self-diagnostic results referring to
NATS.
(If necessary, carry out “C/U INITIALIZATION” with CONSULTII.*)
.

Erase the NATS “SELF-DIAG RESULTS” by using CONSULTII. (Touch “ERASE”)

Do not erase the NATS “SELF-DIAG RESULTS” by using
CONSULT-II.

Start the engine.

Check the engine “SELF-DIAG RESULTS” with CONSULT-II by
using the CONSULT-II generic program card.
(Engine diagnostic software included)
.

Verify no lighting up of the security indicator.

CHECK OUT

Start the engine. Does the engine start properly?
OK

Perform running test with CONSULT-II in engine “SELF-DIAG
RESULTS” mode.

Erase the NATS and engine “SELF-DIAG RESULTS” by using
the CONSULT-II program card for NATS and generic program
card.

NG Verify “NO DTC” displayed on the CONSULT-II screen.

Start the engine.

OK
.

CHECK OUT

EL-205

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses (Cont’d)
SYMPTOM MATRIX CHART 1
(Self-diagnosis related item)
Displayed “SELF-DIAG
RESULTS” on CONSULT-II
screen.

SYMPTOM

ECM INT CIRC-IMMU

CHAIN OF ECM-IMMU

DIAGNOSTIC PROCEDURE
(Reference page)
PROCEDURE 1
(EL-207)

PROCEDURE 2
(EL-208)

+ Security indicator lighting
up*
+ Engine does not start

SYSTEM
(Malfunctioning
part or mode)
ECM

In rare case, “CHAIN OF
ECM-IMMU might be stored
during key registration
procedure, even if the system is not malfunctioning.

—

Open circuit in battery voltage line of IMMU circuit

Open circuit in ignition line
of IMMU circuit

Open circuit in ground line
of IMMU circuit

Open circuit in communication line between IMMU and
ECM

Short circuit between IMMU
and ECM communication
line and battery voltage line

Short circuit between IMMU
and ECM communication
line and ground line

ECM

DIFFERENCE OF KEY

CHAIN OF IMMU-KEY

+ MIL staying ON
+ Security indicator lighting
up*

IMMU

PROCEDURE 3
(EL-210)

Unregistered key

IMMU

PROCEDURE 4
(EL-210)

Malfunction of key ID chip

IMMU

System initialization has not
yet been completed.

ECM

LOCK MODE

Engine trouble data and
NATS trouble data have
been detected in ECM

—

ID DISCORD, IMM-ECM

PROCEDURE 5
(EL-211)

LOCK MODE

PROCEDURE 6
(EL-212)

DON’T ERASE BEFORE
CHECKING ENG DIAG

REFERENCE PART NO.
OF ILLUSTRATION ON
DIAGNOSTIC SYSTEM
DIAGRAM

WORK FLOW
(EL-205)

*: When NATS detects trouble, the security indicator lights up while ignition key is in the “ON” position.

SYMPTOM MATRIX CHART 2
(Non self-diagnosis related item)
SYMPTOM

Security ind. does not light up.

DIAGNOSTIC PROCEDURE
(Reference page)

PROCEDURE 7
(EL-213)

SYSTEM
(Malfunctioning part or mode)

REFERENCE PART NO. OF
ILLUSTRATION ON DIAGNOSTIC SYSTEM DIAGRAM

Security ind.

—

Open circuit between Fuse and NATS IMMU

—

Continuation of initialization mode

—

NATS IMMU

EL-206

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC SYSTEM DIAGRAM

SEL087WI

DIAGNOSTIC PROCEDURE 1
Self-diagnostic results:
“ECM INT CIRC-IMMU” displayed on CONSULT-II screen

Confirm SELF-DIAGNOSTIC RESULTS “ECM INT CIRC-IMMU” displayed on CONSULT-II screen.
Ref. part No. B.

SEL152X

Replace ECM.

Perform initialization with CONSULT-II.
For the operation of initialization, refer to “CONSULT-II operation
manual NATS”.

EL-207

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 2
Self-diagnostic results:
“CHAIN OF ECM-IMMU” displayed on CONSULT-II screen
*: In rare case, “CHAIN OF
ECM-IMMU” might be
stored during key registration procedure, even if the
system is not malfunctioning.

Confirm SELF-DIAGNOSTIC
RESULTS “CHAIN OF ECMIMMU”* displayed on CONSULT-II
screen.
OK
SEL153X
.

CHECK POWER SUPPLY CIRCUIT FOR
IMMU.
Check voltage between terminal V
8 of
IMMU and ground.
Voltage: Battery voltage

NG
c

.
SEL782Y

CHECK IGN SW. ON SIGNAL.
Check voltage between terminal V
7 of
IMMU and ground while ignition switch is
in the “ON” position.
Voltage: Battery voltage

NG
c

SEL783Y

CHECK GROUND CIRCUIT FOR IMMU.
Check harness continuity between IMMU
terminal V
4 and ground.
Continuity should exist.

Check the following:
+ 10A fuse (No. 50 ,
located in the fuse and
fusible link box)
+ Harness for open or
short between fuse and
IMMU connector
Ref. part No. C1

Check the following:
+ 10A fuse [No. 25 ,
located in the fuse
block (J/B)]
+ Harness for open or
short between fuse and
IMMU connector
Ref. part No. C2

Repair harness.
Ref. part No. C3

Repair harness.
Ref. part No. C4

OK
.

CHECK COMMUNICATION ON OPEN
CIRCUIT.
Check harness continuity between ECM
terminal 167 and IMMU terminal V
1 .
Continuity should exist.
OK
.
SEL156X

A
V

SEL924Y

EL-208

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses (Cont’d)
A
V

SEL925Y

CHECK COMMUNICATION LINE BATTERY SHORT CIRCUIT.
1. Disconnect ECM connector and IMMU
connector.
2. Turn ignition switch to ON.
3. Check voltage between ECM terminal
167 or IMMU terminal V
1 and
ground.
No voltage should exist.

NG
c

Repair harness.
Ref. part No. C4

OK
.

CHECK COMMUNICATION LINE
GROUND SHORT CIRCUIT.
1. Turn ignition switch OFF.
2. Check continuity between ECM terminal 167 or IMMU terminal V
1 and
ground.
Continuity should not exist.
OK

SEL926Y
.

SIGNAL FROM ECM TO IMMU CHECK
1. Check the signal between ECM terminal 167 and ground with CONSULT-II
or oscilloscope when ignition switch is
turned “ON”.
2. Make sure signals which are shown in
the figure below can be detected during 750 msec. just after ignition switch
is turned “ON”.
OK
SEL193X

+ IMMU is malfunctioning.
1. Replace IMMU. Ref. part No. A
2. Perform initialization with CONSULT-II.
For the initialization procedure, refer to
“CONSULT-II operation manual NATS”.

EL-209

NG
c

+ ECM is malfunctioning.
1. Replace ECM. Ref.
part No. B
2. Perform initialization
with CONSULT-II.
For the initialization
procedure, refer to
“CONSULT-II operation
manual NATS”.

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 3
Self-diagnostic results:
“DIFFERENCE OF KEY” displayed on CONSULT-II screen
Confirm SELF-DIAGNOSTIC
RESULTS “DIFFERENCE OF
KEY” displayed on CONSULT-II
screen.
OK
SEL163X

PERFORM INITIALIZATION.
Perform initialization with CONSULT-II.
Re-register all NATS ignition key IDs.
For the initialization procedure, refer to
“CONSULT-II operation manual NATS”.

Initialization
with CONSULT-II
incomplete or
failed

+ IMMU is malfunctioning.
c 1. Replace
IMMU.
Ref. part No.
A
2. Perform initialization with
CONSULT-II.
For the initialization
procedure,
refer to “CONSULT-II operation manual
NATS”.

Initialization
completed

SEL566W

Start engine.
.

END.
(The ignition key was unregistered.)
Ref. part No. D

DIAGNOSTIC PROCEDURE 4
Self-diagnostic results:
“CHAIN OF IMMU-KEY” displayed on CONSULT-II screen
Confirm SELF-DIAGNOSTIC
RESULTS “CHAIN OF IMMU-KEY”
displayed on CONSULT-II screen.
OK
.

SEL165X

CHECK NATS IGNITION KEY ID CHIP.
Start engine with another registered NATS ignition key.
Does the engine start?
No

+ IMMU is malfunctioning.
1. Replace IMMU.
Ref part No. A
2. Perform initialization with CONSULT-II.
For the initialization procedure, refer to
“CONSULT-II operation manual NATS”.

EL-210

Yes

c + Ignition key ID chip is mal-

functioning.
1. Replace the ignition key.
Ref. part No. E
2. Perform initialization with
CONSULT-II.
For the initialization
procedure, refer to “CONSULT-II operation manual
NATS”.

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 5
Self-diagnostic results:
“ID DISCORD, IMM-ECM” displayed on CONSULT-II screen
Confirm SELF-DIAGNOSTIC
RESULTS “ID DISCORD, IMMECM*” displayed on CONSULT-II
screen.

SEL166X

SEL566W
.

Start engine. (END)
(System initialization was not completed.
Ref. part No. F)

EL-211

* “ID DISCORD, IMM-ECM”:
Registered ID of IMMU is
in discord with that of
ECM.

Initialization
with CONSULT-II
incomplete or
failed

+ ECM is malfunctioning.
c 1. Replace ECM.
Ref. part No.
B
2. Perform initialization with
CONSULT-II.
For the initialization
procedure,
refer to “CONSULT-II operation manual
NATS”.

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 6
Self-diagnostic results:
“LOCK MODE” displayed on CONSULT-II screen
Confirm SELF-DIAGNOSTIC RESULTS
“LOCK MODE” is displayed on CONSULT-II screen.
.
SEL167X

Yes
c

System is OK.
(Now the system is
escaped from “LOCK
MODE”.)

No
.
SEL566W

CHECK NATS IMMU INSTALLATION.
Refer to “How to Replace NATS IMMU” in
EL-214.

NG
c

Reinstall NATS IMMU correctly.

OK
.

Go to DIAGNOSTIC PROCEDURE 4,
EL-210 to check “CHAIN OF IMMU-KEY”.

EL-212

Yes
c

System is OK.

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Trouble Diagnoses (Cont’d)
DIAGNOSTIC PROCEDURE 7
“SECURITY IND. DOES NOT LIGHT UP”
Check 7.5A fuse [No. 24 , located in the
fuse block (J/B)].

NG
c

Replace fuse.

OK
.

NATS INITIALIZATION
1) Install the 7.5A fuse.
2) Perform initialization with CONSULT-II.
For the operation of
initialization, refer to “CONSULT-II operation manual
NATS”.

Turn ignition switch “OFF”.

Start engine and turn ignition switch
“OFF”.

Check the security ind. lighting.

OK
c

END

NG
.

1. Disconnect security ind. connector.
2. Check voltage between security ind.
connector terminal V
1 and ground.
Voltage: Battery voltage

NG
c

Check harness for open or
short between fuse and
security ind.

OK
SEL931UA

CHECK INDICATOR LAMP.

NG
c

Replace security indicator
lamp.

NATS IMMU is malfunctioning. Replace IMMU.

OK
.

CHECK NATS IMMU FUNCTION.
1. Connect security ind. connector.
2. Check continuity between NATS IMMU
terminal V
6 and ground.
Continuity should exist intermittently.
OK

SEL164X

Check harness for open or short between
security indicator and NATS IMMU.

EL-213

Perform initialization with CONSULT-II.
For the operation
of initialization,
refer to “CONSULT-II operation
manual NATS”.

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
How to Replace NATS IMMU
NOTE:
+ If NATS IMMU is not installed correctly, NATS system
will not operate properly and SELF-DIAG RESULTS on
CONSULT-II screen will show “LOCK MODE”.

SEL096WD

EL-214

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/For Europe

TEL731M

EL-215

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/LHD Models for
Europe

TEL732M

EL-216

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/RHD Models for
Europe

TEL805M

EL-217

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/Except for
Europe

TEL806M

EL-218

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Wiring Diagram — CAN —

TEL615M

EL-219

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Trouble Diagnoses
WORK FLOW
1. Print all the data of “SELF-DIAG RESULTS” and “DATA MONITOR” for “ENGINE” and “A/T” displayed
on CONSULT-II. Refer to “DTC U1000 CAN COMMUNICATION LINE” (EC section) for “ENGINE” and
“DTC U1000 CAN COMMUNICATION LINE” (AT section) for “A/T”.
2. Attach the printed sheet of “SELF-DIAG RESULTS” and “DATA MONITOR” onto the check sheet. Refer
to “CHECK SHEET” (EL-221).
3. Based on the data monitor results, put “v” marks onto the items with “UNKWN” or “NG” in the check sheet
table. Refer to “CHECK SHEET” (EL-221).
NOTE: If “NG” is displayed on “CAN COMM” for the diagnosed control unit, replace the control unit.
4. According to the check sheet results (example), start inspection. Refer to “CHECK SHEET RESULTS
(EXAMPLE)” (EL-222).

EL-220

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Trouble Diagnoses (Cont’d)
CHECK SHEET

SEL601Y

EL-221

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Trouble Diagnoses (Cont’d)
CHECK SHEET RESULTS (EXAMPLE)

SEL602Y

NOTE: If “NG” is displayed on “CAN COMM” for the diagnosed control unit, replace the control unit.

EL-222

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Trouble Diagnoses (Cont’d)
INSPECTION
Proceed trouble diagnosis according to the check sheet results (example).
Case 1: Replace ECM.
Case 2: Replace TCM.
Case 3: Check ECM Circuit. Refer to “ECM CIRCUIT CHECK” (EL-223).
Case 4: Check TCM Circuit. Refer to “TCM CIRCUIT CHECK” (EL-223).
Case 5: Check Combination meter Circuit. Refer to “COMBINATION METER CIRCUIT CHECK” (EL-224).
Case 6: Check CAN communication Circuit. Refer to “CAN COMMUNICATION CIRCUIT CHECK” (EL-225).

ECM CIRCUIT CHECK
1
1.
2.
+
+
+

CHECK CONNECTOR
Turn ignition switch OFF.
Check following terminals and connector for damage, bend and loose connection. (Control module-side and harness-side)
ECM
Harness connector F6
Harness connector M51
OK or NG

c GO TO 2.

c Repair terminal or connector.

CHECK HARNESS FOR OPEN CIRCUIT

1. Disconnect ECM connector.
2. Check resistance between ECM harness connector F39 terminals 174 (G/B) and 171 (W/R).

SEL603Y

174 (G/B) — 171 (W/R): Approx. 108 — 132Ω
OK or NG
OK

c Replace ECM.

c Repair harness between ECM and harness connector M88.

TCM CIRCUIT CHECK
1
1.
2.
+
+
+

CHECK CONNECTOR
Turn ignition switch OFF.
Check following terminals and connector for damage, bend and loose connection. (Control module-side and harness-side)
TCM
Harness connector E106
Harness connector M88
OK or NG

c GO TO 2.

c Repair terminal or connector.

EL-223

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Trouble Diagnoses (Cont’d)
2

CHECK HARNESS FOR OPEN CIRCUIT

1. Disconnect TCM connector.
2. Check resistance between TCM harness connector E123 terminals 6 (G/B) and 7 (W/R).

SEL604Y

6 (G/B) — 7 (W/R): Approx. 54 — 66Ω
OK or NG
OK

c Replace TCM.

c Repair harness between TCM and harness connector M51.

COMBINATION METER CIRCUIT CHECK
1

CHECK CONNECTOR

1. Turn ignition switch OFF.
2. Check terminals and connector of combination meter for damage, bend and loose connection. (Meter-side and harness-side)
OK or NG
OK

c GO TO 2.

c Repair terminal or connector.

CHECK HARNESS FOR OPEN CIRCUIT

1. Disconnect combination meter connector.
2. Check resistance between combination meter harness connector M143 terminals 66 (G/B) and 67 (W/R).

SEL605Y

66 (G/B) — 67 (W/R): Approx. 108 -132Ω
OK or NG
OK

c Replace combination meter.

c Repair harness between combination meter and harness connector M88.

EL-224

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Trouble Diagnoses (Cont’d)
CAN COMMUNICATION CIRCUIT CHECK
1

CHECK CONNECTOR

1. Turn ignition switch OFF.
2. Check following terminals and connector for damage, bend and loose connection. (Control module-side, meter-side and harness-side)
+ ECM
+ TCM
+ Combination meter
+ Between ECM and TCM
OK or NG
OK

c GO TO 2.

c Repair terminal or connector.

CHECK HARNESS FOR SHORT CIRCUIT

1. Disconnect ECM connector and harness connector F6.
2. Check continuity between ECM harness connector F39 terminals 174 (G/B) and 171 (W/R).

SEL603Y

174 (G/B) — 171 (W/R): Continuity should not exist.
OK or NG
OK

c GO TO 3.

c Repair harness between ECM and harness connector F6.

CHECK HARNESS FOR SHORT CIRCUIT

Check continuity between ECM harness connector F39 terminals 174 (G/B), 171 (W/R) and ground.

SEL606Y

174 (G/B) — Ground: Continuity should not exist.
171 (W/R) — Ground: Continuity should not exist.
OK or NG
OK

c GO TO 4.

c Repair harness between ECM and harness connector F6.

EL-225

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Trouble Diagnoses (Cont’d)
4

CHECK HARNESS FOR SHORT CIRCUIT

1. Disconnect TCM connector and harness connector E106.
2. Check continuity between TCM harness connector E123 terminals 6 (G/B) and 7 (W/R).

SEL604Y

6 (G/B) — 7 (W/R): Continuity should not exist.
OK or NG
OK

c GO TO 5.

c Repair harness between TCM and harness connector E106.

CHECK HARNESS FOR SHORT CIRCUIT

Check continuity between TCM harness connector E123 terminals 6 (G/B), 7 (W/R) and ground.

SEL607Y

6 (G/B) — Ground: Continuity should not exist.
7 (W/R) — Ground: Continuity should not exist.
OK or NG
OK

c GO TO 6.

c Repair harness between TCM and harness connector F106.

EL-226

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Trouble Diagnoses (Cont’d)
6

CHECK HARNESS FOR SHORT CIRCUIT

1. Disconnect combination meter connector.
2. Check continuity between combination meter harness connector M143 terminals 66 (G/B) and 67 (W/R).

SEL605Y

66 (G/B) — 67 (W/R): Continuity should not exist.
OK or NG
OK

c GO TO 7.

c + Repair harness between combination meter and harness connector M88.
+ Repair harness between combination meter and harness connector M51.

CHECK HARNESS FOR SHORT CIRCUIT

Check continuity between combination meter harness connector M143 terminals 66 (G/B), 67 (W/R) and ground.

SEL608Y

66 (G/B) — Ground: Continuity should not exist.
67 (W/R) — Ground: Continuity should not exist.
OK or NG
OK

c GO TO 8.

c + Repair harness between combination meter and harness connector M88.
+ Repair harness between combination meter and harness connector M51.

ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION

Check components inspection. Refer to “ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION” (EL-228).
OK or NG
OK

c Reconnect all connectors to perform “SELF-DIAG RESULTS” and “DATA MONITOR” for
“ENGINE” and “A/T” displayed on CONSULT-II. Refer to “DTC U1000 CAN COMMUNICATION
LINE” (EC section) for “ENGINE” and “DTC U1000 CAN COMMUNICATION LINE” (AT section)
for “A/T”.

c Replace ECM and/or combination meter.

EL-227

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
Component Inspection
ECM/COMBINATION METER INTERNAL CIRCUIT
INSPECTION
+ Remove ECM and combination meter from vehicle.
+ Check resistance between ECM terminals 174 and 171.
+ Check resistance between combination meter terminals 66
and 67.

SEL609Y

Unit

Terminal

ECM

174 — 171

Combination meter

66 — 67

Resistance value (Ω)
Approx. 108 — 132

EL-228

LOCATION OF ELECTRICAL UNITS
Engine Compartment

CEL449M

EL-229

LOCATION OF ELECTRICAL UNITS
Engine Compartment (Cont’d)

CEL450M

EL-230

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — LHD Models

CEL451M

EL-231

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — LHD Models
(Cont’d)

CEL452M

EL-232

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — RHD Models

CEL453M

EL-233

LOCATION OF ELECTRICAL UNITS
Passenger Compartment — RHD Models
(Cont’d)

CEL454M

EL-234

LOCATION OF ELECTRICAL UNITS
NOTE

EL-235

HARNESS LAYOUT
How to Read Harness Layout
Example:
G2

B/6

: ASCD ACTUATOR

Connector color / Cavity
Connector number
Grid reference

The following Harness Layouts use a map style grid to help locate connectors on the drawings:
+ Main Harness
+ Engine Room Harness (Engine Compartment)
To
1)
2)
3)
4)
5)

CONNECTOR SYMBOL
Main symbols of connector (in Harness Layout) are indicated in the below.
Water proof type

Standard type

Connector type
Male

Female

—

Male

+ Cavity: Less than 4
+ Relay connector
+ Cavity: From 5 to 8
+ Cavity: More than 9
+ Ground terminal etc.

—

EL-236

Female

HARNESS LAYOUT
Main Harness/LHD Models

CEL455M

EL-237

HARNESS LAYOUT
Main Harness/LHD Models (Cont’d)

CEL456M

EL-238

HARNESS LAYOUT
Main Harness/LHD Models (Cont’d)

CEL457M

EL-239

HARNESS LAYOUT
NOTE

EL-240

HARNESS LAYOUT
Main Harness/RHD Models

CEL458M

EL-241

HARNESS LAYOUT
Main Harness/RHD Models (Cont’d)

CEL459M

EL-242

HARNESS LAYOUT
Main Harness/RHD Models (Cont’d)

CEL460M

EL-243

HARNESS LAYOUT
Main Harness/RHD Models (Cont’d)

CEL461M

EL-244

HARNESS LAYOUT
Engine Room Harness/LHD Models
GASOLINE ENGINE MODELS

CEL462M

EL-245

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)

CEL463M

EL-246

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)

CEL486M

EL-247

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)
NOTE

EL-248

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)
DIESEL ENGINE MODELS

CEL464M

EL-249

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)

CEL465M

EL-250

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)
PASSENGER COMPARTMENT

CEL466M

EL-251

HARNESS LAYOUT
Engine Room Harness/LHD Models (Cont’d)

CEL467M

EL-252

HARNESS LAYOUT
Engine Room Harness/RHD Models
GASOLINE ENGINE MODELS

CEL468M

EL-253

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)

CEL469M

EL-254

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)
DIESEL ENGINE MODELS

CEL470M

EL-255

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)

CEL471M

EL-256

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)
PASSENGER COMPARTMENT

CEL472M

EL-257

HARNESS LAYOUT
Engine Room Harness/RHD Models (Cont’d)

CEL473M

EL-258

HARNESS LAYOUT
Engine Harness
TB48DE ENGINE

CEL485M

EL-259

HARNESS LAYOUT
NOTE

EL-260

HARNESS LAYOUT
(Cont’d)
ZD ENGINE

CEL475M

EL-261

HARNESS LAYOUT
NOTE

EL-262

HARNESS LAYOUT
Engine Control Harness
TB48DE ENGINE

CEL476M

EL-263

HARNESS LAYOUT
Engine Control Harness (Cont’d)

CEL477M

EL-264

HARNESS LAYOUT
Body Harness/LHD Models
WAGON

CEL478M

EL-265

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)

CEL479M

EL-266

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)
HARDTOP

CEL487M

EL-267

HARNESS LAYOUT
Body Harness/LHD Models (Cont’d)

CEL488M

EL-268

HARNESS LAYOUT
Body Harness/RHD Models
WAGON

CEL480M

EL-269

HARNESS LAYOUT
Body Harness/RHD Models (Cont’d)

CEL481M

EL-270

HARNESS LAYOUT
Body No. 2 Harness/LHD Models
WAGON

CEL418M

EL-271

HARNESS LAYOUT
Body No. 2 Harness/LHD Models (Cont’d)
HARDTOP

CEL419M

EL-272

HARNESS LAYOUT
Body No. 2 Harness/RHD Models
WAGON

CEL482M

EL-273

HARNESS LAYOUT
Body No. 2 Harness/RHD Models (Cont’d)
HARDTOP

CEL483M

EL-274

HARNESS LAYOUT
Chassis Harness

CEL489M

EL-275

HARNESS LAYOUT
Back Door Harness and Rear Window
Defogger Harness

CEL420M

EL-276

Section

Wiring Diagram Name

Code

Section

Wiring Diagram Name

A/C, A

Auto Air Conditioner

EGVC/V

EGR Volume Control Valve

A/C, M

Manual Air Conditioner

ETC1

Throttle Control Motor

A/T

ETC2

Throttle Control Motor

ABS

Anti-lock Brake System

ETC3

Throttle Control Motor

APPS1

Accelerator Pedal Position Sensor

F/FOG

Front Fog Lamp

APPS2

Accelerator Pedal Position Sensor

F/PUMP

Fuel Pump

APPS3

Accelerator Pedal Position Sensor

FCUT

Fuel Cut System

APS

Accelerator Position Sensor

FICD

IACV-FICD Solenoid Valve

ASCD

Automatic Speed Control Device

FPSW1

ATF Pressure Switch 1

AT/IND

A/T Indicator Lamp

FPSW3

ATF Pressure Switch 3

AUDIO

Audio

FPSW5

ATF Pressure Switch 5

BACK/L

Back-up Lamp

FPSW6

ATF Pressure Switch 6

BRK/SW

Brake Switch Signal

FR/B

Front Brake Solenoid Valve

CAN

CAN Communication Line

FR/BF

Front Brake Solenoid Valve

CAN

CAN Communication Line

FTS

CAN

CAN Communication Line

A/T Fluid Temperature Sensor Circuit

CD/CHG

CD Auto Changer

FUELB1

Fuel Injection System Function
(Bank 1)

CHARGE

Charging System

CHIME

Warning Chime

FUELB2

Fuel Injection System Function
(Bank 2)

CIGAR

Cigarette Lighter

GLOW

Quick Glow System

CKPS

Crankshaft Position Sensor

H/AIM

Headlamp Aiming Control System

CLOCK

Clock

H/LAMP

Headlamp

CMPS

Camshaft Position Sensor

HLC

Headlamp Washer

COMPAS

Compass and Thermometer

COOL/F

Cooling Fan Control

HLR/C

High and Low Reverse Clutch Solenoid Valve

D/C

Direct Clutch Solenoid Valve

HLR/CF

D/CF

Direct Clutch Solenoid Valve

High and Low Reverse Clutch Solenoid Valve

D/LOCK

Power Door Lock

I/C

Input Clutch Solenoid Valve

DEF

Rear Window Defogger

I/CF

Input Clutch Solenoid Valve

DEICER

Wiper Deicer

I/LOCK

A/T Interlock

IATS

Intake Air Temperature Sensor

IGNSYS

Ignition Signal

ILL

Illumination

INJECT

Injector

INJPMP

Electronic Control Fuel Injection
Pump

INT/V

Intake Air Control Valve Control
Solenoid Valve

DIFF/L

Differential Lock

DLC

Data Link Connector

DTRL

Headlamp — Daytime Light System

E/BRE

A/T 1st Engine Braking

ECMRLY

ECM Relay

ECTS

Engine Coolant Temperature Sensor

EGRC-Solenoid Valve and Throttle
Control Solenoid Valve

EGRC/V

EL-277

WIRING DIAGRAM CODES (CELL CODES)
Wiring Diagram Codes (Cell Codes) (Cont’d)
Code

Section

Wiring Diagram Name

IVC

Intake Valve Timing Control Solenoid
Valve

ROOM/L

Interior Room Lamp

RP/SEN

Refrigerant Pressure Sensor

Knock Sensor

S/LOCK

Power Door Lock — Super Lock —

LC/B

Low Coast Brake Solenoid Valve

S/SIG

Start Signal

LC/BF

Low Coast Brake Solenoid Valve

S/TANK

Sub Fuel Tank Control System

LOAD

Electrical Load Signal

SEN/PW

Sensor Power Supply

LPSV

Line Pressure Solenoid Valve

SHIFT

A/T Shift Lock System

MAFS

Mass Air Flow Sensor

SRS

Supplemental Restraint System

MAIN

Main Power Supply and Ground Circuit

STAB

Stabilizer Release Device

METER

Meter and Gauges

START

Starting System

MIL

Mulfunction Indicator Lamp

STSIG

Start Signal Circuit

MMSW

Manual Mode Switch

TAIL/L

Parking, License and Tail Lamps

MULTI

Multi-remote Control System

TCCSIG

A/T TCC Signal (Lock Up)

NATS

Nissan Anti-Theft System

TCV

Torque Converter Clutch Solenoid
Valve

NLS

Needle Lift Sensor

TCV

Injection Timing Control Valve

NONDTC

Non-detective Items

THEFT

Theft Warning System

Heated Oxygen Sensor 1 Heater
(B1) (Front)

TPS1

Throttle Position Sensor

TPS2

Throttle Position Sensor

TPS3

Throttle Position Sensor

TRQ/SG

Engine Torque Control Signal

TRSA/T

Turbine Revolution Sensor

O2H1B1

Code

Section

Wiring Diagram Name

O2H1B2

Heated Oxygen Sensor 1 Heater
(B2) (Front)

O2H2B1

Heated Oxygen Sensor 2 Heater
(B1) (Rear)

O2H2B2

Heated Oxygen Sensor 2 Heater
(B2) (Rear)

TURN

Turn Signal and Hazard Warning
Lamps

O2S1B1

Heated Oxygen Sensor 1 (B1)
(Front)

VIAS/V

Variable Induction Air Control System

O2S1B2

Heated Oxygen Sensor 1 (B2)
(Front)

VSS

Vehicle Speed Sensor

VSSA/T

Vehicle Speed Sensor A/T

O2S2B1

Heated Oxygen Sensor 2 (B1)
(Rear)

WARN

Warning Lamps

Front Wiper and Washer

Heated Oxygen Sensor 2 (B2)
(Rear)

WIPER

O2S2B2
OILP/W

Engine Oil Pressure Warning System

PGC/V

EVAP Canister Purge Volume Control Solenoid Valve

PNP/SW

Park/Neutral Position Switch

PNP/SW

Park/Neutral Position Switch

POWER

Transmission Control Module (Power
Supply)

POWER

ECM Power Supply For Back-up

POWER

Power Supply Routing

PS/SEN

Power Steering Pressure Sensor

R/COOL

Rear Cooler System

R/FOG

Rear Fog Lamp

EL-278

ENGINE MECHANICAL
SECTION

MODIFICATION NOTICE:
+
+
+

Engine mounting parts have been modified.
Models with three way catalyst have been introduced for the Middle East.
TB48DE engine has been introduced for Europe.

CONTENTS
TB48DE
PREPARATION ……………………………………………………. 2
Special Service Tools ………………………………………… 2
Commercial Service Tools………………………………….. 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING …………………………………………… 4
NVH Troubleshooting Chart — Engine Noise …………. 4
OUTER COMPONENT PARTS ………………………………. 5
POWER VALVE ACTUATOR ………………………………… 8
COMPRESSION PRESSURE…………………………………. 9
Measurement of Compression Pressure………………. 9
OIL PAN…………………………………………………………….. 10
Removal…………………………………………………………. 10
Installation………………………………………………………. 12
TIMING CHAIN …………………………………………………… 15
Components……………………………………………………. 15
Removal…………………………………………………………. 16
Inspection……………………………………………………….. 19
Installation………………………………………………………. 19

OIL SEAL…………………………………………………………… 24
Replacement…………………………………………………… 24
CYLINDER HEAD……………………………………………….. 26
Components……………………………………………………. 26
Removal…………………………………………………………. 27
Disassembly……………………………………………………. 29
Inspection……………………………………………………….. 29
Valve Clearance ……………………………………………… 35
Assembly ……………………………………………………….. 38
Installation………………………………………………………. 38
ENGINE REMOVAL…………………………………………….. 42
CYLINDER BLOCK …………………………………………….. 44
Disassembly……………………………………………………. 45
Inspection……………………………………………………….. 46
Assembly ……………………………………………………….. 52
Assembly ……………………………………………………….. 52
SERVICE DATA AND SPECIFICATIONS (SDS) ……. 55
General Specifications……………………………………… 55
Inspection and Adjustment ……………………………….. 55

TB48DE

PREPARATION
Special Service Tools
Tool number
Tool name

Description

KV10111100
Seal cutter

Removing steel oil pan and timing chain case

NT046

KV101056S0
Ring gear stopper
1 KV10105630
Adapter
2 KV10105610
Plate

Preventing crankshaft from rotating

a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)

NT617

Commercial Service Tools
Tool name

Description

Spark plug wrench

Removing and installing spark plug

NT047

Valve oil seal drift

Installing valve oil seal
a: 25 (0.98) dia.
b: 14.4 (0.567) dia.
c: 11.8 (0.465) dia.
d: 10 (0.39)
e: 11 (0.43)
f: 9 (0.35)
Unit: mm (in)

NT602

Valve guide drift

Removing and installing valve guide

Intake & Exhaust
a = 10 mm (0.39 in) dia.
b = 6.5 mm (0.256 in) dia.

NT015

EM-2

PREPARATION
Commercial Service Tools (Cont’d)
Tool name

TB48DE

Description

Valve guide reamer

Reaming valve guide V
1 or hole for oversize
valve guide V
2
Intake & Exhaust
d1 = 7.000 mm (0.2756 in) dia.
d2 = 11.19 mm (0.4406 in) dia.

NT016

Valve seat cutter set

Finishing valve seat dimensions

NT048

Front oil seal drift

Installing front oil seal

a = 80 mm (3.15 in) dia.
b = 58 mm (2.28 in) dia.

NT049

Piston pin drift

Removing and installing piston pin

a = 22.5 mm (0.886 in) dia.
b = 12.5 mm (0.492 in) dia.

NT074

Piston ring expander

Removing and installing piston ring

NT030

EM-3

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING

TB48DE

Type of
noise

Front of
engine
Timing
chain cover

When
starting

When
idling

When
racing

While
driving

Source of
noise

Check item

Reference
page

Ticking or
clicking

—

Tappet
noise

Valve clearance

EM-35

Rattle

—

Camshaft
bearing
noise

Camshaft journal clearance
Camshaft runout

EM-30

—

Piston pin
noise

Piston and piston pin clearance
Connecting rod bushing
clearance

EM-46, 51

Piston slap
noise

Piston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsion

EM-46, 47

Connecting rod bushing
clearance (Small end)
Connecting rod bearing
clearance (Big end)

EM-50, 51

Slap or
knock

Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil pan

Before
After
warm-up warm-up

—

Slap or rap

—

Knock

Connecting
rod bearing
noise

Knock

—

Main bearing noise

Main bearing oil clearance
Crankshaft runout

EM-49

Timing chain cracks and
wear
Timing chain tensioner
operation

EM-15, 19

Drive belts deflection

Tapping or
ticking

—

Timing
chain and
chain tensioner noise

Squeaking
or fizzing

—

Drive belts
(Sticking or
slipping)

Creaking

Drive belts
(Slipping)

MA section
(“Checking
Drive Belts”,
“ENGINE
MAINTEIdler pulley bearing operation
NANCE”)

Front of
engine
Squall
Creak

A: Closely related

B: Related

—

C: Sometimes related

—: Not related

EM-4

Water pump
Water pump operation
noise

LC section
(“Water
Pump
Inspection”,
“ENGINE
COOLING
SYSTEM”)

OUTER COMPONENT PARTS

TB48DE

SEM018H

EM-5

OUTER COMPONENT PARTS

TB48DE

SEM044H

EM-6

OUTER COMPONENT PARTS

TB48DE

CAUTION:
+ Be careful not to damage heated oxygen sensor.
+ Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m
(19.7 in) onto a hard surface such as a concrete floor; use a new one.
+ Perform procedures for “Throttle Valve Closed Position Learning” whenever harness connector
of electric throttle control actuator is disconnected. Refer to BASIC SERVICE PROCEDURE in EC
section.
+ If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after finishing repairs. Refer to BASIC SERVICE PROCEDURE, in EC section.

EM-7

POWER VALVE ACTUATOR

TB48DE

DISASSEMBLY
1. Remove washer and E-ring.
2. Remove actuator assembly.
3. Disconnect shaft lever from actuator rod.

ASSEMBLY
1.
2.
3.
+
MEM266A

Connect shaft lever with actuator rod.
Install actuator assembly with stopper.
Install washer and E-ring.
Use a new E-ring.

ADJUSTMENT
1. Apply vacuum pressure of 33.3 to 40.0 kPa (333 to 400
mbar, 250 to 300 mmHg, 9.84 to 11.81 inHg) to the actuator.
2. Loosen adjusting screw until it is separated from the lever.
3. Screw in adjusting screw until it contacts the shaft lever, and
then screw it in two turns ±45°.
4. Apply vacuum pressure of 40.0±13.3 kPa (400±133 mbar,
300±100 mmHg, 11.81±3.94 inHg) to the actuator. Switch on
and off power valve to check more than three times if the
valve operates smoothly with no play or looseness.

EM-8

COMPRESSION PRESSURE

TB48DE

Measurement of Compression Pressure
1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure.
Refer to “Releasing Fuel Pressure” in EC section.
4. Disconnect ignition coil harness connector.
5. Remove air intake duct, upper collector, throttle body (or
electric throttle control actuator), ignition coil and all spark
plugs.

6.
7.
8.
+

SEM040H

+
+

Attach a compression tester to No. 1 cylinder.
Crank the engine and record the highest gauge indication.
Repeat the measurement on each cylinder as shown below.
Always use a fully-charged battery to obtain specified
engine revolution.
Compression pressure: kPa (bar, kg/cm2, psi)/rpm
Standard
1,226 (12.26, 12.5, 178)/200
Minimum
1,030 (10.30, 10.5, 149)/200
Difference limit between cylinders:
98 (0.98, 1.0, 14)/200
If cylinder compression in one or more cylinders is low, pour
a small amount of engine oil into cylinders through the spark
plug holes and retest compression.
If adding oil helps the compression, piston rings may be
worn or damaged. If so, replace piston rings after checking piston.
If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat.
(Refer to SDS.) If valve or valve seat is damaged
excessively, replace them.
If compression in any two adjacent cylinders is low and
if adding oil does not help the compression, there is
leakage past the gasket surface. If so, replace cylinder
head gasket.

EM-9

OIL PAN

TB48DE

SEM061H

Removal
1.
2.
3.
+

Remove engine undercover.
Drain engine oil.
Remove steel oil pan bolts.
Loosen steel oil pan bolts in reverse order.

SEM740F

SEM751F

EM-10

OIL PAN
Removal (Cont’d)
4.
a.
+
+

TB48DE

Remove steel oil pan.
Insert SST between aluminum oil pan and steel oil pan.
Be careful not to damage aluminum mating surface.
Do not insert screwdriver, or oil pan flange will be
deformed.

SEM741F

b. Slide SST by tapping on the side of the SST with a hammer.

SEM742F

5. Remove steel oil pan.

SEM743F

6. Disconnect left side of the tie rod end.
Refer to “STEERING LINKAGE” in ST section.

SEM714F

7. Remove transmission bolts.

SEM744F

EM-11

OIL PAN
Removal (Cont’d)

TB48DE

8. Remove aluminum oil pan bolts.
+ Loosen aluminum oil pan bolts in reverse order.

MEM203A

9. Remove aluminum oil pan using SST.
+ Be careful not to damage aluminum mating surface.
+ Do not insert screwdriver, or oil pan flange will be
deformed.
10. Remove oil strainer.

SEM746F

Installation
1. Install oil strainer.
2. Install aluminum oil pan.
a. Use a scraper to remove all traces of liquid gasket from
mating surfaces.
+ Also remove traces of liquid gasket from mating surface of
cylinder block, front cover and steel oil pan.
+ Remove old liquid gasket from the bolt hole and thread.
SEM747F

b. Apply a continuous bead of liquid gasket to mating surface
of aluminum oil pan.
+ Use Genuine Liquid Gasket or equivalent.

SEM159F

c. Apply liquid gasket to inner sealing surface as shown in figure.
+ Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
in diameter.
+ Attaching should be done within 5 minutes after coating.

SEM745F

EM-12

OIL PAN
Installation (Cont’d)
d.
+
+
+
+

TB48DE

Install aluminum oil pan.
Apply liquid gasket to the shank of the bolts marked with ★.
Use Genuine Liquid Gasket or equivalent.
Tightening should be done within 5 minutes after coating.
Tighten bolts in numerical order.
Tightening torque:
★: 8.43 — 10.8 Nzm (0.86 — 1.1 kg-m, 75 — 95 in-lb)
Others: 20.6 — 26.5 Nzm (2.1 — 2.7 kg-m, 16 — 19
ft-lb)

MEM203A

3. Install the transmission bolts. Refer to Service Manual NISSAN Y61 SUPPLEMENT-V 1st Revision (Publication No.
SM1E-Y61EG1), AT-199.

SEM744F

4. Install steel oil pan.
a. Use a scraper to remove all traces of liquid gasket from
mating surfaces.
+ Also remove traces of liquid gasket from mating surface of
aluminum oil pan.

SEM749F

b. Apply a continuous bead of liquid gasket to mating surface
of aluminum oil pan.
+ Use Genuine Liquid Gasket or equivalent.
+ Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
in diameter.
+ Attaching should be done within 5 minutes after coating.

SEM159F

EMO0252D

EM-13

OIL PAN
Installation (Cont’d)
c.
+
+
4.

TB48DE

Install steel oil pan.
Tighten in numerical order as shown in the figure.
Wait at least 30 minutes before refilling engine oil.
Connect left side of the tie rod end.
Refer to “STEERING LINKAGE” in ST section.
5. Install in reverse order of removal for remaining steps paying attention to the following.
+ After refilling engine oil, check engine oil level.
+ Start engine and check that there is no leakage of engine oil.
SEM751F

EM-14

TB48DE

TIMING CHAIN
Components

SEM062H

1.
2.
3.
4.
5.

Chain tensioner
Camshaft sprocket (Intake)
Camshaft sprocket (Exhaust)
O-ring
Timing chain slack guide

6. Timing chain tension guide
7. Timing chain
8. Crankshaft sprocket
9. Oil pump drive spacer
10. Front cover

EM-15

11.
12.
13.
14.
15.
16.

Dowel pin
Front oil seal
Crankshaft pulley
Cylinder head front cover
Camshaft position sensor
Chain guide

TIMING CHAIN
Components (Cont’d)

TB48DE

CAUTION
+ After removing timing chain, do not turn and camshaft
separately, or valves will strike piston heads.
+ When installing chain tensioner, oil seats, or other sliding parts, lubricate contacting surfaces with new engine
oil.
+ Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprocket and crankshaft pulley.
+ When removing oil pump assembly, remove camshaft
position sensor (PHASE), then remove timing chain from
engine.
+ Be careful not to damage sensor edges.

Removal
1. Remove engine undercover.
2. Drain engine oil.
3. Drain engine coolant from radiator.
Be careful not to spill engine coolant on drive belts.
4. Remove radiator and radiator shroud.
Refer to “Radiator” in LC section.
5. Release fuel pressure.
Refer to “Fuel Pressure Release” in EC section.
6. Remove the following belts.
+ A/C compressor drive belt
+ Power steering oil pump drive belt
+ Alternator drive belt
7. Remove fan coupling with fan.
8. Remove power steering oil pump and power steering oil
pump bracket.
9. Remove A/C compressor idler pulley.
10. Remove alternator and alternator bracket.
11. Remove oil pans. Refer to EM-13, “Removal” of OIL PAN.
(Publication No. SM1E-Y61EG0)
12. Remove air duct from intake manifold collector.

13. Remove vacuum hoses, fuel hoses, and so on.
14. Remove ignition coils.
15. Remove spark plugs.

MEM205A

EM-16

TIMING CHAIN
Removal (Cont’d)

TB48DE

16. Remove rocker cover bolts in numerical order as shown in
the figure.

MEM206A

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

MEM207A

+ Rotate crankshaft until mating mark on camshaft
sprocket is set at position indicated in figure.

MEM208A

18. Remove camshaft position sensor.
+ Do not allow any magnetic materials to contact the camshaft position sensor.
+ Be careful not to drop or damage sensor.
19. Remove cylinder head front cover using Seal cutter [SST:
KV10111100].

MEM209AA

20. Remove timing chain guide from camshaft bracket.
21. Attach a suitable stopper pin to chain tensioner to hold
plunger at its compressed position.
22. Remove chain tensioner.

MEM210A

EM-17

TIMING CHAIN
Removal (Cont’d)

TB48DE

23. Loosen camshaft sprocket bolts holding camshaft at hexagonal area.
+ Apply paint to timing chain and cam sprockets for alignment during installation.
24. Remove camshaft sprockets.

SEM041H

25. Remove front cover bolts at cylinder head front side.

MEM212A

26. Remove starter motor, and set ring gear stopper (SST) using
mounting bolt holes of starter motor.

EMO0299D

27. Loosen crankshaft pulley bolt.
28. Remove crankshaft pulley with a suitable puller.

MEM214A

29. Remove water pump pulley and water pump. Refer to LC-13,
“Water Pump” (Publication No. SM1E-Y61EG1).
30. Remove front cover bolts as shown.
31. Remove front cover carefully using Seal cutter [SST:
KV10111100].
+ Be careful not to damage or bend front end of cylinder
head gasket.
+ If cylinder head gasket is damaged, replace it with a new
one.
MEM215A

EM-18

TIMING CHAIN
Removal (Cont’d)
32. Remove
33. Remove
34. Remove
35. Remove

TB48DE

timing chain.
oil pump drive spacer.
tension guide and slack guide.
crankshaft sprocket.

SEM019H

36. Remove O-rings from front cover.

MEM217A

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

SEM885F

Installation
1. Install crankshaft sprocket on crankshaft.
+ There is no installation direction.

MEM267A

2. Position crankshaft so that No. 1 piston is at TDC and key
way is at 12 o’clock.

MEM218A

EM-19

TIMING CHAIN
Installation (Cont’d)

TB48DE

3. Install timing chain on crankshaft sprocket.
+ Support chain with a suitable tool to keep the mating
mark aligned.

SEM021H

4. Install timing chain slack guide and timing chain tension
guide.

SEM020H

5. Install camshaft sprocket.
+ Set timing chain by aligning mating marks with those of
camshaft sprockets.

MEM221A

6. Install camshaft sprocket bolts and tighten them to specified
torque holding camshaft at hexagonal area.
+ Apply new engine oil to bolt threads and seat surface.

SEM042H

7. Install chain tensioner.
+ Before installing chain tensioner, insert a suitable pin
into pin hole of chain tensioner to keep plunger compressed.
+ After installing chain tensioner, remove the pin to
release plunger.
8. Install timing chain guide to camshaft bracket.

MEM223A

EM-20

TIMING CHAIN
Installation (Cont’d)

TB48DE

9. Replace front oil seal with new one, and remove all traces of
liquid gasket from mating surface using a scraper.
+ Also remove traces of liquid gasket from mating surface of
cylinder block.
+ For front oil seal replacement, refer to “FRONT OIL SEAL”,
EM-24.

MEM224A

10. Apply a continuous bead of liquid gasket to mating surface
of front cover.
+ Use Genuine Liquid Gasket or equivalent.
+ Attaching should be done within 5 minutes after coating.

MEM225A

11. Install front cover.
+ Lift front cover at an angle and install it to mounting
position so that front cover will come in contact with
both cylinder head gasket lower surface and cylinder
block front surface at the same time.
+ Be careful not to damage cylinder head gasket.

PBIC0563E

Bolt No.
a.
b.

Tightening torque Nzm (kg-m, in-lb)
6.9 — 9.5 (0.70 — 0.97, 61 — 84)

Bolt length
mm (in)
45 (1.77)
16 (0.63)

MEM226A

+ Make sure three O-rings are present and new ones.
+ Be careful not to damage oil seal when installing front
cover.

MEM217A

EM-21

TIMING CHAIN
Installation (Cont’d)

TB48DE

12. Install front cover bolts at cylinder head front side.

MEM212A

MEM227A

13. Install oil pump drive spacer.
14. Install water pump and water pump pulley.
Refer to “Water Pump” in LC section.
15. Install idler pulley and bracket.
16. Install oil pan. Refer to EM-15, “Installation” (Publication No.
SM1E-Y61EG0).
17. Install crankshaft pulley.
+ Tightening procedure
a. Tighten bolt to 54.0 to 63.8 Nzm (5.5 to 6.5 kg-m, 39.8
to 47.0 ft-lb).
b. Turn bolt 120 to 125 degrees clockwise using marks
provided on bolt flange.
Turning for one mark equals 120 degrees.
18. Remove ring gear stopper.
19. Install starter motor.

20. Install cylinder head front cover.
+ Apply liquid gasket to cylinder head front cover.
+ Use Genuine Liquid Gasket or equivalent.

MEM228A

21. Install camshaft position sensor with new O-ring.

MEM209AA

EM-22

TIMING CHAIN
Installation (Cont’d)

TB48DE

22. Before installing rocker cover, apply a continuous bead of
liquid gasket to mating surface of cylinder head.
+ Use Genuine Liquid Gasket or equivalent.

MEM229A

MMA120A

23. Install rocker cover with new rocker cover gasket and tighten
bolts in numerical order as shown in the figure.
24. Install spark plugs.
25. Install ignition coils.
26. Install alternator and alternator bracket.
27. Install power steering oil pump and power steering oil pump
bracket.
28. Install fan coupling with fan.
29. Drive belts.
For adjusting drive belt deflection, refer to “Checking Drive
Belts” in MA section.
30. Reinstall parts in reverse order of removal.

EM-23

OIL SEAL

TB48DE

Replacement
VALVE OIL SEAL
1. Remove rocker cover.
2. Remove camshaft.
3. Remove valve spring. Refer to “Removal”, EM-31 (Publication No. SM1E-Y61EG1).
4. Remove valve oil seal with suitable tool.
Piston concerned should be set at TDC to prevent valve
from falling.
MEM230A

5. Apply new engine oil to new valve oil seal, and install it with
[SST: KV10116300] to dimension as shown.

MEM231A

FRONT OIL SEAL
1. Remove the following parts:
+ Engine under cover
+ Radiator and radiator shroud: Refer to “Radiator” in LC section.
+ Drive belts and cooling fan
+ Crankshaft pulley and oil pump drive spacer: Refer to “TIMING CHAIN”, EM-15.
2. Remove front oil seal from front cover.
+ Be careful not to scratch front cover.
MEM232A

3. Apply new engine oil to new oil seal and install it using a
suitable tool.
+ Install new oil seal in the direction as shown in the figure.

SEM715A

MEM233A

EM-24

OIL SEAL
Replacement (Cont’d)

TB48DE

REAR OIL SEAL
1. Separate clutch assembly or automatic transmission. Refer
to “REMOVAL AND INSTALLATION” in MT or AT section.
2. Remove flywheel or drive plate.
3. Remove bolts fixing from both rear and bottom sides.
4. Remove rear oil seal retainer assembly using Seal cutter
[SST: KV10111100].
5. Remove traces of liquid gasket from mating surface of cylinder block and oil pan using scraper.
+ Replace oil seal and retainer assembly as a single unit.

SEM064H

6. Apply a continuous bead of liquid gasket to mating surfaces
of rear oil seal retainer (both for cylinder block and oil pan
sides).
+ Use Genuine Liquid Gasket or equivalent.
a. Coat of liquid gasket should be maintained within 2.0 to
3.0 mm (0.079 to 0.118 in) and 3.5 to 4.5 mm (0.138 — 0.177
in) dia. range.
b. Attach oil seal retainer to cylinder block within 5 minutes
after coating.
c. Wait at least 30 minutes before refilling engine oil or
starting engine.

EM-25

TB48DE

CYLINDER HEAD
Components

MEM234A

1.
2.
3.
4.

Oil filler cap
Rocker cover
Rocker cover gasket
Intake valve timing control solenoid
valve (If so equipped)
5. Camshaft bracket
6. Intake camshaft
7. Exhaust camshaft

8. Timing chain guide
9. Cylinder head bolt
10. Shim
11. Valve lifter
12. Valve cotter
13. Valve spring retainer
14. Valve spring

EM-26

15.
16.
17.
18.
19.
20.
21.

Valve spring seat
Valve oil seal
Valve guide
Cylinder head
Cylinder head gasket
Valve seat
Valve

CYLINDER HEAD
Components (Cont’d)

TB48DE

CAUTION
+ When installing camshaft, lubricate contacting surfaces
with new engine oil.
+ When tightening cylinder head bolts, camshaft sprocket
bolts and camshaft bracket bolts, lubricate bolt threads
and seat surfaces with new engine oil.
+ Attach tags to valve lifters so as not to mix them up.
+ Be careful not to damage heated oxygen sensor.
+ Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto
a hard surface such as a concrete floor; use a new one.

Removal
1. Remove engine undercovers.
2. Drain engine coolant from radiator and cylinder block.
Be careful not to spill coolant on drive belts.
3. Release fuel pressure.
Refer to “Fuel Pressure Release” in EC section.
4. Remove drive belts.
5. Remove air duct to intake manifold collector.
6. Remove front exhaust tube.
MMA119A

7. Disconnect vacuum hoses, fuel hoses, water hoses, wires,
harness, connectors and so on.
8. Remove intake manifold.
9. Disconnect heated oxygen sensor connectors. (Except for
the Middle East)
10 Remove exhaust manifold.
11. Remove ignition coils.
12. Remove spark plugs.

MEM205A

13. Remove rocker cover bolts in numerical order as shown in
the figure.

MEM206A

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

MEM207A

EM-27

CYLINDER HEAD
Removal (Cont’d)

TB48DE

+ Rotate crankshaft until mating mark on camshaft
sprocket is set at position indicated in figure at left.

MEM208A

15. Remove camshaft position sensor.
+ Do not allow any magnetic materials to contact the camshaft position sensor.
+ Be careful not to damage sensor.
16. Remove cylinder head front cover using Tool (Seal cutter).

MEM209A

17. Remove timing chain guide from camshaft bracket.
18. Attach a suitable stopper pin to chain tensioner to hold
plunger at its compressed position.
19. Remove chain tensioner.

MEM210A

20. Loosen camshaft sprocket bolts holding camshaft at hexagonal area.
+ Apply paint to timing chain and cam sprockets for alignment during installation.
21. Remove camshaft sprockets.

MEM211A

22. Remove camshaft brackets and camshafts.
+ Apply mating marks to brackets to ensure correct reassembly.
+ Bolts should be loosened in two or three steps and in
numerical order as shown.

MEM235A

EM-28

CYLINDER HEAD
Removal (Cont’d)

TB48DE

23. Remove cylinder head bolts.
24. Remove cylinder head.
+ Head warpage or cracking could result from removing in
incorrect order.
+ Cylinder head bolts should be loosened in two or three
steps and in numerical order as shown.

MEM236A

Disassembly
1. Remove valve components with Tool.
2. Remove valve oil seal with a suitable tool.

MEM237A

Inspection
CYLINDER HEAD DISTORTION

MEM238A

+ Clean surface of cylinder head.
+ Use a reliable straightedge and feeler gauge to check the
flatness of cylinder head mating surface.
+ Check along six positions shown in figure.
Head surface flatness:
Standard: Less than 0.07 mm (0.0028 in)
Limit: 0.2 mm (0.008 in)
If beyond the specified limit, replace or resurface it.
Resurfacing limit:
The limit for cylinder head resurfacing is determined by the
amount of cylinder block resurfacing.
Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates
freely by hand. If resistance is felt, replace cylinder head.
Nominal cylinder head height:
130.9 — 131.3 mm (5.15 — 5.17 in)

CAMSHAFT VISUAL CHECK
Check camshaft for scratches, seizure and wear.

EM-29

CYLINDER HEAD
Inspection (Cont’d)

TB48DE

CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal.
Runout (Total indicator reading):
Standard
Less than 0.02 mm (0.0008 in)
Limit
0.1 mm (0.004 in)
2. If it exceeds the limit, replace camshaft.

SEM875A

CAMSHAFT CAM HEIGHT
1. Measure camshaft cam height.
Standard cam height:
Intake
43.465 — 43.655 mm (1.7112 — 1.7187 in)
Exhaust
43.065 — 43.255 mm (1.6955 — 1.7029 in)
Cam wear limit:
0.15 mm (0.0059 in)
2. If wear is beyond the limit, replace camshaft.
SEM549A

CAMSHAFT JOURNAL CLEARANCE
1. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
No. 1 to No. 7 bearing
28.000 — 28.021 mm (1.1024 — 1.1032 in)

MEM239A

SEM012A

3. Measure outer diameter of camshaft journal.
Standard outer diameter:
No. 1 to No. 7 journal
27.935 — 27.955 mm (1.0998 — 1.1006 in)
4. If clearance exceeds the limit, replace camshaft and/or cylinder head.
Camshaft journal clearance:
Standard
0.045 — 0.086 mm (0.0018 — 0.0034 in)
Limit
0.15 mm (0.0059 in)

CAMSHAFT END PLAY
1. Install camshaft in cylinder head. Refer to EM-38.
2. Measure camshaft end play.
Camshaft end play:
Standard
0.115 — 0.188 mm (0.0045 — 0.0074 in)
Limit
0.20 mm (0.0079 in)
3. If limit is exceeded, replace camshaft and remeasure end
play.
SEM918F

EM-30

TB48DE

CYLINDER HEAD
Inspection (Cont’d)

+ If limit is still exceeded after replacing camshaft, replace
cylinder head.

CAMSHAFT SPROCKET RUNOUT
1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
Runout (Total indicator reading):
Limit 0.15 mm (0.0059 in)
3. If it exceeds the limit, replace camshaft sprocket.

MEM240A

VALVE GUIDE CLEARANCE
1. Measure valve deflection as shown in figure. (Valve and
valve guide wear the most in this direction.)
Valve deflection limit (Dial gauge reading):
Intake & Exhaust
0.2 mm (0.008 in)

SEM345D

2. If it exceeds the limit, check valve to valve guide clearance.
a. Measure valve stem diameter and valve guide inner diameter.
b. Calculate valve to valve guide clearance.
Valve to valve guide clearance = valve guide inner diameter − valve stem diameter.
c. Check that clearance is within specification.
Unit: mm (in)

SEM938C

Standard

Limit

Intake

0.020 — 0.053
(0.0008 — 0.0021)

0.1 (0.004)

Exhaust

0.040 — 0.073
(0.0016 — 0.0029)

0.1 (0.004)

+ If it exceeds the limit, replace valve and remeasure clearance.
+ If limit is still exceeded after replacing valve, replace
valve guide.

EM-31

CYLINDER HEAD
Inspection (Cont’d)

TB48DE

VALVE GUIDE REPLACEMENT
1. To remove valve guide, heat cylinder head to 110 to 130°C
(230 to 266°F).

SEM008A

2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2
US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.

SEM931C

3. Ream cylinder head valve guide hole.
Valve guide hole diameter
(for oversize service parts):
Intake & Exhaust
11.175 — 11.196 mm (0.4400 — 0.4408 in)

SEM932C

4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press
service valve guide into cylinder head.
Projection “L”:
13.5 — 13.7 mm (0.531 — 0.539 in)

MEM241A

5. Ream valve guide.
Finished size:
Intake & Exhaust
7.000 — 7.018 mm (0.2756 — 0.2763 in)

SEM932C

EM-32

CYLINDER HEAD
Inspection (Cont’d)

TB48DE

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

SEM934C

REPLACING VALVE SEAT FOR SERVICE PARTS
1. Bore out old seat until it collapses. Set machine depth stop
so that boring cannot contact the bottom face of seat recess
in cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Refer to SDS, EM-57.
Use the valve guide center for reaming to ensure valve seat
will have the correct fit.
SEM795A

3. Heat cylinder head to 110 to 130°C (230 to 266°F).
4. Press fit valve seat until it seats on the bottom.

SEM008A

SEM892B

5. Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS, EM-57, 57.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle “α”:
44°45′
Contacting width “W”:
Intake
1.05 — 1.35 mm (0.0413 — 0.0531 in)
Exhaust
1.25 — 1.55 mm (0.0492 — 0.0610 in)
Valve stem projection (Standard):
Intake
41.46 mm (1.6323 in)
Exhaust
41.31 mm (1.6264 in)

MEM242A

EM-33

CYLINDER HEAD
Inspection (Cont’d)

TB48DE

VALVE DIMENSIONS
Check dimensions of each valve. Refer to SDS, EM-56 for
dimensions.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.

SEM188A

VALVE SPRING
Squareness
1. Measure dimension “S”.
Out-of-square “S”:
Less than 2.2 mm (0.087 in)
2. If it exceeds the limit, replace spring.

SEM288A

Pressure
Check valve spring pressure at specified spring height.
Pressure:
Standard
421 N (42.9 kg, 94.6 lb) at 27.4 mm (1.079 in)
Limit
More than 396 N (40.4 kg, 89.0 lb) at 27.4 mm
(1.079 in)
If it exceeds the limit, replace spring.
EM113

VALVE LIFTER AND VALVE SHIM
1. Check contact and sliding surfaces for wear or scratches.

AEM410

2. Check diameter of valve lifter and valve lifter guide bore.
Valve lifter outside diameter:
33.960 — 33.975 mm (1.3370 — 1.3376 in)

AEM411

EM-34

TB48DE

CYLINDER HEAD
Inspection (Cont’d)

Lifter guide inside diameter:
34.000 — 34.021 mm (1.3386 — 1.3394 in)
Clearance between valve lifter and valve lifter guide:
Standard
0.025 — 0.061 mm (0.0010 — 0.0024 in)
Limit
0.1 mm (0.004 in)
If it exceeds the limit, replace valve lifter or cylinder head
which exceeds the standard diameter tolerance.
SEM920F

Valve Clearance
CHECKING

MEM207A

Check valve clearance while engine is cold and not running.
1. Remove engine ornament cover and rocker cover.
2. Remove all spark plugs.
3. Set No. 1 cylinder at TDC on its compression stroke.
+ Align pointer with TDC mark on crankshaft pulley.
+ Check that all valve lifters on No. 1 cylinder are loose.
+ If not, turn crankshaft one revolution (360°) and align as
described above.
4. Check only those valves shown in the figure.
Crankshaft
position
No. 1
TDC

Valve
No. 1

No. 2

No. 3

No. 4

No. 5

No. 6

INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH
j

MEM243A

+ Using a feeler gauge, measure clearance between valve lifter
and camshaft.
+ Record any valve clearance measurements which are out of
specification. They will be used later to determine the
required replacement adjusting shim.
Valve clearance for checking (Cold):
Intake
0.25 — 0.33 mm (0.010 — 0.013 in)
Exhaust
0.29 — 0.37 mm (0.011 — 0.015 in)
SEM139D

5. Turn crankshaft one revolution (360°) and align mark on
crankshaft pulley with pointer.
6. Check only those valves shown in the figure.
Crankshaft
position

Valve
No. 1

No. 3

No. 4

No. 5

No. 6

INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH

No. 6
TDC
MEM244A

No. 2

+ Use the same procedure as mentioned in step 4.

EM-35

CYLINDER HEAD
Valve Clearance (Cont’d)

TB48DE

7. If all valve clearances are within specification, install the following parts:
+ Rocker cover
+ All spark plugs
+ Engine ornament cover

ADJUSTING
Adjust valve clearance while engine is cold.
1. Turn crankshaft. Position cam lobe upward on camshaft for
valve that must be adjusted.
2. Place Tool (A) around camshaft as shown in figure.
CAUTION:
Be careful not to damage cam surface with Tool (A).

SEM941F

3. Rotate Tool (A) so that valve lifter is pushed down.

SEM924F

4. Place Tool (B) between camshaft and the edge of valve lifter
to retain valve lifter.
CAUTION:
+ Tool (B) must be placed as close to camshaft bracket as
possible.
+ Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).

MEM269A

6. Blow air into the hole on adjusting shim to separate it from
valve lifter.

MEM270A

EM-36

TB48DE

CYLINDER HEAD
Valve Clearance (Cont’d)

MEM271A

7. Remove adjusting shim using a small screwdriver and a
magnetic finger.
8. Determine replacement adjusting shim size using the following formula.
+ Use a micrometer to determine thickness of removed shim.
+ Calculate thickness of new adjusting shim so valve clearance
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake:
N = R + [M − 0.29 mm (0.011 in)]
Exhaust:
N = R + [M − 0.33 mm (0.013 in)]
Shims are available in 37 sizes from 1.96 mm (0.0772 in) to
2.68 mm (0.1055 in), in steps of 0.02 mm (0.0008 in).

SEM145D

+ Select the closest size shim to the calculated thickness.
Refer to chart in SDS, EM-56.

SEM308D

9. Install new shim using a suitable tool.
+ Install with the surface on which the thickness is
stamped facing down.

SEM146D

10. Place Tool (A) as explained in steps 2 and 3.
11. Remove Tool (B).
12. Remove Tool (A).
13. Recheck valve clearance.
Valve clearance:
Unit: mm (in)
Cold*

Hot (reference data)

Intake

0.25 — 0.33 (0.010 — 0.013)

0.32 — 0.40 (0.013 — 0.016)

Exhaust

0.29 — 0.37 (0.011 — 0.015)

0.33 — 0.41 (0.013 — 0.016)

SEM147D

EM-37

TB48DE

CYLINDER HEAD
Valve Clearance (Cont’d)

*: At a temperature of approximately 20°C (68°F)
Whenever valve clearances are adjusted to cold specifications, check
that the clearances satisfy hot specifications and adjust again if necessary.

Assembly
1.
+
+
+

Install valve component parts.
Always use new valve oil seal. Refer to EM-24.
Before installing valve oil seal, install valve spring seat.
After installing valve components, tap valve stem tip
with a plastic hammer to assure a proper fit.
+ Install valve spring with paint mark (narrow pitch) end
toward cylinder head.
MEM245A

Installation

MEM246A

1. Before installing cylinder head gasket, apply a continuous
bead of liquid gasket to mating surface of cylinder block.
2. Install cylinder head gasket.
+ When installing cylinder head, use new cylinder head
gasket.
3. Install cylinder head.
+ Do not rotate crankshaft and camshaft separately, or
valves will strike piston heads.
+ Apply new engine oil to cylinder head bolt threads and
seat surfaces.
+ Tightening procedure
a. Tighten bolts to 98.1 — 107.9 Nzm (10 — 11 kg-m, 73 79 ft-lb).
b. Loosen bolts completely.
c. Tighten bolts to 40.2 — 50.0 Nzm (4.1 — 5.0 kg-m, 30 36 ft-lb).
d. Turn bolts 90 to 95 degrees clockwise.
Tightening torque Nzm (kg-m, ft-lb)

MEM247A

Bolts
(1 — 14)

98.1 — 107.9
(10.0 — 11.0,
73 — 79)

0
(0, 0)

40.2 — 50.0
(4.1 — 5.0,
30 — 36)

90 — 95
degrees

MEM248A

EM-38

CYLINDER HEAD
Installation (Cont’d)

TB48DE

4. Install camshaft.

MEM272A

+ Make sure camshafts are aligned as shown in figure.

MEM249A

5. Install camshaft brackets.
+ Make sure camshaft brackets are aligned as marked during disassembly.

MEM250A

MEM251A

+ Apply new engine oil to bolt threads and seat surface.
+ Tighten camshaft bracket bolts in the following steps.
a. Tighten bolts 13 — 16, then 1 — 12.
: 1.96 Nzm (0.2 kg-m, 17 in-lb)
b. Tighten bolts 1 — 16.
: 5.88 Nzm (0.6 kg-m, 52 in-lb)
c. Tighten bolts 1 — 16.
: 9.02 — 11.8 Nzm (0.92 — 1.20 kg-m, 80 — 104 in-lb)
+ If any part of valve assembly or camshaft is replaced,
check valve clearance according to reference data.
After completing assembly check valve clearance. Refer
to “Checking” and “Adjusting” in “VALVE CLEARANCE”
(EM-35).
Reference data valve clearance (Cold):
Intake
0.25 — 0.33 mm (0.010 — 0.013 in)
Exhaust
0.29 — 0.37 mm (0.011 — 0.015 in)

EM-39

CYLINDER HEAD
Installation (Cont’d)

TB48DE

6. Install camshaft sprocket.
+ Set timing chain by aligning mating marks with those of
camshaft sprockets.

MEM221A

7. Install camshaft sprocket bolts to correct torque.
+ Apply new engine oil to bolt threads and seat surface.

MEM222A

8. Install chain tensioner.
+ Before installing chain tensioner, insert a suitable pin
into pin hole of chain tensioner.
+ After installing chain tensioner, remove the pin.
9. Install timing chain guide.

MEM223A

10. Install cylinder head front cover.
+ Apply liquid gasket to cylinder head front cover.
+ Use Genuine Liquid Gasket or equivalent.

MEM228A

11. Install camshaft position sensor.

MEM209A

EM-40

CYLINDER HEAD
Installation (Cont’d)

TB48DE

12. Before installing rocker cover, apply a continuous bead of
liquid gasket to mating surface of cylinder head.

MEM229A

MMA120A

13. Install rocker cover with rocker cover gasket and tighten bolts
in numerical order as shown in the figure.
14. Install spark plugs.
15. Install ignition coils.
16. Install exhaust manifold.
17. Install intake manifold.
18. Connect vacuum hoses, fuel hoses, water hose, wire,
harness, connectors and so on.
19. Connect heated oxygen sensor. (Except for the Middle East
models)
20. Install front exhaust tube.
21. Install engine undercovers.
22. Install air duct to intake manifold collector.
23. Drive belts.
For adjusting drive belt deflection, refer to “Checking Drive
Belts” in MA section.
24. Reinstall parts in reverse order of removal.

EM-41

ENGINE REMOVAL

TB48DE

SEM063H

CAUTION:
+ Before removing engine assembly and transmission
assembly, be sure to remove crankshaft position sensor
on models for Europe.
+ Be careful not to drop or damage crankshaft position
sensor.

EM-42

ENGINE REMOVAL

TB48DE

WARNING:
+ Situate vehicle on a flat and solid surface.
+ Place chocks at front and back of rear wheels.
+ Do not remove engine until exhaust system has completely cooled off.
Otherwise, you may burn yourself and/or fire may break
out in the fuel line.
+ For safety during subsequent steps, the tension of wires
should be slackened against the engine.
+ Before disconnecting fuel hose, release fuel pressure
from fuel line.
Refer to “Releasing Fuel Pressure” in EC section.
+ Be sure to hoist engine in a safe manner.
CAUTION:
+ When lifting engine, be careful not to strike adjacent
parts, especially accelerator wire casing, brake lines,
and brake master cylinder.
+ In hoisting the engine, always use engine slingers in a
safe manner.
+ For engines not equipped with engine slingers, attach
proper slingers and bolts described in the PARTS CATALOG.
MEM262A

+ Remove engine after removing transmission with transfer
from vehicle paying attention to the following.
(1) Remove radiator. Refer to LC section.
(2) For transmission and transfer removal, refer to MT or AT
section.

MEM263A

(3) When removing two mounting bolts from upper side of
transmission, remove front engine mounts and lower engine
to the minimum level of the front mount where the bolt
removal is possible.

MEM264A

(4) When separating transmission and rear plate, remove transmission mounting bolts. Position Tool into mating surface of
transmission and rear plate, and slide it along mating surface.
+ Be careful not to damage mating surfaces.

SEM943B

EM-43

CYLINDER BLOCK

TB48DE

SEM043H

EM-44

CYLINDER BLOCK

TB48DE

CAUTION:
+ When installing sliding parts such as bearings and
pistons, be sure to apply engine oil on the sliding surfaces.
+ Place the removed parts such as bearings and bearing
caps in their proper order and direction.
+ When tightening connecting rod nuts, main bearing cap
bolts and flywheel bolts, apply engine oil to the thread
portion and seating surface of them.

Disassembly
PISTON AND CRANKSHAFT

MEM253A

1. Place engine on work stand.
2. Drain coolant and remove water pump.
3. Drain oil.
4. Remove oil pan and oil strainer.
5. Remove rocker cover.
6. Remove cylinder head front cover.
7. Remove crankshaft pulley.
8. Remove front cover.
9. Remove timing chain.
10. Remove camshaft.
11. Remove cylinder head.
12. Remove flywheel or drive plate.

13. Remove pistons.
+ When disassembling piston and connecting rod, remove
snap rings first, then heat piston to 60 to 70°C (140 to 158°F)
or use piston pin press stand at room temperature.

SEM877B

14. Remove bearing cap and crankshaft.
+ Before removing bearing cap, measure crankshaft end
play.

SEM985B

EM-45

CYLINDER BLOCK

TB48DE

Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole “dp”.
Standard diameter “dp”:
22.993 — 23.005 mm (0.9052 — 0.9057 in)

SEM149B

2. Measure outer diameter of piston pin “Dp”.
Standard diameter “Dp”:
22.989 — 23.001 mm (0.9051 — 0.9055 in)
3. Calculate piston pin clearance.
−0.002 to 0.010 mm (−0.0001 to 0.0004 in)
If it exceeds the limit, replace piston assembly with pin.

SEM821B

PISTON RING SIDE CLEARANCE

SEM024AC

Side clearance:
Top ring
0.040 — 0.080 mm (0.0016 — 0.0031 in)
2nd ring
0.030 — 0.070 mm (0.0012 — 0.0028 in)
Oil ring
0.065 — 0.135 mm (0.0026 — 0.0053 in)
Max. limit of side clearance (Top and 2nd rings):
0.1 mm (0.004 in)
If out of specification, replace piston and piston pin assembly.

PISTON RING GAP

SEM822B

Standard ring gap:
Top ring
0.30 — 0.45 mm (0.0118 — 0.0177 in)
2nd ring
0.30 — 0.45 mm (0.0118 — 0.0177 in)
Oil ring
0.20 — 0.60 mm (0.0079 — 0.0236 in)
Max. limit of ring gap:
1.5 mm (0.059 in)
If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, rebore the cylinder and use oversized
piston and piston ring assembly.
Refer to SDS, EM-59.
+ When replacing the piston, inspect cylinder block surface for
scratches or seizure. If scratches or seizure is found, hone
or replace the cylinder block.

EM-46

CYLINDER BLOCK
Inspection (Cont’d)

TB48DE

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

SEM150B

CYLINDER BLOCK DISTORTION AND WEAR

MEM254A

1. Clean upper face of cylinder block and measure the distortion.
Limit: 0.10 mm (0.0039 in)
2. If out of specification, resurface it.
The resurfacing limit is determined by the cylinder head
resurfacing in engine.
Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
254.95 — 255.05 mm (10.0374 — 10.0413 in)
3. If necessary, replace cylinder block.

PISTON-TO-BORE CLEARANCE
Method A (Using bore gauge and micrometer)

MEM255A

1. Using a bore gauge, measure cylinder bore for wear, out-ofround or taper.
Standard inner diameter:
99.500 — 99.550 mm (3.9173 — 3.9193 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (X − Y) standard:
0.025 mm (0.0010 in)
Taper (A − B) standard:
0.025 mm (0.0010 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder block
if necessary.
2. Check for scratches or seizure. If seizure is found, hone it.

EM-47

CYLINDER BLOCK
Inspection (Cont’d)

TB48DE

+ If cylinder block or piston is replaced with a new one,
select piston of the same grade number punched on
cylinder block upper surface.

MEM256A

3. Measure piston skirt diameter.
Piston diameter “A”:
Refer to SDS, EM-59.
Measuring point “a” (Distance from the bottom):
20 mm (0.79 in)
4. Check that piston-to-bore clearance is within the specification.
Piston-to-bore clearance “B”:
0.030 — 0.050 mm (0.0012 — 0.0020 in)
SEM990B

5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS.
6. Cylinder size is determined by adding piston-to-bore clearance to piston diameter “A”.
Rebored size calculation:
D=A+B−C
where, D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque
to prevent distortion of cylinder bores in final assembly.
8. Cut cylinder bores.
+ When any cylinder needs boring, all other cylinders
must also be bored.
+ Do not cut too much out of the cylinder bore at a time.
Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
9. Hone the cylinders to obtain specified piston-to-bore clearance.
10. Measure the finished cylinder bore for out-of-round and
taper.
+ Measurement should be done after cylinder bore cools
down.

EM-48

CYLINDER BLOCK
Inspection (Cont’d)

TB48DE

Method B (Using feeler gauge)
Measure the extracting force by pulling feeler gauge straight
upward.
Feeler gauge thickness:
0.04 mm (0.0016 in)
Extracting force:
2.0 — 14.7 N (0.2 — 1.5 kg, 0.4 — 3.3 lb)

EM305

CRANKSHAFT
1. Check crankshaft main and pin journals for score, bias, wear
or cracks.
2. With a micrometer, measure journals for taper and out-ofround.
Out-of-round (X − Y):
Less than 0.003 mm (0.0001 in)
Taper (A − B):
Less than 0.003 mm (0.0001 in)
EM757

3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.02 mm (0.0008 in)

MEM273A

BEARING CLEARANCE
Method A (Using bore gauge and micrometer)
Main bearing clearance
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.

SEM986B

2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order in two or three stages.
3. Measure inner diameter “A” of main bearing.

SEM154B

EM-49

CYLINDER BLOCK
Inspection (Cont’d)

TB48DE

4. Measure outer diameter “Dm” of crankshaft main journal.
5. Calculate main bearing clearance.
Main bearing clearance = A − Dm
Standard: 0.030 — 0.087 mm (0.0012 — 0.0034 in)
Limit: 0.09 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If the clearance cannot be adjusted within the standard of
any bearing, grind crankshaft journal and use undersized
bearing.
SEM506A

a. When grinding crank pin and crank journal, fillet R should be
finished as shown in the figure.
R: All journal
1.5 — 1.7 mm (0.059 — 0.067 in)
All pins
1.5 — 1.7 mm (0.059 — 0.067 in)
b. Refer to SDS for grinding crankshaft and available service
parts.

KBIA0148E

8. If crankshaft, cylinder block and main bearings are replaced
with new ones, check that the clearance of main bearing is
within specifications.

CONNECTING ROD BEARING CLEARANCE (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter “C” of bearing.

SEM153B

4. Measure outer diameter “Dp” of crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C − Dp
Standard: 0.027 — 0.061 mm (0.0011 — 0.0024 in)
Limit: 0.09 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If the clearance cannot be adjusted within the standard of
any bearing, grind crankshaft journal and use undersized
bearing.
Refer to step 7 of “MAIN BEARING CLEARANCE”.
SEM958A

EM-50

CYLINDER BLOCK
Inspection (Cont’d)

TB48DE

Method B (Using plastigage)

EM142

CAUTION:
+ Do not turn crankshaft or connecting rod while the plastigage is being inserted.
+ When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. Then
if excessive bearing clearance exists, use thicker main
bearing or undersized bearing so that the specified bearing clearance is obtained.
Main bearing clearance:
Standard
0.030 — 0.087 mm (0.0012 — 0.0034 in)
Limit
0.1 mm (0.004 in)
Connecting rod bearing clearance:
Standard
0.027 — 0.061 mm (0.0011 — 0.0024 in)
Limit
0.09 mm (0.0035 in)

CONNECTING ROD BUSHING CLEARANCE (Small
end)
1. Measure inner diameter “C” of bushing.

SEM151B

2. Measure outer diameter “Dp” of piston pin.
3. Calculate connecting rod bushing clearance.
C − Dp = 0.005 — 0.017 mm (0.0002 — 0.0007 in)
If it exceeds the limit, replace connecting rod bushing and/or
piston set with pin.

SEM903A

REPLACEMENT OF CONNECTING ROD SMALL END
BUSHING
1. Drive in the small end bushing until it is flush with the end
surface of the rod.
Be sure to align the oil holes.
2. After driving in the small end bushing, ream the bushing.
Small end bushing inside diameter:
Finished size
23.000 — 23.012 mm (0.9055 — 0.9060 in)
SEM062A

EM-51

CYLINDER BLOCK
Inspection (Cont’d)

TB48DE

FLYWHEEL/DRIVE PLATE RUNOUT
Runout (Total indicator reading):
Flywheel (M/T model)
0.1 mm (0.004 in) or less
Drive plate (A/T model)
0.1 mm (0.004 in) or less
If runout exceeds the limit, replace flywheel.
CAUTION:
Do not disassemble flywheel assembly.
SEM929A

Assembly
PISTON
1. Install a new snap ring on one side of the piston pin hole.
Ensure that ends of snap ring face down and fit properly
into groove.

SEM005C

2. Heat piston to 60 to 70°C (140 to 158°F) and assemble
piston, piston pin, connecting rod and new snap ring.
+ Align the direction of piston and connecting rod.
+ Numbers stamped on connecting rod and cap correspond to each cylinder.

SEM015C

+ After assembly, make sure piston swings smoothly.
3. Set piston rings as shown.

SEM160B

Assembly
CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.
+ Do not confuse upper and lower sides of main bearings.

SEM986B

EM-52

CYLINDER BLOCK
Assembly (Cont’d)

TB48DE

2. Install crankshaft and main bearing caps and tighten bolts to
the specified torque.
+ Prior to tightening bearing cap bolts, place bearing cap
in its proper position by shifting crankshaft in the axial
direction.
+ Tighten bearing cap bolts gradually in two or three
stages starting with the center bearing and move outward sequentially.
+ After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
SEM007C

3. Apply a continuous bead of liquid gasket to mating surfaces
of rear oil seal retainer (both for cylinder block and oil pan
sides).
+ Use Genuine Liquid Gasket or equivalent.
a. Coat of liquid gasket should be maintained within 2.0 to
3.0 mm (0.079 to 0.118 in) dia. range.
b. Attach oil seal retainer to cylinder block within 5 minutes
after coating.
c. Wait at least 30 minutes before refilling engine oil or
starting engine.
MEM268A

4. Measure crankshaft end play.
Crankshaft end play:
Standard
0.05 — 0.169 mm (0.0020 — 0.0067 in)
Limit
0.3 mm (0.012 in)
If end play exceeds the limit, replace No. 6 bearing and measure
again.
If it still exceeds the limit, replace crankshaft also.
SEM006C

5. Install connecting rod bearings in connecting rods and connecting rod caps.
+ Confirm that correct bearings are used. Refer to “Inspection”,
EM-47 (Publication No. SM1E-Y61EG1).
+ Install bearings so that oil hole in connecting rod aligns with
oil hole of bearing.

SEM159B

6. Install pistons with connecting rods.
(1) Install them into corresponding cylinders with SST.
+ Be careful not to scratch cylinder wall by connecting
rod.
+ Arrange so that front mark on piston head faces toward
front of engine.

SEM008C

EM-53

CYLINDER BLOCK
Assembly (Cont’d)

EM329

TB48DE

(2) Install connecting rod bearing caps.
Tighten connecting rod bearing cap nuts to the specified
torque.
: Connecting rod bearing nut
(1) Tighten to 38 to 40 Nzm
(3.9 to 4.1 kg-m, 28 to 30 ft-lb)
(2) Tighten to 67 to 71 Nzm
(6.8 to 7.2 kg-m, 49 to 52 ft-lb)
or if you have an angle wrench, tighten bolts to 40
to 45 degrees clockwise.
Angle tightening is preferable.
7. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.20 — 0.35 mm (0.0079 — 0.0138 in)
Limit
0.40 mm (0.0157 in)
If clearance exceeds the limit, replace connecting rod and/or
crankshaft.

SEM162B

8. Install flywheel (M/T) or drive plate (A/T) as shown in the figure.

SEM065H

EM-54

SERVICE DATA AND SPECIFICATIONS (SDS)

TB48DE

General Specifications
Unit: kPa (bar, kg/cm2, psi)/rpm

Cylinder arrangement
Displacement

6, in-line
Compression pressure

cm3 (cu in)

4,759 (290.39)

mm (in)

99.5 x 102.0
(3.917 x 4.016)

Bore and stroke
Valve arrangement
Firing order

Standard

1,226 (12.26, 12.5, 178)/200

Minimum

1,030 (10.30, 10.5, 149)/200

Differential limit between
cylinders

DOHC
1-5-3-6-2-4

Number of piston rings
Compression

Oil

Number of main bearings

Compression ratio

9.0

Inspection and Adjustment
CYLINDER HEAD

MEM257A

Unit: mm (in)
Standard

Limit

Height (H)

130.9 — 131.3
(5.1535 5.1693)

0.2 (0.008)*

Surface distortion

Less than
0.07 (0.0028)

0.2 (0.008)

*: Total amount of cylinder head resurfacing and cylinder block resurfacing

EM-55

98 (0.98, 1.0, 14)/200

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
VALVE

TB48DE

Available shims
Unit: mm (in)

SEM188

Valve head diameter “D”
Intake

38.35 — 38.65 (1.5098 — 1.5217)

Exhaust

33.15 — 33.45 (1.3051 — 1.3169)

Valve length “L”
Intake

99.86 — 100.46 (3.9315 — 3.9551)

Exhaust

98.01 — 98.61 (3.8587 — 3.8823)

Valve stem diameter “d”

Thickness mm (in)

Identificaiton mark

1.96 (0.0772)

196

1.98 (0.0780)

198

2.00 (0.0787)

200

2.02 (0.0795)

202

2.04 (0.0803)

204

2.06 (0.0811)

206

2.08 (0.0819)

208

2.10 (0.0827)

210

2.12 (0.0835)

212

2.14 (0.0843)

214

2.16 (0.0850)

216

2.18 (0.0858)

218

2.20 (0.0866)

220

2.22 (0.0874)

222

2.24 (0.0882)

224

2.26 (0.0890)

226
228

Intake

6.965 — 6.980 (0.2742 — 0.2748)

2.28 (0.0898)

Exhaust

6.945 — 6.960 (0.2734 — 0.2740)

2.30 (0.0906)

230

2.32 (0.0913)

232

2.34 (0.0921)

234

2.36 (0.0929)

236

2.38 (0.0937)

238

2.40 (0.0945)

240

2.42 (0.0953)

242

2.44 (0.0961)

244

2.46 (0.0969)

246

2.48 (0.0976)

248

2.50 (0.0984)

250

2.52 (0.0992)

252

2.54 (0.1000)

254

2.56 (0.1008)

256

2.58 (0.1016)

258

2.60 (0.1024)

260

2.62 (0.1031)

262

2.64 (0.1039)

264

2.66 (0.1047)

266

2.68 (0.1055)

268

Valve seat angle “α”
Intake
45°15′ — 45°45′
Exhaust
Valve margin “T”
Intake

1.25 — 1.55 (0.0492 — 0.0610)

Exhaust

1.45 — 1.75 (0.0571 — 0.0689)

Valve margin “T” limit

More than 0.5 (0.020)

Valve stem end surface
grinding limit

Less than 0.2 (0.008)

Valve clearance
Unit: mm (in)

Cold*

Hot (reference data)

Intake

0.25 — 0.33
(0.010 — 0.013)

0.32 — 0.40
(0.013 — 0.016)

Exhaust

0.29 — 0.37
(0.011 — 0.015)

0.33 — 0.41
(0.013 — 0.016)

*: At temperature of approximately 20°C (68°F)
Whenever valve clearances are adjusted to cold specifications,
check that the clearances satisfy hot specifications and adjust
again if necessary.

EM-56

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Valve spring
Free height

Intake valve seat
mm (in)

50.27 (1.9791)

Pressure height
mm/N (mm/kg, in/lb)

27.4/421 (27.4/42.8, 1.079/94.4)

Assembled height
mm/N (mm/kg, in/lb)

37/217 (37/22.1, 1.457/48.7)

Out-of-square

TB48DE

mm (in)

2.2 (0.087)

Valve lifter
Unit: mm (in)

Standard

Limit

Valve lifter outer
diameter

33.960 — 33.975
(1.3370 — 1.3376)

—

Cylinder block valve
lifter hole diameter

34.000 — 34.021
(1.3386 — 1.3394)

—

Valve lifter to lifter
hole clearance

0.025 — 0.061
(0.0010 — 0.0024)

0.1 (0.004)

*: Total indicator reading

Valve guide

MEM258A

Unit: mm (in)

Standard

Oversize

Valve guide

Exhaust valve seat

Outer diameter
Intake
Exhaust

11.023 — 11.034
(0.4340 -0.4344)

11.223 — 11.234
(0.4418 — 0.4423)

Valve guide
Inner diameter
[Finished size]
Intake
Exhaust

7.000 — 7.018 (0.2756 — 0.2763)

Cylinder head valve guide
hole diameter
Intake
Exhaust

10.975 — 10.996
(0.4321 — 0.4329)

11.175 — 11.196
(0.4400 — 0.4408)

Interference fit of valve
guide
Intake
Exhaust

0.027 — 0.059 (0.0011 — 0.0023)
Standard

Limit

Stem to guide clearance
Intake

0.020 — 0.053
(0.0008 — 0.0021)

Exhaust

0.040 — 0.073
(0.0016 — 0.0029)

Valve deflection limit

—

0.1 (0.004)

0.2 (0.008)
MEM259A

EM-57

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
CAMSHAFT AND CAMSHAFT BUSHING

TB48DE

Valve timing

Unit: mm (in)

Camshaft journal to
bushing clearance
[Oil clearance]

Standard

Limit

0.045 — 0.086
(0.0018 — 0.0034)

0.15 (0.0059)

28.000 — 28.021
(1.1024 — 1.1032)

—

27.935 — 27.955
(0.9817 — 1.1006)

—

Less than
0.02 (0.0008)

0.1 (0.004)

0.115 — 0.188
(0.0045 — 0.0074)

0.2 (0.0079)

Inner diameter of
camshaft bearing
1st-7th (Rear)
Outer diameter of
camshaft journal
1st-7th (Rear)
Camshaft runout (Total
indicator reading)
Camshaft end play

MEM260A

Unit: degree

Intake
valve
timing
control
solenoid

EM671

Cam height “A”
Intake

43.465 — 43.655 (1.7112 — 1.7187)

Exhaust

43.065 — 43.255 (1.6955 — 1.7029)

Wear limit of cam
height

0.15 (0.0059)

EM-58

240

248

OFF

240

248

−1

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
CYLINDER BLOCK

TB48DE

PISTON, PISTON RING AND PISTON PIN
Unit: mm (in)

Available piston
Unit: mm (in)

MEM261A

Surface flatness
Standard
Limit

Less than 0.03 (0.0012)

SEM891B

Piston skirt diameter “A”
Standard

0.10 (0.0039)

Grade No. 1

Cylinder bore
Grade No. 2

Inner diameter
Standard
Grade No. 1
Grade No. 2
Grade No. 3
Grade No. 4
Grade No. 5

Grade No. 3
99.500
(3.9173
99.510
(3.9177
99.520
(3.9181
99.530
(3.9185
99.540
(3.9189

—

99.510
3.9177)
99.520
3.9181)
99.530
3.9185)
99.540
3.9189)
99.550
3.9193)

Wear limit

0.20 (0.0079)

Out-of-round (X − Y)

Less than 0.025 (0.0010)

Taper (A − B)

Less than 0.025 (0.0010)

Difference in inner
diameter between
cylinders
Standard

Less than 0.05 (0.0020)

Wear limit

0.20 (0.0079)

Grade No. 4
Grade No. 5

99.460
(3.9157
99.470
(3.9161
99.480
(3.9165
99.490
(3.9169
99.500
(3.9173

—

99.470
3.9161)
99.480
3.9165)
99.490
3.9169)
99.500
3.9173)
99.510
3.9177)

Oversize
0.50 (0.0197)
(mark: “50”)

99.960 — 100.010
(3.9354 — 3.9374)

1.00 (0.0394)
(mark: “100”)
“a” dimension

100.460 — 100.510
(3.9551 — 3.9571)
20 (0.79)

Piston pin hole diameter

22.993 — 23.005
(0.9052 — 0.9057)

Piston clearance to cylinder block

0.030 — 0.050
(0.0012 — 0.0020)

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

EM-59

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
Piston ring

TB48DE

CRANKSHAFT
Unit: mm (in)

Standard

Limit

Side clearance
Top

0.040 — 0.080
(0.0016 — 0.0031)

2nd

0.030 — 0.070
(0.030 — 0.070)

Ring gap
at master bore
D = 99.500
(3.9173)

[

70.897 — 70.921 (2.7912 — 2.7922)

Pin journal dia. “Dp”

56.913 — 56.926 (2.2407 — 2.2412)

Center distance “r”

50.95 — 51.05 (2.0059 — 2.0098)

Out-of-round (X − Y)
0.1 (0.004)

Standard

Less than 0.003 (0.0001)

Taper (A − B)

0.065 — 0.135
(0.0026 — 0.0053)

Oil

Unit: mm (in)

Main journal dia. “Dm”

Standard

Less than 0.003 (0.0001)

Runout [TIR]*

]

Standard

Less than 0.02 (0.0008)

Free end play

Top

0.30 — 0.45
(0.0118 — 0.0177)

2nd

0.30 — 0.45
(0.0118 — 0.0177)

Oil

0.20 — 0.60
(0.0079 — 0.0236)

Standard
Limit

0.05 — 0.169 (0.0020 — 0.0067)
0.30 (0.0118)

1.5 (0.059)

Piston pin
Unit: mm (in)

Piston pin outer diameter
Interference fit of piston pin to
piston
Piston pin to connecting rod
bushing clearance

22.989 — 23.001 (0.9051 0.9055)
SEM645

−0.002 to 0.010
(−0.0001 — 0.0004)
0.005 — 0.017 (0.0002 — 0.0007)

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

CONNECTING ROD
Unit: mm (in)

Center distance

163.45 — 163.55 (6.4350 — 6.4390)

EM715

Bend, torsion [per 100 (3.94)]
*: Total indicator reading

Limit

Bend 0.15 (0.0059)
Torsion 0.3 (0.012)

Piston pin bushing inner
diameter

23.000 — 23.012 (0.9055 — 0.9060)

Connecting rod big end inner
diameter

59.987 — 60.000 (2.3617 — 2.3622)

Side clearance
Standard
Limit

0.20 — 0.35 (0.0079 — 0.0138)
0.40 (0.0157)

EM-60

SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
AVAILABLE MAIN BEARING

TB48DE

MISCELLANEOUS COMPONENTS
Unit: mm (in)

Thickness “T”
Standard

2.008 — 2.012
(0.0791 — 0.0792)

Main journal diameter “Dm”
—

Unit: mm (in)

Flywheel/Drive plate
Runout [TIR]*

Less than 0.1 (0.004)

*: Total indicator reading

Undersize
0.50 (0.0197)

2.258 — 2.262
(0.0889 — 0.0891)

1.00 (0.0394)

2.508 — 2.512
(0.0987 — 0.0989)

Grind so that bearing clearance is the
specified value.

Bearing clearance
Unit: mm (in)

Main bearing clearance
Standard
Limit

AVAILABLE CONNECTING ROD BEARING
Unit: mm (in)

Standard

Thickness “T”

Crank pin journal
diameter “Dp”

1.513 — 1.517
(0.0596 — 0.0597)

—

1.638 — 1.642
(0.0645 — 0.0646)

0.50 (0.0197)

1.763 — 1.767
(0.0694 — 0.0696)

0.75 (0.0295)

1.888 — 1.892
(0.0743 — 0.0745)

1.00 (0.0394)

2.013 — 2.017
(0.0793 — 0.0794)

0.09 (0.0035)

Connecting rod bearing
clearance
Standard
Limit

Undersize
0.25 (0.0098)

0.030 — 0.087 (0.0012 — 0.0034)

Grind so that bearing clearance is the
specified value.

EM-61

0.027 — 0.061 (0.0011 — 0.0024)
0.09 (0.0035)

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
SECTION

MODIFICATION NOTICE:
+

TB48DE engine model has been added.

CONTENTS
ACCELERATOR CONTROL SYSTEM ……………………. 2
Accelerator Control System………………………………… 2
Adjusting Accelerator Wire …………………………………. 3
TROUBLE DIAGNOSES ……………………………………….. 4
Self-diagnosis for Sub Fuel Tank Control Module …. 4

Circuit Diagram — S/TANK — ………………………………… 5
Wiring Diagram — S/TANK — ………………………………… 6
Component Inspection……………………………………… 10
FUEL SYSTEM …………………………………………………… 11
EXHAUST SYSTEM ……………………………………………. 12

ACCELERATOR CONTROL SYSTEM
Accelerator Control System
CAUTION:
The accelerator wire should be adjusted when removing and replacing any parts of the accelerator
control system, shown in the illustration.
a. Warm up engine to normal operating temperature. Then stop it.
b. Check to see if throttle valve fully opens when accelerator pedal is fully depressed and if it returns
to idle position when released.
c. Adjust accelerator pedal free play by turning adjusting nut.
d. Check accelerator control parts for improper contact with any adjacent parts.
e. When connecting accelerator wire, be careful not to twist or scratch its inner wire.
f. Apply a light coat of recommended multi-purpose grease to all sliding or friction surfaces. Do
not apply grease to wire.
g. For ASCD wire adjustment, refer to “ASCD Wire Adjustment” in EL section.

FE-2

ACCELERATOR CONTROL SYSTEM
TB48DE ENGINE MODELS

MFE028A

Adjusting Accelerator Wire
1. Loosen lock nut, and tighten adjusting nut until throttle drum
starts to move.
2. From that position turn back adjusting nut 1.5 to 2 turns, and
fasten it with lock nut.

MFE029A

FE-3

TROUBLE DIAGNOSES
Self-diagnosis for Sub Fuel Tank Control
Module
SUB FUEL TANK CONTROL MODULE TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values, and measured between each terminal and V
11 (ground)
with a voltmeter.
WIRE
COLOR

TERMINAL
NO.

ITEM

CONDITION

Wagon and
Hardtop
R

Power source

Ignition switch “ON”

DATA
(DC voltage)

Approximately 12V

Ignition switch “ON”
Sub fuel tank switch is “ON”.
Main fuel tank is not full.
Sub fuel tank is not empty.

G/B

Sub fuel pump

G/W

Power source

Ignition switch “ON” or “ACC”

Approximately 12V

L/Y
B*1

Grounding

Ignition switch “ON”

Approximately 0V

W/L

Sub fuel gauge

Ignition switch “ON”

Approximately 0 — 4V

Full switch

Approximately 12V

Ignition switch “ON”
Approximately 5V
Main fuel tank is not full.
7

Fuel gauge

Ignition switch “ON”

Approximately 0 — 2.5V

PU/R
W/G*1

Engine running

Approximately 12V

G/B

Sub fuel tank switch

Ignition switch “ON”

Approximately 5V

Indicator

Ignition switch “ON”

Approximately 12V

Power source

Any time

Approximately 12V

W/R

Sub fuel tank warning
lamp

Ignition switch “ON”

Approximately 0V

*1: Except for TB45S engine models

FE-4

TROUBLE DIAGNOSES
Circuit Diagram — S/TANK —
WAGON AND HARDTOP MODELS

TFE035M

FE-5

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK —
WAGON AND HARDTOP MODELS

TFE036M

FE-6

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)
WAGON AND HARDTOP MODELS

TFE039M

FE-7

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)
WAGON AND HARDTOP MODELS (LHD)

TFE038M

FE-8

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)
WAGON AND HARDTOP MODELS (RHD)

TFE040M

FE-9

TROUBLE DIAGNOSES
Component Inspection
SUB FUEL TANK GAUGE UNIT
Refer to “METER AND GAUGES” in EL section.

Sub fuel pump
Check resistance between terminals V
4 and V
5 with ohmmeter.
Resistance: Approximately less than 2Ω

MFE034A

FE-10

FUEL SYSTEM

MFE036A

FE-11

EXHAUST SYSTEM

SFE813A

FE-12

FUSE AND FUSIBLE LINK BOX
Terminal Arrangement

CEL484M

JOINT CONNECTOR (J/C)
Terminal Arrangement

CEL275M

Edition: October 2002
Release: November 2002 (01)
Publication No.: SM2E00-1Y61E0E
Reference No.: 7711346699

QUICK REFERENCE INDEX

GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL

PATROL GR

ENGINE LUBRICATION &
COOLING SYSTEMS

MODEL Y61 SERIES

ENGINE CONTROL SYSTEM

ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEM

CLUTCH

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

TRANSFER

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

FRONT AXLE & FRONT SUSPENSION

REAR AXLE & REAR SUSPENSION

BRAKE SYSTEM

STEERING SYSTEM

RESTRAINT SYSTEM

BODY & TRIM

HEATER & AIR CONDITIONER

ELECTRICAL SYSTEM

ALPHABETICAL INDEX

IDX

NISSAN EUROPE S.A.S.
© 2002 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.

NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

GENERAL INFORMATION
SECTION

OUTLINE OF MODIFICATIONS:
For Europe:
+
+
+
+
+
+

TB48DE engine (cold area specification) has been adopted.
5-speed automatic transmission (RE5R05A) has been adopted on models with TB48DE engine.
Exterior and interior design has been changed.
Electronic throttle control actuator has been adopted on models with TB48DE engine.
ASCD (Automatic Speed Control Device) has been adopted on models with TB48DE engine.
Refrigerant pressure sensor on liquid tank has been adopted on models with TB48DE engine.

APPLIED FROM:
Wagon and Hardtop models
For Europe:
JN1TFSY61U0000001

CONTENTS
CONSULT-II CHECKING SYSTEM…………………………. 2
Function and System Application ………………………… 2
Nickel Metal Hydride Battery Replacement…………… 2
Checking Equipment………………………………………….. 3
CONSULT-II Data Link Connector (DLC) Circuit …… 3

IDENTIFICATION INFORMATION ………………………….. 4
Model Variation…………………………………………………. 4
Identification Number…………………………………………. 6
Dimensions ………………………………………………………. 6

CONSULT-II CHECKING SYSTEM
Function and System Application
Diagnostic test mode

Function

ENGINE

A/T

ABS

AIR
BAG

NATS*1

SMART
ENTRANCE

x*2

—

Work support

This mode enables a technician to adjust
some devices faster and more accurate by
following the indications on CONSULT-II.

Self-diagnostic results

Self-diagnostic results can be read and
erased quickly.

—

Trouble diagnostic
record

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

—

ECU discriminated
No.

Classification number of a replacement ECU
can be read to prevent an incorrect ECU
from being installed.

—

Data monitor

Input/Output data in the ECU (ECM) can be
read.

—

DTC work support

This mode enables a technician to set operating conditions to confirm self-diagnosis
status/results.

—

Active test

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

—

ECU (ECM) part numECU (ECM) part number can be read.
ber
Control unit initialization

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

—

Self-function check

ECM checks its own NATS communication
interface.

—

x*3

—

DTC confirmation

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

x*2

—

x*4

—

A maximum of four IDs (identifications) can
REMO CONT ID SET be registered in the memory using the
remote controller. These IDs can be also be
UP
confirmed and erased as required.
Function test

Conducted by CONSULT-II instead of a
technician to determine whether each system is “OK” or “NG” (No Good).

x: Applicable
*1: NATS (Nissan Anti-Theft System)
*2: Not available for diesel engine models.
*3: Except for ZD30DDTi engine models.
*4: Right-hand drive models for Europe only.

Nickel Metal Hydride Battery Replacement

GI-2

CONSULT-II CHECKING SYSTEM
Checking Equipment
When ordering the below equipment, contact your NISSAN distributor.
Tool name

Description

NISSAN CONSULT-II
1 CONSULT-II unit (Tester
V
internal software: Resident version 3.3.0) and
accessories
2 Program card AED01C
V
and AEN00B (For NATS)
To confirm the best combination of those softwares, refer
to CONSULT-II Operation
SGI100A
Manual.

CONSULT-II Data Link Connector (DLC)
Circuit

SOM397

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

Check item

CONSULT-II cannot access any
system.

+ CONSULT-II DLC power supply circuit (Terminal and ground circuit (Terminal 4)
(For detailed circuit, refer to EC section, “MIL & DATA LINK CONNECTORS”.)
+ CONSULT-II (DDL) cable

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

GI-3

IDENTIFICATION INFORMATION
Model Variation
WAGON AND HARDTOP MODELS
Model

Rear seat arrangement
Destination

Steering
position

Hardtop

Station Wagon

2nd seat

2nd center split bench seat

Forward facing

Engine

Side facing or
Seatless

Front differential

3rd seat
Seatless

Forward facing

Side facing

H233B

Rear differential
Transmission

Transfer

FS5R50B

RE4R03A
FS5R50B

RHD

RE4R03A
FS5R50B

RE4R03A
FS5R50B
ZD30DDTi

Europe

RE4R03A
FS5R50B

TX12A
SE

RE4R03A

LHD

FS5R50B

RE4R03A
TB48DE

RE5R05A

H233B/H260

Grade

KWSSREFY61UEA

—

TWSSREFY61UEA

—

TWSSREAY61UEA

—

KWSSRFFY61UEA

—

TWSSRFFY61UEA

—

KWSSRFAY61UEA

—

TWSSRFAY61UEA

—

TWSSRHFY61UEA

—

TWSSRHAY61UEA

—

KWSSLEFY61UGA KWSSLEFY61USP TWSSLEFY61USP TWSSLEFY61UGA
—

—

TWSSLEAY61UGA

—
—

KWSSLFFY61UGA

—

TWSSLFFY61UGA

—

TWSSLFFY61USA

—

KWSSLFAY61UGA

—

TWSSLFAY61UGA

—

TWSSLFAY61USA

—

TWSSLHFY61UGA

—

TWSSLHFY61USA

—

TWSSLHAY61UGA

—

TWSSLHAY61USA

—

TGPSLHNY61ESA

—

GI-4

IDENTIFICATION INFORMATION
Model Variation (Cont’d)
Prefix and suffix designations
T

Y61

A
A: 3rd/2nd seat forward facing
Q: 3rd/2nd seat side facing
P: 3rd/2nd seat seatless

R: Except for the Middle East and Europe
K: Middle East
E: RHD for Europe
G: Central/South Europe
S: North Europe
S: Carburetor engine
E: Multiport fuel injection system engine
N: Diesel engine
U: Turbocharger engine
F: 5-speed floor shift manual transmission
A: 4-speed floor shift automatic transmission
N: 5-speed floor shift automatic transmission
A: S, STD, DX E: GL (SGL), ST, S F: SGL, TI, SAFARI, SE
H: GRX, S-SAFARI, SE
L: LH drive R: RH drive
S: Long wheelbase (4WD)
GN: TB45S or TB45E engine VT: TD42 engine
WS: ZD30DDTi engine GP: TB48DE engine
T: Station Wagon
K: Hardtop

GI-5

IDENTIFICATION INFORMATION
Identification Number
VEHICLE IDENTIFICATION NUMBER (Chassis number)
Prefix and suffix designations
For Europe (Except for Israel)
JN1

Y61

XXXXXX
Vehicle serial number

0: Stopgap (no meaning)
U: Europe
S: Long wheelbase (4WD)
Engine type
E: ZD30DDTi F: TB48DE
Body type
T: Station Wagon K: Hardtop
Manufacturer
JN1: Japan produced vehicle

Dimensions
FOR EUROPE
Wagon

Hardtop

Overall length

mm (in)

5,070 (199.6)*1
5,065 (199.4)*2
5,020 (197.6)*3

4,495 (177.0)*2
4,450 (175.2)*3

Overall width

mm (in)

1,930 (76.0)*1, *2
1,840 (72.4)*3

1,930 (76.0)*2
1,840 (72.4)*3

Overall height

mm (in)

1,855 (73.0)

1,840 (72.4)

Front tread

mm (in)

1,605 (63.2)*1, *2
1,555 (61.2)*3

1,605 (63.2)*2
1,555 (61.2)*3

Rear tread

mm (in)

1,625 (64.0)*1, *2
1,575 (62.0)*3

1,625 (64.0)*2
1,575 (62.0)*3

Wheelbase

mm (in)

2,970 (116.9)

2,400 (94.5)

*1: For models equipped with 275/70R16 tires
*2: For models equipped with 265/70R16 tires
*3: For models equipped with 235/80R16 tires

GI-6

HEATER &
AIR CONDITIONER
SECTION

MODIFICATION NOTICE:
+ Wiring diagram has been changed.
+ Relief valve to compressor has been added.
+ Rear thermo amp. and rear solenoid valve relay have been eliminated. (Except for the Middle East)
+ Trouble diagnosis procedure for magnet clutch (auto) has been added. (Model with TB48 engine for
Europe)

CONTENTS
MANUAL AND AUTO
PRECAUTIONS AND PREPARATION ……………………. 2
Supplemental Restraint System (SRS) ″AIR
BAG″ and ″SEAT BELT PRE-TENSIONER″ ………… 2
DESCRIPTION ……………………………………………………… 3
Refrigeration Cycle ……………………………………………. 3

AUTO
DESCRIPTION ……………………………………………………… 4
Control Operation ……………………………………………… 4

TROUBLE DIAGNOSES ……………………………………….. 6
Circuit Diagram — A/C, A -/TB48 Engine ………………. 6
Wiring Diagram — A/C, A -/TB48 Engine ………………. 7
Auto Amp. Terminals and Reference Value………… 11
Magnet Clutch (For Europe)……………………………… 13
Magnet Clutch…………………………………………………. 18

REAR COOLER
TROUBLE DIAGNOSES ……………………………………… 19
Wiring Diagram — R/COOL -/With Front Auto A/C… 19

PRECAUTIONS AND PREPARATION

MANUAL AND AUTO

HA-2

DESCRIPTION

MANUAL AND AUTO

Refrigeration Cycle
REFRIGERANT SYSTEM PROTECTION
Pressure Relief Valve
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an unusual level [more than 3,727 kPa (38
kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant
into the atmosphere.

SHA652FA

HA-3

DESCRIPTION

AUTO

Control Operation

RHA210I

AUTO SWITCH
The compressor, air intake doors, air mix door, mode doors, and blower speed are automatically controlled
so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the
operator.
The air conditioning cooling function operates only when the engine is running.

ECON SWITCH
Fully automatic control with the compressor off. With the compressor off, the system will not remove heat
(cool) or de-humidify. The system will maintain the in-vehicle temperature at the set temperature when the
set temperature is above the ambient (outside) temperature.

TEMPERATURE SWITCH (Potentio Temperature Control)
Increases or decreases the set temperature.

OFF SWITCH
The compressor and blower are off, the air intake doors are set to the outside air position. Then, the mode
doors are set to the foot (80% foot and 20% defrost) position. In the off position, the A/C system uses the
vehicle’s “flow through” ventilation. It tries to maintain the interior temperature based on the last set temperature of the system.

FAN SWITCH
Manual control of the blower speed. Four speeds are available for manual control (as shown on the display
screen):
low
, medium low
, medium high
, high

MODE SWITCH
Manual control of the air discharge outlets. Four selections are available (as shown on the display screen):
face
, bi-level
, foot
, defrost/foot

HA-4

DESCRIPTION
Control Operation (Cont’d)

AUTO

RECIRCULATION (REC) SWITCH
ON position: Interior air is recirculated inside the vehicle.
OFF position: Automatic control resumes.
Recirculation is canceled when AUTO, DEF or ECON is selected. Recirculation resumes when another mode
is chosen.

DEFROSTER (DEF) SWITCH
Positions the mode doors to the defrost position. Also positions the air intake doors to the outside air position.

HA-5

TROUBLE DIAGNOSES

AUTO

Circuit Diagram — A/C, A —/TB48 Engine

THA133M

HA-6

TROUBLE DIAGNOSES

AUTO

Wiring Diagram — A/C, A —/TB48 Engine

THA134M

HA-7

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TB48 Engine
(Cont’d)

THA135M

HA-8

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TB48 Engine
(Cont’d)

THA136M

HA-9

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TB48 Engine
(Cont’d)

THA137M

HA-10

TROUBLE DIAGNOSES

AUTO

Auto Amp. Terminals and Reference Value
INSPECTION OF AUTO AMP.
+ Measure voltage between each terminal and body ground by
following “AUTO AMP. INSPECTION TABLE”.

SHA739F

SHA758F

+ Pin connector terminal layout

RHA501GF

HA-11

AUTO
TROUBLE DIAGNOSES
Auto Amp. Terminals and Reference Value
(Cont’d)

AUTO AMP. INSPECTION TABLE
TERMINAL
No.
(Wire color)

ITEM

VOLTAGE
V

CONDITION

1 (RY)

Power supply for IGN

—

Approximately 12

2 (Y)

Power supply for BAT

—

Approximately 12

3 (B)

Ground

—

4 (Y)*2
(LG)*4

5 (L)
8 (GY/R)

Compressor ON signal

Approximately 0

OFF

Approximately 12

Compressor

LAN signal

—

Approximately 5.5

In-vehicle sensor

—

9 (PU)

Ambient sensor

—

10 (R)

Sunload sensor

—

11 (B)

Ground

12 (L/B)

Power supply for illumination

13 (OR/B)

Intake door position switch

14 (P)

Intake door position switch

15 (G/Y)

Power supply for mode and air mix
door motor

17 (GY/L)

Fan control amp. control signal

18 (L/W)

Blower motor feed back

19*1 (Y/L)

Fan ON signal

—
—

—

Illumination switch ON

Approximately 12

RECIRCULATION

Approximately 0

FRESH or 20% FRESH

Approximately 12

FRESH

Approximately 0

RECIRCULATION or 20% FRESH

Approximately 12

—

Approximately 12

Low, middle low or middle high

Approximately 2.5 — 3.0

High

Approximately 9 — 10

Low

Approximately 7 — 10

Approximately 0

Fan speed

Blower fan

OFF

Power supply for blower motor

21 (Y/R)

Thermal transmitter

23 (OR)

Intake door position switch

24 (G/Y)

Sensor ground

—

25 (G/W)

Intake sensor

—

27*2 (Y/B)

FICD ON signal

28 (LG/B)

Rear cooler relay

35 (Y/L)*5
(OR/L)*6

Rear cooler switch

36*3 (Y)

*1:
*2:
*3:
*4:
*5:
*6:

—

Approximately 5

20 (L/R)

—

Approximately 12
—

20% FRESH

Approximately 0

RECIRCULATION or FRESH

Approximately 12

Compressor
ON

Ambient temperature 20.5°C or
less

Approximately 0

Ambient temperature 23.5°C or
more

Approximately 12

Rear cooler ON

Approximately 0

Rear cooler OFF

Approximately 12

Rear cooler switch ON

Approximately 0

Rear cooler switch OFF

Approximately 12

Front solenoid valve relay

A/T models
Except for Europe
For the Middle East with cool box
Except for the Middle East
With rear cooler front switch and without cool box
Without rear cooler front switch

HA-12

Cool box switch ON

Approximately 0

Cool box switch OFF

Approximately 12

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (For Europe)
TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH (FOR TB48 ENGINE)
SYMPTOM:
+ Magnet clutch does not engage.

Inspection flow

SHA764F

*1: HA-64 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E

*5: HA-104 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E

*9: HA-79 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E

*2: HA-65 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E

*6: HA-106 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E

*10: HA-70 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E

*3: HA-67 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E
*4: HA-14

*7: HA-108 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E
*8: HA-110 in Y61 SERVICE MANUAL,

*11: HA-69 in Y61 SERVICE MANUAL,
publication No. SM8E-0Y61E0E
*12: HA-119 in Y61 SERVICE MANUAL,

publication No. SM8E-0Y61E0E

HA-13

publication No. SM8E-0Y61E0E

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (For Europe) (Cont’d)

DIAGNOSTIC PROCEDURE (TB48 ENGINE FOR
EUROPE)
SYMPTOM: Magnet clutch does not engage when A/C
switch and fan switch are ON.
Yes
CHECK POWER SUPPLY FOR COMPRESSOR.
Disconnect compressor harness connector.
Do approx. 12 volts exist between compressor harness connector terminal No. V
1
and body ground?
.

Check magnet clutch coil.
NG
.

Replace magnet clutch.

Disconnect A/C relay harness connector.
Note

CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS CONNECTOR TERMINAL NO. V
3 AND COMPRESSOR HARNESS CONNECTOR
TERMINAL NO. V
1 .
Continuity should exist.
If OK, check harness for short.
SHA738F

OK
.

CHECK POWER SUPPLY FOR A/C
RELAY.
Reconnect A/C relay harness connector.
Do approx. 12 volts exist between A/C
relay harness connector terminal Nos. V
1 ,
5 and body ground?
V

No
c

Yes
.

CHECK POWER SUPPLY
CIRCUIT AND 20A (No.
) FUSE AT FUSE
BLOCK.
Refer to EL section (“Wiring Diagram”, “POWER
SUPPLY ROUTING”).

CHECK A/C RELAY AFTER DISCONNECTING IT.
Refer to HA-18.

Replace A/C relay.

SHA788F
.

V
(Go to next page.)

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

SHA580F

SHA581FA

HA-14

TROUBLE DIAGNOSES
Magnet Clutch (For Europe) (Cont’d)

AUTO

A
V
.

Reconnect A/C relay harness connector.

SHA582FA

CHECK COIL SIDE CIRCUIT OF A/C
RELAY.
Do approx. 12 volts exist between ECM
harness connector terminal No. V
24 and
body ground?

No
c

Disconnect A/C relay harness connector.
Disconnect ECM harness
connector.

Yes

CHECK CIRCUIT CONTINUITY BETWEEN A/C
RELAY HARNESS CONNECTOR TERMINAL NO.
2 AND ECM HARNESS
V
CONNECTOR TERMINAL
NO. V
24 .
Continuity should exist.
If OK, check harness for
short.

.
SHA583F

Note

Disconnect thermo control amp. harness
connector.

CHECK THERMO CONTROL AMP. CIRCUIT.
Do approx. 12 volts exist between thermo
control amp. harness connector terminal
No. V
3 and body ground?

c C

Yes
RHA660G

CHECK POWER SUPPLY FOR THERMO
CONTROL AMP.
Do approx. 12 volts exist between thermo
control amp. harness connector terminal
No. V
1 and body ground?

No
c

Check power supply circuit
and 20A fuse (No.
,
located in the fuse block).

Yes
.

B
V

(Go to next page.)

RHA661G

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-15

TROUBLE DIAGNOSES
Magnet Clutch (For Europe) (Cont’d)

AUTO

B
V
.

Disconnect auto amp. harness connector.

Note

RHA662G

Check circuit continuity between thermo
control amp. harness connector terminal
No. V
2 and auto amp. harness connector
terminal No. V
4 .
Continuity should exist.
If OK, check harness for short.
OK
.

CHECK THERMO CONTROL AMP.
Refer to HA-59 in Y61 SERVICE
MANUAL, (publication No. SM7E2Y61G1).

Replace thermo control
amp.

Replace refrigerant pressure sensor.

OK
.

RHA190I

CHECK REFRIGERANT PRESSURE
SENSOR. Refer to HA-18.
OK
.

CHECK FAN SIGNAL.
Measure voltage between auto amp. harness connector terminal No. V
19 and body
ground.
Terminal No.
⊕

Body
ground

Condition

Voltage

A/C: ON

A/C: OFF

INSPECTION END
c

RHA191I

NG
.

If the voltage is approx. 0V when A/C
switch OFF, go to A.
If the voltage is approx. 5V when A/C
switch ON, go to B.

Replace auto amp.
c

A
.

Disconnect combination meter harness
connector.

Note

Check circuit continuity between auto amp.
harness connector terminal No. V
19 and
combination meter harness connector terminal No. V
43 .
OK
.

Check combination meter.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-16

TROUBLE DIAGNOSES
Magnet Clutch (For Europe) (Cont’d)

AUTO

C
V
.

Disconnect combination meter harness
connector.

Note

SHA700FA

Check circuit continuity between combination meter harness connector terminal No.
42 and thermo control amp. harness conV
nector terminal No. V
3 .
Continuity should exist.
If OK, check harness for short.
OK
.

Check combination meter.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-17

TROUBLE DIAGNOSES

AUTO

Magnet Clutch
COMPONENT INSPECTION
A/C Relay
Check continuity between terminal Nos. 3 and 5.
Conditions

SHA479F

Continuity

12V direct current supply between terminal Nos. 1 and 2

Yes

No current supply

If NG, replace relay.

Refrigerant Pressure Sensor
Make sure that higher A/C refrigerant-pressure results in higher
refrigerant-pressure sensor output voltage.
Check voltage between ECM harness connector terminal No. 88
(R/G) and body ground. Refer to refrigerant pressure sensor in
ECM.

SHA701FA

SHA315FI

HA-18

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/With Front
Auto A/C

THA138M

HA-19

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/With Front
Auto A/C (Cont’d)

THA070M

HA-20

ALPHABETICAL INDEX
SECTION

IDX

ALPHABETICAL INDEX
A

A/C control operation (auto A/C) ……………. HA-4
A/C, A — Wiring diagram ………………………… HA-7
A/T — Wiring diagram — AT — FTS ………… AT-111
A/T — Wiring diagram — AT — LPSV ………… AT-98
A/T — Wiring diagram — AT NONDTC ……………………………………… AT-166
A/T — Wiring diagram — AT PNP/SW …………………………………………. AT-83
A/T — Wiring diagram — AT — TCV ………….. AT-95
A/T — Wiring diagram — AT — VSS/AT …….. AT-88
A/T — Wiring diagram …………………………….. AT-7
A/T IND — Wiring diagram …………………… EL-104
A/T fluid temperature sensor ………………. AT-110
A/T self-diagnoses ………………………… AT-68, 73
A/T shift lock system — Wiring
diagram ………………………………………… AT-189
A/T shift lock system …………………………. AT-188
A/T trouble diagnoses …………………………. AT-39
ABS — Wiring diagram …………………………… BR-6
APS — Wiring diagram ……………………….. EC-498
ASCD (automatic speed control
device) …………………………………………. EL-122
ASCD — Wiring diagram ……………………… EL-123
Accelerator control system …………………….. FE-2
Accelerator position sensor ……………….. EC-498
Accelerator wire adjustment …………………… FE-3
Air cleaner filter replacement ………………. MA-16
Air conditioner cut control ……………………. EC-28
Alternator …………………………………………… EL-45
Anti-lock brake system — Wiring
diagram …………………………………………… BR-5
Audio ……………………………………………….. EL-115
Auto air conditioner — Wiring
diagram …………………………………………… HA-7
Automatic speed control system — See
ASCD …………………………………………… EL-122

BACK/L — Wiring diagram ……………………..
Back-up lamp ………………………………………
Basic inspection ………………………………….
Battery ……………………………………………….

Camshaft position sensor (CMPS) ……… EC-257
Charging system …………………………………. EL-43
Chassis and body maintenance …………… MA-21
Cigarette lighter ………………………………… EL-109
Clock ……………………………………………….. EL-121
Closed loop control …………………………….. EC-25
Combination meter ……………………………… EL-82
Combination switch …………………………….. EL-38
Compression pressure …………………………. EM-9
Connecting rod bearing clearance ……….. EM-50
Connecting rod bushing clearance ……….. EM-51
Connecting rod ………………………………….. EM-47
Coolant mixture ratio ………………………….. MA-12
Coolant replacement ………………………….. MA-12
Cooling circuit (engine) …………………………. LC-9
Cooling fan control system …………………… LC-14
Cooling fan control ……………………………. EC-489
Cooling fan motor …………………………….. EC-371
Cooling fan relay ………………………………. EC-371
Crankcase ventilation system — See
Positive crankcase ventilation …………. EC-481
Crankshaft position sensor (OBD) .. EC-251, 381
Crankshaft ………………………………………… EM-49
Cruise control — See ASCD ………………… EL-122
Cylinder block boring ………………………….. EM-47
Cylinder block ……………………………………. EM-44
Cylinder head bolt tightening ……………….. EM-38
Cylinder head ……………………………………. EM-26

D/LOCK — Wiring diagram ………………….. EL-140
DEICER — Wiring diagram ………………….. EL-111
DTC work support ………………………………. EC-98
DTRL — Wiring diagram ……………………….. EL-49
Daytime light system …………………………… EL-49
Diagnostic trouble code (DTC) for
OBD system …………………………………….. EC-9
Diagnostic trouble code (DTC) inspection priority chart …………………………….. EC-64
Drive belt inspection …………………………… MA-11

EL-57
EL-57
EC-66
EL-40

CD/CHG — Wiring diagram ………………….. EL-119
CHARGE — Wiring diagram ………………….. EL-43
CIGAR — Wiring diagram ……………………. EL-109
CKPS — Wiring diagram ……………… EC-253, 383
CLOCK — Wiring diagram …………………… EL-121
CMPS — Wiring diagram …………………….. EC-257
COMPAS — Wiring diagram ………………….. EL-89
CONSULT for engine ………………………….. EC-89
COOL/F — Wiring diagram …………… EC-364, 489
Camshaft inspection …………………………… EM-29

ECCS-D control module ……………………. EC-499
ECM input/output signal ………………………. EC-80
ECTS — Wiring diagram ……………………… EC-154
EGR — Wiring diagram ………………………. EC-500
EGR volume control valve …………………. EC-500
EVAP canister purge volume control
valve ……………………………………………. EC-269
EVAP vapor lines inspection ……………….. MA-20
Electrical load signal circuit ……………….. EC-470
Electrical units location ………………………. EL-229
Electronic fuel injection pump …………….. EC-497
Electronic ignition (EI) system ……………… EC-27
Engine control circuit diagram …… EC-7, 78, 485

IDX-2

ALPHABETICAL INDEX
Engine control component parts
location ………………………………………….. EC-74
Engine control module (ECM) ……………. EC-283
Engine control system diagram and
chart ……………………………………………… EC-22
Engine coolant temperature sensor
(ECTS) ………………………………………… EC-152
Engine fail-safe system ……………………….. EC-65
Engine oil filter replacement ………………… MA-18
Engine oil replacement ……………………….. MA-17
Engine outer component parts ………………. EM-5
Engine removal ………………………………….. EM-42
Exhaust system ………………………………….. EC-12

IATS — Wiring diagram ………………………. EC-149
ILL — Wiring diagram ……………………………. EL-70
INJECT — Wiring diagram …………………… EC-454
IVC — Wiring diagram ………………………… EC-296
Idle speed …………………………………………. EC-30
Ignition control system ……………….. EC-112, 428
Ignition timing …………………………………….. EC-30
Illumination …………………………………………. EL-69
Injector removal and installation …………… EC-35
Injector ……………………………………………. EC-453
Intake air temperature sensor …………….. EC-147
Intake valve timing control solenoid
valve …………………………………….. EC-294, 298

F/FOG — Wiring diagram ………………………. EL-58
F/PUMP — Wiring diagram ………………….. EC-459
Fluid temperature sensor (A/T) …………… AT-110
Fluids …………………………………………………. MA-9
Flywheel runout …………………………………. EM-52
Front disc brake …………………………………… BR-2
Fuel cut control (at no load & high
engine speed) ………………………………… EC-28
Fuel filter replacement ………………………… MA-16
Fuel gauge …………………………………………. EL-82
Fuel injection system …………………. EC-218, 227
Fuel line inspection …………………………….. MA-16
Fuel pressure check …………………………… EC-34
Fuel pressure regulator ……………………….. EC-34
Fuel pump and gauge …………………………. FE-10
Fuel pump relay ………………………… EC-459, 464
Fuel pump ……………………………………….. EC-459
Fuel system ……………………………………….. FE-11
Fuse ………………………………………………… EL-279
Fusible link ……………………………………….. EL-279

Gauges ……………………………………………… EL-82
Generic scan tool (GST) ……………………. EC-101
Grease ……………………………………………….. MA-9
Ground distribution ……………………………… EL-17

H/AIM — Wiring diagram ……………………….. EL-47
H/LAMP — Wiring diagram ……………………. EL-46
HLC — Wiring diagram ………………………… EL-106
Harness layout ………………………………….. EL-236
Hazard warning lamp ………………………….. EL-63
Headlamp aiming control ……………………… EL-47
Headlamp washer ……………………………… EL-106
Headlamp ………………………………………….. EL-46
How to erase DTC for OBD system ……… EC-49

KS — Wiring diagram …………………………. EC-248
Keyless entry system — See Multi-remote control system ………………………. EL-169
Knock sensor (KS) ……………………………. EC-247

LOAD — Wiring diagram …………………….. EC-471
License lamp ……………………………………… EL-51
Line pressure solenoid valve ……………….. AT-97
Line pressure test (A/T) ……………….. AT-52, 201
Location of electrical units ………………….. EL-229
Lubricants …………………………………………… MA-9
Lubrication circuit (engine) …………………….. LC-3

MAFS — Wiring diagram ……………… EC-142, 487
MAIN — Wiring diagram ………………. EC-113, 486
Magnet clutch …………………………………….. HA-13
Maintenance (engine) …………………………. MA-10
Maintenance ……………………………………… MA-10
Manifold tightening torque (intake &
exhaust) ………………………………………… MA-10
Mass air flow sensor (MAFS) …………….. EC-140
Meter …………………………………………………. EL-82
Misfire ……………………………………………… EC-241
Multi-remote control system ……………….. EL-169
Multiport fuel injection (MFI) system ……… EC-24

NATS (Nissan Anti-theft System) …. EL-200, 215
NATS — Wiring diagram … EL-201, 215, 216, 218
NVH troubleshooting (EM) ……………………. EM-4

IDX-3

ALPHABETICAL INDEX
O

Oil change (capacity) ……………………………. MA-9
Oil cooler (engine) ………………………………… LC-7
Oil jet ………………………………………………….. LC-6
Oil pan (engine) …………………………………. EM-10
Oil pressure (engine) …………………………….. LC-4
Oil pressure relief valve (engine) ……………. LC-6
Oil pump (engine) …………………………………. LC-4
Oil pump regulator valve (engine) …………… LC-6
Oil seal replacement (engine) ……………… EM-24
Oversize piston ………………………………….. EM-59

PCV (positive crankcase ventilation) …… EC-482
PGC/V — Wiring diagram ……………………. EC-271
PNP/SW — Wiring diagram …………………. EC-390
POWER — Wiring diagram ……………………… EL-7
Park/Neutral position switch ………………. EC-388
Park/neutral position switch (A/T) ….. AT-82, 164
Parking brake control ……………………………. BR-4
Parking lamp ………………………………………. EL-51
Piston assembly ………………………………… EM-52
Piston pin inspection ………………………….. EM-46
Piston ring inspection …………………………. EM-46
Piston to bore clearance …………………….. EM-47
Power door lock ………………………………… EL-139
Power supply routing …………………………….. EL-6
Pressure test (A/T) ………………………. AT-52, 201

R/COOL — Wiring diagram (front
auto A/C) …………………………………………… HA-19
Radiator …………………………………………….. LC-13
Radio — See Audio …………………………….. EL-115
Rear axle (drum brake type) ………………….. RA-2
Rear disc brake ……………………………………. BR-3
Rear window defogger ………………………. EL-112
Refrigeration cycle ……………………………….. HA-3
Removal and installation (A/T) ……………. AT-199
Revolution sensor (A/T) ………………………. AT-86

S/LOCK — Wiring diagram …………………… EL-153
S/SIG — Wiring diagram ……………………… EC-451
S/TANK — Wiring diagram ………………………. FE-6
SHIFT — Wiring diagram …………………….. AT-189
STAB — Wiring diagram …………………………. RA-3
Self-diagnostic results …………………………. EC-51
Shift lock system ………………………………. AT-188
Shift schedule ……………………………… AT-58, 201
Spark plug replacement ………………… MA-14, 18
Speedometer ……………………………………… EL-82

Stabilizer release device — Wiring
diagram …………………………………………… RA-3
Stabilizer release device ……………………….. RA-3
Stall test (A/T) …………………………….. AT-50, 201
Start signal ………………………………………. EC-450
Starter ……………………………………………….. EL-42
Starting system …………………………………… EL-41
Steering switch …………………………………… EL-39
Steering wheel and column ……………………. ST-2
Sub fuel tank control system ………………….. FE-4
Super lock ………………………………………… EL-152
Supplemental restraint system — Wiring
diagram ……………………………………….. RS-3, 7
Symptom matrix chart …………………………. EC-71
System readiness test (SRT) code ……….. EC-42

TAIL/L — Wiring diagram ………………………. EL-51
TCM circuit diagram ………………………… AT-6, 49
TCM inspection table ………………………….. AT-64
THEFT — Wiring diagram …………….. EL-189, 194
TURN — Wiring diagram ……………………….. EL-63
Tachometer ………………………………………… EL-82
Tail lamp ……………………………………………. EL-51
Theft warning system ………………………… EL-188
Thermostat ………………………………………… LC-11
Three way catalyst ……………………………. EC-264
Throttle chambers ………………………………… EM-5
Throttle position sensor
(TPS) ……………… EC-157, 235, 372, 374, 415
Throttle position switch ………………………. AT-164
Timing chain ……………………………………… EM-15
Torque converter clutch solenoid
valve ……………………………………………… AT-94
Torque converter installation ………………. AT-200
Turbine revolution sensor …………………… AT-115
Turn signal lamp …………………………………. EL-63
Two trip detection logic ……………………….. EC-37

VIAS — Wiring diagram ………………………. EC-448
VIAS ……………………………………………….. EC-446
VSS — Wiring diagram ……………………….. EC-488
Vacuum hose drawing (Engine control) … EC-23
Valve clearance …………………………………. EM-35
Valve guide ……………………………………….. EM-31
Valve lifter …………………………………………. EM-34
Valve seat …………………………………………. EM-33
Valve spring ………………………………………. EM-34
Variable induction air control
system (VIAS) ………………………………….. EC-446
Vehicle speed sensor (VSS) ………. EC-276, 488

IDX-4

ALPHABETICAL INDEX
W

WARN — Wiring diagram ………………………. EL-92
Warning lamps ……………………………………. EL-90
Water pump ……………………………………….. LC-11

Water temperature gauge ……………………. EL-82
Wiper deicer …………………………………….. EL-111
Wrist pin — See Piston pin inspection ……. EM-46

IDX-5

ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION

MODIFICATION NOTICE:
+

TB48DE engine model has been added.

CONTENTS
TB48DE
PRECAUTIONS AND PREPARATION ……………………. 2
Liquid Gasket Application Procedure …………………… 2
Special Service Tools ………………………………………… 2
ENGINE LUBRICATION SYSTEM………………………….. 3
Lubricating Circuit ……………………………………………… 3
Oil Pressure Check……………………………………………. 4
Oil Pump ………………………………………………………….. 4
Oil Jet………………………………………………………………. 6
Oil Filter …………………………………………………………… 7
Oil Cooler…………………………………………………………. 7

ENGINE COOLING SYSTEM…………………………………. 9
Cooling Circuit ………………………………………………….. 9
System Check…………………………………………………… 9
Water Pump……………………………………………………. 11
Thermostat……………………………………………………… 11
Water Outlet……………………………………………………. 12
Radiator …………………………………………………………. 13
Cooling Fan Control System (For Europe)………….. 14
SERVICE DATA AND SPECIFICATIONS (SDS) ……. 15
Engine Lubrication System……………………………….. 15
Engine Cooling System ……………………………………. 15

TB48DE

PRECAUTIONS AND PREPARATION
Liquid Gasket Application Procedure

SEM164F

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

AEM080

Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool name

Description

ST25051001*
Oil pressure gauge

Measuring oil pressure
Maximum measuring range:
2,452 kPa (24.5 bar, 25
kg/cm2, 356 psi)
NT558

ST25052000*
Hose

Adapting oil pressure gauge
to cylinder block

NT559

EG17650301
Radiator cap tester
adapter

Adapting radiator cap tester
to radiator filler neck and reservoir tank cap

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

NT564

LC-2

ENGINE LUBRICATION SYSTEM

TB48DE

Lubricating Circuit

MLC113A

LC-3

ENGINE LUBRICATION SYSTEM

TB48DE

3. Install pressure gauge.
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
Engine speed
rpm

Approximate discharge pressure
kPa (bar, kg/cm2, psi)

Idle speed
2,800

More than 49 (0.49, 0.5, 7)
294 — 490 (2.94 — 4.90, 3.0 — 5.0, 43 — 71)

MLC114A

If difference is extreme, check oil passage and oil pump.
6. Install oil pressure switch with sealant.
Oil pressure switch:
: 10 — 16 Nzm (1.0 — 1.6 kg-m, 87 — 139 in-lb)

Oil Pump
REMOVAL AND INSTALLATION
1. Drain engine oil.
2. Drain coolant from radiator and cylinder block. Refer to MA
section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”).
3. Remove power steering pump drive belt, alternator drive belt
and A/C compressor drive belt.
4. Remove radiator and radiator shroud.
5. Remove fan coupling with fan.
6. Remove crankshaft pulley.
7. Remove water pump.
8. Remove power steering pump and power steering pump
bracket.
9. Remove alternator and alternator bracket.
10. Remove left side of the tie rod end.
11. Remove oil pans. Refer to “Removal” of “OIL PAN” in EM
section.
12. Remove cylinder head front cover.
13. Remove front cover assembly.
14. Remove oil pump assembly.
15. Reinstall any part removed in reverse order of removal.

LC-4

TB48DE

ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
DISASSEMBLY AND ASSEMBLY

MLC115A

1 Oil pump cover
V
2 Inner gear
V
3 Outer gear
V

4 Front cover
V
5 O-ring
V
6 Regulator valve
V

7 Spring
V
8 Regulator plug
V

+ When installing oil pump, apply engine oil to gears.

OIL PUMP INSPECTION
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
Body to outer gear clearance V
1
Inner gear to outer gear tip clearance V
2

MLC116A

0.114 — 0.260 (0.0045 — 0.0102)
Below 0.18 (0.0071)

Body to inner gear clearance V
3

0.030 — 0.070 (0.0012 — 0.0028)

Body to outer gear clearance V
4

0.030 — 0.190 (0.0012 — 0.0075)

Inner gear to brazed portion of housing
clearance V
5

0.045 — 0.091 (0.0018 — 0.0036)

+ If the tip clearance (V
2 ) exceeds the limit, replace gear
set.
+ If body to gear clearances (V
1 , V
3 , V
4 , V
5 ) exceed the
limit, replace oil pump body assembly.

MLC117A

LC-5

ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)

TB48DE

SLC182B

REGULATOR VALVE INSPECTION
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump cover.

SLC183B

4. Check regulator valve to oil pump cover clearance.
Clearance:
6 : 0.040 — 0.097 mm (0.0016 — 0.0038 in)
V
If it exceeds the limit, replace oil pump cover.

SLC184B

OIL PRESSURE RELIEF VALVE INSPECTION (For oil
cooler)
Inspect oil pressure relief valve for movement, cracks and breaks
by pushing the ball. If replacement is necessary, remove valve
by prying it out with suitable tool.
Install a new valve in place by tapping it.

SLC185B

Oil Jet
INSPECTION (For timing chain)
Make sure that the holes are not clogged. Clean them with a wire
if necessary.
Drive oil jet into place after positioning alignment mark on cylinder block.

MLC118A

LC-6

ENGINE LUBRICATION SYSTEM

TB48DE

Oil Filter
The oil filter is a small, full-flow cartridge type and is provided
with a relief valve.

SLC035B

Oil Cooler

MLC119A

REMOVAL AND INSTALLATION
1. Disconnect water hoses from oil cooler, pinching hoses near
oil cooler to prevent engine coolant from spilling.
2. Remove oil cooler. Put mating marks for easier installation.
3. Installation is in reverse order of removal.
+ Do not spill engine oil and engine coolant on the drive
belt.
+ Completely wipe off any engine oil and engine coolant
that adheres to the engine and the vehicle.
4. Check oil level and add engine oil.
5. After warming up engine, check that there is no leakage of
engine oil and engine coolant.

INSPECTION
1. Check oil cooler for cracks.

LC-7

ENGINE LUBRICATION SYSTEM
Oil Cooler (Cont’d)

TB48DE

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

LC-8

ENGINE COOLING SYSTEM

TB48DE

Cooling Circuit

SLC466B

System Check
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping
from the radiator.
Wrap a thick cloth around the cap. Slowly turn it a quarter
turn to allow built-up pressure to escape. Carefully remove
the cap by turning it all the way.
CAUTION:
Do not install the reservoir tank cap (pressure side), which
is provided with valves, to radiator on models for the Middle
East.

CHECKING COOLING SYSTEM HOSES
Check hoses for the following:
+ Improper attachment
+ Leaks
+ Cracks
+ Damage
+ Chafing
+ Deterioration

LC-9

ENGINE COOLING SYSTEM
System Check (Cont’d)

TB48DE

CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with
a tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher pressure than specified may cause radiator damage.

SLC134B

CHECKING RADIATOR CAP
Except for the Middle East
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
108 — 127 kPa
(1.08 — 1.27 bar, 1.1 — 1.3 kg/cm2, 16 — 18 psi)
Limit
59 kPa (0.59 bar, 0.6 kg/cm2, 9 psi)
SLC135B

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

SMA967B

CHECKING RESERVOIR TANK CAP (PRESSURE
SIDE)
For the Middle East

SLC135B

To check reservoir tank cap (pressure side), apply pressure to
cap with a tester.
Reservoir tank cap relief pressure:
Standard
78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2, 11 — 14 psi)
Limit
59 kPa (0.59 bar, 0.6 kg/cm2, 9 psi)

LC-10

ENGINE COOLING SYSTEM
System Check (Cont’d)

TB48DE

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

SMA967B

REMOVAL
1. Drain coolant from radiator and cylinder block.
Refer to MA section (“Changing Engine Coolant”, “ENGINE
MAINTENANCE”).
2. Remove power steering pump drive belt, alternator drive belt
and A/C compressor drive belt.
3. Remove radiator shroud.
4. Remove fan coupling with fan.
5. Remove water pump.
MMA119A

INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
2. Check for rough operation due to excessive end play.

MLC122A

Thermostat
+ After installation, run engine for a few minutes and
check for leaks.
+ Be careful not to spill coolant in engine compartment.
Use a rag to absorb coolant.

REMOVAL
Drain coolant from radiator and cylinder block. Refer to MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”).
MLC123A

LC-11

TB48DE

ENGINE COOLING SYSTEM
Thermostat (Cont’d)
INSPECTION

1. Check valve seating condition at ordinary temperatures. It
should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Gulf standard model
Valve opening temperature
Maximum valve lift

SLC252B

°C (°F)

mm/°C (in/°F)

76.5 (170)
10/90 (0.39/194)

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

Water Outlet
INSPECTION
Visual inspection for water leaks. If there is leakage, replace
gasket.

MLC124A

LC-12

ENGINE COOLING SYSTEM

TB48DE

Radiator
FOR EUROPE

SLC521B

LC-13

ENGINE COOLING SYSTEM

TB48DE

Cooling Fan Control System (For Europe)
Cooling fan is controlled by ECM (Engine control module). For
details, refer to EC section [“Cooling Fan”, “DTC P1217 ENGINE
OVER TEMPERATURE (OVERHEAT)”].

SLC522B

LC-14

SERVICE DATA AND SPECIFICATIONS (SDS)

TB48DE

Engine Lubrication System
OIL PRESSURE CHECK

OIL PUMP INSPECTION
Unit: mm (in)

Engine rpm

Approximate discharge pressure
kPa (bar, kg/cm2, psi)

Body to outer gear clearance V
1

0.114 — 0.260 (0.0045 — 0.0102)

Idle speed
2,800

More than 49 (0.49, 0.5, 7)
294 — 490 (2.94 — 4.90, 3.0 — 5.0, 43 — 71)

Inner gear to outer gear tip clearance V
2

Below 0.18 (0.0071)

Body to inner gear clearance V
3

0.030 — 0.070 (0.0012 — 0.0028)

Body to outer gear clearance V
4

0.030 — 0.190 (0.0012 — 0.0075)

Inner gear to brazed portion of
housing clearance V
5

0.045 — 0.091 (0.0018 — 0.0036)

Regulator valve to oil pump cover
6
V

0.040 — 0.097 (0.0016 — 0.0038)

Engine Cooling System
RADIATOR

THERMOSTAT

Except for the Middle East

Standard

Unit: kPa (bar, kg/cm2, psi)

Radiator cap
Standard
Limit
Leakage test pressure

108 — 127
(1.08 — 1.27, 1.1 — 1.3, 16 — 18)

Valve opening temperature
°C (°F)
Max. valve lift

59 (0.59, 0.6, 9)
157 (1.57, 1.6, 23)

For the Middle East
Unit: kPa (bar, kg/cm2, psi)

Reservoir tank cap
(pressure side)
Standard
Limit
Leakage test pressure

78 — 98
(0.78 — 0.98, 0.8 — 1.0, 11 — 14)
59 (0.59, 0.6, 9)
157 (1.57, 1.6, 23)

LC-15

mm/°C (in/°F)

76.5 (170)
10/90 (0.39/194)

MAINTENANCE
SECTION

MODIFICATION NOTICE:
+
+
+
+

Platinum-tipped spark plugs have been used on models with three way catalyst for the Middle East and
Europe. (TB48DE engine)
Specifications of drive belt deflection have been modified. (TB48DE engine)
TB48DE engine maintenance information for Europe has been added.
Chassis and body maintenance information for the Middle East and Europe has been added. (TB48DE
engine)

CONTENTS
PRECAUTIONS AND PREPARATION ……………………. 2
Special Service Tools ………………………………………… 2
PERIODIC MAINTENANCE (For Europe) ………………. 3
Maintenance Schedule for Petrol Engines
(Annual Mileage < 30,000 km/year) …………………….. 3
Chassis and Body Maintenance………………………….. 4
Maintenance Under Severe Driving Conditions
(Annual Driving Distance < 30,000 km/year) ………… 5
Maintenance Schedule for Petrol Engines
(Annual Mileage > 30,000 km/year) …………………….. 6
Chassis and Body Maintenance………………………….. 7
Maintenance Under Severe Driving Conditions
(Annual Driving Distance > 30,000 km) ……………….. 8
RECOMMENDED FLUIDS AND LUBRICANTS……….. 9
Fluids and Lubricants ………………………………………… 9

TB48DE
ENGINE MAINTENANCE …………………………………….. 10
Checking Tightening Torque …………………………….. 10
Checking Drive Belts ……………………………………….. 11
Changing Engine Coolant…………………………………. 12

Changing Spark Plugs (Platinum-Tipped Type)…… 14
Checking Cooling System ………………………………… 15
Checking Fuel Lines ………………………………………… 16
Changing Fuel Filter ………………………………………… 16
Cleaning and Changing Air Cleaner Filter ………….. 16
Checking Cyclone Pre-air Cleaner …………………….. 17
Changing Engine Oil………………………………………… 17
Changing Oil Filter…………………………………………… 18
Checking and Changing Spark Plugs ………………… 18
Checking Positive Crankcase Ventilation (PCV)
System …………………………………………………………… 19
Checking Vacuum Hoses and Connections………… 20
Checking Vapor Lines ……………………………………… 20

CHASSIS AND BODY MAINTENANCE ………………… 21
Checking A/T Fluid ………………………………………….. 21
Changing A/T Fluid………………………………………….. 21
Checking Disc Brake ……………………………………….. 22
SERVICE DATA AND SPECIFICATIONS (SDS) ……. 23
Engine Maintenance (TB48DE)…………………………. 23

PRECAUTIONS AND PREPARATION
Special Service Tools
Tool number
Tool name

Engine application
Description
TB48DE

EG17650301
Radiator cap
tester adapter

Adapting radiator cap tester
to radiator filler neck and reservoir tank cap
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

NT564

KV10115801
Oil filter wrench

Removing oil filter

NT362

MA-2

PERIODIC MAINTENANCE (For Europe)
The following tables show the normal maintenance schedule. Depending upon weather and atmospheric
conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent
maintenance may be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.

Maintenance Schedule for Petrol Engines
(Annual Mileage < 30,000 km/year)
TB48DE ENGINE
Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATION

MAINTENANCE INTERVAL
15
(9)
12

30
(18)
24

45
(27)
36

60
(36)
48

75
(45)
60

90
(54)
72

105
(63)
84

120
(72)
96

Reference
pages

Engine oil (Use recommended oil)★

—

Engine oil filter (Use NISSAN genuine
part or equivalent)★

—

Drive belts

MA-11

Cooling system

—

Perform on a kilometer basis, but on an
annual basis when driving less than
15,000 km (9,000 miles) per year

km x 1,000
(miles x 1,000)
Months

Engine compartment and under vehicle

Engine anti-freeze coolant (Use genuine
NISSAN Anti-Freeze Coolant (L2N) or
equivalent)

See NOTE (1)

Air cleaner filter (Viscous paper type)★
Intake and exhaust valve clearance

See NOTE (2)

—
—

Fuel and EVAP vapour lines
Spark plugs (Platinum-tipped type)

Replace every 100,000 km (60,000 miles)

Fuel filter★

—
MA-14
—

NOTE: (1) First replace at 90,000 km (54,000 miles)/60 months, then every 60,000 km (36,000 miles)/48 months. Perform “I”
(Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
(2) Periodic maintenance is not required. However, if valve noise increases, check valve clearance.
★ Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving Conditions”.

MA-3

PERIODIC MAINTENANCE (For Europe)
Chassis and Body Maintenance
Abbreviations: R = Replace, I = Inspect: Correct or replace if necessary, L = Lubricate, T = Tighten, [ ] = At the specified mileage only

MAINTENANCE OPERATION

MAINTENANCE INTERVAL
km x 1,000

105

120

(miles x 1,000)

(9)

(18)

(27)

(36)

(45)

(54)

(63)

(72)

Months

Headlamp aiming

—

Wheel alignment (if necessary, balance &
rotate wheels)

—

Brake pads, rotors & other brake components★

MA-22

Foot brake, parking brake & clutch (for free
play, stroke & operation)

—

Perform on a kilometer basis, but on an
annual basis when driving less than 15,000
km (9,000 miles) per year.

Reference
pages

Underhood and under vehicle

Brake booster vacuum hoses, connections
& check valve

Brake & clutch, systems and fluid (for level
and leaks)

Brake fluid★

I
I

Power steering fluid and lines (for level and
leaks)

Ventilation air filter★

R
I

ASCD vacuum hoses

R
I

—

Greasing point of propeller shaft★

See NOTE (1)

—

Transfer fluid and differential gear oil (for
level & leaks or replace)★

See NOTE (2)

—

Drive shafts & steering damper★

—

Front wheel bearing grease★

—

Front axle joint in knuckle flange

Free-running hub grease★

—

Body mounting bolts & nuts

—

Steering gear & linkage, axle & suspension
parts, propeller shaft & exhaust system★

—

Body corrosion

See NOTE (3)

—

NOTE: (1) The propeller shaft should be re-greased after being immersed in water.
(2) Including differential gear with differential lock.
(3) Inspect once per year.
★ Maintenance items with “★” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-4

PERIODIC MAINTENANCE (For Europe)
Maintenance Under Severe Driving
Conditions (Annual Driving Distance < 30,000
km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be
performed on the following items as shown in the table.
A
B
C
D
E

—
—
—
—
—

Driving in dusty conditions
Repeatedly driving short distances
Towing a trailer or caravan
Extensive idling
Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely
high
F — Driving in high humidity or mountainous
areas
Driving condition

Maintenance item

Engine oil & engine oil filter

Air cleaner filter

Fuel filter

Brake pads, rotors & other
brake components

Brake fluid

Ventilation air filter

Automatic transmission fluid

Greasing point of propeller
shaft

Transfer fluid and differential
gear oil

Drive shafts & steering
damper

Front wheel bearing grease

Free-running hub grease

Steering gear & linkage, axle
& suspension parts, propeller
shaft & exhaust system

MA-5

Maintenance
operation

Maintenance interval

Replace

Every 7,500 km (4,500 miles) or 6 months

Replace

Every 30,000 km (18,000 miles) or 24 months

Replace

Every 45,000 km (27,000 miles) or 36 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

Replace

Every 15,000 km (9,000 miles) or 12 months

Replace

Every 15,000 km (9,000 miles) or 12 months

Replace

Every 30,000 km (18,000 miles) or 24 months

Lubricate

Every 7,500 km (4,500 miles) or 6 months

Replace

Every 30,000 km (18,000 miles) or 24 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

Inspect

Every 7,500 km (4,500 miles) or 6 months

PERIODIC MAINTENANCE (For Europe)
Maintenance Schedule for Petrol Engines
(Annual Mileage > 30,000 km/year)
TB48DE ENGINE
Abbreviations: R = Replace I = Inspect: Correct or replace if necessary
MAINTENANCE OPERATION

MAINTENANCE INTERVAL
15
(9)

30
(18)

45
(27)

60
(36)

75
(45)

90
(54)

105
(63)

120
(72)

Reference
pages

Engine oil (Use recommended oil)★

—

Engine oil filter (Use NISSAN genuine part or equivalent)★

—

Drive belts

MA-11

—

Perform on a kilometer basis only.

km x 1,000
(miles x 1,000)

Engine compartment and under vehicle

Cooling system
Engine anti-freeze coolant (Use
genuine NISSAN Anti-Freeze Coolant (L2N) or equivalent)

See NOTE (1)

Air cleaner filter (Viscous paper
type)★
Intake & exhaust valve clearance

See NOTE (2)

—

Fuel and EVAP vapor lines
Spark plugs (Platinum-tipped type)

Replace every 100,000 km (60,000 miles)

Fuel filter★

MA-14
—

NOTE: (1) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles). Perform “I” (checking the mixture
ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
(2) Periodic maintenance is not required. However, if valve noise increases, check valve clearance.
★ Maintenance items with “★” should be performed more frequently according to “Maintenance Under Severe Driving Conditions”.

MA-6

PERIODIC MAINTENANCE (For Europe)
Chassis and Body Maintenance
Abbreviations: R = Replace, I = Inspect: Correct or replace if necessary, L = Lubricate, T = Tighten
MAINTENANCE OPERATION
Perform on a kilometer
basis only

MAINTENANCE INTERVAL
km x 1,000
(miles x 1,000)

120

(18)

(36)

(54)

(72)

Reference
pages

Underhood and under vehicle
Headlamp aiming

Wheel alignment (if necessary, balance & rotate wheels)

—

Brake pads, rotors & other brake components★

MA-22

Foot brake, parking brake & clutch (for free play, stroke & operation)

—

Brake booster vacuum hoses, connections & check valve

Brake & clutch, systems and fluid (for level and leaks)

Brake fluid★

—

Power steering fluid and lines (for level and leaks)

—

Ventilation air filter★

—

ASCD vacuum hoses

—

Greasing point of propeller shaft★

See NOTE (1)

—

Transfer fluid and differential gear oil
(for level & leaks or replace)★

See NOTE (2)

—

Drive shafts & steering damper★

—

Front wheel bearing grease★

—

Front axle joint in knuckle flange

—

Free-running hub grease★

L
I

—

Body mounting bolts & nuts

—

Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system★
Body corrosion

See NOTE (3)

—
—

MA-7

PERIODIC MAINTENANCE (For Europe)
Maintenance Under Severe Driving
Conditions (Annual Driving Distance > 30,000
km)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be
performed on the following items as shown in the table.
A
B
C
D
E

—
—
—
—
—

Maintenance item

Engine oil & engine oil filter

Air cleaner filter

Fuel filter

Brake pads, rotors & other brake components

Brake fluid

Ventilation air filter

Automatic transmission fluid

Greasing point of propeller shaft

Transfer fluid and differential gear oil

Drive shafts & steering damper

Front wheel bearing grease

Free-running hub grease

Steering gear & linkage, axle & suspension parts,
propeller shaft & exhaust system

MA-8

Maintenance
operation

Maintenance interval

Replace

Every 7,500 km (4,500 miles)

Replace

Every 30,000 km (18,000 miles)

Replace

Every 45,000 km (27,000 miles)

Inspect

Every 15,000 km (9,000 miles)

Replace

Every 30,000 km (18,000 miles)

Replace

Every 15,000 km (9,000 miles)

Replace

Every 60,000 km (36,000 miles)

Lubricate

Every 15,000 km (9,000 miles)

Replace

Every 30,000 km (18,000 miles)

Inspect

Every 15,000 km (9,000 miles)

Inspect

Every 15,000 km (9,000 miles)

Inspect

Every 15,000 km (9,000 miles)

Inspect

Every 15,000 km (9,000 miles)

RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants
Capacity (Approximate)
Liter
Imp measure
Engine oil (Refill)
With oil filter

Without oil filter

TB45E, TB45S

7.6

TB48DE

6.8

6 qt

TD42, TD42T

10.5

9-1/4 qt

ZD30DDTi

8.2

7-1/4 qt

TB45E, TB45S

7.3

6-3/8 qt

TB48DE

6.5

5-3/4 qt

TD42, TD42T

9.3

8-1/8 qt

7.7

6-3/4 qt

12.0
13.2

10-5/8 qt
11-5/8 qt

13.0

11-1/2 qt

13.8

12-1/8 qt

15.1
12.7
13.0
12.9
13.2
11.3

13-1/4 qt
11-1/8 qt
11-1/2 qt
11-3/8 qt
11-5/8 qt
10 qt

12.5

11 qt

13.3

11-3/4 qt

14.4
12.0
14.1

12-5/8 qt
10-5/8 qt
12-3/8 qt

13.9

12-1/4 qt

ZD30DDTi
Cooling system (with reservoir tank)
With front heater TB45E, TB45S
RHD
TB48DE

LHD

Except for the
Middle East &
Europe
For the Middle
East & Europe

TD42, TD42T
RHD
ZD30DDTi
LHD
Without front
heater

Except Europe
For Europe
Except Europe
For Europe

TB45E, TB45S
Except for the
Middle East
For the Middle
East

TB48DE
TD42, TD42T
ZD30DDTi
With rear heater

RHD
TB48DE

TD42

LHD

Except for the
Middle East &
Europe
For the Middle
East & Europe

14.7

LHD
RHD

ZD30DDTi
LHD

Except Europe
For Europe
Except Europe
For Europe

Manual transmission oil
FS5R50B
Differential carrier gear oil (without limited slip differential)
Without diff. lock
With diff. lock
Differential carrier gear oil (with limited slip differential)
Except Europe
Transfer fluid
TX12A
Automatic transmission fluid
RE5R05A
RE4R03A
Power steering fluid
Brake and clutch fluid

Multi-purpose grease
Propeller shaft grease

6-3/4 qt

+ Except for Europe
Nissan Genuine Engine Coolant or
equivalent in its quality*6
+ For Europe
Genuine Nissan Anti-freeze Coolant
(L250) or equivalent*6

13 qt

16.0
13.8
14.1
14.0
14.3

14-1/8
12-1/8
12-3/8
12-3/8
12-5/8

3.5

6-1/8 qt

API GL-4, Viscosity SAE 75W-85

2.4
3.0

4-1/4 qt
5-1/4 qt

API GL-5*1

2.1

3-3/4 qt

1.9

1-5/8 qt

qt
qt
qt
qt
qt

9-1/8 — 9-3/8
qt
11.8
10-3/8 qt
Refill to the proper oil level
according to the instructions in
the “Maintenance and do-ityourself” section of the owner’s
manual.
—
—
10.4 — 10.7

Air conditioning system refrigerant
Air conditioning system lubricants

Recommended Fluids/Lubricants
Gasoline engine: API SE, SF, SG SH, SJ
or SL*1
ILSAC grade GF-I, GF-II,
GF-III or SG+*1
Diesel engine: API CC, CD, CE, CF, CF-4
or JASO DH-1*1 for TD42,
TD42T
API CF4 or ACEA B3-96.98
or ACEA B3/E3-96.98 or
JASO DH-1*5 for Europe,
ZD30DDTi
And API CD, CE, CF, CF-4
or JASO DH-1*1, *5 except
for Europe, ZD30DDTi

—

Gear Oil Hypoid LSD
or equivalent*2
Genuine Nissan ATF or equivalent*4 or API
GL-4*1
Genuine Nissan ATF Matic Fluid J*3
Genuine Nissan ATF or equivalent*4
Type DEXRONTMIII or equivalent
For Europe: DOT 3 or DOT 4 (U.S. FMVSS
No. 116)*7
Except for Europe: DOT 3 (U.S. FMVSS
No. 116)
NLGI No. 2 (Lithium soap base)
NLGI No. 2 (Molybdenum disulphide lithium
soap base)
HFC-134a (R-134a)
Nissan A/C System Oil Type S or
exact equivalent

*1: For further details, see “SAE viscosity number”.
*2: API GL-5, SAE 140 and 10% volume of LSD Friction Modifier
*3: Using automatic transmission fluid other than Nissan Genuine ATF Matic Fluid J will cause deterioration in driveability and automatic transmission
durability, and may damage the automatic transmission, which is not covered by the warranty.
*4: For more information regarding suitable fluids, contact a Nissan dealer for correct brand(s) of DEXRONTMIII/MERCONTM Automatic Transmission Fluid.
*5: Never use API CG-4.
*6: Use Nissan Genuine Engine Coolant [For Europe, use Genuine Nissan Anti-freeze Coolant (L2N)] or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be covered by the warranty
even if such incidents occurred during the warranty period.

*7: Never mix DOT 3 & DOT 4.

MA-9

ENGINE MAINTENANCE

TB48DE

Checking Tightening Torque
+ Checking should be performed while engine is cold.

MANIFOLD BOLTS AND NUTS
Intake manifold:
: 24.5 — 31.4 Nzm (2.5 — 3.2 kg-m, 18 — 23 ft-lb)
Exhaust manifold:
: 28.4 — 32.4 Nzm (2.9 — 3.3 kg-m, 21 — 23 ft-lb)

EXHAUST TUBE NUTS
: 51 — 64.7 Nzm (5.2 — 6.5 kg-m, 38 — 47 ft-lb)

MA-10

TB48DE

ENGINE MAINTENANCE
Checking Drive Belts

MMA121A

1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,
replace with a new one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
Adjust if belt deflections exceed the limit.
Belt deflection:
Unit: mm (in)
Used belt deflection
Deflection of
new belt

Limit

Deflection after
adjustment

Alternator

10 (0.39)

8 (0.31)

7 (0.28)

Air conditioner
compressor

12 (0.47)

9 (0.35)

8 (0.31)

Power steering oil
pump

21 (0.83)

17 — 18
(0.67 — 0.71)

13 — 14
(0.51 — 0.55)

Applied pushing
force

98 N (10 kg, 22 lb)

Inspect drive belt deflections when engine is cold.

MA-11

ENGINE MAINTENANCE

TB48DE

Changing Engine Coolant
EXCEPT FOR THE MIDDLE EAST

SMA972C

WARNING:
To avoid being scalded, never change the coolant when the
engine is hot.
— DRAINING ENGINE COOLANT —
1. Turn the ignition switch from “OFF” to “ON” and make sure
that the A/C display indicates “32”. Then turn ignition switch
to “OFF” for models with AUTO air conditioner.
Turn the temperature control knob to full hot position for
models with MANUAL air conditioner.

2. Open radiator drain cock at the bottom of radiator, and
remove radiator cap to drain.
+ Be careful not to allow coolant to contact drive belts.

SMA156D

3. Remove air relief plug at front top of intake manifold collector (upper).

MMA134A

4.
5.
6.
—
7.
8.

Remove cylinder block drain plug to drain.
Remove reservoir tank to drain and clean.
If drained coolant is contaminated, flush the cooling system.
FLUSHING COOLING SYSTEM —
Close drain cock and drain plug, then install air relief plug.
Install reservoir tank.

MMA119A

MA-12

ENGINE MAINTENANCE
Changing Engine Coolant (Cont’d)

TB48DE

9. Fill radiator and reservoir tank with water, and close radiator
cap and reservoir tank cap.
10. Run engine and warm it up to normal operating temperature.
11. Race engine 2 or 3 times under no-load.
12. Stop engine and wait until it cools down.
13. Repeat step 2 through step 11 until clear water begins to
drain from radiator.
14. Drain water.
— REFILLING ENGINE COOLANT —
15. Remove air relief plug. Close drain cock and tighten drain
plug securely.
+ Apply sealant to the thread of drain plug.
Cylinder block drain plug
: 34.3 — 44.1 Nzm (3.5 — 4.5 kg-m, 26 — 32 ft-lb)

SMA182B

SMA412B

16. Fill radiator with coolant up to the filler neck and install radiator cap. Install air relief plug when coolant overflows from air
relief hole.
Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water.
For coolant mixture ratio, refer to “RECOMMENDED
FLUID AND LUBRICANTS” of original Service Manual.
Coolant capacity (With reservoir tank): liter (lmp qt)
With rear heater
LHD models 13.9 (12-1/4)
RHD models 14.1 (12-3/8)
With front heater
LHD models 13.0 (11-1/2)
RHD models 13.2 (11-5/8)
Without front heater
12.5 (11)
Reservoir tank capacity (for MAX level):
0.6 liter (1/2 lmp qt)
Pour coolant through coolant filler neck slowly to allow air
in system to escape.

17. Fill reservoir tank with coolant up to “MAX” level and then
install cap.
18. Warm up engine to normal operating temperature.
19. Run engine at 2,000 rpm for 10 seconds and return to idle
speed.
+ Repeat 2 or 3 times.
Watch coolant temperature gauge so as not to overheat the
engine.
20. Stop engine and cool it down.
+ Cool down using a fan to reduce the time.
21. Refill reservoir tank to Max line with coolant.
22. Repeat step 18 through step 21 two or more times.

MA-13

ENGINE MAINTENANCE
Changing Engine Coolant (Cont’d)

TB48DE

23. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 2,000 rpm with heater temperature control set at several positions between COOL and
HOT.
+ Sound may be noticeable at heater water cock.
24. If sound is heard, bleed air from cooling system by repeating steps 18 through 23 until coolant level no longer drops.
+ Clean excess coolant from engine.

Changing Spark Plugs (Platinum-Tipped
Type)
MODELS WITH THREE WAY CATALYST FOR THE
MIDDLE EAST AND EUROPE
1. Disconnect harness connectors and remove ignition coils
from spark plugs.

MMA129A

2. Remove spark plugs with spark plug wrench.
Spark plug:
Make

SMA581C

NGK

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Use standard type spark plug under normal conditions. The hot
type spark plug is suitable when fouling occurs with the standard
spark plug under conditions such as:
+ Frequent engine starts
+ Low ambient temperature
The cold type spark plug is suitable when spark knock occurs
with the standard spark plug under conditions such as:
+ Extended highway driving
+ Frequent high engine revolution
3. Check insulator for cracks or chips, gasket for damage or
deterioration and electrode for wear and burning. If they are
excessively worn away, replace with new spark plugs.
Gap (Nominal): 1.1 m (0.043 in)

CAUTION:
+ Do not use a wire brush for cleaning.
+ If plug tip is covered with carbon, spark plug cleaner
may be used.
Cleaner air pressure:
Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi)
Cleaning time:
Less than 20 seconds

SMA773C

MA-14

TB48DE
ENGINE MAINTENANCE
Changing Spark Plugs (Platinum-Tipped
Type) (Cont’d)
+ Checking and adjusting plug gap is not required
between change intervals.
4. Install spark plugs. Install ignition coils to spark plugs and
reconnect harness connector of ignition coil.
Spark plug:
: 19.6 — 29.4 Nzm (2.0 — 3.0 kg-m, 15 — 21 ft-lb)

SMA806CA

Checking Cooling System
CHECKING HOSES
Check hoses for proper attachment and for leaks, cracks,
damage, loose connections, chafing and deterioration.

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

SMA967B

CHECKING COOLING SYSTEM FOR LEAKS
Apply pressure to the cooling system with cap tester to check for
leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher pressure than the specified value may cause damage
to radiator.

MMA125A

MA-15

ENGINE MAINTENANCE

TB48DE

Checking Fuel Lines
Inspect fuel lines and tank for proper attachment and for leaks,
cracks, damage, loose connections, chafing and deterioration. If
necessary, repair or replace faulty parts.

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

SMA804AC

Changing Fuel Filter
WARNING:
Before removing fuel filter, release fuel pressure from fuel
line to eliminate danger.
1. Release fuel pressure from fuel line.
Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”).

2. Loosen fuel hose clamps.
3. Replace fuel filter.
+ Be careful not to spill fuel over engine compartment.
Place a shop towel to absorb fuel.
+ Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter.
+ When tightening fuel hose clamps, refer to “Checking
Fuel Lines”.

MMA127A

Cleaning and Changing Air Cleaner Filter
Viscous paper type
The viscous paper type filter does not need cleaning
between renewals.

SMA979C

MA-16

TB48DE
ENGINE MAINTENANCE
Cleaning and Changing Air Cleaner Filter
(Cont’d)
Dry paper type
It is necessary to clean the element or replace it at the recommended intervals, more often under dusty driving conditions.

SMA980CA

+ To properly tighten wing nuts, position clamps at four
places and tighten wing nuts until they touch air cleaner.
Then tighten them three more turns.
+ Clean inside air cleaner body when changing the
element, or cleaning for dry paper type.

SMA981C

Checking Cyclone Pre-air Cleaner
1. Remove dust exhaust valve and check duct for dust clogging.
Clean away any dust.
Dust exhaust valve can be removed through the front left
wheelwell.
2. Install the dust exhaust valve and its cover provided at the
wheelwell to original position.

MMA133A

Changing Engine Oil
WARNING:
Be careful not to burn yourself, as the engine oil is hot.
1. Warm up engine, and check for oil leakage from engine components.
2. Remove drain plug and oil filler cap.
3. Drain oil and refill with new engine oil.
Oil grade: API SE, SF, SG, SH or SJ
Viscosity:
See “RECOMMENDED FLUIDS AND LUBRICANTS”.
MMA128A

Refill oil capacity (Approximately):
Unit: liter (lmp qt)
With oil filter change
Without oil filter change

6.8 (6)
6.5 (5-3/4)

CAUTION:
+ Be sure to clean drain plug and install with new washer.
Drain plug:
: 29.4 — 39.2 Nzm (3.0 — 4.0 kg-m, 22 — 28 ft-lb)
+ Use recommended engine oil.

MA-17

ENGINE MAINTENANCE
Changing Engine Oil (Cont’d)

TB48DE

4. Check oil level on a level surface.
5. Start engine and check area around drain plug and oil filter
for oil leakage.
6. Run engine for a few minutes, then turn it off. After more than
10 minutes, check oil level.

SMA155D

Changing Oil Filter
1. Remove oil filter with a suitable tool.
WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.

SMA985CA

2. Before installing new oil filter, clean the oil filter mounting
surface on cylinder block, and coat the rubber seal of oil filter with a little engine oil.

SMA010

3. Screw in the oil filter until a slight resistance is felt, then
tighten additionally more than 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.

SMA886B

Checking and Changing Spark Plugs
1. Disconnect harness connectors and remove ignition coils
from spark plugs.

MMA129A

MA-18

ENGINE MAINTENANCE
Checking and Changing Spark Plugs
(Cont’d)

TB48DE

2. Remove spark plugs with spark plug wrench.
Spark plug:
Make

SMA581C

NGK

Standard type

LFR5A-11

Hot type

LFR4A-11

Cold type

LFR6A-11

Use standard type spark plug under normal conditions. The hot
type spark plug is suitable when fouling occurs with the standard
spark plug under conditions such as:
+ frequent engine starts
+ low ambient temperature
The cold type spark plug is suitable when spark knock occurs
with the standard spark plug under conditions such as:
+ extended highway driving
+ frequent high engine revolution
3. Clean plugs in sand blast cleaner.
4. Check insulator for cracks or chips, gasket for damage or
deterioration and electrode for wear and burning. If they are
excessively worn away, replace with new spark plugs.
5. Check spark plug gap.
Gap: 1.0 — 1.1 mm (0.039 — 0.043 in)
6. Install spark plugs. Install ignition coils to spark plugs and
reconnect harness connector of ignition coil.
Spark plug:
: 19.6 — 29.4 Nzm (2.0 — 3.0 kg-m, 15 — 21 ft-lb)

SMA476

Checking Positive Crankcase Ventilation
(PCV) System
CHECKING PCV VALVE
With engine running at idle, remove ventilation hose from rocker
cover; if valve is working properly, a hissing noise will be heard
as air passes through it and a strong vacuum should be felt
immediately when a finger is placed over valve inlet.

MMA130A

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

MMA131A

MA-19

ENGINE MAINTENANCE

TB48DE

Checking Vacuum Hoses and Connections
Check vacuum hoses for improper attachment and for leaks,
cracks, damage, loose connections, chafing and deterioration.

Checking Vapor Lines
1. Visually inspect vapor lines for proper attachment and for
cracks, damage, loose connections, chafing and deterioration.
2. Inspect vacuum relief valve of fuel tank filler cap for clogging,
sticking, etc.
Refer to EVAPORATIVE EMISSION CONTROL SYSTEM
INSPECTION in EC section.
MMA132A

MA-20

CHASSIS AND BODY MAINTENANCE
Checking A/T Fluid
— RE5R05A —

SMA for checking A/T fluid

Changing A/T Fluid
— RE5R05A —
NOTE:
Use only service part of A/T fluid level gauge.
1.Warm up A/T fluid.
2. Stop engine.
3. Remove the oil charging pipe cap.
4. Drain A/T fluid from drain plug and refill with new A/T fluid. Always refill same volume with drained fluid.
+ To replace the A/T fluid, pour in new oil at the oil charging pipe with the engine idling and at the same
time drain the old oil from the radiator cooler hose return side.
+ When the color of the oil coming out is abut the same as the color of the new oil, the replacement is
complete. The amount of new transmission fluid to use should be 30 to 50% of the stipulated amount.
A/T fluid: Nissan Matic Fluid J
Fluid capacity: 10.4 — 10.7 liter (9-1/8 — 9-3/8 Imp qt)
CAUTION:
+ Use only Nissan Genuine ATF Matic Fluid J. Do not mix with other fluid.
+ Using automatic transmission fluid other than Nissan Genuine ATF Matic Fluid J will cause deterioration in driveability and automatic transmission durability, and may damage the automatic
transmission, which is not covered by the warranty.
Drain plug: 29 — 39 Nzm (3.0 — 4.0 kg-m, 22 — 29 ft-lb)
5.Run engine at idle speed for 5 minutes.
6. Check fluid level and condition. Refer to MA-21, “Checking A/T Fluid”. If fluid is still dirty, repeat step 2
through 5.
+ Make sure A/T fluid level gauge is removed then install the oil charging pipe cap.
Bolt: 4.4 — 5.8 Nzm (0.45 — 0.59 kg-m, 39.1 — 51.2 in-lb)

MA-21

CHASSIS AND BODY MAINTENANCE
Checking Disc Brake
ROTOR

SMA260A

Check condition and thickness.
Standard thickness:
Front CL41VA 34 mm (1.34 in)
CL36VE 32 mm (1.26 in)
Rear CL20VA 18 mm (0.71 in)
CL18VF 18 mm (0.71 in)
Minimum thickness:
Front CL41VA 32 mm (1.26 in)
CL36VE 30 mm (1.18 in)
Rear CL20VA 16 mm (0.63 in)
CL18VF 16 mm (0.63 in)

CALIPER
Check for leakage.

SMA922A

PAD
Check for wear or damage.
Standard thickness:
Front CL41VA 10 mm (0.39 in)
CL36VE 12 mm (0.47 in)
Rear CL20VA 11 mm (0.43 in)
CL18VF 10 mm (0.39 in)
Minimum thickness:
2.0 mm (0.079 in)
SMA847B

MA-22

SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Maintenance (TB48DE)
INSPECTION AND ADJUSTMENT

Cooling system check

Drive belt deflection

Except for the Middle East
Unit: kPa (bar, kg/cm2, psi)

Unit: mm (in)

Cooling system testing pressure

Used belt deflection
Deflection of
new belt

Limit

Deflection after
adjustment

Alternator

10 (0.39)

8 (0.31)

7 (0.28)

Air conditioner
compressor

12 (0.47)

9 (0.35)

8 (0.31)

Power steering
oil pump

21 (0.83)

17 — 18
(0.67 — 0.71)

13 — 14
(0.51 — 0.55)

Applied pushing
force

Radiator cap relief
pressure

108 — 127
(1.08 — 1.27, 1.1 1.3, 16 — 18)

Limit

59 (0.59, 0.6, 9)

Unit: kPa (bar, kg/cm2, psi)

98 N (10 kg, 22 lb)
Cooling system testing pressure

Unit: ! (lmp qt)

Without oil filter change

Standard

For the Middle East

Oil capacity (Refill capacity)
With oil filter change

157 (1.57, 1.6, 23)

Radiator cap relief
pressure

6.8 (6)
6.5 (5-3/4)

157 (1.57, 1.6, 23)

Standard

78 — 98
(0.78 — 0.98, 0.8 1.0, 11 — 14)

Limit

59 (0.59, 0.6, 9)

Spark plug type (Platinum-tipped type)
Models with three way catalyst for the Middle
East and Europe
Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type
Plug gap (Nominal)

MA-23

PLFR6A-11
1.1 mm (0.043 in)

PROPELLER SHAFT &
DIFFERENTIAL CARRIER
SECTION

MODIFICATION NOTICE:
+
+

Wiring Diagrams have been changed.
Service Data and Specifications have been changed.

CONTENTS
DIFFERENTIAL LOCK ………………………………………….. 2
Wiring Diagram — DIFF/L — ………………………………….. 2

SERVICE DATA AND SPECIFICATIONS (SDS) ……… 4
Propeller Shaft ………………………………………………….. 4
Final Drive………………………………………………………… 5

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —

TPD016M

PD-2

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L — (Cont’d)

TPD015M

PD-3

SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft
GENERAL SPECIFICATIONS
Front propeller shaft
Applied model

Except for ZD30DDTi engine

Propeller shaft model

2F80B

Number of joints

Type of journal bearing

Solid (Disassembly type)

Coupling type with transmission

Flange type

Distance between yokes

73 (2.87)

mm (in)
Shaft length (Spider-to-spider)
mm (in)

810 (31.89)

Shaft outer diameter

50.8 (2.000)

mm (in)

Rear propeller shaft
Applied model

TB48DE

Transmission

5A/T

Body

ZD30DDTi
M/T

Wagon

A/T
Hardtop

Propeller shaft model

Wagon

Hardtop

2F100H

Number of joints

Type of journal bearing

Solid (Disassembly type)

Coupling type with transmission

Flange type

Distance between yokes

94 (3.70)

mm (in)
Shaft length (Spider-to-spider)
mm (in)

1,025 (40.35)

1,011 (39.80)

440 (17.32)

1,044 (41.10)

480 (18.90)

90 (3.54)

89.6 (3.528)

57 (2.24)

89.6 (3.528)

75.2 (2.961)

Shaft outer diameter
mm (in)

Available snap rings
2F100H

2F80B
Thickness mm (in)

Color

Part Number

1.99 (0.0783)

White

37146-C9400

2.02 (0.0795)

Yellow

37147-C9400

2.05 (0.0807)

Red

37148-C9400

2.08 (0.0819)

Green

37149-C9400

2.11 (0.0831)

Blue

37150-C9400

2.14 (0.0843)

Light brown

37151-C9400

2.17 (0.0854)

Black

37152-C9400

2.20 (0.0866)

Colorless

37153-C9400

PD-4

Thickness mm (in)

Color

Part Number

1.95 (0.0768)

White

37146-61502

1.98 (0.0780)

Yellow

37147-61502

2.01 (0.0791)

Red

47148-61502

2.04 (0.0803)

Green

47149-61502

2.07 (0.0815)

Blue

37150-61502

2.10 (0.0827)

Light brown

37151-61502

2.13 (0.0839)

Pink

47146-61502

2.16 (0.0850)

Gold

37147-61502

2.19 (0.0862)

Black

47148-61502

2.22 (0.0874)

Colorless

37149-61502

SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive
GENERAL SPECIFICATIONS
Wagon
Engine

TB48DE

Transmission

ZD30DDTi

5A/T

5M/T, 4A/T
Standard

Front final drive

H233B
2-pinion

Gear ratio

3.545

4.375

Number of teeth (Ring
gear/drive pinion)

39/11

35/8

Oil capacity (Approx.)
! (Imp pt)

5.4 (9-1/2)
Standard

Optional

Rear final drive
[Grade]

Standard

Optional

H233B
4-pinion

LSD

Diff. lock

LSD

Diff. lock

4-pinion

LSD

Diff. lock

Gear ratio

3.545

4.375

Number of teeth (Ring
gear/drive pinion)

39/11

35/8

LSD

Diff. lock

Oil capacity (Approx.)
2.4 (4-1/4) 2.1 (3-3/4) 3.0 (5-1/4) 2.1 (3-3/4) 3.0 (5-1/4) 2.4 (4-1/4) 2.1 (3-3/4) 3.0 (5-1/4) 2.1 (3-3/4) 3.0 (5-1/4)
! (Imp pt)

Hardtop
Engine

ZD30DDTi

Transmission

5M/T

4A/T
Standard

Front final drive

H233B
2-pinion

Gear ratio

4.375

Number of teeth (Ring
gear/drive pinion)

35/8

Oil capacity (Approx.)
! (Imp pt)

5.4 (9-1/2)
Standard

Optional

Rear final drive
[Grade]

Standard

H233B
4-pinion

LSD

Diff. lock

LSD

Diff. lock

Gear ratio

4.375

Number of teeth (Ring
gear/drive pinion)

35/8

Oil capacity (Approx.)
! (Imp pt)

Optional

2.4 (4-1/4)

2.1 (3-3/4)

3.0 (5-1/4)

2.1 (3-3/4)

PD-5

3.0 (5-1/4)

4-pinion

Diff. lock

LSD

Diff. lock

2.4 (4-1/4)

3.0 (5-1/4)

2.1 (3-3/4)

3.0 (5-1/4)

SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont’d)
Differential actuator mounting adjusting
shim
Thickness mm (in)

Part number

0.4 (0.016)

38154 06J00

1.0 (0.039)

38154 06J01

0.9 (0.035)

38154 06J02

1.5 (0.059)

38154 06J03

Diff. lock actuator adjustment
Standard length A

PD-6

mm (in)

80.9 — 84.8 (3.185 — 3.340)

REAR AXLE &
REAR SUSPENSION
SECTION

MODIFICATION NOTICE:
+
+

Tightening torque for bearing cage has been changed.
Wiring diagrams have been changed.

CONTENTS
REAR AXLE…………………………………………………………. 2
Components……………………………………………………… 2

STABILIZER RELEASE DEVICE……………………………. 3
Wiring Diagram …………………………………………………. 3

REAR AXLE
Components
DRUM BRAKE TYPE

SRA887A

RA-2

STABILIZER RELEASE DEVICE
Wiring Diagram

TRA007M

RA-3

STABILIZER RELEASE DEVICE
Wiring Diagram (Cont’d)

TRA008M

RA-4

RESTRAINT SYSTEM
SECTION

MODIFICATION NOTICE:
Air bag system wiring diagram has been changed.

CONTENTS
TROUBLE DIAGNOSES — Supplemental
Restraint System (SRS) ……………………………………….. 2
Schematic ………………………………………………………… 2

Wiring Diagram — SRS -/LHD Models…………………… 3
Wiring Diagram — SRS -/RHD Models ………………….. 7

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Schematic

TRS061M

RS-2

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models
LHD MODELS

TRS062M

RS-3

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models
(Cont’d)

TRS063M

RS-4

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models
(Cont’d)
LHD MODELS WITH CONSULT-II (EXCEPT FOR TD ENGINE MODELS WITH NATS)

TRS065M

RS-5

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/LHD Models
(Cont’d)

TRS066M

RS-6

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models
RHD MODELS

TRS072M

RS-7

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models
(Cont’d)

TRS073M

RS-8

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models
(Cont’d)
RHD MODELS WITH CONSULT-II (EXCEPT FOR TD ENGINE MODELS WITH NATS)

TRS075M

RS-9

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS —/RHD Models
(Cont’d)

TRS076M

RS-10

STEERING SYSTEM
SECTION

MODIFICATION NOTICE:
+

Tightening torque for air bag module has been changed.

CONTENTS
STEERING WHEEL AND STEERING COLUMN ……… 2

Removal and Installation ……………………………………. 2

STEERING WHEEL AND STEERING COLUMN
Removal and Installation

SST013D

1
V
2
V
3
V

Air bag module
Steering wheel
Spiral cable

4
V
5
V
6
V

Combination switch
Steering column assembly
Column cover

ST-2

7
V
8
V

Lower shaft
Coupling

AUTOMATIC TRANSMISSION
SECTION

MODIFICATION NOTICE:
+
+

Wiring diagrams have been changed.
Service data and Specifications (SDS) have been changed.

CONTENTS
RE4R03A
OVERALL SYSTEM …………………………………………..4002
Circuit Diagram ………………………………………………4002
Wiring Diagram — A/T —………………………………..4003
RE5R05A
TROUBLE DIAGNOSIS………………………………………4011
Circuit Diagram ………………………………………………4011
TROUBLE DIAGNOSES FOR SYMPTOMS………….4012
Wiring Diagram — AT — NONDTC…………………..4012

SERVICE DATA AND SPECIFICATIONS (SDS) ……4014
General Specifications…………………………………….4014
Vehicle Speed When Shifting Gears …………………4014
Vehicle Speed When Performing and Releasing
Lock-up …………………………………………………………4014
Stall Revolution………………………………………………4014
Line Pressure…………………………………………………4014
Solenoid Valves ……………………………………………..4015
A/T Fluid Temperature Sensor………………………….4015
Turbine Revolution Sensor ………………………………4015
Revolution Sensor ………………………………………….4015

AT-4001

OVERALL SYSTEM

RE4R03A

Circuit Diagram

TAT141M

AT-4002

OVERALL SYSTEM

RE4R03A

Wiring Diagram — A/T —

TAT061M

AT-4003

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT136M

AT-4004

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT142M

AT-4005

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT146M

AT-4006

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT111M

AT-4007

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT143M

AT-4008

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT128M

AT-4009

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT114M

AT-4010

TROUBLE DIAGNOSIS

RE5R05A

Circuit Diagram

TAT144M

AT-4011

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

Wiring Diagram — AT — NONDTC

TAT106M

AT-4012

RE5R05A
TROUBLE DIAGNOSES FOR SYMPTOMS
Wiring Diagram — AT — NONDTC (Cont’d)

TAT145M

AT-4013

RE5R05A

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Engine

TB48DE

Automatic transmission model

RE5R05A

Destination

Except for Europe

For Europe

91X69

91X68

Transmission model code number
Stall torque ratio

2.0 : 1
1st

3.540

2nd

2.264

3rd

1.471

4th

1.000

5th

0.834

Reverse

2.370

Transmission gear ratio

Recommended fluid

Genuine Nissan ATF Matic Fluid J*1

Fluid capacity

10.4 — 10.7 liter (9-1/8 — 9-3/8 Imp qt)

CAUTION:
+ Use only Genuine Nissan ATF Matic Fluid J*1. Do not mix with other fluid.
+ Using automatic transmission fluid other than Genuine Nissan ATF Matic Fluid J*1 will deteriorate in driveability and automatic transmission durability, and may damage the automatic transmission, which is not covered by the warranty.
*1: Refer to MA section, “Fluids and Lubricants”.

Vehicle Speed When Shifting Gears
Vehicle Speed km/h (MPH)

Throttle position

D 1 → D2

D2 → D 3

D3 → D 4

D 4 → D5

D5 → D 4

D4 → D 3

D3 → D 2

D2 → D 1

Full throttle

52 — 56
(32 — 35)

81 — 89
(50 — 55)

126 — 136
(78 — 85)

188 — 198
(117 — 123)

184 — 194
(114 — 121)

116 — 126
(72 — 78)

70 — 78
(43 — 48)

36 — 40
(22 — 25)

Half throttle

32 — 36
(20 — 22)

62 — 68
(39 — 42)

104 — 112
(65 — 70)

126 — 134
(78 — 83)

100 — 108
(62 — 67)

61 — 69
(38 — 43)

37 — 43
(23 — 27)

10 — 14
(6 — 9)

At half throttle, the accelerator opening is 4/8 of the full opening.

Vehicle Speed When Performing and Releasing
Lock-up
Vehicle speed km/h (MPH)
Throttle position
Closed throttle
Half throttle

+
+

Lock-up “ON”

Lock-up “OFF”

64 — 72 (39 — 45)

61 — 69 (38 — 43)

164 — 172 (102 — 107)

130 — 138 (81 — 86)

At closed throttle, the accelerator opening is less than 1/8.
At half throttle, the accelerator opening is 4/8 of the full opening.

Stall Revolution
Stall revolution

1,900 — 2,200 rpm

Line Pressure
Line Pressure kPa (bar, kg/cm2, psi)
Engine speed (rpm)
“R” position

“D”, “M” positions

Idling Revolution

392 — 441 (3.9 — 4.4, 4.0 — 4.5, 57 — 64)

373 — 422 (3.7 — 4.2, 3.8 — 4.3, 54 — 61)

Stall Revolution

1,700 — 1,890 (17.0 — 18.9, 17.3 — 19.3, 247 — 274)

1,310 — 1,500 (13.1 — 15.0, 13.4 — 15.3, 191 — 218)

AT-4014

RE5R05A

SERVICE DATA AND SPECIFICATIONS (SDS)
Solenoid Valves
Name

Resistance (Approx.) (Ω)

Terminal No.

Line pressure solenoid valve

Torque converter clutch solenoid valve

Input clutch solenoid valve

6
3-9

High & low reverse clutch solenoid valve

Front brake solenoid valve

Direct clutch solenoid valve

Low coast brake solenoid valve

20 — 40

A/T Fluid Temperature Sensor
Name

A/T fluid temperature sensor-1

A/T fluid temperature sensor-2

Condition

CONSULT-II “DATA MONITOR”
(Approx.) (V)

Resistance (Approx.) (kΩ)

0°C (32°F)

2.2

20°C (68°F)

1.8

0.6

80°C (176°F)

0.6

0.9

0°C (32°F)

2.2

20°C (68°F)

1.7

80°C (176°F)

0.45

0.5

Turbine Revolution Sensor
Name

Condition

Turbine revolution
sensor-1

Turbine revolution
sensor-2

Data (Approx.)

1.3 (kHz)

Revolution Sensor
Name
Revolution sensor

Condition
When moving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle diagnosis connector.

AT-4015

Data (Approx.)
185 (Hz)

BRAKE SYSTEM
SECTION

MODIFICATION NOTICE:
+
+

Engine direction indicator stamp has been added to brake booster hose.
Service data and specifications (SDS) have been changed.

CONTENTS
VACUUM PIPING……………………………………………….4002
Vacuum Hose ………………………………………………..4002

SERVICE DATA AND SPECIFICATIONS (SDS) ……4003
General Specifications…………………………………….4003

BR-4001

VACUUM PIPING
Vacuum Hose

SBR374F

BR-4002

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Body
Applied model

Wagon/Hardtop
ZD30DDTi (For Europe)
TB45E (For the Middle East)

TB48DE

TD42 (For the Middle East)

Front brake
Type
Cylinder bore diameter
mm (in)

CL41VA disc brake

CL36VE disc brake

51.1 (2.012) x 2

48.1 (1.894) x 2

Pad dimension
Length x width x thick145 x 56.5 x 10 (5.79 x 2.224 x 0.39)
ness
mm (in)
Rotor outer diameter x
thickness
mm (in)

147 x 56.5 x 12 (5.79 x 2.224 x 0.47)

316 x 34 (12.44 x 1.34)

306 x 32 (12.05 x 1.26)

Rear brake
Type

CL20VA disc brake

CL18VF disc brake

LT30 drum brake

Cylinder bore diameter
mm (in)

51.1 (2.012)

48.1 (1.894)

25.4 (1.00)

Lining or pad dimension
Length x width x thickness
mm (in)

111 x 34 x 11
(4.37 x 1.34 x 0.43)

111 x 41.8 x 10
(4.37 x 1.646 x 0.39)

296 x 50 x 6.1
(11.65 x 1.97 x 0.240)

Drum inner diameter
mm (in)

—

295 (11.61)

Rotor outer diameter x
thickness
mm (in)

330 x 18 (12.99 x 0.71)

316 x 18 (12.44 x 0.71)

—

Brake booster
Model

235T

Diaphragm diameter
mm (in)

Primary: 252 (9.92)
Secondary: 230 (9.06)

Master cylinder bore diameter
mm (in)

26.9 (17/16)

Control valve
Type
Split point x reducing
ratio
kPa (bar, kg/cm2, psi)
Recommended brake fluid

LSV
(Variable) x 0.3

(Variable) x 0.3
DOT 3 or DOT 4

BR-4003

(Variable) x 0.15

BODY & TRIM
SECTION

MODIFICATION NOTICE:
Following parts have been changed:
+ Front bumper
+ Rear bumper
+ Instrument panel
+ Overfender
+ License lamp finisher
+ Rear seat

CONTENTS
BODY END ……………………………………………………….4002
Body Front End………………………………………………4002
Body Rear End and Opener…………………………….4005
INSTRUMENT PANEL………………………………………..4006

EXTERIOR ………………………………………………………..4009
SEAT ………………………………………………………………..4012
Rear Seat………………………………………………………4012

★ For seat belt, refer to MA and RS section.
★ For wiring diagrams of body electrical systems, refer to EL section.

BT-4001

BODY END
Body Front End
+
+
+
+
+

REMOVAL — Front bumper assembly
j
1
j
2
j
3
j
4
j
5
j
6
j
7
j
8

Remove front guard bar. Refer to “EXTERIOR” for details, BT-9.
Remove clips securing front grille and remove the front grille.
Remove left and right headlamp washer nozzle. (If equipped.)
Remove screws and bolts securing left and right front bumper side bracket.
Remove bolts securing bumper lower to engine under cover.
Remove bolts securing left and right front bumper stay upper (without winch).
Remove bolts securing left and right front bumper stay side.
Extract bumper assembly.

PIIB1965E

BT-4002

BODY END
Body Front End (Cont’d)

PIIB1966E

BT-4003

BODY END
Body Front End (Cont’d)

PIIB1967E

BT-4004

REMOVAL — Rear bumper assembly
j
1
j
2
j
3
j
4

Remove
Remove
Remove
Remove

rear bumper finisher.
screws securing left and right mudguard.
bolts securing rear bumper to bumper reinforcement.
nuts securing rear bumper reinforcement.

PIIB1968E

BT-4005

REMOVAL — Instrument panel assembly
Instrument panel assembly

Combination meter

Remove air bag module (driver) and steering wheel.
Refer to “SUPPLEMENTAL RESTRAINT SYSTEM” in RS section for details.
Remove dash side lower finishers.
Refer to “Side and Floor Trim” in “INTERIOR TRIM” for
details, BT-15 in Service Manual (Pub. No. SM7E2Y61G1).
j
1 Steering column cover and combination switch
+ Remove screws.
j
2 Lower instrument panel on driver side
+ Remove bolts and screws.
j
3 Cluster lid A
+ Remove screws then disconnect harness connectors.
j
4 Combination meter
+ Remove screws then disconnect harness connectors.
j
5 Cluster lid C
+ Pull out then disconnect harness connectors.
+ Remove screws then remove in-vehicle sensor.
j
6 Audio
+ Remove screws then disconnect harness connectors.
j
7 A/C control unit
+ Remove screws then disconnect harness connectors.
j
8 Console M/T or A/T finisher
+ Remove screws then disconnect harness connectors.
j
9 Console box assembly
+ Remove screws then disconnect harness connectors.
j
10 Instrument panel stay cover
+ Remove screws then disconnect harness connectors.
j
11 Glove box assembly and lower instrument panel on
passenger side
+ Remove screws.
j
12 Mirror control switch
+ Disconnect harness connector.
Remove front pillar garnish.
Refer to “Side and Floor Trim” in “INTERIOR TRIM” for
details, BT-15 in Service Manual (Pub. No. SM7E2Y61G1).
j
13 Mask instrument LH/RH or sensors.
+ Disconnect harness connectors (models with sensors).
j
14 Instrument panel and pads
+ Remove bolts and nuts then disconnect harness
connectors.

BT-4006

Audio & A/C control

Console box

INSTRUMENT PANEL

PIIB1969E

BT-4007

INSTRUMENT PANEL

PIIB1970E

BT-4008

EXTERIOR

PIIB1974E

BT-4009

EXTERIOR
j
13 Over fender

PIIB1972E

BT-4010

EXTERIOR
j
21 License lamp finisher

PIIB1973E

BT-4011

SEAT
Rear Seat
WAGON (Type-III)

PIIB1975E

BT-4012

CLUTCH
SECTION

MODIFICATION NOTICE:
+
+

Clutch cover has been changed, and clutch orifice has been added to 2-door models based on the grade
of ZD30DDTi engine.
Service Data and Specifications (SDS) have been changed.

CONTENTS
CLUTCH PIPING ……………………………………………….4002
Removal and Installation …………………………………4002
SERVICE DATA AND SPECIFICATIONS (SDS) ……4003

General Specifications…………………………………….4003
Inspection and Adjustment ………………………………4003

CL-4001

CLUTCH PIPING
Removal and Installation

PCIB0685E

PCIB0681E

Carefully observe the following steps during clutch tube removal
and installation.
+ Do not spill clutch fluid onto painted surfaces. If it spills, wipe
up immediately and wash the affected area with water.
+ When fixing clutch hose to bracket, align clutch hose metal fittings with bracket positioning emboss and lock plate to secure.
At this time, prevent twisting or damage of clutch hose. In
addition, be careful not to damage clutch hose.
+ Tighten clutch tube flare nut to the specified torque.
CAUTION:
Be careful not to damage flare nut and clutch tube.
+ Tighten the union bolt to the specified torque.
CAUTION:
Do not reuse the copper washer.
+ After installation, bleed the clutch tube.

CL-4002

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
CLUTCH DISC
TB45E
Applied model

275
Pickup

Facing size
(Outer dia. x inner dia.
x thickness) mm (in)

Thickness of disc
assembly with load
mm (in)/N (kg, lb)

TB48DE

TD42

300

H/T

Wagon

Wagon and Pickup

300 x 190 x 3.5
(11.81 x 7.48 x
0.14)

7.8 — 8.4 (0.31 — 0.33)/
7,845 (800, 1,764)

TD42Ti

275

Wagon

275 x 180 x 3.5
(10.83 x 7.09 x 0.14)
7.7 — 8.3
(0.30 0.33)/
6,865
(700,
1,543)

ZD30DDTi

275 x 180 x 3.5
(10.83 x 7.09 x 0.14)

7.7 — 8.3 (0.30 7.8 — 8.4 (0.31 — 0.33)/
0.33)/
7,845 (800, 1,764)
8,340 (851, 1,875)

7.8 — 8.2
(0.31 — 0.32)/
6,865 (700, 1,543)

7.9 — 8.5
(0.31 0.34)/
7,845
(800,
1,764)

CLUTCH COVER
TB45E
Applied
model

TB48DE

275
Pickup

7,355 — 8,335
Full load
(750 — 850, 1,653 N (kg, lb)
1,874)

ZD30DDTi

TD42

300

H/T

275

Wagon

7,670 — 9,010
(780 — 920, 1,724 — 2,025)

TD42Ti

H/T and Wagon

Wagon and Pickup

7,650 — 9,030
7,670 — 9,010
(780 — 921, 1,720 (780 — 920, 1,724 — 2,025)
2,030)

6,473 7,257
(660 — 740,
1,455 1,631)

7,355 8,335
(750 — 850,
1,653 1,874)

Inspection and Adjustment
CLUTCH DISC
Unit: mm (in)

Applied model
Pickup

TB45E

TB48DE

275

300

H/T

Wagon

ZD30DDTi

TD42

TD42Ti

275
H/T

Wear limit of facing surface to rivet head

0.3 (0.012)

Runout limit of facing

1.3 (0.051)

Wagon

Wagon and Pickup

Distance of runout check point (from the
hub center)

130 (5.12)

145
(5.71)

130 (5.12)

Maximum backlash of spline (at outer
edge of disc)

1.1 (0.043)

1.2
(0.047)

1.1 (0.043)

CLUTCH COVER
Unit: mm (in)

Applied model
Pickup

TB45E

TB48DE

275

300

H/T

Wagon

Diaphragm spring height “A”
Uneven limit of diaphragm spring toe
height

ZD30DDTi

TD42
275

H/T

Wagon

44 — 46 (1.732 — 1.811)
0.7 (0.028)

1.0
(0.039)

CL-4003

TD42Ti

0.7 (0.028)

Wagon and Pickup

ENGINE CONTROL SYSTEM
SECTION

MODIFICATION NOTICE:
+
+

Wiring diagrams have been modified.
MAF sensor has been changed for ZD30DDTi engine models.

CONTENTS
TB45E
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM……………………………………………………………4003
Circuit Diagram ………………………………………………4003
TROUBLE DIAGNOSIS FOR NON-DETECTABLE
ITEMS……………………………………………………………….4004
Vehicle Speed Sensor (VSS) …………………………..4004
TB48DE M/T
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM……………………………………………………………4005
Circuit Diagram ………………………………………………4005
VEHICLE SPEED SENSOR (VSS) ………………………4007
Wiring Diagram ………………………………………………4007
ELECTRICAL LOAD SIGNAL……………………………..4008
Wiring Diagram ………………………………………………4008
Diagnostic Procedure ……………………………………..4009
TB48DE A/T
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM……………………………………………………………4013
Circuit Diagram ………………………………………………4013
SNOW MODE SWITCH ………………………………………4015
Wiring Diagram ………………………………………………4015
ELECTRICAL LOAD SIGNAL……………………………..4016
Wiring Diagram ………………………………………………4016
Diagnostic Procedure ……………………………………..4018
TB48DE A/T (WITH EURO-OBD)
TROUBLE DIAGNOSIS………………………………………4022
Circuit Diagram ………………………………………………4022
SNOW MODE SWITCH ………………………………………4024
Wiring Diagram ………………………………………………4024
ELECTRICAL LOAD SIGNAL……………………………..4025

Wiring Diagram ………………………………………………4025
Diagnostic Procedure ……………………………………..4027
TD42
QUICK-GLOW SYSTEM……………………………………..4031
Circuit Diagram ………………………………………………4031
Wiring Diagram ………………………………………………4033
FAST IDLE CONTROL CIRCUIT …………………………4036
Wiring Diagram ………………………………………………4036
ZD30DDTi
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM……………………………………………………………4037
Circuit Diagram ………………………………………………4037
TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION …………………………………………………..4038
CONSULT-II Reference Value in Data Monitor
Mode …………………………………………………………….4038
ECM Terminals and Reference Value ……………….4040
DTC 0102 MASS AIR FLOW SEN……………………….4047
Component Description …………………………………..4047
CONSULT-II Reference Value in Data Monitor
Mode …………………………………………………………….4047
ECM Terminals and Reference Value ……………….4047
On Board Diagnosis Logic……………………………….4047
DTC Confirmation Procedure …………………………..4048
Wiring Diagram ………………………………………………4049
Diagnostic Procedure ……………………………………..4050
DTC 0104 VEHICLE SPEED SEN ……………………….4053
Wiring Diagram ………………………………………………4053
HEAT UP SWITCH …………………………………………….4054
Wiring Diagram ………………………………………………4054
Diagnostic Procedure ……………………………………..4055
AIR CONDITIONER CONTROL …………………………..4058
Wiring Diagram ………………………………………………4058

EC-4001

CONTENTS
TD42Ti
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM……………………………………………………………4059
Circuit Diagram ………………………………………………4059

(Cont’d)

TROUBLE DIAGNOSES FOR NON-DETECTABLE
ITEMS……………………………………………………………….4060
Vehicle Speed Sensor (VSS) …………………………..4060

EC-4002

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

TB45E

Circuit Diagram

TEC515M

EC-4003

TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS

TB45E

Vehicle Speed Sensor (VSS)

TEC532M

EC-4004

ENGINE AND EMISSION CONTROL OVERALL
SYSTEM

TB48DE M/T

Circuit Diagram

TEC516M

EC-4005

ENGINE AND EMISSION CONTROL OVERALL
SYSTEM
Circuit Diagram (Cont’d)

TB48DE M/T

TEC533M

EC-4006

VEHICLE SPEED SENSOR (VSS)

TB48DE M/T

Wiring Diagram

TEC534M

EC-4007

ELECTRICAL LOAD SIGNAL

TB48DE M/T

Wiring Diagram

TEC517M

EC-4008

TB48DE M/T

ELECTRICAL LOAD SIGNAL
Diagnostic Procedure
INSPECTION START

Do you have CONSULT-II?

No
c

A . (Without CONGo to j
SULT-II)

Check rear window defogB .)
ger circuit. (Go to j

Check lighting switch cirC .)
cuit. (Go to j

Yes
.
PBIB0103E

CHECK OVERALL FUNCTION-I.
With CONSULT-II
1. Turn ignition switch ON.
2. Check “LOAD SIGNAL” in “DATA
MONITOR” mode with CONSULT-II.
Rear window defogger ON
LOAD SIGNAL: ON
Rear window defogger OFF
LOAD SIGNAL: OFF

OK
.
PBIB0296E

CHECK OVERALL FUNCTION-II.
With CONSULT-II
Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULT-II.
Lighting switch ON at 2nd position
LOAD SIGNAL: ON
Lighting switch OFF
LOAD SIGNAL: OFF
OK
.

INSPECTION END

PBIB0103E

PBIB0296E

EC-4009

ELECTRICAL LOAD SIGNAL
Diagnostic Procedure (Cont’d)

TB48DE M/T

j
A

SEC022E

CHECK OVERALL FUNCTION-I.
Without CONSULT-II
1. Turn ignition switch ON.
2. Check voltage between ECM terminal
j
96 and ground with tester.
Rear window defogger ON
Voltage: Battery voltage
Rear window defogger OFF
Voltage: 0V

NG
c

Check rear window defogB .)
ger circuit. (Go to j

Check lighting switch cirC .)
cuit. (Go to j

OK
.

SEC010E

CHECK OVERALL FUNCTION-II.
Without CONSULT-II
Check voltage between ECM terminal j
97
and ground with tester.
Lighting switch ON at 2nd position
Voltage: Battery voltage
Lighting switch OFF
Voltage: 0V
OK
.

INSPECTION END

EC-4010

ELECTRICAL LOAD SIGNAL
Diagnostic Procedure (Cont’d)

TB48DE M/T

j
B
.

CHECK REAR WINDOW DEFOGGER
FUNCTION.
1. Start engine.
2. Turn ON the rear window defogger
switch.
3. Check the rear windshield.
Is the rear windshield heated up?

No
c

Refer to EL section.

Yes

PBIB0302E
.

CHECK POWER SUPPLY CIRCUIT.
1. Stop engine.
2. Disconnect rear window defogger relay.
3. Check voltage between rear window
defogger relay terminal j
3 and ground
with CONSULT-II or tester.
Voltage: Battery voltage

NG
c

CHECK INPUT SIGNAL CIRCUIT FOR
OPEN OR SHORT.
1. Disconnect ECM harness connector.
2. Check harness continuity between rear
window defogger relay terminal j
5 and
ECM terminal j
96 .
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground
and short to power.

NG
c

CHECK REAR WINDOW DEFOGGER
RELAY.
Refer to EL section.
OK
.

CHECK INTERMITTENT INCIDENT.
Refer to “TROUBLE DIAGNOSIS FOR
INTERMITTENT INCIDENT”, EC-125 in
Service Manual (Publication No. SM1EY61EG1).

INSPECTION END

EC-4011

NG
c

Check the following.
+ 15A fuse
+ Harness for open or
short between rear window defogger relay and
battery
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M50 , F5
+ Harness for open or
short between rear window defogger relay and
ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Replace rear window
defogger relay.

ELECTRICAL LOAD SIGNAL
Diagnostic Procedure (Cont’d)

TB48DE M/T

j
C

SEC011E

CHECK POWER SUPPLY.
1. Turn ignition switch OFF.
2. Disconnect combination switch harness
connector.
3. Check voltage between combination
switch terminal j
5 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

NG
c

OK
.

SEC012E

CHECK INPUT SIGNAL CIRCUIT FOR
OPEN OR SHORT.
1. Disconnect ECM harness connector.
2. Check harness continuity between
combination switch terminals j
6 ,j
7
and ECM terminal j
97 .
Continuity should exist.
3. Also check harness for short to ground
and short to power.

NG
c

CHECK COMBINATION SWITCH.
Refer to EL section.
OK
.

SEC013E

CHECK INTERMITTENT INCIDENT.
Refer to “TROUBLE DIAGNOSIS FOR
INTERMITTENT INCIDENT”, EC-125 in
Service Manual (Publication No. SM1EY61EG1).

INSPECTION END

EC-4012

NG
c

Check the following.
+ 15A fuse
+ Harness for open or
short between combination switch and battery
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Check the following.
+ Harness connectors
E127 , M21
+ Harness connectors
M50 , F5
+ Diode E108
+ Harness for open or
short between combination switch and ECM
If NG, repair open circuit or
short to ground or short to
power in harness or connectors.

Replace combination
switch.

ENGINE AND EMISSION CONTROL OVERALL
SYSTEM

TB48DE A/T

Circuit Diagram

TEC518M

EC-4013

ENGINE AND EMISSION CONTROL OVERALL
SYSTEM
Circuit Diagram (Cont’d)

TB48DE A/T

TEC519M

EC-4014

SNOW MODE SWITCH

TB48DE A/T

Wiring Diagram
WITH SNOW MODE SWITCH

TEC521M

EC-4015

ELECTRICAL LOAD SIGNAL

TB48DE A/T

Wiring Diagram

TEC522M

EC-4016

ELECTRICAL LOAD SIGNAL
Wiring Diagram (Cont’d)

TB48DE A/T

TEC523M

EC-4017

ELECTRICAL LOAD SIGNAL

TB48DE A/T

Diagnostic Procedure
1

CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I

With CONSULT-II
1. Turn ignition switch “ON”.
2. Connect CONSULT-II and select “DATA MONITOR” mode.
3. Select “LOAD SIGNAL” and check indication under the following conditions.

PBIB0103E

MTBL1594

OK or NG
OK

c GO TO 2.

c GO TO 3.

EC-4018

ELECTRICAL LOAD SIGNAL
Diagnostic Procedure (Cont’d)
2

TB48DE A/T

CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II

With CONSULT-II
Check “LOAD SIGNAL” indication under the following conditions.

PBIB0103E

MTBL1595

OK or NG
OK

c INSPECTION END

c GO TO 7.

CHECK REAR WINDOW DEFOGGER FUNCTION

1. Start engine.
2. Turn “ON” the rear window defogger switch.
3. Check the rear windshield. Is the rear windshield heated up?
Yes or No
Yes

c GO TO 4.

c Check rear window defogger circuit. Refer to EL section.

CHECK REAR WINDOW DEFOGGER INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1.
2.
3.
4.

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

EC-4019

ELECTRICAL LOAD SIGNAL
Diagnostic Procedure (Cont’d)
6

TB48DE A/T

CHECK COMBINATION METER

Refer to EL section.
OK or NG
OK

c GO TO 11.

c Replace combination meter.

CHECK HEADLAMP FUNCTION

1. Start engine.
2. Lighting switch “ON” at 2nd position.
3. Check that headlamp high beams are illuminated.
OK or NG
OK

c GO TO 8.

c Check headlamp circuit. Refer to EL section.

8
1.
2.
3.
4.

SEC014E

MTBL1596

5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

EC-4020

ELECTRICAL LOAD SIGNAL
Diagnostic Procedure (Cont’d)
10

TB48DE A/T

CHECK COMBINATION METER

Refer to EL section.
OK or NG
OK

c GO TO 11.

c Replace combination meter.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-125 in Service Manual (Publication No. SM1E-Y61EG1).
c INSPECTION END

EC-4021

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Circuit Diagram

TEC410M

EC-4022

TROUBLE DIAGNOSIS TB48DE A/T (WITH EURO-OBD)
Circuit Diagram (Cont’d)

TEC520M

EC-4023

SNOW MODE SWITCH TB48DE A/T (WITH EURO-OBD)
Wiring Diagram

TEC521M

EC-4024

ELECTRICAL LOAD
SIGNAL

TB48DE A/T (WITH EURO-OBD)

Wiring Diagram

TEC522M

EC-4025

ELECTRICAL LOAD
TB48DE A/T (WITH EURO-OBD)
SIGNAL
Wiring Diagram (Cont’d)

TEC523M

EC-4026

ELECTRICAL LOAD
SIGNAL

TB48DE A/T (WITH EURO-OBD)

Diagnostic Procedure
1

CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I
With CONSULT-II

With GST
1. Turn ignition switch “ON”.
2. Connect CONSULT-II or GST and select “DATA MONITOR” mode.
3. Select “LOAD SIGNAL” and check indication under the following conditions.

PBIB0103E

MTBL1594

OK or NG
OK

c GO TO 2.

c GO TO 3.

EC-4027

ELECTRICAL LOAD
TB48DE A/T (WITH EURO-OBD)
SIGNAL
Diagnostic Procedure (Cont’d)
2

CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II

With CONSULT-II
Check “LOAD SIGNAL” indication under the following conditions.

PBIB0103E

MTBL1595

OK or NG
OK

c INSPECTION END

c GO TO 7.

CHECK REAR WINDOW DEFOGGER FUNCTION

1. Start engine.
2. Turn “ON” the rear window defogger switch.
3. Check the rear windshield. Is the rear windshield heated up?
Yes or No
Yes

c GO TO 4.

c Check rear window defogger circuit. Refer to EL section.

CHECK REAR WINDOW DEFOGGER INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1.
2.
3.
4.

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

EC-4028

ELECTRICAL LOAD
TB48DE A/T (WITH EURO-OBD)
SIGNAL
Diagnostic Procedure (Cont’d)
6

CHECK COMBINATION METER

Refer to EL section.
OK or NG
OK

c GO TO 11.

c Replace combination meter.

CHECK HEADLAMP FUNCTION

1. Start engine.
2. Lighting switch “ON” at 2nd position.
3. Check that headlamp high beams are illuminated.
OK or NG
OK

c GO TO 8.

c Check headlamp circuit. Refer to EL section.

8
1.
2.
3.
4.

SEC014E

MTBL1596

5. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 10.

c GO TO 9.

DETECT MALFUNCTIONING PART

EC-4029

ELECTRICAL LOAD
TB48DE A/T (WITH EURO-OBD)
SIGNAL
Diagnostic Procedure (Cont’d)
10

CHECK COMBINATION METER

Refer to EL section.
OK or NG
OK

c GO TO 11.

c Replace combination meter.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-145 in Service Manual (Publication No. SM2E-Y61FG1).
c INSPECTION END

EC-4030

QUICK-GLOW SYSTEM

TD42

Circuit Diagram
EXCEPT FOR COLD AREAS

TEC524M

EC-4031

QUICK-GLOW SYSTEM
Circuit Diagram (Cont’d)

TD42

FOR COLD AREAS

TEC525M

EC-4032

QUICK-GLOW SYSTEM

TD42

Wiring Diagram
FOR COLD AREAS

TEC535M

EC-4033

QUICK-GLOW SYSTEM
Wiring Diagram (Cont’d)

TD42

TEC536M

EC-4034

QUICK-GLOW SYSTEM
Wiring Diagram (Cont’d)

TD42

TEC537M

EC-4035

FAST IDLE CONTROL CIRCUIT

TD42

Wiring Diagram

TEC526M

EC-4036

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ZD30DDTi

Circuit Diagram

TEC527M

EC-4037

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ZD30DDTi

CONDITION

CKPSzRPM (TDC)

SPECIFICATION

+ Run engine and compare CONSULT-II value with the tachometer indication.

Almost the same speed as the
tachometer indication.

COOLAN TEMP/S

+ Engine: After warming up

More than 70°C (158°F)

VHCL SPEED SE

+ Turn drive wheels and compare CONSULT-II value with the speedometer indication

Almost the same speed as the
speedometer indication

FUEL TEMP SEN

+ Engine: After warming up

More than 40°C (104°F)

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully released

0.40 — 0.60V

ACCEL POS SEN

Accelerator pedal: fully depressed

Approx. 4.5V

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully depressed

Except above

OFF

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully released

Accelerator pedal: slightly open

OPEN

+ Ignition switch: ON
(Engine stopped)

Accelerator pedal: fully released

OFF ACCEL SW

Accelerator pedal: slightly open

OFF

SPILL/V

+ Engine: After warming up

Approx. 13°CA

BATTERY VOLT

+ Ignition switch: ON (Engine stopped)

11 — 14V

P/N POSI SW

+ Ignition switch: ON

START SIGNAL

+ Ignition switch: ON → START → ON

AIR COND SIG

+ Engine: After warming up, idle the
engine

CMPSzRPM-PUMP

FULL ACCEL SW

ACCEL SW (FC)

BRAKE SW
IGN SW
WARM UP SW

Shift lever: Park/Neutral

Except above

OFF
OFF → ON → OFF

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

Brake pedal: depressed

Brake pedal: released

OFF

+ Ignition switch: ON
+ Ignition switch: ON → OFF

ON → OFF
Heat up switch: ON

Heat up switch: OFF

OFF

+ Ignition switch: ON
+ Ignition switch: ON (Engine stopped)

Approx. 0.4V
Idle

MAS AIR/FL SE

+
+
+
+

Engine: After warming up
Air conditioner switch: OFF
Shift lever: Neutral position
No-load

DECELER F/CUT

+ Engine: After warming up

INJ TIMG C/V

+ Engine: After warming up, idle the engine.

AIR COND RLY

+ Engine: After warming up, idle the
engine

GLOW RLY

1.5 — 1.9V

1.5 — 1.9 to Approx. 4.0V (Check for
Engine is revving from idle to about 4,000 liner voltage rise in response to
rpm
engine being increased to about
4,000 rpm.)
Idle

OFF
Approx. 50 — 70%

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

+ Refer to EC-252 in Service Manual (Publication No. SM9E-Y61CG3).
+ When cooling fan is stopped.

OFF

+ When cooling fan operates.

COOLING FAN

EC-4038

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
CONSULT-II Reference Value in Data Monitor
Mode (Cont’d)
MONITOR ITEM

EGR VOL CON/V

VNT S/V 1

CONDITION
+
+
+
+

Engine: After warming up
Air conditioner switch: “OFF”
Shift lever: Neutral position
No-load

After 1 minute of idling

More than 10 steps

Revving engine from idle to 3,200 rpm

0 step

+
+
+
+

Engine: After warming up
Air conditioner switch: “OFF”
Shift lever: Neutral position
No-load

Idle

Approx. 56%

2,000 rpm

Approx. 20%

BARO SEN

+ Ignition switch: ON

SWRL CON S/V 1

+ Lift up the vehicle
+ Engine: After warming up let it idle for
more than 1 second.
+ Air conditioner switch: “OFF”
+ No-load

EXH/GAS REG V*

SPECIFICATION

+
+
+
+

Shift lever: Neutral position

OFF

Vehicle: Stopped
Engine speed: Below 1,200 rpm
Engine coolant temperature: Below 87°C (189°F)
Heat up switch: ON

Except above

OFF

*: This item is applicable for cold area models. On other models, “OFF” is always displayed.

EC-4039

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

ZD30DDTi

ECM Terminals and Reference Value
ECM INSPECTION TABLE
Remarks: Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Engine is running.
2

R/W

Intake air control valve
control solenoid valve

DATA (DC Voltage and Pulse
Signal)
BATTERY VOLTAGE
(11 — 14V)

Ignition switch “OFF”
For a few seconds after turning ignition
switch “OFF”

Approximately 0.1V

Ignition switch “ON”
Ignition switch “OFF”
4

B/Y

ECM relay (Self-shutoff)

Approximately 0.25V

For a few seconds after turning ignition
switch “OFF”
Ignition switch “OFF”
A few seconds passed after turning ignition
switch “OFF”

BATTERY VOLTAGE
(11 — 14V)
Approximately 5.7V

Engine is running.
Warm-up condition
Idle speed

SEF255Z

Y/B

Tachometer
Approximately 6V

Engine is running.
Warm-up condition
Engine speed is 2,000 rpm

SEF256Z

EC-4040

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)

Engine is running.

BR/Y

Exhaust gas control
valve control solenoid
valve

Approximately 0.1V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

Cooling fan relay
Engine is running.
Approximately 0.1V
Cooling fan is operating
Engine is running.
Air conditioner switch is “OFF”

Y/L

Air conditioner relay

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Both air conditioner switch and blower fan
switch are “ON”
(Compressor is operating)

Approximately 0.1V

Ignition switch “ON”
Approximately 1V
Glow lamp is “ON”
16

L/W

Glow lamp
Ignition switch “ON”
Glow lamp is “OFF”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”
Approximately 0V
Brake pedal fully released
17

G/Y

Stop lamp switch
Ignition switch “ON”
Brake pedal depressed

Malfunction indicator
lamp

Ignition switch “ON”

Approximately 1V

Engine is running.

BATTERY VOLTAGE
(11 — 14V)

Idle speed

LG/R

R/W

Engine coolant temperature sensor

BATTERY VOLTAGE
(11 — 14V)

Engine is running.

Approximately 0 — 4.8V
Output voltage varies with
engine coolant temperature

Ignition switch “ON”

Approximately 0V

Ignition switch “START”

BATTERY VOLTAGE
(11 — 14V)

Start signal

EC-4041

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Engine is running.
Air conditioner switch is “OFF”
21

LG/B

Air conditioner switch

DATA (DC Voltage and Pulse
Signal)
BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Both air conditioner switch and blower fan
switch are “ON”
(Compressor is operating)

Approximately 0.1V

Ignition switch “ON”

P/B

Park/Neutral position
switch

Gear position is “Neutral” (M/T models)
Gear position is “P” or “N” (A/T models)
Ignition switch “ON”
Except the above gear position

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”
0.4 — 0.6V
23

Accelerator position sensor

Accelerator pedal fully released
Ignition switch “ON”
Approximately 4.5V
Accelerator pedal fully depressed
Voltage goes high up once in
a few seconds

Engine is running.
24

PU/W

A/T signal No. 1

Warm-up condition
Idle speed

SEF448Z

0 — Approximately 4.8V

Engine is running.
Lift up the vehicle
In 1st gear position
Vehicle speed is 10 km/h (6 MPH)

SEF257Z

L/OR

Vehicle speed sensor
Approximately 2.2V

Engine is running.
Lift up the vehicle
In 2nd gear position
Vehicle speed is 30 km/h (19 MPH)

SEF258Z

EC-4042

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

Ignition switch “ON”
Accelerator pedal fully released
29

R/L

DATA (DC Voltage and Pulse
Signal)
BATTERY VOLTAGE
(11 — 14V)

Accelerator switch (F/C)
Ignition switch “ON”
Approximately 0V
Accelerator pedal depressed
Engine is running.
Warm-up condition
Idle speed

Approximately 0V

A/T signal No. 3
Engine is running.
Warm-up condition
Engine speed is 2,000 rpm
Ignition switch “ON”

R/L

Accelerator position
switch (Idle)

Accelerator pedal fully released

Approximately 7.7V

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”
Approximately 0V
Accelerator pedal depressed
Ignition switch “ON”
Approximately 0V

W/G

Accelerator position
switch (Full)

Accelerator pedal released
Ignition switch “ON”
Accelerator pedal fully depressed

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
33

G/Y

Electronic control fuel
injection pump

Warm-up condition
Idle speed
Ignition switch “ON”

Approximately 2.5V

Approximately 0.4V

Engine is running.
Warm-up condition
Idle speed
35

1.5 — 1.9V

Mass air flow sensor
Engine is running.
Warm-up condition
Engine is revving from idle to about 4,000
rpm

1.5 — 1.9 to Approximately
4.0V (Check for liner voltage
rise in response to engine
being increased to about
4,000 rpm.)
Voltage goes high up once in
a few seconds

Engine is running.
37

P/B

A/T signal No. 2

Warm-up condition
Idle speed

SEF448Z

EC-4043

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

39
43

WIRE
COLOR

B/Y

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)

Ignition switch “OFF”

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch

Engine is running.

B
B

ECM ground

R/B

Electronic control fuel
injection pump

L/G

Y/G

Y/R

Approximately 0V
Idle speed
Engine is running.
Warm-up condition
Idle speed
Engine is running.

Data link connector

Idle speed (CONSULT-II is connected and
turned on)

Approximately 2.5V

Approximately 0V
Approximately 0V
Less than 9V
Approximately 0V

Engine is running.
Warm-up condition
Idle speed

SEF333Y

Crankshaft position sensor (TDC)

Approximately 0V

Engine is running.
Warm-up condition
Engine speed is 2,000 rpm

SEF334Y

Engine is running.
L

Charge air pressure sensor

B/W

Crankshaft position sensor (TDC) ground

G/R

Accelerator position sensor power supply

Ignition switch “ON”

Approximately 5V

Sensor power supply

Ignition switch “ON”

Approximately 5V

Warm-up condition
Idle speed

Approximately 2.0V

Engine is running.
Warm-up condition
Idle speed

Approximately 0V

Engine is running.
50

Sensor ground

Warm-up condition
Idle speed

EC-4044

Approximately 0V

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)

Engine is running.
51

L/W

Accelerator position sensor ground

L/B

Electronic control fuel
injection pump

Engine is running.

Electronic control fuel
injection pump

Engine is running.

L/R

Warm-up condition
Idle speed

Approximately 0V

Approximately 0.1V
Idle speed
Approximately 1.0V
Idle speed
Engine is running.

L/B

Swirl control valve control solenoid valve

Warm-up condition
At idle speed for more than 1 second
Lift up the vehicle
Gear position is in positions other than “P”
and “Neutral”

Approximately 0.1V

Engine is running.
Idle speed
Lift up the vehicle
Gear position is in “P” or “Neutral”
56
61
116

W
W
W

Power supply for ECM

Ignition switch “ON”

BATTERY VOLTAGE
(11 — 14V)

BATTERY VOLTAGE
(11 — 14V)
Voltage goes high up once in
a few seconds

Engine is running.
58

L/OR

A/T signal No. 4

Warm-up condition
Idle speed

SEF448Z

Ignition switch “ON”
Approximately 0V
Heat up switch is “ON”
59

BR/W

Heat up switch
Ignition switch “ON”
Heat up switch is “OFF”

BATTERY VOLTAGE
(11 — 14V)

Ignition switch “ON”
0.4 — 0.6V
68

B/W

Accelerator position sensor signal output

Accelerator pedal fully released
Ignition switch “ON”
Approximately 4.5V
Accelerator pedal fully depressed

EC-4045

ZD30DDTi
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
ECM Terminals and Reference Value (Cont’d)
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage and Pulse
Signal)
Approximately 6.8V

Engine is running.
Warm-up condition
Idle speed

101

R/B

Variable nozzle turbocharger control solenoid
valve

SEF253Z

Approximately 11V

Engine is running.
Warm-up condition
Engine speed is 2,000 rpm

SEF254Z

Engine is running.
102

G/R

Current return
Idle speed

103
105
109
115

L/Y
L/W
L
R/L

EGR volume control
valve

106
112
118

B
B
B

ECM ground

111

LG/B

Glow relay

BATTERY VOLTAGE
(11 — 14V)

Engine is running.
Warm-up condition
Idle speed

0.1 — 14V

Engine is running.
Approximately 0V
Idle speed
Refer to “GLOW CONTROL SYSTEM”, EC-252 in Service Manual (Publication No.
SM9E-Y61CG3).

EC-4046

ZD30DDTi

DTC 0102 MASS AIR FLOW SEN
Component Description

The mass air flow (MAF) sensor is placed in the stream of intake
air. It measures the intake air flow rate by measuring a part of the
entire intake air flow. The mass air flow sensor controls the temperature of the hot wire to a certain amount. The heat generated
by the hot wire is reduced as the intake air flows around it. The
more air, the greater the heat loss.
Therefore, the electric current supplied to hot wire is changed to
maintain the temperature of the hot wire as air flow increases. The
ECM detects the air flow by means of this current change.
PBIB1604E

CONSULT-II Reference Value in Data Monitor
Mode

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

+ Ignition switch: ON (Engine stopped)
+
+
+
+

MAS AIR/FL SE

Engine: After warming up
Air conditioner switch: “OFF”
Shift lever: Neutral position
No-load

Approx. 0.4V
Idle

1.5 — 1.9V

Engine is revving from idle to about
4,000 rpm

1.5 — 1.9 to Approx. 4.0V (Check for liner
voltage rise in response to engine being
increased to about 4,000 rpm.)

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Ignition switch “ON”

Approximately 0.4V

Engine is running.
1.5 — 1.9V

Warm-up condition
Idle speed
35

Mass air flow sensor
Engine is running.
Warm-up condition
Engine is revving from idle to about 4,000 rpm

1.5 — 1.9 to Approximately
4.0V (Check for liner voltage rise in response to
engine being increased to
about 4,000 rpm.)

Engine is running.
50

Sensor ground

Approximately 0V

Warm-up condition
Idle speed

On Board Diagnosis Logic
Malfunction is detected when …

Check Items (Possible Cause)

+ An excessively high or low voltage from the sensor is sent to
ECM.

+ Harness or connectors
(The sensor circuit is open or shorted.)
+ Mass air flow sensor

EC-4047

DTC 0102 MASS AIR FLOW SEN

ZD30DDTi

DTC Confirmation Procedure
WITH CONSULT-II
1)
2)
3)
4)

WITHOUT CONSULT-II
SEF817Y

1) Turn ignition switch “ON”, and wait at least 6 seconds.
2) Start engine and wait at least 3 seconds.
3) Turn ignition switch “OFF”, wait at least 5 seconds and then turn
“ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic results)” with
ECM.
5) If DTC is detected, go to “Diagnostic Procedure”, EC-4050.

EC-4048

DTC 0102 MASS AIR FLOW SEN

ZD30DDTi

Wiring Diagram

TEC528M

EC-4049

DTC 0102 MASS AIR FLOW SEN

ZD30DDTi

Diagnostic Procedure
1

CHECK MAF SENSOR POWER SUPPLY CIRCUIT

1. Turn ignition switch “OFF”.
2. Disconnect mass air flow sensor harness connector.

SEF226Z

3. Turn ignition switch “ON”.
4. Check voltage between mass air flow sensor terminal 2 and ground with CONSULT-II or tester.

SEC015E

OK or NG
OK

c GO TO 3.

c GO TO 2.

DETECT MALFUNCTIONING PART

EC-4050

DTC 0102 MASS AIR FLOW SEN
Diagnostic Procedure (Cont’d)
3

ZD30DDTi

CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.
2. Loosen and retighten engine ground screws.

SEF227Z

3. Disconnect ECM harness connector.
4. Disconnect TCM harness connector.
5. Check harness continuity between mass air flow sensor terminal 3 and ECM terminal 50, TCM terminal 42. Refer to Wiring Diagram.
Continuity should exist.
6. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 5.

c GO TO 4.

DETECT MALFUNCTIONING PART

CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between mass air flow sensor terminal 4 and ECM terminal 35. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 7.

c GO TO 6.

DETECT MALFUNCTIONING PART

EC-4051

DTC 0102 MASS AIR FLOW SEN
Diagnostic Procedure (Cont’d)
7

ZD30DDTi

CHECK SHIELD CIRCUIT

1. Disconnect harness connectors E230, F12.
2. Check harness continuity between harness connector F12 terminal 5 and ground.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK

c GO TO 9.

c GO TO 8.

DETECT MALFUNCTIONING PART

Check the following.
+ Joint connector-4
+ Harness for open or short between harness connector F12 and ground
c Repair open circuit or short to power in harness or connectors.
9

CHECK MASS AIR FLOW SENSOR

1. Reconnect harness connectors disconnected.
2. Start engine and warm it up to normal operating temperature.
3. Check voltage between ECM terminal 35 (Mass air flow sensor signal) and ground.

SEF400YA

4. If the voltage is out of specification, proceed the following.
a. Check for the cause of uneven air flow through mass air flow sensor. Refer to the following.
+ Crushed air ducts
+ Malfunctioning seal of air cleaner element
+ Uneven dirt of air cleaner element
+ Improper specification of intake air system parts
b. If NG, repair or replace malfunctioning part and perform steps 2 to 4 again.
5. Turn ignition switch “OFF”.
6. Disconnect MAFS harness connector and connect it again.
7. Perform steps 2 and 3 again.
OK or NG
OK

c GO TO 10.

c Replace mass air flow sensor.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-107 in Service Manual (Publication No. SM9E-Y61CG3).
c INSPECTION END

EC-4052

DTC 0104 VEHICLE SPEED SEN

ZD30DDTi

Wiring Diagram

TEC538M

EC-4053

HEAT UP SWITCH

ZD30DDTi

Wiring Diagram

TEC529M

EC-4054

HEAT UP SWITCH

ZD30DDTi

Diagnostic Procedure
1

INSPECTION START

Do you have CONSULT-II?
Yes or No
Yes

c GO TO 2.

c GO TO 3.

CHECK OVERALL FUNCTION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Check “WARM UP SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

SEF302Z

OK or NG
OK

c INSPECTION END

c GO TO 4.

CHECK OVERALL FUNCTION

Without CONSULT-II
1. Turn ignition switch “ON”.
2. Check voltage between ECM terminal 59 and ground under the following conditions.

SEF303Z

OK or NG
OK

c INSPECTION END

c GO TO 4.

EC-4055

HEAT UP SWITCH
Diagnostic Procedure (Cont’d)
4
1.
2.
3.
4.
5.

ZD30DDTi

SEC016E

OK or NG
OK

c GO TO 6.

c GO TO 5.

DETECT MALFUNCTIONING PART

CHECK HEAT UP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1. Turn ignition switch “OFF”.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 59 and heat up switch terminals 3, 5. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK

c GO TO 8.

c GO TO 7.

DETECT MALFUNCTIONING PART

Check the following.
+ Harness connectors M51, F6
+ Harness for open or short between heat up switch and ECM
c Repair open circuit or short to ground or short to power in harness or connectors.

EC-4056

HEAT UP SWITCH
Diagnostic Procedure (Cont’d)
8

ZD30DDTi

CHECK HEAT UP SWITCH INDICATOR LAMP GROUND CIRCUIT FOR OPEN OR SHORT

1. Check harness continuity between heat up switch terminal 6 and ground.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to power.
OK or NG
OK

c GO TO 9.

c Repair open circuit or short to power in harness or connectors.

CHECK HEAT UP SWITCH INDICATOR LAMP

Check harness continuity between heat up switch terminals 5 and 6 under the following conditions.

SEC018E

OK or NG
OK

c GO TO 10.

c Replace heat up switch.

CHECK HEAT UP SWITCH

Check continuity between heat up switch terminals 1 and 3 under the following conditions.

SEC017E

OK or NG
OK

c GO TO 11.

c Replace heat up switch.

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-107 in Service Manual (Publication No. SM9E-Y61CG3).
c INSPECTION END

EC-4057

AIR CONDITIONER CONTROL

ZD30DDTi

Wiring Diagram

TEC530M

EC-4058

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

TD42Ti

Circuit Diagram

TEC539M

EC-4059

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS

TD42Ti

Vehicle Speed Sensor (VSS)

TEC540M

EC-4060

ELECTRICAL SYSTEM
SECTION

MODIFICATION NOTICE:
+

Wiring Diagrams have been changed.

CONTENTS
POWER SUPPLY ROUTING/WAGON AND
HARDTOP MODELS ………………………………………….4005
Schematic ……………………………………………………..4005
Wiring Diagram — POWER —…………………………4006
GROUND DISTRIBUTION/WAGON AND
HARDTOP MODELS ………………………………………….4016
Main Harness/LHD Models………………………………4016
Main Harness/RHD Models ……………………………..4019
Engine Room Harness/LHD Models …………………4022
Engine Room Harness/RHD Models…………………4024
Body Harness/LHD Models ……………………………..4026
Body Harness/RHD Models……………………………..4028
Body No. 2 Harness/LHD Models …………………….4030
Body No. 2 Harness/RHD Models…………………….4031
Back Door and Rear Window Defogger Harness/
LHD Models …………………………………………………..4032
Back Door and Rear Window Defogger Harness/
RHD Models ………………………………………………….4033
COMBINATION SWITCH…………………………………….4034
Check……………………………………………………………4034
STEERING SWITCH…………………………………………..4036
Check/RHD Models for Europe and LHD Models.4036
Check/RHD Models Except for Europe……………..4038
HEADLAMP/WAGON AND HARDTOP MODELS
— Conventional Type —……………………………………4040
Wiring Diagram — H/LAMP —…………………………4040
HEADLAMP/WAGON AND HARDTOP MODELS
— Xenon Type —………………………………………………4041
Bulb Replacement ………………………………………….4041
Wiring Diagram — H/LAMP —…………………………4042

HEADLAMP/WAGON AND HARDTOP MODELS
— Headlamp Aiming Control — ………………………..4044
Wiring Diagram — H/AIM —/Except for the
Middle East ……………………………………………………4044
HEADLAMP/WAGON AND HARDTOP MODELS
— Daytime Light System — ………………………………4047
Wiring Diagram — DTRL — …………………………….4047
PARKING, LICENSE AND TAIL LAMPS/WAGON
AND HARDTOP MODELS ………………………………….4049
Wiring Diagram — TAIL/L —/Type A…………………4049
Wiring Diagram — TAIL/L —/Type B…………………4051
Wiring Diagram — TAIL/L —/Type C ………………..4053
BACK-UP LAMP/WAGON AND HARDTOP
MODELS …………………………………………………………..4055
Wiring Diagram — BACK/L —/LHD Models
Except TB48 Engine with A/T…………………………..4055
Wiring Diagram — BACK/L —/LHD Models for
TB48 Engine with A/T……………………………………..4056
Wiring Diagram — BACK/L —/RHD Models
Except TB48 Engine with A/T…………………………..4057
Wiring Diagram — BACK/L —/RHD Models
for TB48 Engine with A/T ………………………………..4058
STOP LAMP/WAGON AND HARDTOP MODELS …4059
Wiring Diagram — STOP/L —/Type A ………………4059
Wiring Diagram — STOP/L —/Type B ………………4060
FRONT FOG LAMP/WAGON AND HARDTOP
MODELS …………………………………………………………..4061
Wiring Diagram — F/FOG —/Except for Europe
and China ……………………………………………………..4061

EL-4001

CONTENTS
Wiring Diagram — F/FOG —/RHD Models for
Europe and China…………………………………………..4062
Wiring Diagram — F/FOG —/LHD Models for
Europe ………………………………………………………….4063
REAR FOG LAMP/WAGON AND HARDTOP
MODELS …………………………………………………………..4064
Wiring Diagram — R/FOG —/For Europe and
China…………………………………………………………….4064
TURN SIGNAL AND HAZARD WARNING LAMPS/
WAGON AND HARDTOP MODELS …………………….4067
Schematic ……………………………………………………..4067
Wiring Diagram — TURN —/Type A …………………4068
Wiring Diagram — TURN —/Type B…………………4073
Wiring Diagram — TURN —/Type C…………………4075
Wiring Diagram — TURN —/Type D…………………4077
ILLUMINATION/WAGON AND HARDTOP
MODELS …………………………………………………………..4079
Schematic ……………………………………………………..4079
Wiring Diagram — ILL — ………………………………..4080
INTERIOR ROOM LAMP/WAGON AND HARDTOP
MODELS — With Timer —…………………………………4088
Schematic/LHD Models Except for China ………….4088
Wiring Diagram — ROOM/L —/LHD Models
Except for China …………………………………………….4089
Wiring Diagram — ROOM/L —/RHD Models for
Europe ………………………………………………………….4092
INTERIOR ROOM LAMP/WAGON AND HARDTOP
MODELS — Without Timer — ……………………………4094
Wiring Diagram — ROOM/L —/RHD Models……..4094
METER AND GAUGES/WAGON AND HARDTOP
MODELS …………………………………………………………..4095
Combination Meter …………………………………………4095
Schematic ……………………………………………………..4096
Wiring Diagram — METER —………………………….4097
COMPASS AND THERMOMETER/WAGON AND
HARDTOP MODELS ………………………………………….4099
Wiring Diagram — COMPAS —……………………….4099
WARNING LAMPS/WAGON AND HARDTOP
MODELS …………………………………………………………..4100
Schematic ……………………………………………………..4100
Wiring Diagram — WARN — …………………………..4102
WARNING CHIME/WAGON AND HARDTOP
MODELS …………………………………………………………..4113
Wiring Diagram — CHIME —/Except for Europe
and with Theft Warning System Models…………….4113
Wiring Diagram — CHIME —/LHD Models for
Europe ………………………………………………………….4114
Wiring Diagram — CHIME —/RHD Models for
Europe ………………………………………………………….4115
Wiring Diagram — CHIME —/With Theft Warning
System Models ………………………………………………4116

(Cont’d)

FRONT WIPER AND WASHER/WAGON AND
HARDTOP MODELS ………………………………………….4117
Wiring Diagram — WIPER — ………………………….4117
REAR WIPER AND WASHER/WAGON AND
HARDTOP MODELS ………………………………………….4118
Wiring Diagram — WIP/R —……………………………4118
HEADLAMP WASHER/WAGON AND HARDTOP
MODELS …………………………………………………………..4122
Wiring Diagram — HLC — ………………………………4122
HORN/WAGON AND HARDTOP MODELS…………..4124
Wiring Diagram — HORN —……………………………4124
WIPER DEICER/WAGON AND HARDTOP
MODELS …………………………………………………………..4125
Wiring Diagram — DEICER —…………………………4125
REAR WINDOW DEFOGGER/WAGON AND
HARDTOP MODELS ………………………………………….4126
Wiring Diagram — DEF —/LHD Models Without
Theft Warning System …………………………………….4126
Wiring Diagram — DEF —/RHD Models Except
for Europe and With Theft Warning System ………4128
Wiring Diagram — DEF —/LHD Models With
Theft Warning System …………………………………….4130
Wiring Diagram — DEF —/RHD Models for
Europe ………………………………………………………….4132
Wiring Diagram — DEF —/RHD Models With
Theft Warning System …………………………………….4134
AUDIO/WAGON AND HARDTOP MODELS………….4136
Schematic/LHD Models with Sub-harness …………4136
Wiring Diagram — AUDIO —/LHD Models with
Sub-harness…………………………………………………..4137
Schematic/RHD Models with Sub-harness ………..4140
Wiring Diagram — AUDIO —/RHD Models with
Sub-harness…………………………………………………..4141
Schematic/LHD Models without Sub-harness …….4144
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness ……………………………………….4145
Schematic/RHD Models without Sub-harness ……4149
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness ……………………………………….4150
Wiring Diagram — CD AUTO CHANGER —……..4154
Wiring Diagram — REMOTE —……………………….4155
Wiring Diagram — P/ANT —/LHD Models…………4159
Wiring Diagram — P/ANT —/RHD Models ………..4160
TELEPHONE (PRE WIRE) ………………………………….4161
Wiring Diagram — PHONE — …………………………4161
NAVIGATION SYSTEM ………………………………………4162
System Description…………………………………………4162
Precautions for NAVI Control Unit Replacement ..4173
Component Parts And Harness Connector
Location ………………………………………………………..4173
Schematic ……………………………………………………..4174
Wiring Diagram — NAVI — ……………………………..4175

EL-4002

CONTENTS
Terminals and Reference Value for NAVI Control
Unit……………………………………………………………….4183
Terminals and Reference Value for Display ……….4185
Terminals and Reference Value for NAVI Switch ..4186
Terminals and Reference Value for Transfer Unit .4187
Terminals and Reference Value for Voice
Change Relay ………………………………………………..4188
Self-Diagnosis Function…………………………………..4189
Self-Diagnosis Mode……………………………………….4189
Confirmation/Adjustment Mode ………………………..4192
Trouble Diagnoses………………………………………….4198
Example of Symptoms Judged Not Malfunction …4218
Program Loading ……………………………………………4226
DOOR MIRROR/WAGON AND HARDTOP
MODELS …………………………………………………………..4227
Wiring Diagram — MIRROR —/LHD Models……..4227
Wiring Diagram — MIRROR —/RHD Models …….4229
HEATED SEAT/WAGON AND HARDTOP
MODELS …………………………………………………………..4231
Wiring Diagram — HSEAT —…………………………..4231
AUTOMATIC SPEED CONTROL DEVICE (ASCD)/
WAGON AND HARDTOP MODELS …………………….4233
Schematic/TB48 and TD42Ti Engine Models …….4233
Wiring Diagram — ASCD —/TB48 and TD42Ti
Engine Models ……………………………………………….4234
POWER WINDOW/WAGON AND HARDTOP
MODELS …………………………………………………………..4238
Schematic ……………………………………………………..4238
Wiring Diagram — WINDOW — ………………………4239
POWER DOOR LOCK/WAGON AND HARDTOP
MODELS …………………………………………………………..4244
Schematic/Without Theft Warning System
Models ………………………………………………………….4244
Wiring Diagram — D/LOCK —/Without Theft
Warning System Models………………………………….4245
Schematic/With Theft Warning System Models ….4249
Wiring Diagram — D/LOCK —/LHD Models With
Theft Warning System …………………………………….4250
Wiring Diagram — D/LOCK —/RHD Models With
Theft Warning System …………………………………….4254
POWER DOOR LOCK/WAGON AND HARDTOP
MODELS …………………………………………………………..4258
Schematic — Super Lock — ……………………………4258
Wiring Diagram — S/LOCK — …………………………4259
MULTI-REMOTE CONTROL SYSTEM/WAGON
AND HARDTOP MODELS ………………………………….4264
Wiring Diagram — MULTI —/LHD Models Except
for Europe, The Middle East and With Theft
Warning System …………………………………………….4264
Wiring Diagram — MULTI —/RHD Models
Except for Europe, South Africa and With Theft
Warning System …………………………………………….4266

(Cont’d)

Schematic/With Theft Warning System Models ….4268
Wiring Diagram — MULTI —/LHD Models with
Theft Warning System …………………………………….4269
Wiring Diagram — MULTI —/RHD Models with
Theft Warning System …………………………………….4273
Wiring Diagram — MULTI —/LHD Models for
Europe and The Middle East……………………………4276
THEFT WARNING SYSTEM/WAGON AND
HARDTOP MODELS ………………………………………….4278
Schematic ……………………………………………………..4278
Wiring Diagram — THEFT —/LHD Models………..4279
Wiring Diagram — THEFT —/RHD Models ……….4284
SUPER LOCK CONTROL UNIT/WAGON AND
HARDTOP MODELS ………………………………………….4290
Schematic/RHD Models for Europe ………………….4290
UNIFIED METER CONTROL UNIT (TIME
CONTROL SYSTEM)/WAGON AND HARDTOP
MODELS …………………………………………………………..4292
Schematic/Except RHD Models for Europe and
With Theft Warning System Models ………………….4292
NATS (Nissan Anti-Theft System)/TB48DE
ENGINE MODELS FOR EUROPE ……………………….4293
Wiring Diagram — NATS —…………………………….4293
NATS (Nissan Anti-Theft System)/ZD ENGINE
MODELS …………………………………………………………..4295
Wiring Diagram — NATS —/LHD Models for
Europe ………………………………………………………….4295
Wiring Diagram — NATS —/RHD Models for
Europe ………………………………………………………….4297
LOCATION OF ELECTRICAL UNITS/WAGON
AND HARDTOP MODELS ………………………………….4300
Engine Compartment………………………………………4300
Passenger Compartment — LHD Models………….4302
Passenger Compartment — RHD Models …………4304
HARNESS LAYOUT …………………………………………..4307
How to Read Harness Layout ………………………….4307
HARNESS LAYOUT/WAGON AND HARDTOP
MODELS …………………………………………………………..4308
Main Harness/LHD Models………………………………4308
Main Harness/RHD Models ……………………………..4312
Engine Room Harness/LHD Models …………………4316
Engine Room Harness/RHD Models…………………4322
Engine Harness ……………………………………………..4328
Body Harness/LHD Models ……………………………..4330
Body Harness/RHD Models……………………………..4334
Body No. 2 Harness/LHD Models …………………….4338
Body No. 2 Harness/RHD Models…………………….4340
Chassis Harness…………………………………………….4342
Front Door Harness (Driver side) ……………………..4343
Front Door Harness (Passenger side) ………………4344
Rear Door Harness…………………………………………4345

EL-4003

CONTENTS
Back Door Harness and Rear Window Defogger
Harness…………………………………………………………4346
WIRING DIAGRAM CODES (CELL CODES)………..4347
Wiring Diagram Codes (Cell Codes) …………………4347

EL-4004

(Cont’d)

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Schematic

TEL961M

EL-4005

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER —
BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

TEL962M

EL-4006

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL963M

EL-4007

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL964M

EL-4008

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL965M

EL-4009

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL966M

EL-4010

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON”

TEL967M

EL-4011

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START”

TEL968M

EL-4012

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL969M

EL-4013

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL970M

EL-4014

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL971M

EL-4015

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models

CEL559M

EL-4016

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

CEL560M

EL-4017

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

CEL561M

EL-4018

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/RHD Models

CEL562M

EL-4019

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

CEL563M

EL-4020

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

CEL564M

EL-4021

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models

CEL555M

EL-4022

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)

CEL556M

EL-4023

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models

CEL557M

EL-4024

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models (Cont’d)

CEL558M

EL-4025

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/LHD Models

CEL565M

EL-4026

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)

CEL566M

EL-4027

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/RHD Models

CEL567M

EL-4028

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)

CEL568M

EL-4029

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models

CEL569M

EL-4030

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body No. 2 Harness/RHD Models

CEL570M

EL-4031

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Back Door and Rear Window Defogger
Harness/LHD Models

CEL571M

EL-4032

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Back Door and Rear Window Defogger
Harness/RHD Models

CEL572M

EL-4033

COMBINATION SWITCH
Check
RHD MODELS FOR EUROPE AND LHD MODELS

CEL573M

EL-4034

COMBINATION SWITCH
Check (Cont’d)
RHD MODELS EXCEPT FOR EUROPE

CEL574M

EL-4035

STEERING SWITCH
Check/RHD Models for Europe and LHD Models
WITH ASCD AND AUDIO SWITCH

CEL575M

EL-4036

STEERING SWITCH
Check/RHD Models for Europe and LHD Models
(Cont’d)
WITHOUT ASCD AND AUDIO SWITCH

CEL577M

EL-4037

STEERING SWITCH
Check/RHD Models Except for Europe
WITH ASCD AND AUDIO SWITCH

CEL576M

EL-4038

STEERING SWITCH
Check/RHD Models Except for Europe (Cont’d)
WITH ASCD AND AUDIO SWITCH

CEL578M

EL-4039

HEADLAMP/WAGON AND HARDTOP MODELS — Conventional Type —
Wiring Diagram — H/LAMP —

TEL972M

EL-4040

HEADLAMP/WAGON AND HARDTOP MODELS — Xenon Type —
Bulb Replacement
CAUTION:
+ After replacing a new xenon bulb, be sure to make aiming
adjustments.
+ Hold only the plastic base when handling the bulb. Never
touch the glass envelope.
+ Do not leave headlamp reflector without bulb for a long
period of time. Dust, moisture, smoke, etc. entering headlamp body may affect the performance of the headlamp.
Remove headlamp bulb from the headlamp reflector just
before a replacement bulb is installed.
1. Disconnect negative battery cable.
2. Remove side combination lamp and radiator grille.
3. Disconnect headlamp connector.
4. Remove headlamp assembly.
WARNING:
Never service a xenon headlamp with wet hands.

XENON BULB (HIGH AND LOW BEAM)
1. Remove headlamp seal cover by turning it counterclockwise.
2. Turn bulb socket counterclockwise with keep pushing, then
remove it.

CEL586M

SEL442V

3. Release retaining pin.
4. Remove the xenon bulb.
5. Install in the reverse order of removal.
CAUTION:
+ When disposing of the xenon bulb, do not break it; always
dispose of it as is.
+ Make sure to install the bulb securely; if the xenon bulb is
improperly installed in its socket, high-tension current
leaks occur. This may lead to a melted bulb and/or bulb
socket.
SEL378Y

EL-4041

HEADLAMP/WAGON AND HARDTOP MODELS — Xenon Type —
Wiring Diagram — H/LAMP —

TEL973M

EL-4042

HEADLAMP/WAGON AND HARDTOP MODELS — Xenon Type —
Wiring Diagram — H/LAMP — (Cont’d)

TEL974M

EL-4043

HEADLAMP/WAGON AND HARDTOP MODELS — Headlamp Aiming Control —
Wiring Diagram — H/AIM —/Except for the
Middle East

TEL975M

EL-4044

HEADLAMP/WAGON AND HARDTOP MODELS — Headlamp Aiming Control —
Wiring Diagram — H/AIM —/Except for the
Middle East (Cont’d)

TEL976M

EL-4045

HEADLAMP/WAGON AND HARDTOP MODELS — Headlamp Aiming Control —
Wiring Diagram — H/AIM —/Except for the
Middle East (Cont’d)

TEL977M

EL-4046

HEADLAMP/WAGON AND HARDTOP MODELS — Daytime Light System —
Wiring Diagram — DTRL —

TEL978M

EL-4047

HEADLAMP/WAGON AND HARDTOP MODELS — Daytime Light System —
Wiring Diagram — DTRL — (Cont’d)

TEL656M

EL-4048

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type A
Rear combination lamps are not located on rear bumper.

TEL979M

EL-4049

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type A (Cont’d)

TEL980M

EL-4050

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type B
LHD MODELS FOR EUROPE

Rear combination lamps are located on rear bumper.

TEL981M

EL-4051

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type B (Cont’d)

TEL982M

EL-4052

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type C
RHD MODELS FOR EUROPE, CHINA, AUSTRALIA AND SOUTH AFRICA
Rear combination lamps are located on rear bumper.

TEL983M

EL-4053

PARKING, LICENSE AND TAIL LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — TAIL/L —/Type C (Cont’d)

TEL984M

EL-4054

BACK-UP LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — BACK/L —/LHD Models
Except TB48 Engine with A/T

TEL985M

EL-4055

BACK-UP LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — BACK/L —/LHD Models for
TB48 Engine with A/T

TEL986M

EL-4056

BACK-UP LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — BACK/L —/RHD Models
Except TB48 Engine with A/T

TEL987M

EL-4057

BACK-UP LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — BACK/L —/RHD Models
for TB48 Engine with A/T

TEL988M

EL-4058

STOP LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — STOP/L —/Type A
REAR COMBINATION LAMPS ARE NOT LOCATED ON REAR BUMPER

TEL989M

EL-4059

STOP LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — STOP/L —/Type B
REAR COMBINATION LAMPS ARE LOCATED ON REAR BUMPER

TEL990M

EL-4060

FRONT FOG LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — F/FOG —/Except for Europe
and China

TEL991M

EL-4061

FRONT FOG LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — F/FOG —/RHD Models for
Europe and China

TEL992M

EL-4062

FRONT FOG LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — F/FOG —/LHD Models for
Europe

TEL993M

EL-4063

REAR FOG LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — R/FOG —/For Europe and
China
WITH FRONT FOG LAMP

TEL994M

EL-4064

REAR FOG LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — R/FOG —/For Europe and
China (Cont’d)
WITH FRONT FOG LAMP

TEL995M

EL-4065

REAR FOG LAMP/WAGON AND HARDTOP MODELS
Wiring Diagram — R/FOG —/For Europe and
China (Cont’d)
WITHOUT FRONT FOG LAMP

TEL996M

EL-4066

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Schematic
LHD MODELS EXCEPT FOR EUROPE AND CHINA (TYPE A)
Rear combination lamps are not located on rear bumper.

TEL997M

EL-4067

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type A
LHD MODELS EXCEPT FOR EUROPE AND CHINA

Rear combination lamps are not located on rear bumper.

TEL998M

EL-4068

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type A (Cont’d)

TEL999M

EL-4069

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type A (Cont’d)

TEL001N

EL-4070

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type A (Cont’d)

TEL002N

EL-4071

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type A (Cont’d)

TEL003N

EL-4072

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type B
FOR CHINA

Rear combination lamps are located on rear bumper.

TEL004N

EL-4073

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type B (Cont’d)

TEL005N

EL-4074

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type C
FOR EUROPE

Rear combination lamps are located on rear bumper.

TEL006N

EL-4075

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type C (Cont’d)

TEL007N

EL-4076

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type D
FOR AUSTRALIA AND SOUTH AFRICA

Rear combination lamps are located on rear bumper.

TEL008N

EL-4077

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —/Type D (Cont’d)

TEL009N

EL-4078

ILLUMINATION/WAGON AND HARDTOP MODELS
Schematic

TEL010N

EL-4079

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL —

TEL011N

EL-4080

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL012N

EL-4081

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL013N

EL-4082

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL014N

EL-4083

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL015N

EL-4084

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL016N

EL-4085

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL017N

EL-4086

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL018N

EL-4087

INTERIOR ROOM LAMP/WAGON AND HARDTOP MODELS — With Timer —
Schematic/LHD Models Except for China

TEL411M

EL-4088

INTERIOR ROOM LAMP/WAGON AND HARDTOP MODELS — With Timer —
Wiring Diagram — ROOM/L —/LHD Models
Except for China

TEL412M

EL-4089

INTERIOR ROOM LAMP/WAGON AND HARDTOP MODELS — With Timer —
Wiring Diagram — ROOM/L —/LHD Models
Except for China (Cont’d)

TEL413M

EL-4090

INTERIOR ROOM LAMP/WAGON AND HARDTOP MODELS — With Timer —
Wiring Diagram — ROOM/L —/LHD Models
Except for China (Cont’d)

TEL674M

EL-4091

INTERIOR ROOM LAMP/WAGON AND HARDTOP MODELS — With Timer —
Wiring Diagram — ROOM/L —/RHD Models for
Europe

TEL019N

EL-4092

INTERIOR ROOM LAMP/WAGON AND HARDTOP MODELS — With Timer —
Wiring Diagram — ROOM/L —/RHD Models for
Europe (Cont’d)

TEL020N

EL-4093

INTERIOR ROOM LAMP/WAGON AND HARDTOP MODELS — Without Timer —
Wiring Diagram — ROOM/L —/RHD Models

TEL021N

EL-4094

METER AND GAUGES/WAGON AND HARDTOP MODELS
Combination Meter

CEL587M

EL-4095

METER AND GAUGES/WAGON AND HARDTOP MODELS
Schematic

TEL022N

EL-4096

METER AND GAUGES/WAGON AND HARDTOP MODELS
Wiring Diagram — METER —

TEL023N

EL-4097

METER AND GAUGES/WAGON AND HARDTOP MODELS
Wiring Diagram — METER — (Cont’d)

TEL024N

EL-4098

COMPASS AND THERMOMETER/WAGON AND HARDTOP MODELS
Wiring Diagram — COMPAS —

TEL144N

EL-4099

WARNING LAMPS/WAGON AND HARDTOP MODELS
Schematic

TEL899M

EL-4100

WARNING LAMPS/WAGON AND HARDTOP MODELS
Schematic (Cont’d)

TEL143N

EL-4101

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN —

TEL901M

EL-4102

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL902M

EL-4103

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL903M

EL-4104

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL904M

EL-4105

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL905M

EL-4106

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL906M

EL-4107

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL025N

EL-4108

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL908M

EL-4109

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL909M

EL-4110

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
LHD MODELS

TEL910M

EL-4111

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
RHD MODELS

TEL026N

EL-4112

WARNING CHIME/WAGON AND HARDTOP MODELS
Wiring Diagram — CHIME —/Except for Europe
and with Theft Warning System Models

TEL027N

EL-4113

WARNING CHIME/WAGON AND HARDTOP MODELS
Wiring Diagram — CHIME —/LHD Models for
Europe

TEL028N

EL-4114

WARNING CHIME/WAGON AND HARDTOP MODELS
Wiring Diagram — CHIME —/RHD Models for
Europe

TEL029N

EL-4115

WARNING CHIME/WAGON AND HARDTOP MODELS
Wiring Diagram — CHIME —/With Theft
Warning System Models

TEL030N

EL-4116

FRONT WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIPER —

TEL031N

EL-4117

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R —
LHD MODELS

TEL032N

EL-4118

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R — (Cont’d)
LHD MODELS

TEL033N

EL-4119

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R — (Cont’d)
RHD MODELS

TEL034N

EL-4120

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R — (Cont’d)
RHD MODELS

TEL035N

EL-4121

HEADLAMP WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — HLC —

TEL036N

EL-4122

HEADLAMP WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — HLC — (Cont’d)

TEL037N

EL-4123

HORN/WAGON AND HARDTOP MODELS
Wiring Diagram — HORN —

TEL038N

EL-4124

WIPER DEICER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEICER —

TEL039N

EL-4125

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/LHD Models Without
Theft Warning System

TEL040N

EL-4126

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/LHD Models Without
Theft Warning System (Cont’d)

TEL041N

EL-4127

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/RHD Models Except
for Europe and With Theft Warning System

TEL042N

EL-4128

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/RHD Models Except
for Europe and With Theft Warning System
(Cont’d)

TEL043N

EL-4129

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/LHD Models With
Theft Warning System

TEL044N

EL-4130

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/LHD Models With
Theft Warning System (Cont’d)

TEL045N

EL-4131

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/RHD Models for
Europe

TEL046N

EL-4132

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/RHD Models for
Europe (Cont’d)

TEL047N

EL-4133

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/RHD Models With
Theft Warning System

TEL140N

EL-4134

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/RHD Models With
Theft Warning System (Cont’d)

TEL141N

EL-4135

AUDIO/WAGON AND HARDTOP MODELS
Schematic/LHD Models with Sub-harness

TEL048N

EL-4136

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models with
Sub-harness

TEL049N

EL-4137

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models with
Sub-harness (Cont’d)

TEL050N

EL-4138

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models with
Sub-harness (Cont’d)

TEL051N

EL-4139

AUDIO/WAGON AND HARDTOP MODELS
Schematic/RHD Models with Sub-harness

TEL053N

EL-4140

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models with
Sub-harness

TEL054N

EL-4141

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models with
Sub-harness (Cont’d)

TEL055N

EL-4142

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models with
Sub-harness (Cont’d)

TEL056N

EL-4143

AUDIO/WAGON AND HARDTOP MODELS
Schematic/LHD Models without Sub-harness

TEL057N

EL-4144

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness

TEL058N

EL-4145

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness (Cont’d)

TEL059N

EL-4146

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness (Cont’d)

TEL060N

EL-4147

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness (Cont’d)

TEL061N

EL-4148

AUDIO/WAGON AND HARDTOP MODELS
Schematic/RHD Models without Sub-harness

TEL062N

EL-4149

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness

TEL063N

EL-4150

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness (Cont’d)

TEL064N

EL-4151

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness (Cont’d)

TEL065N

EL-4152

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness (Cont’d)

TEL066N

EL-4153

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — CD AUTO CHANGER —
WITH 1-DIN TYPE CD AUTO CHANGER

TEL067N

EL-4154

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — REMOTE —
WITH SUB-HARNESS AND ASCD

TEL068N

EL-4155

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — REMOTE — (Cont’d)
WITH SUB-HARNESS WITHOUT ASCD

TEL069N

EL-4156

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — REMOTE — (Cont’d)
WITHOUT SUB-HARNESS WITH ASCD

TEL070N

EL-4157

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — REMOTE — (Cont’d)
WITHOUT SUB-HARNESS AND ASCD

TEL071N

EL-4158

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — P/ANT —/LHD Models

TEL072N

EL-4159

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — P/ANT —/RHD Models

TEL073N

EL-4160

TELEPHONE (PRE WIRE)
Wiring Diagram — PHONE —

TEL139N

EL-4161

NAVIGATION SYSTEM
System Description
OUTLINE

SKIA0370E

The navigation system periodically calculates the vehicle’s current
position according to the following three signals: Travel distance of
the vehicle as determined by the vehicle speed sensor, turning
angle of the vehicle as determined by the gyroscope (angular
velocity sensor), and the direction of vehicle travel as determined
by the GPS antenna (GPS information).
The current position of the vehicle is then identified by comparing
the calculated vehicle position with map data read from the map
DVD-ROM, which is stored in the DVD-ROM drive (map-matching),
and indicated on the screen with a current location mark.

By comparing the vehicle position detection results found by the
GPS and by map-matching, more accurate vehicle position data
can be used.
The current vehicle position will be calculated by detecting the distance the vehicle moved from the previous calculation point and its
direction.

SEL684V

TRAVEL DISTANCE
Travel distance calculations are based on the vehicle speed sensor input signal. Therefore, the calculation may become incorrect
as the tires wear down. To prevent this, an automatic distance fine
adjustment function has been adopted.

TRAVEL DIRECTION
Change in the travel direction of the vehicle is calculated by a
gyroscope (angular velocity sensor) and a GPS antenna (GPS
information). As the gyroscope and GPS antenna have both merit
and demerit, input signals from them are prioritized in each situation. However, this order of priority may change in accordance with
more detailed travel conditions so that the travel direction is
detected more accurately.
Type

Advantage

Disadvantage

Gyroscope (angular velocity sensor)

+ Can detect the vehicle’s turning angle
quite accurately.

+ Direction errors may accumulate when
the vehicle is driven for long distances
without stopping.

GPS antenna (GPS information)

+ Can detect the vehicle’s travel direction
(North/South/East/West).

+ Correct direction cannot be detected
when the vehicle speed is low.

EL-4162

NAVIGATION SYSTEM
System Description (Cont’d)
MAP-MATCHING

SEL685V

Map-matching is a function that repositions the vehicle on the road
map when a new location is judged to be the most accurate. This
is done by comparing the current vehicle position, calculated by the
method described in the position detection principle, with the road
map data around the vehicle, read from the map DVD-ROM stored
in the DVD-ROM drive.
Therefore, the vehicle position may not be corrected after the
vehicle is driven over a certain distance or time in which GPS
information is hard to receive. In this case, the current location
mark on the display must be corrected manually.
NOTE:
The road map data is based on data stored in the map DVD-ROM.

In map-matching, alternative routes to reach the destination will
be shown and prioritized, after the road on which the vehicle is
currently driven has been judged and the current location mark
has been repositioned.
If there is an error in distance and/or direction, the alternative
routes will be shown in different order of priority, and the wrong
road can be avoided.
If two roads are running in parallel, they are of the same priority. Therefore, the current location mark may appear on either
of them alternately, depending on maneuvering of the steering
wheel and configuration of the road.

Map-matching does not function correctly when the road on
which the vehicle is driving is new and not recorded in the map
DVD-ROM, or when the road pattern stored in the map data
and the actual road pattern are different due to repair.
When driving on a road not present in the map, the map-matching function may find another road and position the current
location mark on it. Then, when the correct road is detected, the
current location mark may leap to it.
Effective range for comparing the vehicle position and travel
direction calculated by the distance and direction with the road
data read from the map DVD-ROM is limited. Therefore, when
there is an excessive gap between the current vehicle position
and the position on the map, correction by map-matching is not
possible.

SEL686V

+
SKIA0613E

EL-4163

NAVIGATION SYSTEM
System Description (Cont’d)
GPS (GLOBAL POSITIONING SYSTEM)

SEL526V

GPS (Global Positioning System) has been developed and controlled by the US Department of Defense. The system utilizes GPS
satellite (NAVSTAR), sending out radio waves while flying on an
orbit around the earth at the height of approx. 21,000 km (13,000
miles).
The GPS receiver calculates the vehicle’s position in three dimensions (latitude/longitude/altitude) according to the time lag of the
radio waves received from four or more GPS satellites (three-dimensional positioning). If radio waves were received only from
three GPS satellites, the GPS receiver calculates the vehicle’s
position in two dimensions (latitude/longitude), utilizing the altitude
data calculated previously by using radio waves from four or more
GPS satellites (two-dimensional positioning).
Accuracy of the GPS will deteriorate under the following conditions.
+ In two-dimensional positioning, the GPS accuracy will deteriorate when the altitude of the vehicle position changes.
+ There may be an error of approximately 10 m (30 ft.) in position detected by three-dimensional positioning, which is more
accurate than two-dimensional positioning. The accuracy can
be even lower depending on the arrangement of the GPS satellites utilized for the positioning.
+ Position detection is not possible when the vehicle is in an area
where radio waves from the GPS satellite do not reach, such
as in a tunnel, parking lot in a building, and under an elevated
highway. Radio waves from the GPS satellites may not be
received when some object is located over the GPS antenna.
+ Position correction by GPS is not available while the vehicle is
stopped.

COMPONENT DESCRIPTION
NAVI control unit
+
+

The gyro (angular speed sensor) and the DVD-ROM drive are
built-in units that control the navigation functions.
Signals are received from the gyro, the vehicle speed sensor,
and the GPS antenna. Vehicle location is determined by combining this data with the data contained in the DVD-ROM map.
Locational information is shown on liquid crystal display panel.

PKIA0248E

DVD-ROM drive
Maps, traffic control regulations, and other pertinent information
can be easily read from the DVD-ROM disc.

Map DVD-ROM
+
+

PKIA0249E

The map DVD-ROM has maps, traffic control regulations, and
other pertinent information.
To improve DVD-ROM map matching and route determination
functions, the DVD-ROM uses an exclusive Nissan format.
Therefore, the use of a DVD-ROM provided by other manufacturers cannot be used.

EL-4164

NAVIGATION SYSTEM
System Description (Cont’d)
Gyro (Angular speed sensor)
+
+

The oscillator gyro sensor is used to detect changes in vehicle
steering angle.
The gyro is built into the navigation (NAVI) control unit.

BIRDVIEWT
The BIRDVIEWT provides a detailed and easily seen display of
road conditions covering the vehicle’s immediate to distant area.
+ MAP DISPLAY

SKIA1377E

BIRDVIEWT

SKIA1378E

Description
+
+
+
+

Display area: Trapezoidal representation showing approximate
distances (Wn, D, and Wd).
Ten horizontal grid lines indicate display width while six vertical
grid lines indicate display depth and direction.
Drawing line area shows open space, depth, and immediate
front area. Each area is to a scale of approximately 5:6:25.
Pushing the “ZOOM IN” button during operation displays the
scale change and the view point height on the left side of the
screen.
The height of the view point increases or decreases when
“ZOOM” or “WIDE” is selected.

SEL691V

EL-4165

NAVIGATION SYSTEM
System Description (Cont’d)
MAP DISPLAY
Function of each icon is as follows:
1. Azimuth indication.
2. Position marker.
— The tip of the arrow shows the current location. The shaft of the
arrow indicates the direction in which the vehicle is traveling.
3. GPS reception signal (indicates current reception conditions).
4. Distance display (shows the distance in a reduced scale).

SKIA1379E

FUNCTION OF NAVI SWITCH
Display with pushed “DEST” switch
+

Easy Mode

Expert Mode

SKIA9542E

SKIA9142E

The Function of Each Icon Is as Follows:
MODE
Icon

Description
Easy

Address Book

Expert
x

Favorite place can be saved to memory.

Address (City/Street)

The destination can be searched from the address.

Point of Interest (POI)

The destination of favorite facility can be searched.

Phone Number

The destination can be searched from the phone number.

Previous Dest.

The previous ten destinations stored in memory are displayed.

Intersection

The destination can be searched from the intersection.

City Center

The destination can be searched from city name.

Map

The destination can be searched from the map.

Home

Sets the home as a destination.

Help

Explanation of navigational functions appear on the display.

EL-4166

NAVIGATION SYSTEM
System Description (Cont’d)
Display with pushed “ROUTE” switch
+

Easy Mode

Expert Mode

SKIA1382E

SKIA1383E

The Function of Each Icon Is as Follows:
MODE
Icon

Description
Easy

Expert

Quick Stop

The selected facility is set as the destination or waypoint.
(Route guidance has been turned OFF or the destination has been reached)

Where am I?

Next, current and previous street names can be displayed.

Route Info.*

The following can be set.
+ Complete Route
+ Turn List
+ Route Simulation
(Displayed only when the destination area has been set.)

Edit Route*

Change the destination or add the transit points of the route set in the route guide. (Displayed only when the automatic reroute function has been turned OFF and the recommended route is not followed.)

Route Calculation

This key is used to start the route calculation after all the settings are completed.

Help

Explanation of navigational functions appear on the display.

*: When destinations have been entered, route guidance has been turned OFF or destination has been reached, “Route Info.” and “Edit Route” are not
displayed.

EL-4167

NAVIGATION SYSTEM
System Description (Cont’d)
Display with pushed “SETTING” switch

SKIA9143E

The Function of Each Icon Is as Follows:
Icon

Description

Display

Settings of display can be performed.

Language

Language can be selected for the display and voice guidance.
Use the program CD-ROM disc to change the language.

Navigation

Settings and adjusting of navigation can be performed.

Navigation Expert Mode

Easy Mode and Expert Mode can be switched.

Guidance Volume

The volume and/or on/off of voice prompt can be controlled by the joystick.

Help

Explanation of navigational functions appear on the display.

Display with pushed “INFO” button
+
+

When the “INFO” button is pushed, the following will display on the screen.
Warning message (if there are any) → DRIVE INFORMATION → MAINTENANCE INFOMATION → OFF.
Display items

Display/Setting contents
Elapsed Time

DRIVE INFORMATION

MAINTENANCE INFOMATION

Displays driving time with a range of 0:00:00 to 9999:59:59.

Driving Distance
[(km) or (miles)]

Displays driving distance with a range of 0.0 to 99999.9.

Average speed
[(km/h) or (MPH)]

Displays average speed with a range of 0.0 to 999.9.

Reminder 1

Maintenance intervals of vehicle’s consumables and setting of cycles.

Reminder 2

Maintenance intervals of vehicle’s consumables and setting of cycles.

Reminder 3

Maintenance intervals of vehicle’s consumables and setting of cycles.

“LANGUAGE SETTINGS” mode
+ Select one of the languages which appear on the screen.
NOTE:
Languages that do not appear on the screen must be loaded from
program disk.

SKIA1399E

EL-4168

NAVIGATION SYSTEM
System Description (Cont’d)
“NAVIGATION SETTINGS” mode
How To Perform Navigation Settings
1. Start the engine.
2. Push “SETTING” button.
3. Select “Navigation” key.
+ Easy Mode

SKIA9543E

Expert Mode

SKIA1385E

Application Items
MODE
Icon

Description
Easy Expert

Reference
page

View

Map display mode can be switched.

EL-4170

Heading

Heading of the map display can be customized for either north heading or the actual driving direction of the vehicle.

EL-4170

Nearby Display Icons

Icons of facilities can be displayed.
Facilities to be displayed can be selected from the variety selections.

EL-4170

Save Current Location

Current vehicle location can be registered in Address Book.

EL-4170

Edit Address Book

Address Book can be edited.

EL-4170

Clear Memory

Address Book, Previous destination or Avoid area can be deleted.

EL-4171

Auto Re-route On/Off

On/Off of Auto Re-route can be switched.

EL-4171

Quick Stop Customer Settings

One facility of your selection can be added to your Quick Stop.

EL-4171

Set Average speed for Estimated Journey Time

Average vehicle speed can be set to calibrate estimated journey time
for the destination.

EL-4171

GPS Information

The GPS data includes longitude, latitude and altitude (distance above
sea level) of the present vehicle position, and current date and time
for the area in which the vehicle is being driven.
Also indicated are the GPS reception conditions and the GPS satellite
position.

EL-4171

Avoid Area Setting

A particular area can be avoided when routing.

EL-4172

Tracking On/Off

Tracking to the present vehicle position can be displayed.

EL-4172

Adjust Current Location

Current location of position marker can be adjusted. Direction of position marker also can be calibrated when heading direction of the
vehicle on the display is not matched with the actual direction.

EL-4172

Switch beep On/Off

Button tone can be selected On/Off.

EL-4172

EL-4169

NAVIGATION SYSTEM
System Description (Cont’d)
“VIEW” mode
1. Select “BIRDVIEWT” or “Plan View” icon.
+ To open the map screen display with BIRDVIEWT, select
“BIRDVIEWT”.
+ To open the map screen display with Plan View, select
“Plan View”.

SKIA0554E

“HEADING” mode
+
+

To display the car heading up, select “Heading up”.
To display North up, select “North up”.

SKIA0561E

“NEARBY DISPLAY ICONS” mode
+

Select an icon to display on the map screen.

SKIA1394E

“SAVE CURRENT LOCATION” mode
+

The current vehicle location can be registered in “Address
Book”.
NOTE:
“Address Book” can store 50 items max.

SKIA1388E

“EDIT ADDRESS BOOK” mode
+

Edit the items registered in Address Book.

SKIA0560E

EL-4170

NAVIGATION SYSTEM
System Description (Cont’d)
“CLEAR MEMORY” mode
+

To delete all the stored places in “Address Book”, “Avoid Area”
and “Previous Dest”, select “Yes”.

SKIA9146E

“AUTO RE-ROUTE” mode
+
+

To Perform the auto re-route of route, select “ON”.
Not to Perform the auto re-route of route, select “OFF”.

SKIA0558E

“QUICK STOP CUSTOMER SETTINGS” mode
+

Select a category for the “Quick Stop” menu.

SKIA1389E

“SET AVERAGE SPEED” mode
+
+

Set the average vehicle speed to calibrate the estimated journey time for the destination.
Set three items; “Motorway”, “Main Roads”, and “Ordinary
Roads”.

SKIA9544E

“GPS INFORMATION” mode
Latitude, longitude, altitude, astrometric state, and satellite
location are displayed as GPS information.
NOTE:
Altitude is displayed only in three-dimensional status.
+

SKIA0555E

EL-4171

NAVIGATION SYSTEM
System Description (Cont’d)
“AVOID AREA SETTING” mode
+

Areas to avoid can be registered.

SKIA0563E

“TRACKING” mode
+ To leave the tracking marks on the map, select “On”.
+ To delete the tracking marks on the map, select “Off”.
NOTE:
When a trail display is turned OFF, trail data is erased from the
memory.

SKIA9545E

“ADJUST CURRENT LOCATION” mode
1. Select an icon “right” or “left” to calibrate the heading direction.
(Arrow marks will rotate corresponding to the calibration key.)

SKIA1395E

2. Select “Set”. Then the vehicle mark will be matched to the
arrow mark.

SKIA1396E

“BUTTON TONE/BEEP RESPONSE” mode
Select “Switch Beep”.
+ When Beep Setting is on (indicator light on), a beep will sound
if the button is pushed.
NOTE:
Items in exception of Beep Setting ON/OFF.
+ An error beep.
+ An interrupted-screen beep.

SKIA9148E

EL-4172

NAVIGATION SYSTEM
Precautions for NAVI Control Unit Replacement
When replacing the NAVI control unit, eject the map DVD-ROM before disconnecting the battery.
The NAVI control unit has the following information stored in its memory. Record the memory contents
before replacing the control unit, and input them in the new unit as necessary.

+ Brightness of light when ON/OFF
+ Dimming switching
+ Display color switching

+ Latest status (map screen/BIRDVIEWT, reduced scale, rotation angle of map screen,
route guide ON/OFF, track ON/OFF, etc.)
+ Current position
+ Destination, passing point 1 — 5
+ Registered places, their names, etc.
NOTE:
Only removing the battery does not erase the memory.

+
+

Component Parts And Harness Connector
Location

PKIB1033E

EL-4173

NAVIGATION SYSTEM
Schematic

TEL074N

EL-4174

NAVIGATION SYSTEM
Wiring Diagram — NAVI —

TEL075N

EL-4175

NAVIGATION SYSTEM
Wiring Diagram — NAVI — (Cont’d)

TEL076N

EL-4176

NAVIGATION SYSTEM
Wiring Diagram — NAVI — (Cont’d)

TEL077N

EL-4177

NAVIGATION SYSTEM
Wiring Diagram — NAVI — (Cont’d)

TEL078N

EL-4178

NAVIGATION SYSTEM
Wiring Diagram — NAVI — (Cont’d)
LHD MODELS

TEL079N

EL-4179

NAVIGATION SYSTEM
Wiring Diagram — NAVI — (Cont’d)

TEL080N

EL-4180

NAVIGATION SYSTEM
Wiring Diagram — NAVI — (Cont’d)
RHD MODELS

TEL081N

EL-4181

NAVIGATION SYSTEM
Wiring Diagram — NAVI — (Cont’d)

TEL082N

EL-4182

NAVIGATION SYSTEM
Terminals and Reference Value for NAVI
Control Unit
+ Measure using circuit tester and oscilloscope.
+ Measure with connector connected unless otherwise specified.
CAUTION:
Confirm voltage between negative terminal on each unit and ground is approximately 0V.
+ If ignition switch ON is required in measurement condition, measure with engine running to prevent battery discharge.
Terminal No.
(wire color)

Item

Example of symptom

—

Approx. 0V

—

Battery voltage

—

Approx. 0V

—

Battery

Input

Ground

—

1 (B)

Ground

Ground
Ground

4 (B)

Reference value
Operation

(−)

3 (R/G)

Condition
Ignition
switch

(+)

2 (R/G)

Signal
input/
output

6 (L/OR)

Ground

ACC power

Input

ACC

7 (Y)

8 (BR)

Voice guide
signal

Output

—

Shield

—

12 (R)

RGB area
signal

output

—

System does not work
properly.
—
System does not work
properly.

Battery voltage

Only route guide and
operation guide are not
heard.

Push the “VOICE”
switch

SKIA0171J

—

Push the “D/N”
switch.

RGB screen is not
shown.

SKIA0162E

15 (B)

RGB signal
(B: blue)

Output

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

RGB screen looks yellowish.

SKIA0167E

16 (W)

RGB synchronizing
signal

Output

Ground

RGB shield

—

18 (R)

RGB signal
(R: red)

Output

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

Push the “MAP”
switch.

RGB screen is rolling.

SKIA0164E

Approx. 0V

—

RGB screen looks bluish.

SKIA0165E

EL-4183

NAVIGATION SYSTEM
Terminals and Reference Value for NAVI
Control Unit (Cont’d)
Terminal No.
(wire color)
(+)

(−)

21 (G)

Item

RGB signal
(G: green)

Signal
input/
output

Output

Condition
Reference value

Ignition
switch

Operation

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

Example of symptom

RGB screen looks reddish.

SKIA0166E

25 (L/B)

26 (R/W)

Illumination
signal

Input

Ground

IGN signal

Input

Ground

Reverse
signal

Ground

Lighting switch position 1st or 2nd

Battery voltage

Lighting switch position OFF

Approx. 0V

—

Battery voltage

Select R-position
27 (Y)

Input

Vehicle
speed signal

Ground

—

Shield

44 (W)

Communication signal
(+)

Vehicle information setting is not possible.
The navigation current
location mark moves
strangely when the
vehicle is moving backwards.

Battery voltage

ON
Other position

28 (R/W)

Night illumination for
switches does not illuminate.

Input

When vehicle speed
is approx. 40 km/h
(25 MPH)

—

Input/
Output

—

Approx. 0V

Navigation current location mark does not indicate the correct position.

ELF1084D

—

System does not work
properly.

SKIA0175E

Communication signal
(—)

Ground

GPS
antenna signal

—

45 (B)

Input/
Output

System does not work
properly

—

SKIA0176E

Shield

Input

—

Connector is not
connected.
—

EL-4184

Approx. 5V
—

GPS correction is not
possible.
—

NAVIGATION SYSTEM
Terminals and Reference Value for Display
Terminal No.
(wire color)
(+)

(−)

1 (R)

Item

RGB signal
(R: red)

Signal
input/
output

Input

Condition
Reference value

Ignition
switch

Operation

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

Example of symptom

RGB screen looks bluish.

SKIA0165E

2 (G)

RGB signal
(G: green)

Input

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

RGB screen looks reddish.

SKIA0166E

3 (B)

RGB signal
(B: blue)

Input

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

RGB screen looks yellowish.

SKIA0167E

—

Shield

7 (W)

RGB synchronizing
signal

—

Input

—

Push the “MAP”
switch.

RGB screen is rolling.

SKIA0164E

8 (R)

Ground

RGB area
signal

Input

Push the “D/N”
switch.

RGB screen is not
shown.

SKIA0162E

15 (OR)

Ground

Communication signal
(DISP-SW)

Output

Push the “INFO”
switch.

System does not work
properly.

SKIA0835E

16 (B)

Communication signal
(NAVI-DISP)

Input

Push the “INFO”
switch.

System does not work
properly.

SKIA0832E

EL-4185

NAVIGATION SYSTEM
Terminals and Reference Value for Display
(Cont’d)
Terminal No.
(wire color)
(+)

(−)

—

Item

Shield

Signal
input/
output
—

Condition
Reference value

Ignition
switch

Operation

—

Example of symptom

—

19 (L/OR)

Ground

ACC power

Input

ACC

—

Battery voltage

System does not work
properly.

21 (R/G)

Ground

Battery
power supply

Input

—

Battery voltage

System does not work
properly.

22 (B)

Ground

—

Approx. 0V

23 (R/G)

Ground

Battery
power supply

Input

—

Battery voltage

24 (B)

Ground

—

Approx. 0V

—
System does not work
properly.
—

Terminals and Reference Value for NAVI Switch
Terminal No.
(wire color)

Item

Signal
input/
output

(+)

(−)

1 (L/OR)

Ground

ACC power

3 (B)

Illumination
signal

Input

Communication signal
(DISP-SW)

Input

2 (L/B)

4 (OR)

Ground

Input

Condition
Reference value

Ignition
switch

Operation

ACC

—

Battery voltage

Lighting switch position 1st or 2nd

Battery voltage

Lighting switch position OFF

Approx. 0V

Example of symptom

All operations do not
work.
Night illumination for
switches does not illuminate.

Push the “INFO”
switch

System does not work
properly.

SKIA0835E

5 (L/W)

Communication signal
(SW-NAVI)

—

7 (B)

Ground

Push the “INFO”
switch

System does not work
properly.

Output

Shield

—

Ground

—

Approx. 0V

SKIA0832E

EL-4186

—
All operations do not
work.

NAVIGATION SYSTEM
Terminals and Reference Value for Transfer
Unit
Terminal No.
(wire color)
(+)

(−)

1 (L)

2 (PU)

Item

Voice guide
signal

Signal
input/
output

Output

Condition
Ignition
switch

Reference value

Example of symptom

Operation

Only route guide and
operation guide are not
heard.

Push the “VOICE”
switch

ELL0234D

Voice
change
relay ON
signal

6 (BR)

4 (R)

—

8 (Y)

10 (BR)

—

Shield

11 (W)

Communication signal
(+)

Shield

Voice guide
signal

Push the “VOICE”
switch

Output

—

Input

—

Input/
Output

—

Only route guide and
operation guide are not
heard.

Approx. 5V

—

Only route guide and
operation guide are not
heard.

Push the “VOICE”
switch

SKIA0171E

—

System does not work
properly.

SKIA0175E

13 (B)

Communication signal
(−)

Input/
Output

System does not work
properly.

—

SKIA0176E

—

Shield

18 (L/W)

Communication signal
(SW-NAVI)

—

Input

—

System does not work
properly.

SKIA0832E

—

Shield

—

EL-4187

—

NAVIGATION SYSTEM
Terminals and Reference Value for Transfer
Unit (Cont’d)
Terminal No.
(wire color)
(+)

(−)

20 (B)

Item

Communication signal
(NAVI-DISP)

Signal
input/
output

Input

Condition
Reference value

Ignition
switch

Operation

—

Example of symptom

System does not work
properly.

SKIA0832E

25 (B)

Ground

—

Approx. 0V

27 (B)

Ground

—

Approx. 0V

—
—

29
(L/OR)

Ground

ACC power

Input

ACC

—

Battery voltage

System does not work
properly.

31 (R/G)

Ground

Battery

Input

OFF

—

Battery voltage

System does not work
properly.

32 (R/G)

Ground

Battery

Input

OFF

—

Battery voltage

System does not work
properly.

Terminals and Reference Value for Voice
Change Relay
Terminal No.
(wire color)

Item

Signal
input/
output

Condition
Ignition
switch

Reference value

Example of symptom

Operation

(+)

(−)

2 (BR)

1 (R)

Voice
change
relay ON
signal

Input

Push the “VOICE”
switch

3 (OR)

5 (G)

Audio sound
signal

Input

Receive audio signal

Only route guide and
operation guide are not
heard.

Approx. 5V

No sound from door
speaker and tweeter LH

SKIA0177E

4 (L)*1
(BR)*2

8 (B/W)*1 Voice guide
(B/R)*2 signal

Output

Only route guide and
operation guide are not
heard.

Push the “VOICE”
switch

ELL0234D

6 (L)

7 (PU)

Voice guide
signal

Input

Only route guide and
operation guide are not
heard.

Push the “VOICE”
switch

ELL0234D

*1 : LHD models.
*2 : RHD models.

EL-4188

NAVIGATION SYSTEM
Self-Diagnosis Function
DESCRIPTION
+
+
+

Diagnosis function consists of the self-diagnosis mode performed automatically and the CONFIRMATION/
ADJUSTMENT mode operated manually.
Self-diagnosis mode checks for connections between the units constituting this system, analyzes each
individual unit at the same time, and displays the results on the LCD screen.
CONFIRMATION/ADJUSTMENT mode is used to perform trouble diagnosis that require operation and
judgment by an operator (malfunction that cannot be automatically judged by the system), to check/change
the set value, and to display the History of Errors of the navigation system.

DIAGNOSIS ITEM
Mode

Description
+ NAVI Control unit diagnosis (DVD-ROM drive will not be diagnosed when no
map DVD-ROM is in it.).
+ Performs diagnosis of each unit and connections between control unit and
GPS antenna, as well as between control unit and each unit.

Self-diagnosis

Display

Color tone and shading of the screen can be checked by the display of a color
bar and a gray scale.

Vehicle signals

Analyzes the following vehicle signals: Vehicle speed signal, light signal, ignition
switch signal, and reverse signal.
Display Longitude & Latitude

Confirmation/
Adjustment

Navigation

Display the map. Use the joystick to adjust position. Longitude and latitude will be
displayed.

Under ordinary conditions, the navigation system distance measuring function will
automatically compensate for minute decreases in wheel and tire diameter
Speed Calibracaused by tire wear or low-pressure. Speed calibration immediately restores systion
tem accuracy in cases such as when distance calibration is needed because of
the use of tire chains in inclement weather.
Angle Adjustment

Corrects difference between actual turning angle of a vehicle and turning angle of
the car mark on the display.

Initialize Location

This mode is for initializing the current location. Use when the vehicle is transported a long distance on a trailer, etc.
Diagnosis results previously stored in the memory (before turning ignition switch
ON) are displayed in this mode. Time and location when/where the errors
occurred are also displayed.

History of Errors

Self-Diagnosis Mode
OPERATION PROCEDURE
1. Start the engine.
2. Push and hold “MAP” and “DAY/NIGHT” switches simultaneously for 5 seconds or more.
+ Push the “BACK” switch and the initial system screen will
be shown.

PKIB1537E

EL-4189

NAVIGATION SYSTEM
Self-Diagnosis Mode (Cont’d)
3. The initial trouble diagnosis screen will be shown, and items
“Self-Diagnosis” and “Confirmation/Adjustment” will become
selective.

SKIA0381E

4. Perform self-diagnosis by selecting the “Self-Diagnosis”.
+ Self-diagnosis subdivision screen will be shown and the operation enters the self-diagnosis mode.
+ A bar graph shown below the self-diagnosis subdivision screen
indicates progress of the diagnosis.

SKIA0382E

SKIA9192E

SKIA9193E

5. On the “SELF-DIAGNOSIS” screen, each unit name will be
colored according to the diagnosis result, as follows.
Green: No malfunctioning.
Yellow: Cannot be judged by self-diagnostic results.
Red: Unit is malfunctioning.
Gray: Diagnosis has not been done.
+ If several malfunctions are present in a unit, color of its switch
on the screen will be either red, yellow, or gray, determined by
the malfunction of the highest priority.
+ Lines between navigation unit and GPS antenna are green or
yellow based on diagnosis results.
+ Lines between control unit and units other than those above are
gray regardless of diagnosis results.
CAUTION:
+ Navigation Unit = NAVI control unit
+ Communication converter = Transfer unit
+ Satellite Switch = NAVI switch

6. Select a switch on the “SELF-DIAGNOSIS” screen and comments for the diagnosis results will be shown.
+ When the switch is green, the following comment will be
shown. “Self-Diagnosis was successful. Further diagnosis
and adjustments are recommended. Follow the
“confirmation/adjustments” menu or refer to the service
manual.”
+ When the switch is yellow, the following comment will be
shown. “Connection to the following unit is not responding.
See the service manual for further diagnosis.”
+ When the switch is red, the following comment will be
shown. “Navigation Unit is abnormal.”

EL-4190

NAVIGATION SYSTEM
Self-Diagnosis Mode (Cont’d)
+

When the switch is gray, the following comment will be
shown. “Self-diagnosis for DVD-ROM DRIVER of NAVI
was not conducted due to no insertion of DVD-ROM.”

SELF-DIAGNOSIS RESULT
Quick reference table
1. Select an applicable diagnosis No. in the diagnosis result quick reference table.
2. Find estimated malfunctioning system in the diagnosis No. table and perform check.
3. Turn the ignition switch to OFF and perform self-diagnosis again.
Diagnosis result quick reference table
Screen switch
Diagnosis No.
Switch color

Navigation Unit

Red

Gray

Yellow

GPS antenna

CAUTION:
Check the following when the self-diagnosis mode cannot be used.
+ NAVI control unit power supply and ground.
+ Display power supply and ground.
+ NAVI switch power supply and ground.
+ Transfer unit power supply and ground.
+ AV communication line between NAVI switch and Display, AV communication line between Display and
Transfer unit, AV communication line between Transfer unit and NAVI control unit.

Method of diagnosis for malfunctioning system
When system does not start, indicate malfunction connection between units by outbreak sound from system.
Diagnosis procedure.
1. Turn ignition switch ON. Make sure whether or not route guide start sound which is output from NAVI control unit indicate 10 seconds after.
2. Push and hold “MAP” and “DAY/NIGHT” switches simultaneously for 5 seconds or more. Make sure
whether or not 2 times of beep sound or route guide start sound indicate.
3. According to the former two steps, select an proper diagnosis No. in the diagnosis result quick reference
table.
4. Find estimated malfunctioning system from the diagnosis No. table and perform check.
Diagnosis result quick reference table
+

Procedure 1
10 seconds after turn ignition switch ON.

Procedure 2
Push and hold “MAP” and “DAY/NIGHT”
switches simultaneously for 5 seconds or more.

Diagnosis No.

Route guide start sound indicates

There is no sound

Two times of beep sound from NAVI switch *

There is no sound

Route guide start sound appears

There is no sound
*: Indicated when pushing both “MAP” and “DAY/NIGHT” simultaneously. (Unnecessary to push them 5 seconds or more.)

EL-4191

NAVIGATION SYSTEM
Self-Diagnosis Mode (Cont’d)
Self-diagnosis codes
Diagnosis No.

Possible cause

Reference
page

NAVI control unit malfunction

—

NAVI control unit judged no map DVD-ROM is inserted.

—

When “DVD-ROM is not recognized. Please check the disc.” is shown.
1. Eject map DVD-ROM and check if it is compatible with the system.
2. Check ejected DVD-ROM for dirt, damage, and warps.
3. If no error is found, insert a known good map DVD-ROM of the same type and perform selfdiagnosis again. If same result is shown, the NAVI control unit is malfunctioning. If result is
normal, the map DVD-ROM is malfunctioning.

—

If “Error found in DVD-ROM or DVD-ROM driver in control unit. Please perform diagnosis in
accordance with service manual” is shown, performed same inspection as diagnosis No. 3.

—

GPS antenna system
1. Visually check for a broken wire in the GPS antenna coaxial cable.
2. Disconnect the GPS antenna connector and make sure that approximately 5V is supplied
from NAVI control unit. If not, the NAVI control unit is inoperative. If the voltage is supplied,
replace the GPS antenna and perform self-diagnosis again. If the same result is shown, the
NAVI control unit is inoperative.

—

Display power supply and ground circuit.
Communication line between display and NAVI switch.

EL-4203

NAVI switch power supply and ground circuit.
Communication line between NAVI switch and transfer unit.

EL-4204

NAVI control unit power supply and ground circuit.
Communication line between NAVI control unit and transfer unit.

EL-4204

Transfer unit power supply and ground circuit.
Communication line between transfer unit and display.

EL-4205

Confirmation/Adjustment Mode
OPERATION PROCEDURE
1. Start the engine.
2. Push and hold “MAP” and “DAY/NIGHT” switches simultaneously for 5 seconds or more.
+ Push the “BACK” switch and the initial system screen will
be shown.

PKIB1537E

3. The initial trouble diagnosis screen will be shown, and items
“Self-Diagnosis” and “Confirmation/Adjustment” will become
selective.

SKIA0381E

EL-4192

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
4. When “Confirmation/Adjustment” is selected on the initial
trouble diagnosis screen, the operation will enter the
CONFIRMATION/ADJUSTMENT mode. In this mode, check
and adjustment of each item will become possible.
5. Select each switch on “Confirmation/Adjustment” screen to display the relevant diagnosis screen.

SKIA9190E

DISPLAY

SKIA2251E

CAUTION:
When Display Color Spectrum Bar screen is completed after “BACK” switch is Pushed, the screen
color changes once. This is normal.
+ When RGB signal error occurred in the RGB system, tone of the color bar will change as follows.
R (red) signal error: Screen looks bluish.
G (green) signal error: Screen looks reddish.
B (blue) signal error: Screen looks yellowish.
+ When the color of the screen looks unusual, refer to EL-4209.

VEHICLE SIGNALS
+

A comparison check can be made of each actual vehicle signal and the signals recognized by the system.

SKIA1997E

EL-4193

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
Diagnosis item

Vehicle speed

Display

Condition

Vehicle speed > 0 km/h (0 MPH)

OFF

Vehicle speed = 0 km/h (0 MPH)

—

Ignition switch in ACC position

Lighting switch ON

OFF

Lighting switch OFF

Ignition switch ON

OFF

Ignition switch ACC

Selector lever in R position

OFF

Selector lever in other than R position

Remarks
Changes in indication may be delayed by
approx. 1.5 seconds. This is normal.

Light

—

IGN

—

Reverse

—

+
+
+
+

If
If
If
If

Changes in indication may be delayed by
approx. 1.5 seconds. This is normal.

Ignition switch in ACC position

vehicle speed is NG, refer to EL-4206.
light is NG, refer to EL-4207.
IGN is NG, refer to EL-4208.
reverse is NG, refer to EL-4208.

NAVIGATION
Display longitude & latitude
+

Adjust the pointer with using the joystick and touch “Set”.

The longitude and latitude are displayed.

SKIA1616E

SKIA1617E

Speed calibration
+

During normal driving, distance error caused by tire wear and
tire pressure change is automatically adjusted for by the automatic distance correction function. This function, on the other
hand, is for immediate adjustment, in cases such as driving with
tire chain fitted on tires.

SKIA0365E

EL-4194

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
Angle adjustment
+

Adjust turning angle output detected by the gyroscope.

SKIA0364E

Initialize location
Description
+ Location data for GPS in the Center control unit is initialized in
Europe by this mode. Then it is possible for Center control unit
to receive GPS signals for short time.
How to perform “Initialize Location” mode
1. Select “Initialize Location”, and push “ENTER”.

SKIA1618E

2. A message “Please wait.” is displayed and then backs to
another display of “Confirmation/Adjustment” mode.
NOTE:
+ To continue GPS initialized operation, operate as follows back
to “Map” screen.
— Push “BACK” button twice.
— Push “MAP” button.
+ After above operation, GPS indicator changes to green color
within half a minute, unless improper GPS located condition.
+ This operation should be performed in out side field.
SKIA1619E

HISTORY OF ERRORS

SKIA9553E

EL-4195

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
DIAGNOSIS BY HISTORY OF ERRORS
The “Self-diagnosis” results indicate whether an error occurred during the period from when the ignition switch
is turned to ON until “Self-diagnosis” is completed.
If an error occurred before the ignition switch was turned to ON and does not occur again until the “Self-diagnosis” is completed, the diagnosis result will be judged normal. Therefore, those errors in the past, which
cannot be found by the “Self-diagnosis”, must be found by diagnosing the “History of Errors”.
The History of Errors displays the time and place of the most recent occurrence of that error. However, take
note of the following points.
+ Correct time of the error occurrence may not be displayed when the GPS antenna substrate within the
NAVI control unit has malfunctioned.
+ Place of the error occurrence is represented by the position of the current location mark at the time when
the error occurred. If the current location mark has deviated from the correct position, then the place of
the error occurrence may be located correctly.
+ The maximum number of occurrences which can be stored is 50. For the 51st and later occurrences, the
displayed number remains 50.
When a reproducible malfunction occurred but its cause cannot be identified because several errors are
present, record the item, number and place (longitude/latitude) of error occurrence (or delete the History of
Errors), then turn the ignition switch from OFF to ON to reproduce the malfunction. Check the History of Errors
to find the items which show an increased number of occurrences, and diagnose the item.
Possible causes
Error item

Example of symptom
Action/symptom
Communications malfunction between NAVI control unit
and internal gyro

Gyro sensor
disconnected

+ Perform self-diagnosis.
+ When the NAVI control unit is judged normal by selfdiagnosis, the symptom may be intermittent, caused
by strong radio interference.
Communication error between NAVI control unit and
internal GPS substrate

GPS disconnected

+ Perform self-diagnosis.
+ When the NAVI control unit is judged normal by selfdiagnosis, the symptom may be intermittent, caused
by strong radio interference.

+ Navigation location detection performance has deteriorated. (Angular velocity cannot be detected.)

+ Navigation location detection performance has deteriorated. (Location correction using GPS is not performed.)
+ GPS receiving status remains gray.

Malfunctioning transmission wires to NAVI control unit
and internal GPS substrate
GPS transmis+ Perform self-diagnosis.
sion cable
+ When the NAVI control unit is judged normal by selfmalfunction
diagnosis, the symptom may be intermittent, caused
by strong radio interference.
Malfunctioning receiving wires to NAVI control unit and
internal GPS substrate
GPS input line
+ Perform self-diagnosis.
connection
+ When the NAVI control unit is judged normal by selferror
diagnosis, the symptom may be intermittent, caused
by strong radio interference.

+ During self-diagnosis, GPS diagnosis is not performed.

+ Navigation location detection performance has deteriorated. (Location correction using GPS is not performed.)
+ GPS receiving status remains gray.

Oscillating frequency of the GPS substrate frequency
synchronizing oscillation circuit exceeded (or below) the
specification
GPS TCX0
over
GPS TCX0
under

+ Perform self-diagnosis.
+ When the NAVI control unit is judged normal by selfdiagnosis, the symptom may be intermittent, caused
by strong radio interference, or the control unit may
have been subjected to excessively high or low temperatures.

EL-4196

+ Navigation location detection performance has deteriorated. (Location correction using GPS is not performed.)
+ GPS receiving status remains gray.

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
Possible causes
Error item

Example of symptom
Action/symptom

GPS ROM
malfunction
GPS RAM
malfunction

Contents of ROM (or RAM) in GPS substrate are malfunctioning.
+ Perform self-diagnosis.
+ When the NAVI control unit is judged normal by selfdiagnosis, the symptom may be intermittent, caused
by strong radio interference.
Clock IC in GPS substrate is malfunctioning.

GPS RTC
malfunction

+ Perform self-diagnosis.
+ When the NAVI control unit is judged normal by selfdiagnosis, the symptom may be intermittent, caused
by strong radio interference.

+ Location detection accuracy of the navigation system
will deteriorate, depending on the malfunctioning area
in the memory, because GPS cannot make correct
positioning. (Location correction using GPS is not performed.)
+ Correct time may not be displayed.
+ After the power is turned on, the system always takes
some time until GPS positioning becomes possible.
(The GPS receiver starts positioning without re-collecting the whole satellite information when it judged
the data stored in the receiver is correct.)
+ Correct time of error occurrence may not be stored in
the “History of Errors”.

Malfunctioning connection between GPS substrate in
NAVI control unit and GPS antenna.
GPS antenna
disconnected

+ Perform self-diagnosis.
+ When connection between NAVI control unit and
GPS antenna is judged normal by self-diagnosis, the
symptom may be intermittent, caused by impact or
vibration.

+ Navigation location detection performance has deteriorated. (Location correction using GPS is not performed.)
+ GPS receiving status remains gray.

The power voltage supplied to the GPS circuit board has
decreased.
Low voltage of + Perform self-diagnosis.
+ When connection between NAVI control unit and
GPS
GPS antenna is judged normal by self-diagnosis, the
symptom may be intermittent, caused by impact or
vibration.

+ Navigation location detection performance has deteriorated. (Location correction using GPS is not performed.)
+ GPS receiving status remains gray.

Malfunctioning NAVI control unit
DVD-ROM
Malfunction
DVD-ROM
Read error
DVD-ROM
Response
Error

—

Dedicated map DVD-ROM is in the system, but the data
cannot be read.
+ Is map DVD-ROM damaged, warped, or dirty?
— If damaged or warped, the map DVD-ROM is malfunctioning.
— If dirty, wipe the DVD-ROM clean with a soft cloth.
+ Perform self-diagnosis.
+ When NAVI control unit is judged normal by selfdiagnosis, the symptom is judged intermittent, caused
by vibration.

EL-4197

+
+
+
+
+

The map of a particular location cannot be displayed.
Specific guidance information cannot be displayed.
Map display is slow.
Guidance information display is slow.
System has been affected by vibration.

NAVIGATION SYSTEM
Trouble Diagnoses
POWER SUPPLY AND GROUND CIRCUIT CHECK FOR NAVI CONTROL UNIT
1.

CHECK FUSE

Make sure that the following fuses of the NAVI control unit are not blown.
Terminals
Connector

Power source

Fuse No.

Battery

Ignition switch ACC or ON

Terminal (wire color)
2 (R/G)

NAVI control unit M167

3 (R/G)
6 (L/OR)

OK or NG
OK

GO TO 2.

If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse.
Refer to EL-4005 in “POWER SUPPLY ROUTING”.

CHECK POWER SUPPLY CIRCUIT

Check voltage between NAVI control unit and ground.

SKIA8719E
Terminals
(+)
Connector

Terminal (wire color)
2 (R/G)

NAVI control unit
M167

3 (R/G)

OFF

ACC

Battery voltage

(−)

Ground

6 (L/OR)

OK or NG
OK

GO TO 3.

Repair or replace harness.

EL-4198

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
3.

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit connector.
3. Check continuity between NAVI control unit and ground.

SKIA8720E
Terminals
(+)
Connector

1 (B)

NAVI control unit M167

Continuity

(−)

Terminal (wire color)

Ground

4 (B)

Yes

OK or NG
OK

INSPECTION END

Repair or replace harness.

POWER SUPPLY AND GROUND CIRCUIT CHECK FOR DISPLAY
1.

CHECK FUSE

Make sure that the following fuses of the display are not blown.
Terminals

Unit

Connector

Terminal (wire color)
21 (R/G)

Display

M170

23 (R/G)
19 (L/OR)

Power source

Fuse No.

Battery

Ignition switch ACC or ON

OK or NG
OK

GO TO 2.

If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse.
Refer to EL-4005 in “POWER SUPPLY ROUTING”.

EL-4199

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
2.

CHECK POWER SUPPLY CIRCUIT

Check voltage between display and ground.

SKIA9491E

Terminals
(+)

Unit

(−)

Terminal (wire
color)

Connector

21 (R/G)
Display

M170

23 (R/G)

Ground

19 (L/OR)

OFF

ACC

Battery voltage

OK or NG
OK

GO TO 3.

Repair or replace harness.

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect display connector.
3. Check continuity between display and ground.

SKIA9492E
Terminals
Unit

(+)
Connector

Display

M170

Terminal (wire color)
22 (B)
24 (B)

OK or NG
OK

INSPECTION END

Repair or replace harness.

EL-4200

(−)
Ground

Continuity

Yes

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
POWER SUPPLY AND GROUND CIRCUIT CHECK FOR NAVI SWITCH
1.

CHECK FUSE

Check 10A fuse [No. 10, located in fuse block (J/B)].
OK or NG
OK

GO TO 2.

If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse.
Refer to EL-4005 in “POWER SUPPLY ROUTING”.

CHECK POWER SUPPLY CIRCUIT

Check voltage between NAVI switch and ground.

SKIA8724E
Terminals
(+)

Unit

NAVI switch

Connector

Terminal (wire
color)

(−)

M169

1 (L/OR)

Ground

OFF

ACC

Battery voltage

OK or NG
OK

GO TO 3.

Repair or replace harness.

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect NAVI switch connector.
3. Check continuity between NAVI switch harness connector M169 terminal 7 (B) and ground.

SKIA8725E

Continuity should exist.
OK or NG
OK

INSPECTION END

Repair or replace harness.

EL-4201

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
POWER SUPPLY AND GROUND CIRCUIT CHECK FOR TRANSFER UNIT
1.

CHECK FUSE

Make sure that the following fuses of the transfer unit are not blown.
Terminals

Unit

Connector

Terminal (wire color)

M173

32 (R/G)

Power source

Fuse No.

Battery

Ignition switch ACC or ON

31 (R/G)
Transfer unit

29 (L/OR)

OK or NG
OK

GO TO 2.

If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse.
Refer to EL-4005 in “POWER SUPPLY ROUTING”.

CHECK POWER SUPPLY CIRCUIT

Check voltage between transfer unit and ground.

SKIA9079E
Terminals
(+)

Unit
Connector

(−)

Terminal (wire
color)
31 (R/G)

Transfer unit

M173

32 (R/G)

Ground

29 (L/OR)

OK or NG
OK

GO TO 3.

Repair or replace harness.

EL-4202

OFF

ACC

Battery voltage

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
3.

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect transfer unit connector.
3. Check continuity between transfer unit and ground.

SKIA9081E
Terminals
Unit

(+)
Connector

Transfer unit

M173

Terminal (wire color)
25 (B)
27 (B)

(−)
Ground

Continuity

Yes

OK or NG
OK

INSPECTION END

Repair or replace harness.

COMMUNICATION LINE CHECK (BETWEEN DISPLAY AND NAVI SWITCH)
1.

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. Check system of power supply and ground circuit display. Refer to EL-4199.
OK or NG
OK

GO TO 2.

Check the malfunctioning parts.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect display connector and NAVI switch connector.
3. Check continuity between display harness connector M170 terminal 15 (OR) and NAVI switch harness connector M169
terminal 4 (OR).

SKIA9222E

15 (OR) — 4 (OR) Continuity should exist.
4. Check continuity between display harness connector M170 terminal 15 (OR) and ground.
15 (OR) — Ground Continuity should not exist.
OK or NG
OK

Replace display.

Repair harness or connector.

EL-4203

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
COMMUNICATION LINE CHECK (BETWEEN NAVI SWITCH AND TRANSFER UNIT)
1.

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. Check system of power supply and ground circuit NAVI switch. Refer to EL-4201
OK or NG
OK

GO TO 2.

Check the malfunctioning parts.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect NAVI switch connector and transfer unit connector.
3. Check continuity between NAVI switch harness connector M169 terminals 5 (L/W), 6 and transfer unit harness connector M173 terminals 18 (L/W), 15.

SKIA9223E

5 (L/W) — 18 (L/W) Continuity should exist.
6 — 15 Continuity should exist.
4. Check continuity between NAVI switch harness connector M169 terminals 5 (L/W), 6 and ground.
5 (L/W), 6 — Ground Continuity should not exist.
OK or NG
OK

Replace NAVI switch.

Repair harness or connector.

COMMUNICATION LINE CHECK (BETWEEN NAVI CONTROL UNIT AND TANSFER UNIT)
1.

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. Check system of power supply and ground circuit NAVI control unit. Refer to EL-4198.
OK or NG
OK

GO TO 2.

Check the malfunctioning parts.

EL-4204

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
2.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit connector and transfer unit connector.
3. Check continuity between NAVI control unit and transfer unit.

SKIA9224E
Terminals
NAVI control unit

Transfer unit

Connector

Terminal (wire color)

M168

44 (W)

Continuity

Connector

Terminal (wire color)

M173

11 (W)

45 (B)

Yes

13 (B)

4. Check continuity between NAVI control unit and ground.
Terminals
Connector

Terminal (wire color)

—

Continuity

43
M168

44 (W)

Ground

45 (B)

OK or NG
OK

Replace NAVI control unit.

Repair harness or connector.

COMMUNICATION LINE CHECK (BETWEEN TRANSFER UNIT AND DISPLAY)
1.

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. Check system of power supply and ground circuit transfer unit. Refer to EL-4202.
OK or NG
OK

GO TO 2.

Check the malfunctioning parts.

EL-4205

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
2.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect transfer unit connector and display connector.
3. Check continuity between transfer unit harness connector M173 terminals 19, 20 (B) and display harness connector
M112 terminals 17, 16 (B).

SKIA9225E

19 — 17 Continuity should exist.
20 (B) — 16 (B) Continuity should exist.
4. Check continuity between transfer unit harness connector M173 terminals 19, 20 (B) and ground.
19, 20 (B) — Ground Continuity should not exist.
OK or NG
OK

Replace transfer unit.

Repair harness or connector.

VEHICLE SPEED SIGNAL CHECK
1.

CHECK VEHICLE SPEED OPERATION

Does speedometer is operated normally?
Yes or No
Yes

GO TO 2.

Check combination meter.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit connector and combination meter connector.
3. Check continuity between NAVI control unit harness connector M168 terminal 28 (R/W) and Unified meter control unit
harness connector M143 terminal 64 (R/W).

PKIB0549E

28 (R/W) — 64 (R/W) Continuity should exist.
4. Check continuity between NAVI control unit harness connector M168 terminal 28 (R/W) and ground.
28 (R/W) — Ground Continuity should not exist.
OK or NG
OK

GO TO 3.

Repair harness or connector.

EL-4206

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
3.

CHECK VEHICLE SPEED SIGNAL

1. Connect NAVI control unit and combination meter connector.
2. Start engine and drive vehicle at more than 40 km/h (25 MPH).
3. Check the signal between NAVI control unit harness connector M168 terminal 28 (R/W) and ground with CONSULT-ll or
oscilloscope.

SKIA9106E

28 (R/W) — Ground: Refer to EL-4183.
OK or NG
OK

Replace NAVI control unit.

Replace unified meter control unit.

ILLUMINATION SIGNAL CHECK
1.

CHECK TAIL LAMP OPERATION

When lighting switch turned 1st or 2nd position, does tail lamp illuminate?
Yes or No
Yes

GO TO 2.

Go to tail lamp trouble diagnosis.

CHECK ILLUMINATION SIGNAL

Check voltage between NAVI control unit and ground.

SKIB0315E
Terminals
(+)
Connector

Terminal (wire color)

M168

25 (L/B)

(−)
Ground

OK or NG
OK

Replace NAVI control unit.

Repair harness or connector.

EL-4207

Lighting switch position

Voltage

1st or 2nd position

Battery voltage

OFF

Approx. 0V

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
IGNITION SIGNAL CHECK
1.

CHECK IGNITION SIGNAL

1. Turn ignition switch ON.
2. Check voltage between NAVI control unit harness connector M168 terminal 26 (R/W) and ground.

SKIA9108E

26 (R/W) — Ground: Battery voltage
OK or NG
OK

Replace NAVI control unit.

Check the following.
+ 10A fuse [No. 28, located in fuse block (J/B)]
+ Harness for open or short between NAVI control unit and fuse

REVERSE SIGNAL CHECK
1.

CHECK REVERSE LAMP

1. Turn ignition switch ON.
— With the A/T selector lever in R position, does “R” in the shift position indicator turned on? (With A/T)
— With the shift lever in R position. Are reverse lamps turned on? (With M/T)
Yes or No
Yes

GO TO 2.

Check “BACK-UP LAMP” system.

EL-4208

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
2.

CHECK REVERSE SIGNAL

+ Shift the A/T selector lever in R position. (With A/T)
+ Shift the shift lever in R position. (With M/T)
— Check voltage between NAVI control unit and ground.

SKIA8728E

Terminals
(+)
Connector

Terminal (wire color)

M168

27 (Y)

(−)
Ground

A/T selector lever position

Voltage (V)

R position

Battery voltage

Other than R position

Approx. 0

OK or NG
OK

Replace NAVI control unit.

Check the following.
+ Harness for open or short between NAVI control unit and park/neutral position switch
(A/T models)
+ Harness for open or short between NAVI control unit and back-up lamp switch (M/T
models)

COLOR OF RGB IMAGE IS NOT PROPER
1.

CHECK COLOR BAR DIAGNOSIS

Check color tone by “SCREEN ADJUSTMENT” of CONFIRMATION/ADJUSTMENT function.
OK or NG
OK

INSPECTION END

GO TO 2.

EL-4209

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
2.
1.
2.
3.
+

CHECK RGB HARNESS
Turn ignition switch OFF.
Disconnect NAVI control unit connector and display connector.
Check continuity with the following.
When the screen looks bluish
Terminals
NAVI control unit
Connector
M167

Display

Terminal
(wire color)

Connector

18 (R)

1 (R)

M170

Yes

Terminals
Connector

Terminal (wire color)
18 (R)

M167

Continuity

—
Ground

Continuity

PKIB0550E

+ When the screen looks reddish
Terminals
NAVI control unit
Connector
M167

Display

Terminal
(wire color)

Connector

21 (G)

2 (G)

M170

Yes

Terminals
Connector

Terminal (wire color)
21 (G)

M167

Continuity

—
Ground

Continuity

PKIB0551E

+ When the screen looks yellowish
Terminals
NAVI control unit
Connector
M167

Display

Terminal
(wire color)

Connector

15 (B)

3 (B)

M170

M167

Terminal (wire color)
15 (B)
17

Yes

Terminals
Connector

Continuity

—
Ground

Continuity
No

PKIB0552E

OK or NG
OK

GO TO 3.

Repair harness or connector.

EL-4210

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
3.

CHECK RGB SIGNAL

1. Connect NAVI control unit connector and display connector.

PKIB0553E

2.
3.
4.
+

Turn ignition switch ON.
Display “Color bar” by “CONFIRMATION/ADJUSTMENT” mode.
Check the following with CONSULT-ll or oscilloscope.
When the screen looks bluish.
Voltage signal between NAVI control unit connector M167 terminal 18 (R) and 17.
18 (BR) — 19: Refer to EL-4183.
+ When the screen looks reddish.
Voltage signal between NAVI control unit connector M167 terminal 21 (G) and 17.
21 (W) — 19: Refer to EL-4183.
+ When the screen looks yellowish.
Voltage signal between NAVI control unit connector M167 terminal 15 (B) and 17.
15 (R) — 19: Refer to EL-4183.
OK or NG
OK

Replace display.

Replace NAVI control unit.

RGB SCREEN IS NOT SHOWN
1.

CHECK HARNESS

1. Turn ignition switch OFF.

PKIB0554E

2. Disconnect NAVI control unit connector and display connector.
3. Check continuity between NAVI control unit harness connector M167 terminals 12 (R), 17 and display harness connector M170 terminals 8 (R), 4.
12 (R) — 8 (R) Continuity should exist.
17 — 4 Continuity should exist.
4. Check continuity between NAVI control unit harness connector M167 terminals 12 (R), 17 and ground.
12 (R), 17 — Ground Continuity should not exist.
OK or NG
OK

GO TO 2.

Repair harness or connector.

EL-4211

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
2.
1.
2.
3.
4.

CHECK RGB AREA SIGNAL
Connect NAVI control unit connector and display connector.
Turn ignition switch ON.
Push “INFO” switch.
Check the signal between NAVI control unit connector M167 terminals 12 (R) and 17 with CONSULT-ll or oscilloscope.

PKIB0555E

12 (R) — 17: Refer to EL-4183.
OK or NG
OK

Replace display.

Replace NAVI control unit.

RGB SCREEN IS ROLLING
1.

CHECK RGB SYNCHRONIZING CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit connector and display connector.
3. Check continuity between NAVI control unit harness connector M167 terminals 16 (W), 17 and display harness connector M170 terminals 7 (W), 4.

PKIB0556E

16 (W) — 7 (W) Continuity should exist.
17 — 4 Continuity should exist.
4. Check continuity between NAVI control unit harness connector M167 terminals 16 (W), 17 and ground.
16 (W), 17 — Ground Continuity should not exist.
OK or NG
OK

GO TO 2.

Repair harness or connector.

EL-4212

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
2.
1.
2.
3.
4.

CHECK RGB SYNCHRONIZING SIGNAL
Connect NAVI control unit connector and display connector.
Turn ignition switch ON.
Push the “MAP” switch.
Check the signal between NAVI control unit harness connector M167 terminals 16 (W) and 17 with CONSULT-ll or
oscilloscope.

PKIB0557E

16 (W) — 19: Refer to EL-4183.
OK or NG
OK

Replace display.

Replace NAVI control unit.

GUIDE SOUND IS NOT HEARD
1.

CHECK VOICE GUIDE SETTING

+ While driving in the dark pink route, voice guide does not operate.
NOTE:
Voice guide is only available at intersections that satisfy certain conditions (indicated by + on the map).
Therefore, guidance may not be given even when the route on the map changes direction.
+ Is volume setting not switched ON?
Yes or No
Yes

GO TO 2.

Switch the setting ON and turn the volume up.

EL-4213

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
2.

CHECK VOICE GUIDE CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit connector and transfer unit connector.
3. Check continuity between NAVI control unit harness connector M167 terminals 7 (Y), 8 (BR), and transfer unit harness
connector M173 terminals 8 (Y), 10 (BR).

SKIA9115E

7 (Y) — 8 (Y) Continuity should exist.
8 (BR) — 10 (BR) Continuity should exist.
4. Check continuity between NAVI control unit harness connector M167 terminals 7 (Y), 8 (BR) and ground.
7 (Y), 8 (BR) — Ground Continuity should not exist.
OK or NG
OK

GO TO 3.

+ Check connector housings for disconnected or loose terminals.
+ Repair harness or connector.

3.
1.
2.
3.
4.

CHECK VOICE GUIDE SIGNAL (NAVI CONTROL UNIT)
Connect NAVI control unit connector and transfer unit connector.
Turn ignition switch ON.
Push “VOICE” switch.
Check the signal between NAVI control unit harness connector M167 terminals 7 (Y) and 8 (BR) with CONSULT-ll or
oscilloscope.

SKIA9113E

7 (Y) — 8 (BR): Refer to EL-4183.
OK or NG
OK

GO TO 4.

Replace NAVI control unit.

EL-4214

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
4.

CHECK VOICE CHANGE RELAY CIRCUIT: (1)

1. Turn ignition switch OFF.
2. Disconnect transfer unit connector and voice change relay connector.
3. Check continuity between transfer unit harness connector M173 terminals 1 (L), 2 (PU) and voice change relay harness
connector M174 terminals 6 (L), 7 (PU).

SKIA9122E

1 (L) — 6 (L) Continuity should exist.
2 (PU) — 7 (PU) Continuity should exist.
4. Check continuity between transfer unit harness connector M173 terminals 1 (L), 2 (PU) and ground.
1 (L), 2 (PU) — Ground Continuity should not exist.
OK or NG
OK

GO TO 5.

Repair harness or connector.

5.
1.
2.
3.
4.

CHECK VOICE GUIDE SIGNAL (TRANSFER UNIT)
Connect transfer unit connector and voice change relay connector.
Turn ignition switch ON.
Push “VOICE” switch.
Check the signal between transfer unit harness connector M173 terminals 1 (L) and 2 (PU) with CONSULT-ll or oscilloscope.

SKIA9118E

1 (L) — 2 (PU): Refer to EL-4187.
OK or NG
OK

GO TO 6.

Replace transfer unit.

EL-4215

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
6.

CHECK VOICE CHANGE RELAY CIRCUIT: (2)

1. Turn ignition switch OFF.
2. Disconnect transfer unit connector and voice change relay connector.
3. Check continuity between transfer unit harness connector M173 terminals 6 (BR), 4 (R) and voice change relay harness connector terminals 2 (BR), 1 (R).

SKIA9121E

6 (BR) — 2 (BR) Continuity should exist.
4 (R) — 1 (R) Continuity should exist.
4. Check continuity between transfer unit harness connector M173 terminals 6 (BR), 4 (R) and ground.
6 (BR), 4 (R) — Ground Continuity should not exist.
OK or NG
OK

GO TO 7.

Repair harness or connector.

7.
1.
2.
3.
4.

CHECK VOICE CHANGE RELAY ON SIGNAL
Connect voice transfer unit connector.
Turn ignition switch ON.
Push “VOICE” switch.
Check voltage between transfer unit harness connector M173 terminal 6 (BR) and 4 (R).

SKIA9119E

6 (BR) — 4 (R): Approx. 5V
OK or NG
OK

Replace voice change relay.

Replace transfer unit.

DISPLAY QUALITY CONTROL CANNOT CHANGE SCREEN
1.

CHECK SYMPTOM

Do other systems operate normally?
Yes or No
Yes

Replace display.

Check symptom again.

EL-4216

NAVIGATION SYSTEM
Trouble Diagnoses (Cont’d)
DRIVING TEST
1.

DRIVING TEST 1

1. Scroll the map screen to display the area to make correction. Push “ENTER” and select “CURRENT LOCATION CORRECTION”.
2. Correct direction of the vehicle mark.
3. Perform the distance correction of the “CONFIRMATION/ADJUSTMENT” mode.
NOTE:
Normally, adjustment is not necessary because this system has automatic distance correction function. However, when
a tire chain is fitted, adjustment in accordance with the tire diameter ratio must be made.
4. Are symptoms applicable to the Example of Symptoms Judged Not Malfunction (EL-4218) present after driving the
vehicle?
Yes or No
Yes

Limit of the location detection capacity of the navigation system.

GO TO 2.

DRIVING TEST 2

+ Did any malfunction occur when the proper test in the following test patterns is performed?
+ Test pattern
Driving test finds the difference between the symptoms monitored with and without each sensor.
— Test pattern 1: Test method with no GPS location correction
Disconnect the GPS antenna connector connected to the NAVI control unit. Accurately adjust the current location and
the direction, then drive the vehicle.
— Test pattern 2: Test method with no map-matching
Accurately adjust the current location and the direction. Eject the map DVD-ROM from the NAVI control unit with the
ignition switch turned to OFF, then drive the vehicle. After driving, insert the map DVD-ROM back in the unit, display
the track of the vehicle on the map screen and compare it with the actual road configuration.
+ Sample tests
—
Perform test pattern 1.
—
Perform test pattern 1 and 2.
Compare the track of the vehicle on the map screen and the actual road configuration. For fairly accurate tracking,
plotting shall be made every several hundred meters.
—
Perform test pattern 1 and 2.
Drive on a road of which distance is accurately known (by utilizing distance posts on a highway). Calculate the rate of
change (increased/decreased) of the distance by comparing with the actual distance.
Correction = 1 — A/B
A: Distance shown on the screen
B: Actual distance
Yes or No
Yes

+ If adjustment is insufficient, perform adjustment again.
+ If any error is found in the map, please let us know.
+ Replace NAVI control unit.

Limit of the location detection capacity of the navigation system.

EL-4217

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
BASIC OPERATION
Symptom

Cause

Remedy

Display brightness adjustment is set fully to
DARK side.

Adjust the display brightness.

Volume control is set to OFF, MIN or MAX.

Adjust the audio guide volume.

Audio guidance is not available while the
vehicle is driving on a dark pink route.

System is not malfunction.

Screen is too dark. Motion of the
image is too slow.

Temperature inside the vehicle is low.

Wait until the temperature inside the vehicle
reaches the proper temperature.

Small black or bright spots appear
on the screen.

Symptom peculiar to a liquid crystal display.

System is not malfunction.

No image is shown.

No guide sound is heard. Audio
guide volume is too low or too high.

VEHICLE MARK
Symptom

Cause

Remedy

Map screen and BIRDVIEWT Name
of the place vary with the screen.

Some thinning of the character data is done
to prevent the display becoming to complex.
In some cases and in some locations, the
display contents may differ. The same place System is not malfunction.
name, street name, etc. may not be displayed every time on account of the data processing.

Vehicle mark is not positioned correctly.

Vehicle is transferred by ferry or by towing
after its ignition switch is turned to OFF.

Screen will not switch to nighttime
mode after the lighting switch is
turned ON.

The daytime screen is selected by the
“SWITCH SCREENS” when the last time the
Perform screen dimming and select the nightscreen dimming setting is done.
Switching between daytime/nighttime screen time screen by “SWITCH SCREENS”.
may be inhibited by the automatic illumination
adjustment function.

Map screen will not scroll in accordance with the vehicle travel.

Current location is not displayed.

Push “MAP” switch to display the current
location.

Vehicle mark will not be shown.

Current location is not displayed.

Push “MAP” switch to display the current
location.

GPS satellite signal is intercepted because
the vehicle is in or behind a building.

Move the vehicle out to an open space.

GPS satellite signal cannot be received
Accuracy indicator (GPS satellite
mark) on the map screen stays gray. because an obstacle is placed on top of the
display.

Vehicle location accuracy is low.

Drive the vehicle for a while in the GPS satellite signal receiving condition.

Do not place anything in the center on top of
the display.

GPS satellites are located badly.

Wait until the location becomes better.

Accuracy indicator (GPS satellite mark) on
the map screen stays gray.

Current location is not determined.

Vehicle speed setting by the vehicle speed
pulse has been deviated (advanced or
retarded) from the actual vehicle speed
because tire chain is fitted or the system has
been used on another vehicle.

Drive the vehicle for a while [for approx. 30
minutes at approx. 30 km/h (19 MPH)] and
the deviation will be automatically adjusted. If
advancement or retard still occur, perform the
distance adjustment by “CONFIRMATION/
ADJUSTMENT” mode of diagnosis function.

Map data has error or omission. (Vehicle
mark is always deviated to the same position.)

As a rule, an updated map DVD-ROM will be
released once a year.

EL-4218

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
DESTINATION, PASSING POINTS, AND MENU ITEMS CANNOT BE SELECTED/SET
Symptom
Passing point is not searched when
re-searching the route.

Route information will not be displayed.

Cause

Remedy

The vehicle has already passed the passing
point, or the system judged so.

To include the passing points that have been
passed into the route again, set the route
again.

Route searching has not been done.

Set the destination and perform route searching.

Vehicle mark is not on the recommended
route.

Drive on the recommended route.

Route guide is turned OFF.

Turn the route guide ON.

Route information is not available on the dark
System is not malfunction.
pink route.
After the route searching, no guide
sign will appear as the vehicle goes
near the entrance/exit to the toll
road.

Vehicle mark is not on the recommended
route. (On the display, only guide signs
related to the recommended route will be
shown.)

Drive on the recommended route.

Automatic route searching is not
possible.

Vehicle is driving on a highway (gray route),
or no recommended route is available.

Drive on a road to be searched. Or re-search
the route manually. In this case, however, the
whole route will be searched.

Performed automatic detour search
(or detour search). However, the
result is the same as that of the previous search.

Performed search with every conditions considered. However, the result is the same as
that of the previous search.

System is not malfunction.

Passing points cannot be set.

More than five passing points were set.

Passing points can be set up to five. To stop
at more than five points, perform sharing in
several steps.

When setting the route, the starting
point cannot be selected.

The current vehicle location is always set as
the starting point of a route.

System is not malfunction.

Some menu items cannot be
selected.

The vehicle is being driven.

Stop the vehicle at a safe place and then
operate the system.

VOICE GUIDE
Symptom

Voice guide will not operate.

Voice guide does not match the
actual road pattern.

Cause

Remedy

Note: Voice guide is only available at intersections that satisfy certain conditions (indicated by + on the map). Therefore, guidance System is not malfunction.
may not be given even when the route on the
map changes direction.
The vehicle is not on the recommended
route.

Return to the recommended route or
re-search the route.

Voice guide is turned OFF.

Turn the voice guide ON.

Route guide is turned OFF.

Turn the route guide ON.

Voice guide may vary with the direction to
which the vehicle is turn and the connection
of the road to other roads.

Drive in conformity to the actual traffic rules.

EL-4219

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
ROUTE SEARCHING
Symptom

No route is shown.

Cause

Remedy

No road to be searched is found around the
destination.

Find wider road (orange road or wider)
nearby and reset the destination and passing
points onto it. Take care of the traveling
direction when there are separate up and
down roads.

Starting point and the destination are too
close.

Set the destination at more distant point.

Turn the time-regulating search conditions
Conditional traffic regulation (day of the
OFF. Turn “Avoid regulation time” in the
week/time of the day) is set at the area
around the current location or the destination. search conditions OFF.

Indicated route is intermittent.

In some areas, highways (gray routes) are
not used for the search (Note). Therefore, the
System is not malfunction.
route to the current position or the passing
points may be intermittent.

When the vehicle has passed the
recommended route, it is deleted
from the screen.

A recommended route is controlled by each
section. When the vehicle has passed the
passing point 1, then the map data from the
System is not malfunction.
starting point up to the passing point 1 will be
deleted. (The data may remain undeleted in
some area.)

Detouring route is recommended.

In some areas, highways (gray routes) are
not used for the search (Note). Therefore,
detour route may be recommended.

Set the route closer to the basic route (gray
route).

A detour route may be shown when some
traffic regulation (one-way traffic, etc.) is set
at the area around the starting point or the
destination.

Slightly move the starting point or the
destination, or set the passing point on the
route of your choice.

In the area where highways (gray routes) are
used for the search, left turn has priority
System is not malfunction.
around the current location and the destination (passing points). For this reason, the recommended route may be detouring.
Landmarks on the map do not match This can be happen due to omission or error
the actual ones.
in the map data.
Recommended route is far from the
starting point, passing points, and
destination.

Starting point, passing points, and destination
of the route guide were set far from the
desired points because route searching data
around these area were not stored.

As a rule, an updated map DVD-ROM will be
released once a year. Wait until the latest
map has become available.
Reset the destination onto the road nearby. If
this road is one of the highways (gray
routes), an ordinary road nearby may be displayed as the recommended route.

NOTE:
Except for the ordinance-designated cities and the prefectural capitals (Applicable areas may be changed in
the updated map disc.)

EL-4220

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
EXAMPLES OF CURRENT LOCATION MARK DISPLACEMENT
Vehicle’s travel amount is calculated by reading its travel distance and turning angle. Therefore, if the vehicle
is driven in the following manner, an error will occur in the vehicle’s current location display. If correct location
has not been restored after driving the vehicle for a while, perform location correction.

SEL698V

EL-4221

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
Cause (condition)

Driving condition

Remarks (correction, etc.)

Y-intersections
At a Y intersection or similar gradual
division of roads, error the direction
of travel deduced by the sensor may
result in the current location mark
appearing on the wrong road.
ELK0192D

Spiral roads
When driving on a large, continuous
spiral road (such as loop bridge),
turning angle error is accumulated
and the vehicle mark may deviate
from the correct location.
ELK0193D

Straight roads

Road configuration

Zigzag roads

When driving on a long, straight road
and slow curve without stopping,
map-matching does not work effectively enough and distance errors
may accumulate. As a result, the
vehicle mark may deviate from the
correct location when the vehicle
If after travelling about 10 km (6
turned at a corner.
miles) the correct location has not
ELK0194D
been restored, perform location correction and, if necessary, direction
correction.
When driving on a zigzag road, the
map may be matched to other roads
in the similar direction nearby at
every turn, and the vehicle mark may
deviate from the correct location.
ELK0195D

Roads laid out in a grid pattern
When driving at where roads are laid
out in a grid pattern, where many
roads are running in the similar
direction nearby, the map may be
matched to them by mistake and the
vehicle mark may deviate from the
correct location.
ELK0196D

Parallel roads
When two roads are running in parallel (such as highway and sideway),
the map may be matched to the
other road by mistake and the
vehicle mark may deviate from the
correct location.
ELK0197D

EL-4222

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
Cause (condition)
In a parking lot

Driving condition

Remarks (correction, etc.)

When driving in a parking lot, or
other location where there are no
roads on the map, matching may
place the vehicle mark on a nearby
road. When the vehicle returns to the
road, the vehicle mark may have
deviated from the correct location.
When driving in circle or turning the
steering wheel repeatedly, direction
errors accumulate, and the vehicle
SEL709V mark may deviate from the correct
location.

Turn table
When the ignition switch is OFF, the
navigation system cannot get the
signal from the gyroscope (angular
speed sensor). Therefore, the displayed direction may be wrong and
the correct road may not be easily
returned to after rotating the vehicle
on a turntable with the ignition OFF.

Place

SEL710V

Slippery roads

On snow, wet roads, gravel, or other
roads where tires may slip easily,
accumulated mileage errors may
cause the vehicle mark to deviate
from the correct road.

Slopes

When parking in sloped garages,
when travelling on banked roads, or
in other cases where the vehicle
turns when tilted, an error in the turning angle will occur, and the vehicle
mark may deviate from the road.

Road not displayed on the map
screen

If after travelling about 10 km (6
miles) the correct location has not
been restored, perform location correction and, if necessary, direction
correction.

When driving on new roads or other
roads not displayed on the map
screen, map matching does not function correctly and matches the location to a nearby road. When the
vehicle returns to a road which is on
the map, the vehicle mark may deviate from the correct road.

SEL699V

Map data

Different road pattern (Changed due
to repair)

If the road pattern stored in the map
data and the actual road pattern are
different, map matching does not
function correctly and matches the
location to a nearby road. The
vehicle mark may deviate from the
correct road.

ELK0201D

Vehicle

Use of tire chains

Drive the vehicle for a while. If the
When tire chains are used, the miledistance is still deviated, adjust it by
age is not correctly detected, and the
using the distance adjustment funcvehicle mark may deviate from the
tion. (If the tire chain is removed,
correct road.
recover the original value.)

EL-4223

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
Cause (condition)

Precautions
for driving

Driving condition

Remarks (correction, etc.)

Just after the engine is started

If the vehicle is driven off just after
the engine is started when the gyroscope (angular speed sensor) correction is not completed, the vehicle
can lose its direction and may have
deviated from the correct location.

Wait for a short while before driving
after starting the engine.

Continuous driving without stopping

When driving long distances without
stopping, direction errors may
accumulate, and the current location
mark may deviate from the correct
road.

Stop and adjust the orientation.

Abusive driving

Spinning the wheels or engaging in
other kinds of abusive driving may
result in the system being unable to
perform correct detection, and may
cause the vehicle mark to deviate
from the correct road.

If after travelling about 10 km (6
miles) the correct location has not
been restored, perform location correction and, if necessary, direction
correction.

If the accuracy of location settings is
poor, accuracy may be reduced
when the correct road cannot be
found, particularly in places where
there are many roads.

Enter in the road displayed on the
screen with an accuracy of approx. 1
mm.
NOTE:
Whenever possible, use detailed
map for the correction.

If the accuracy of location settings
during correction is poor, accuracy
may be reduced afterwards.

Perform direction correction.

Position correction accuracy

How to correct
location

SEL699V

Direction when location is corrected

SEL702V

THE CURRENT POSITION MARK SHOWS A POSITION WHICH IS COMPLETELY WRONG
In the following cases, the current location mark may appear on completely different position in the map
depending on the GPS satellite signal receiving conditions. In this case, perform location correction and
direction correction.
+ When location correction has not been done
— If the receiving conditions of the GPS satellite signal is poor, if the current location mark becomes out of
place, it may move to a completely different location and not come back if location correction is not done.
The position will be corrected if the GPS signal can be received.
+ When the vehicle has traveled by ferry, or when the vehicle has been being towed
— Because calculation of the current location cannot be done when travelling with the ignition OFF, for
example when travelling by ferry or when being towed, the location before travel is displayed. If the precise location can be detected with GPS, the location will be corrected.

THE CURRENT POSITION MARK JUMPS
In the following cases, the current location mark may appear to jump as a result of automatic correction of the
current location.
+ When map matching has been done
— If the current location and the current location mark are different when map matching is done, the current
location mark may seem to jump. At this time, the location may be “corrected” to the wrong road or to a
location which is not on a road.
+ When GPS location correction has been done
— If the current location and the current location mark are different when the location is corrected using GPS
measurements, the current location mark may seem to jump. At this time, the location may be “corrected”
to a location which is not on a road.

EL-4224

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
THE CURRENT LOCATION MARK IS IN A RIVER OR THE SEA
The navigation system moves the current location mark with no distinction between land and rivers or sea. If
the location mark is somehow out of place, it may appear that the vehicle is driving in a river or the sea.

WHEN DRIVING ON THE SAME ROAD, SOMETIMES THE CURRENT LOCATION MARK IS IN
THE RIGHT PLACE AND SOMETIMES IT IS THE WRONG PLACE
The conditions of the GPS antenna (GPS data) and gyroscope (angular speed sensor) change gradually.
Depending on the road traveled and the operation of the steering wheel, the location detection results will be
different. Therefore, even on a road on which the location has never been wrong, conditions may cause the
vehicle mark to deviate.

LOCATION CORRECTION BY MAP MATCHING IS SLOW
+
+

The map matching function needs to refer to the data of the surrounding area. It is necessary to drive some
distance for the function to work.
Because map matching operates on this principle, when there are many roads running in similar directions in the surrounding area, no matching determination may be made. The location may not be corrected
until some special feature is found.

ALTHOUGH THE GPS RECEIVING DISPLAY IS GREEN, THE VEHICLE MARK DOES NOT
RETURN TO THE CORRECT LOCATION
+
+
+

The GPS accuracy has an error of about 10 m (30 ft). In some cases the current location mark may not
be on the correct street, even when GPS location correction is done.
The navigation system compares the results of GPS location detection with the results from map-matching location detection. The one which is determined to have higher accuracy is used.
GPS location correction may not be performed when the vehicle is stopped.

THE NAME OF THE CURRENT PLACE IS NOT DISPLAYED
The current place name may not be displayed if there are no place names displayed on the map screen.

CONTENTS OF THE DISPLAY DIFFER FOR THE BIRDVIEWT AND THE (FLAT) MAP SCREEN
Difference of the BIRDVIEWT screen from the flat map screen are as follows.
+
+
+
+
+

The current place name displays names which are primarily in the direction of vehicle travel.
The amount of time before the vehicle travel or turn angle is updated on the screen is longer than for the
(flat) map display.
The conditions for display of place names, roads, and other data are different for nearby areas and for
more distant areas.
Some thinning of the character data is done to prevent the display becoming to complex. In some cases
and in some locations, the display contents may differ.
The same place name, street name, etc. may be displayed multiple times.

EL-4225

NAVIGATION SYSTEM
Program Loading
NOTE:
Program loading is operated when the version of soft is upgraded
to the latest one, or when language is switched.

SKIA9552E

EL-4226

DOOR MIRROR/WAGON AND HARDTOP MODELS
Wiring Diagram — MIRROR —/LHD Models

TEL083N

EL-4227

DOOR MIRROR/WAGON AND HARDTOP MODELS
Wiring Diagram — MIRROR —/LHD Models
(Cont’d)

TEL084N

EL-4228

DOOR MIRROR/WAGON AND HARDTOP MODELS
Wiring Diagram — MIRROR —/RHD Models

TEL085N

EL-4229

DOOR MIRROR/WAGON AND HARDTOP MODELS
Wiring Diagram — MIRROR —/RHD Models
(Cont’d)

TEL086N

EL-4230

HEATED SEAT/WAGON AND HARDTOP MODELS
Wiring Diagram — HSEAT —

TEL087N

EL-4231

HEATED SEAT/WAGON AND HARDTOP MODELS
Wiring Diagram — HSEAT — (Cont’d)

TEL671A

EL-4232

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Schematic/TB48 and TD42Ti Engine Models

TEL088N

EL-4233

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Wiring Diagram — ASCD —/TB48 and TD42Ti
Engine Models

TEL569M

EL-4234

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Wiring Diagram — ASCD —/TB48 and TD42Ti
Engine Models (Cont’d)

TEL570M

EL-4235

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Wiring Diagram — ASCD —/TB48 and TD42Ti
Engine Models (Cont’d)

TEL089N

EL-4236

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Wiring Diagram — ASCD —/TB48 and TD42Ti
Engine Models (Cont’d)

TEL090N

EL-4237

POWER WINDOW/WAGON AND HARDTOP MODELS
Schematic

TEL091N

EL-4238

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW —

TEL254M

EL-4239

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW — (Cont’d)

TEL092N

EL-4240

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW — (Cont’d)

TEL093N

EL-4241

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW — (Cont’d)
LHD WAGON MODELS

TEL094N

EL-4242

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW — (Cont’d)
RHD WAGON MODELS

TEL095N

EL-4243

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Schematic/Without Theft Warning System
Models

TEL096N

EL-4244

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/Without Theft
Warning System Models

TEL097N

EL-4245

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/Without Theft
Warning System Models (Cont’d)

TEL098N

EL-4246

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/Without Theft
Warning System Models (Cont’d)

TEL099N

EL-4247

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/Without Theft
Warning System Models (Cont’d)

TEL100N

EL-4248

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Schematic/With Theft Warning System Models

TEL573M

EL-4249

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/LHD Models With
Theft Warning System

TEL101N

EL-4250

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/LHD Models With
Theft Warning System (Cont’d)

TEL102N

EL-4251

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/LHD Models With
Theft Warning System (Cont’d)

TEL103N

EL-4252

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/LHD Models With
Theft Warning System (Cont’d)

TEL104N

EL-4253

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/RHD Models
With Theft Warning System

TEL105N

EL-4254

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/RHD Models
With Theft Warning System (Cont’d)

TEL106N

EL-4255

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/RHD Models
With Theft Warning System (Cont’d)

TEL107N

EL-4256

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — D/LOCK —/RHD Models
With Theft Warning System (Cont’d)

TEL108N

EL-4257

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Schematic — Super Lock —

TEL109N

EL-4258

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — S/LOCK —

TEL110N

EL-4259

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — S/LOCK — (Cont’d)

TEL111N

EL-4260

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — S/LOCK — (Cont’d)

TEL112N

EL-4261

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — S/LOCK — (Cont’d)

TEL113N

EL-4262

POWER DOOR LOCK/WAGON AND HARDTOP MODELS
Wiring Diagram — S/LOCK — (Cont’d)

TEL114N

EL-4263

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
SMA for VIN
>JN1*ESY61U0140001 and
>JN1*FSY61U0100001

Wiring Diagram — MULTI —/LHD Models
Except for Europe, The Middle East and With
Theft Warning System

TEL829M

EL-4264

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/LHD Models
Except for Europe, The Middle East and With
Theft Warning System (Cont’d)

TEL721M

EL-4265

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/RHD Models
Except for Europe, South Africa and With Theft
Warning System

TEL115N

EL-4266

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/RHD Models
Except for Europe, South Africa and With Theft
Warning System (Cont’d)

TEL116N

EL-4267

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Schematic/With Theft Warning System Models

TEL584M

EL-4268

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/LHD Models with
Theft Warning System

TEL586M

EL-4269

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/LHD Models with
Theft Warning System (Cont’d)

TEL117N

EL-4270

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/LHD Models with
Theft Warning System (Cont’d)

TEL589M

EL-4271

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/LHD Models with
Theft Warning System (Cont’d)

TEL799M

EL-4272

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/RHD Models with
Theft Warning System

TEL118N

EL-4273

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/RHD Models with
Theft Warning System (Cont’d)

TEL592M

EL-4274

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/RHD Models with
Theft Warning System (Cont’d)

TEL119N

EL-4275

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/LHD Models for
Europe and The Middle East

TEL120N

EL-4276

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — MULTI —/LHD Models for
Europe and The Middle East (Cont’d)

TEL121N

EL-4277

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Schematic

TEL122N

EL-4278

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/LHD Models

TEL123N

EL-4279

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/LHD Models
(Cont’d)

TEL124N

EL-4280

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/LHD Models
(Cont’d)

TEL726M

EL-4281

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/LHD Models
(Cont’d)

TEL125N

EL-4282

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/LHD Models
(Cont’d)

TEL126N

EL-4283

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/RHD Models

TEL127N

EL-4284

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/RHD Models
(Cont’d)

TEL128N

EL-4285

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/RHD Models
(Cont’d)

TEL129N

EL-4286

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/RHD Models
(Cont’d)

TEL142N

EL-4287

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — THEFT —/RHD Models
(Cont’d)

TEL130N

EL-4288

THEFT WARNING SYSTEM/WAGON AND HARDTOP MODELS
NOTE

EL-4289

SUPER LOCK CONTROL UNIT/WAGON AND HARDTOP MODELS
Schematic/RHD Models for Europe

TEL131N

EL-4290

SUPER LOCK CONTROL UNIT/WAGON AND HARDTOP MODELS
Schematic/RHD Models for Europe (Cont’d)

TEL132N

EL-4291

UNIFIED METER CONTROL UNIT (TIME CONTROL SYSTEM)/WAGON AND
HARDTOP MODELS
Schematic/Except RHD Models for Europe and
With Theft Warning System Models

TEL133N

EL-4292

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Wiring Diagram — NATS —

TEL134N

EL-4293

NATS (Nissan Anti-Theft System)/TB48DE ENGINE MODELS FOR EUROPE
Wiring Diagram — NATS — (Cont’d)

TEL729M

EL-4294

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/LHD Models for
Europe

TEL135N

EL-4295

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/LHD Models for
Europe (Cont’d)

TEL136N

EL-4296

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/RHD Models for
Europe

TEL137N

EL-4297

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
Wiring Diagram — NATS —/RHD Models for
Europe (Cont’d)

TEL138N

EL-4298

NATS (Nissan Anti-Theft System)/ZD ENGINE MODELS
NOTE

EL-4299

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Engine Compartment

CEL449M

EL-4300

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Engine Compartment (Cont’d)

CEL579M

EL-4301

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — LHD Models

CEL580M

EL-4302

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — LHD Models
(Cont’d)

CEL581M

EL-4303

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — RHD Models

CEL582M

EL-4304

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — RHD Models
(Cont’d)

CEL583M

EL-4305

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
NOTE

EL-4306

HARNESS LAYOUT
How to Read Harness Layout
Example:
G2

B/6

: ASCD ACTUATOR

Connector color / Cavity
Connector number
Grid reference

The following Harness Layouts use a map style grid to help locate connectors on the drawings:
+ Main Harness
+ Engine Room Harness
+ Body Harness
To
1)
2)
3)
4)
5)

CONNECTOR SYMBOL
Main symbols of connector (in Harness Layout) are indicated in the below.
Water proof type

Standard type

Connector type
Male

Female

—

Male

+ Cavity: Less than 4
+ Relay connector
+ Cavity: From 5 to 8
+ Cavity: More than 9
+ Ground terminal etc.

—

EL-4307

Female

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models

TEL071V

EL-4308

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

TEL072V

EL-4309

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

TEL073V

EL-4310

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
NOTE

EL-4311

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models

TEL074V

EL-4312

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

TEL075V

EL-4313

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

TEL076V

EL-4314

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
NOTE

EL-4315

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models
GASOLINE ENGINE MODELS

TEL077V

EL-4316

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)

TEL078V

EL-4317

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)
DIESEL ENGINE MODELS

TEL079V

EL-4318

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)

TEL080V

EL-4319

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)
PASSENGER COMPARTMENT

TEL081V

EL-4320

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)

TEL082V

EL-4321

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models
GASOLINE ENGINE MODELS

TEL083V

EL-4322

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models (Cont’d)

TEL084V

EL-4323

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models (Cont’d)
DIESEL ENGINE MODELS

TEL085V

EL-4324

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models (Cont’d)

TEL086V

EL-4325

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models (Cont’d)
PASSENGER COMPARTMENT

TEL087V

EL-4326

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models (Cont’d)

TEL088V

EL-4327

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Harness
ZD ENGINE

TEL089V

EL-4328

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
NOTE

EL-4329

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/LHD Models
WAGON

TEL090V

EL-4330

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)

TEL091V

EL-4331

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)
HARDTOP

TEL092V

EL-4332

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)

TEL093V

EL-4333

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models
WAGON

TEL094V

EL-4334

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)

TEL095V

EL-4335

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)
HARDTOP

TEL096V

EL-4336

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)

TEL097V

EL-4337

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models
WAGON

TEL098V

EL-4338

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models (Cont’d)
HARDTOP

TEL099V

EL-4339

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/RHD Models
WAGON

TEL100V

EL-4340

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/RHD Models (Cont’d)
HARDTOP

TEL101V

EL-4341

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Chassis Harness

TEL102V

EL-4342

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
LHD MODELS

Front Door Harness (Driver side)

TEL103V

RHD MODELS

TEL104V

EL-4343

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
LHD MODELS

Front Door Harness (Passenger side)

TEL105V

RHD MODELS

TEL106V

EL-4344

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
LH SIDE

Rear Door Harness

TEL107V

RH SIDE

TEL108V

EL-4345

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Back Door Harness and Rear Window Defogger
Harness

TEL109V

EL-4346

Section

Wiring Diagram Name

Code

Section

Wiring Diagram Name

A/C, A

Auto Air Conditioner

R/HEAT

Rear Heater System

A/C, M

Manual Air Conditioner

REMOTE

Audio (Remote Control Switch)

A/CCUT

Air Conditioner Control

ROOM/L

Interior Room Lamp

A/T

S/LOCK

Power Door Lock — Super Lock

ASCD

Automatic Speed Control Device

S/TANK

Sub Fuel Tank Control System

AUDIO

Audio

SRS

Supplemental Restraint System

BACK/L

Back-up Lamp

STAB

Stabilizer Release Device

CD/CHG

CD Auto Changer

STOP/L

Stop Lamp

CHIME

Warning Chime

TAIL/L

Parking, License and Tail Lamps

COMPAS

Compass and Thermometer

THEFT

Theft Warning System

COOL/B

Cool Box

TRQ/SG

Engine Torque Control Signal

D/LOCK

Power Door Lock

TURN

DEF

Rear Window Defogger

Turn Signal and Hazard Warning
Lamps

DEICER

Wiper Deicer

VSS

Vehicle Speed Sensor

DTRL

Headlamp — Daytime Light System

WARN

Warning Lamps

F/FOG

Front Fog Lamp

WINDOW

Power Window

FICD

IACV-FICD Solenoid Valve

WIP/R

Rear Wiper and Washer

GLOW

Quick Glow System

WIPER

Front Wiper and Washer

H/AIM

Headlamp Aiming Control System

H/LAMP

Headlamp

HEATUP

Heat Up Switch

HLC

Headlamp Washer

HORN

Horn

HSEAT

Heated Seat

ILL

Illumination

LOAD

Electrical Load Signal

MAFS

Mass Air Flow Sensor

METER

Meter and Gauges

MIRROR

Door Mirror

MULTI

Multi-remote Control System

NATS

Nissan Anti-Theft System

NAVI

Navigation System

NONDTC

Non-detective Items

P/ANT

Power Antenna

PHONE

Telephone

POWER

Power Supply Routing

R/COOL

Rear Cooler System

R/FOG

Rear Fog Lamp

EL-4347

ENGINE MECHANICAL
SECTION

MODIFICATION NOTICE:
+

Valve lifter of ZD30DDTi engine has been changed from a type without shim to a type with adjusting shim.

CONTENTS
PREPARATION………………………………………………….4002
Special Service Tools ……………………………………..4002
ZD
CAMSHAFT ………………………………………………………4003
Removal and Installation …………………………………4003
Inspection………………………………………………………4003
VALVE CLEARANCE INSPECTIONS AND
ADJUSTMENTS…………………………………………………4005

Adjustments …………………………………………………..4005
TIMING GEAR …………………………………………………..4008
Removal and Installation …………………………………4008
Removal………………………………………………………..4009
Installation……………………………………………………..4012
CYLINDER HEAD………………………………………………4016
Disassembly and Assembly……………………………..4016
SERVICE DATA AND SPECIFICATIONS (SDS) ……4017
Valve …………………………………………………………….4017

EM-4001

PREPARATION
Special Service Tools
Tool number
Tool name

Description
Changing adjusting shims

KV101151S0
Lifter stopper set
j
1 KV10115110
Camshaft pliers
j
2 KV10115120
Lifter stopper

NT041

KV101056S0
Ring gear stopper
j
1 KV10105630
Adapter
j
2 KV10105610
Plate

Preventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)

NT617

KV10111100
Seal cutter

Removing gear case

NT046

WS39930000
Tube presser

Pressing the tube of liquid gasket

NT052

EM-4002

CAMSHAFT

Removal and Installation

SEM350GA

Inspection
VISUAL INSPECTION OF VALVE LIFTER AND
ADJUSTING SHIM
+
+
+

Check if surfaces of valve lifter and adjusting shim have any
wear or cracks.
Replace valve lifter or adjusting shim if necessary.
Select the thickness of adjusting shim so that valve clearance
is the standard when replacing. Refer to EM-4005, “Adjustments”.

SEM160D

VALVE LIFTER OUTER DIAMETER
Measure the outer diameter of the valve lifter with a micrometer.
Standard: 34.450 — 34.465 mm (1.3563 — 1.3569 in)

FEM018

EM-4003

CAMSHAFT
Inspection (Cont’d)

LIFTER GUIDE INNER DIAMETER
Measure the lifter guide inner diameter of the cylinder head with an
inside micrometer.
Standard: 34.495 — 34.515 mm (1.3581 — 1.3589 in)

PBIC0367E

VALVE LIFTER CLEARANCE CALCULATIONS
Clearance = Lifter guide inner diameter − Valve lifter outer diameter
Standard: 0.030 — 0.065 mm (0.0012 — 0.0026 in)
If it exceeds the standard value, refer to the outer diameter and
inner diameter standard values and replace valve lifter and/or cylinder head.

EM-4004

VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTS

Adjustments
NOTE:
Adjust valve clearance while engine is cold.
+ Remove the adjusting shim for parts which are outside the
specified valve clearance.
1. Remove the spill tube. Refer to “BASIC SERVICE PROCEDURE” in EC section.

2. Rotate the crankshaft to face the cam nose for adjusting shims
that are to be removed upward.
3. Thoroughly wipe off engine oil on the upper side of the cylinder
head (for the air gun used in step 7).
4. Move the round hole of the adjusting shim to the front with an
extra-fine screwdriver or like that.
CAUTION:
Perform (the above procedure) while camshaft do not contact
with adjusting shim.
PBIC0373E

FEM029A

5. Grip the camshaft with camshaft pliers (SST), then using the
camshaft as a support point, push the adjusting shim downward
to compress the valve spring.
CAUTION:
Do not damage the camshaft, cylinder head, and the outer circumference of the valve lifter.
6. With the valve spring in a compressed state, remove the camshaft pliers (SST) by securely setting the outer circumference
of the valve lifter with the end of the lifter stopper (SST).
+ Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as the camshaft
will be damaged.

7. Remove the adjusting shim from the valve lifter by blowing air
through the round hole of the adjusting shim with an air gun.
CAUTION:
+ When blowing, use goggles to protect your eye.
+ To prevent any remaining oil from being blown around,
thoroughly wipe the area clean.

PBIC0374E

EM-4005

VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTS
Adjustments (Cont’d)
8. Remove the adjusting shim by using a magnetic holder.

PBIC0375E

SEM145D

9. Measure the thickness of the adjusting shim using a micrometer.
+ Measure near the center of the shim (the part that touches the
camshaft).
10. Select the new adjusting shim from the following methods.
Calculation method of the adjusting shim thickness:
t = t1 + (C1 − C2)
t = Thickness of replacement adjusting shim
t1 = Thickness of removed adjusting shim
C1 = Measured valve clearance
C2 = Specified valve clearance
When engine is cold [Approximately 20°C (68°F)]
0.35 mm (0.014 in)

JEM184G

New adjusting shims have the thickness stamped on the rear
side.
Stamped

Shim thickness

2.35
2.40
.
.
.
3.05

2.35 (0.0925)
2.40 (0.0945)
.
.
.
3.05 (0.1201)

mm (in)

The thickness of the adjusting shim ranges from 2.35 to 3.05
mm (0.0925 to 0.1201 in), where in the space of 0.05 mm
(0.0020 in). There are 15 types of shims available.
11. Fit the selected adjusting shim to the valve lifter.
CAUTION:
Place the stamped side of the adjusting shim to the valve lifter.
+

EM-4006

VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTS
Adjustments (Cont’d)

12. Compress the valve spring using the camshaft pliers (SST) and
remove the lifter stopper (SST).

FEM029A

13. Rotate the crankshaft 2 to 3 times by hand.
14. Confirm that the valve clearance is within the specification.
Valve clearance:
When engine is cold [Approximately 20°C (68°F)]
Intake and exhaust
0.30 — 0.40 mm (0.012 — 0.016 in)
15. Install remaining parts in the reverse order of removal.

EM-4007

TIMING GEAR
Removal and Installation
2 idler gears are shown in this chapter. Idler gear (A) has scissors gear, and idler gear (B) does not.

SEM185HB

EM-4008

TIMING GEAR

Removal
1.
+
+
+
+
+
+
+
+
+

Remove the following parts.
Undercover
Engine oil (Drain)
Engine coolant (Drain)
Engine cover
Intercooler
Air inlet pipe
Air cleaner case
Throttle body
Swirl and intake air control valve control solenoid valve and
bracket
+ Vacuum tank
+ Glow plate
+ Rocker cover
+ Spill tube
+ Radiator shrouds (Rear and Lower)
+ Cooling fan
+ Radiator hose (Upper and Lower)
+ Auxiliary belt and auto tensioner.
2. Remove the alternator.
3. Remove the A/C compressor and bracket with piping connected. Move and support it at the LH side of engine bay with
a rope to avoid putting load on piping.
Refer to HA section in NISSAN Service Manual (Publication No.
SM9E-Y61CG2 or SM9E-Y61CG3).

4. Remove the chain cover, timing chain and other parts in connection.
Before removing timing chain, remove injection pump sprocket
with No. 1 cylinder being positioned at TDC. Refer to the figure. Refer to “TIMING CHAIN”, EM-37 in NISSAN Service
Manual (Publication No. SM9E-Y61CG2 or SM9E-Y61CG3).
CAUTION:
After removing timing chain, never rotate crankshaft, or the
piston will push the valve up and damage the valve.
+ Do not paint the match mark on the timing chain beforehand as
the No. 1 cylinder is set at the TDC during assembly.
SEM376G

5. Remove the TDC sensor.
CAUTION:
+ Do not drop or hit the sensor.
+ Store in a clean place free of iron filings, etc.
+ Do not place near any magnetic equipment.
6. Remove the water pump and its stud bolts.
Refer to “WATER PUMP” in LC section in NISSAN Service
Manual (Publication No. SM9E-Y61CG2 or SM9E-Y61CG3).
7. Remove the water inlet.

EM-4009

TIMING GEAR
Removal (Cont’d)

8. Remove the crankshaft pulley.
+ To fix the crankshaft, remove the starter motor, and set ring
gear stopper (SST).
CAUTION:
+ Do not damage or magnetize the signal detection protrusions of the crankshaft pulley.
+ After removing timing chain, never rotate crankshaft, or
the piston will push the valve up and damage the valve.

FEM051

9. Remove the gear case.
+ Using the grooved places shown in the figure, remove the gear
case by using a screwdriver and a seal cutter (SST).
10. Remove the front oil seal from the gear case by using a screwdriver.
CAUTION:
Do not damage the gear case.

FEM052

SEM377G

11. Fix the internal mechanism setting bolt [part No.: 81-20620-28,
screw dia.: M6, dimension below neck: 20 mm (0.79 in)] to the
bolt hole of the idler gear (A) and tighten to the specification.
: 2.5 — 3.4 Nzm (0.25 — 0.35 kg-m, 22 — 30 in-lb)
CAUTION:
+ Only use the genuine setting bolt, or the idler gear (A) will
be damaged.
+ Do not rotate the crankshaft as the head of the setting
bolts interferes with the gear case.
+ Do not remove the setting bolt from the idler gear (A) until
the timing chain and all of the parts in connection have
been installed.
+ If these bolts are not installed, internal mechanism will
disengage after the idler gear is removed. This will prohibit
the idler gear from being reusable.

12. Remove the idler gears (A) and (B).
+ Check the backlash of each gear before removing. Refer to
EM-52, “BACKLASH OF EACH GEAR”, “Inspection” in
NISSAN Service Manual (Publication No. SM9E-Y61CG2 or
SM9E-Y61CG3).
CAUTION:
+ Do not loosen the internal mechanism setting bolt of the
idler gear (A). (The idler gear cannot be reused when the
internal mechanism is released.)
+ During removal of the idler gears (A) and (B), do not face
the rear side downward as the idler shaft will drop.
SEM348G

EM-4010

TIMING GEAR
Removal (Cont’d)

13. Set the fuel injection timing gear with the pulley holder (SST).
14. Remove injection pump timing gear.

SEM378G

15. Extract the balancer shaft taking care not to damage the inner
bushes of the cylinder block.
16. Remove the fuel injection pump.
17. Remove the front plate.

SEM352G

EM-4011

TIMING GEAR

Installation

SEM206H

1. Install the front plate.
1) Install the O-ring and gasket to the cylinder block.
+ Apply liquid gasket uniformly and thinly to the front and reverse
sides of gasket.
Use Genuine Liquid Gasket or equivalent.
2) Install the front plate.
+ Before installing, apply liquid gasket to the mating surfaces of
the cylinder block and the oil pan (upper).
Use Genuine Liquid Gasket or equivalent.
+ Lightly tap with a hammer if the dowel pin cannot be inserted
easily.
CAUTION:
Make sure that the O-ring does not pop out.

SEM207H

2. Install the fuel injection pump.
+ After installing the front plate, align the 6 mm (0.24 in) dia. hole
of the pump flange and the 6 mm (0.24 in) dia. hole position of
the pump body.
3. Install each timing gear.
+ Align the match marks of the timing gears by referring to the
figure below.
+ When installing timing gear, follow the order (j
1 ,j
2 ) shown in
the dotted box in the figure below to facilitate installation.
FEM042

EM-4012

TIMING GEAR
Installation (Cont’d)

FEM043

FEM044

5. Install the gear case.
1) Before installing gear case, remove all traces of liquid gasket
from mating surface using a scraper.
2) Align gasket with dowel and install.

SEM353G

EM-4013

TIMING GEAR
Installation (Cont’d)

FEM045

3) Install the O-rings to the gear case.
+ The O-ring at the top position shown in the figure can be
installed in during cylinder head installation.
4) Apply a continuous bead of liquid gasket to the gear case and
the oil pan (upper).
+ Use Genuine Liquid Gasket or equivalent.
CAUTION:
Apply the liquid gasket around the bolt holes shown by the
arrows in the figure.
a. Coat of liquid gasket should be maintained within the
specified range as shown in the figure.
b. Attach gear case to cylinder block within 5 minutes after
coating.
c. Wait at least 30 minutes before refilling engine oil or starting engine.

SEM208H

5) Install the gear case.
+ Insert the gear case diagonally to prevent it from dragging over
the liquid gasket applied on the timing gear case and the oil pan
(upper).
+ Align the dowel pin at the lower position of cylinder block with
the hole on the gear case side.
+ Tap the area around the dowel pin with a plastic hammer if it
cannot be inserted easily.
CAUTION:
Do not pop out the O-rings.
SEM209H

FEM046

6. Install the crankshaft pulley.
+ Insert by aligning the 2 sides of the oil pump with the 2 sides
of the shaft on the rear side of the crankshaft pulley.
CAUTION:
Do not damage the oil seal lip when inserting.
+ Refer to EM-51, “Removal” in NISSAN Service Manual (Publication No. SM9E-Y61CG2 or SM9E-Y61CG3) for the crankshaft setting procedures when tightening the holding nut.
7. Install the water pump.
+ Install it before installing the TDC sensor. Refer to “Water
Pump” in LC section.

EM-4014

TIMING GEAR
Installation (Cont’d)

SEM349G

8. Install the TDC sensor.
+ Align the bracket knock pin with the hole on the gear case side
and tighten the holding bolt.
+ Confirm that the clearance between the end of the sensor and
the signal detection protrusion of the crankshaft pulley is within
the specification.
Standard: 1±0.8 mm (0.039±0.031 in)
+ Arrange the TDC sensor harness to the position shown in the
figure.
CAUTION:
Confirm that the harness has no deflection around the crankshaft pulley when installing the clamp.
9. Install the timing chain, other parts in connection with the timing chain, and the chain cover. Refer to EM-37, “TIMING
CHAIN” in NISSAN Service Manual (Publication No. SM9EY61CG2 or SM9E-Y61CG3).

10. Remove the internal mechanism setting bolt of the idler gear
(A).
11. Apply liquid gasket to the plug thread.
12. Install in the reverse order of removal.

FEM047

EM-4015

CYLINDER HEAD

Disassembly and Assembly

FEM081A

EM-4016

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve
VALVE CLEARANCE
Unit: mm (in)
Items

Cold*

Intake and exhaust

0.30 — 0.40 (0.012 — 0.016)

*: Approximately 20°C (68°F)

AVAILABLE SHIMS
Thickness mm (in)

Identification mark

2.35 (0.0925)

2.35

2.40 (0.0945)

2.40

2.45 (0.0965)

2.45

2.50 (0.0984)

2.50

2.55 (0.1004)

2.55

2.60 (0.1024)

2.60

2.65 (0.1043)

2.65

2.70 (0.1063)

2.70

2.75 (0.1083)

2.75

2.80 (0.1102)

2.80

2.85 (0.1122)

2.85

2.90 (0.1142)

2.90

2.95 (0.1161)

2.95

3.00 (0.1181)

3.00

3.05 (0.1201)

3.05

JEM184G

VALVE LIFTER
Unit: mm (in)
Valve lifter outer diameter

34.450 — 34.465 (1.3563 — 1.3569)

Lifter guide inner diameter

34.495 — 34.515 (1.3581 — 1.3589)

Clearance between lifter and lifter guide

0.030 — 0.065 (0.0012 — 0.0026)

EM-4017

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
SECTION

MODIFICATION NOTICE:
+

Wiring diagram of sub fuel tank control system has been modified.

CONTENTS
TROUBLE DIAGNOSES …………………………………….4002
Self-diagnosis for Sub Fuel Tank Control Module.4002
Circuit Diagram — S/TANK — …………………………4003

Wiring Diagram — S/TANK — …………………………4004
EXHAUST SYSTEM …………………………………………..4008

FE-4001

TERMINAL
NO.

ITEM

CONDITION

Wagon and
Hardtop
R

Power source

Ignition switch “ON”

DATA
(DC voltage)

Approximately 12V

Ignition switch “ON”
Sub fuel tank switch is “ON”.
Main fuel tank is not full.
Sub fuel tank is not empty.

G/B

Sub fuel pump

G/W

Power source

Ignition switch “ON” and “ACC”

Approximately 12V

Grounding

Any time

Approximately 0V

W/L

Sub fuel gauge

Ignition switch “ON”

Approximately 0 — 4V

Full switch

Approximately 12V

Ignition switch “ON”
Approximately 5V
Main fuel tank is not full.
7

Fuel gauge

Ignition switch “ON”

Approximately 0 — 2.5V

W/G

Engine running

Approximately 12V

G/B

Sub fuel tank switch

Ignition switch “ON”
Approximately 5V
Sub fuel tank switch is “OFF”.
Ignition switch “ON”
10

Indicator

Approximately 12V
Sub fuel tank switch is “OFF”.

Grounding

Any time

Approximately 0V

Power source

Any time

Approximately 12V

Ignition switch “ON”
13

W/R

Sub fuel tank warning lamp

Engine is not running.
Sub fuel tank control system is
in normal condition.

FE-4002

Approximately 0V

TROUBLE DIAGNOSES
Circuit Diagram — S/TANK —
WAGON AND HARDTOP MODELS

TFE061M

FE-4003

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK —
WAGON AND HARDTOP MODELS

TFE051M

FE-4004

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)
WAGON AND HARDTOP MODELS

TFE062M

FE-4005

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)
WAGON AND HARDTOP MODELS (LHD)

TFE063M

FE-4006

TROUBLE DIAGNOSES
Wiring Diagram — S/TANK — (Cont’d)
WAGON AND HARDTOP MODELS (RHD)

TFE064M

FE-4007

EXHAUST SYSTEM

SFE872A

FE-4008

SUPER MULTIPLE JUNCTION (SMJ)
LHD MODELS
Installation
To install SMJ, tighten bolts until orange “fulltight” mark appears
and then retighten to specified torque as required.
: 3 — 5 Nzm
(0.3 — 0.5 kg-m, 26 — 43 in-lb)
CAUTION:
Do not overtighten bolts, otherwise, they may be damaged.

CEL773

CEL789

CEL842

RHD MODELS
Installation
To install SMJ, tighten bolts until orange “fulltight” mark appears
and then retighten to specified torque as required.
: 3 — 5 Nzm
(0.3 — 0.5 kg-m, 26 — 43 in-lb)
CAUTION:
Do not overtighten bolts, otherwise, they may be damaged.

CEL841

EL-4348

SUPER MULTIPLE JUNCTION (SMJ)
Terminal Arrangement

CEL584M

EL-4349

FUSE AND FUSIBLE LINK BOX/WAGON AND HARDTOP MODELS
Terminal Arrangement

CEL585M

EL-4350

Edition: July 2004
Release: July 2004 (01)
Publication No.: SM4E00-1Y61E0E
Reference No.: 7711347233

QUICK REFERENCE INDEX

GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL

PATROL

ENGINE LUBRICATION &
COOLING SYSTEMS

MODEL Y61 SERIES

ENGINE CONTROL SYSTEM

ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEM

CLUTCH

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

TRANSFER

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

FRONT AXLE & FRONT SUSPENSION

REAR AXLE & REAR SUSPENSION

BRAKE SYSTEM

STEERING SYSTEM

RESTRAINT SYSTEM

BODY & TRIM

HEATER & AIR CONDITIONER

ELECTRICAL SYSTEM

ALPHABETICAL INDEX

IDX

NISSAN EUROPE S.A.S.
© 2004 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.

FOREWORD
This manual contains maintenance and repair procedures for NISSAN
PATROL, model Y61 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

GENERAL INFORMATION
SECTION

OUTLINE OF MODIFICATIONS:
+
+

Manual transmission gear ratio has been modified corresponding to the increase of ZD30DDTi engine
horsepower for Europe.
Navigation system has been adopted for Europe.

APPLIED FROM:

For Europe:
JN1TESY61U0140001
JN1KESY61U0140001
JN1TFSY61U0010001

Wagon and Hardtop models
For the Middle East:
JN8BY15Y*5X507001
JN6BY11Y*5X507001
JN8CY15Y*5X470001
JN6CY11Y*5X470001
JN8BY14Y*5X520001
JN8FY15Y*5X540001

For Israel:
JN1TESY61*5X806001
JN1KESY61*5X806001

CONTENTS
CONSULT-II CHECKING SYSTEM ………………………4002
Function and System Application ……………………..4002
Nickel Metal Hydride Battery Replacement………..4002
Checking Equipment……………………………………….4003
CONSULT-II Data Link Connector (DLC) Circuit ..4003

IDENTIFICATION INFORMATION………………………..4005
Model Variation ………………………………………………4005
Identification Number………………………………………4007
Dimensions ……………………………………………………4008
Wheels & Tires ………………………………………………4009

GI-4001

CONSULT-II CHECKING SYSTEM
Function and System Application
Diagnostic test mode

Function

ENGINE

A/T

ABS

AIR
BAG

NATS*1

SMART
ENTRANCE

x*2

x*4

—

Work support

This mode enables a technician to adjust
some devices faster and more accurate by
following the indications on CONSULT-II.

Self-diagnostic results

Self-diagnostic results can be read and
erased quickly.

—

Trouble diagnostic
record

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

—

ECU discriminated
No.

Classification number of a replacement ECU
can be read to prevent an incorrect ECU
from being installed.

—

Data monitor

Input/Output data in the ECU (ECM) can be
read.

—

DTC work support

This mode enables a technician to set operating conditions to confirm self-diagnosis
status/results.

—

Active test

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

—

ECU (ECM) part numECU (ECM) part number can be read.
ber
Control unit initialization

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

—

Self-function check

ECM checks its own NATS communication
interface.

—

x*3

—

DTC confirmation

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

x*2

—

A maximum of four IDs (identifications) can
REMO CONT ID SET be registered in the memory using the
remote controller. These IDs can be also be
UP
confirmed and erased as required.

—

x*5

—

Function test

Conducted by CONSULT-II instead of a
technician to determine whether each system is “OK” or “NG” (No Good).

x: Applicable
*1: NATS (Nissan Anti-Theft System)
*2: Not available for diesel engine models.
*3: Except for ZD30DDTi engine models.
*4: RE4R03A models only
*5: Right-hand drive models for Europe only.

Nickel Metal Hydride Battery Replacement

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

GI-4002

CONSULT-II CHECKING SYSTEM
Checking Equipment
When ordering the below equipment, contact your NISSAN distributor.
Tool name

Description

NISSAN CONSULT-II
j
1 CONSULT-II unit (Tester
internal software: Resident version 3.3.0) and
accessories
j
2 Program card AED01C
and AEN00A or AEN00B
(For NATS)
SGI100A

CONSULT-II Data Link Connector (DLC) Circuit
(For TD42Ti engine models and TD engine models with NATS)

TGI005M

GI-4003

CONSULT-II CHECKING SYSTEM
CONSULT-II Data Link Connector (DLC) Circuit
(Cont’d)
(For ECM equipped models except TD42Ti engine and TD engine with NATS)

TGI006M

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

Check item

CONSULT-II cannot access any
system.

+ CONSULT-II DLC power supply circuit (Terminal and ground circuit (Terminal 4)
(For detailed circuit, refer to EC section, “MIL & DATA LINK CONNECTORS”.)
+ CONSULT-II (DDL) cable

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

GI-4004

IDENTIFICATION INFORMATION
Model Variation
WAGON AND HARDTOP MODELS
Model

Rear seat arrangement
Destination

Steering
position

Hardtop

Station Wagon

2nd seat

2nd center split bench seat

Forward facing

Engine

Side facing or
Seatless

Front differential

3rd seat
Seatless

Forward facing

Side facing

H233B

Rear differential
Transmission

Transfer

S
GL

TB45E

FS5R50B

Middle
East

LHD

TX12A

TB48DE

RE5R05A

TD42

FS5R50B

FS5R50B
FS5R50B
RHD

FS5R50B

FS5R50B
ZD30DDTi

Europe

FS5R50B

—

TGNSLEFY61EKA

—

TGPSLEFY61EKQ

SGL

—

TGPSLEFY61EKA

—

SAFARI

—

TGPSLFFY61EKA

—

S-SAFARI

—

TGPSLHFY61EKA

—

TGPSLENY61EKQ

SGL

—

TGPSLENY61EKA

—

SAFARI

—

TGPSLFNY61EKA

—

S-SAFARI

—

TGPSLHNY61EKA

—

TVTSLAFY61NKQ

—

TVTSLEFY61NKQ

SGL

—

TVTSLEFY61NKA

—

KWSSREFY61UEA

—

TWSSREFY61UEA

—

KWSSRFFY61UEA

—

TWSSRFFY61UEA

—

KWSSRFAY61UEA

—

TWSSRFAY61UEA

—

TWSSRHFY61UEA

—

TWSSRHAY61UEA

—

KWSSLEFY61UGA KWSSLEFY61USP

—

TWSSLEFY61UGA

—

KWSSLFFY61UGA

—

TWSSLFFY61UGA

—
—

FS5R50B

RE5R05A

TGNSLEFY61EKQ

—

LHD

TB48DE

TGNSLAFY61EKQ

—

RE4R03A

—

KGNSLFFY61EKA

TX12A

—

SGL

RE4R03A

KGNSLAFY61EKA KGNSLAFY61EKQ
KGNSLEFY61EKA

SAFARI

RE4R03A

H233B/H260

Grade

—

TWSSLFFY61USA

KWSSLFAY61UGA

—

TWSSLFAY61UGA

—

TWSSLFAY61USA

—

TWSSLHFY61UGA

—

TWSSLHFY61USA

—

TWSSLHAY61UGA

—

TWSSLHAY61USA

—

TGPSLHNY61ESA

—

GI-4005

IDENTIFICATION INFORMATION
Model Variation (Cont’d)
PREFIX AND SUFFIX DESIGNATIONS
T

Y61

A
A: 3rd/2nd seat forward facing
Q: 3rd/2nd seat side facing
P: 3rd/2nd seat seatless

K: Middle East
E: RHD for Europe
G: Central/South Europe
S: North Europe
E: Multiport fuel injection system engine
N: Diesel engine
U: Turbocharger engine
F: 5-speed floor shift manual transmission
A: 4-speed floor shift automatic transmission
N: 5-speed floor shift automatic transmission
A: S, STD, DX E: GL (SGL), ST, S F: SGL, TI, SAFARI, SE
H: GRX, S-SAFARI, SE
L: LH drive R: RH drive
S: Long wheelbase
GN: TB45E engine VT: TD42 engine
WS: ZD30DDTi engine GP: TB48DE engine
T: Station Wagon
K: Hardtop

GI-4006

IDENTIFICATION INFORMATION
Identification Number
VEHICLE IDENTIFICATION NUMBER (Chassis number)
Prefix and suffix designations
For the Middle East

SGI993-R

For Europe (Except for Israel)
JN1

Y61

XXXXXX
Vehicle serial number

0: Stopgap (no meaning)
U: Europe
S: Long wheelbase (4WD)
Engine type
E: ZD30DDTi F: TB48DE
Body type
T: Station Wagon K: Hardtop
Manufacturer
JN1: Japan produced vehicle

GI-4007

IDENTIFICATION INFORMATION
Identification Number (Cont’d)
For Israel
JN1

Y61

XXXXXX
Vehicle serial number

Manufacturing plant
X: Hiratsuka
Model year
5: 2005 model year
S: Long wheelbase (4WD)
Engine type
E: ZD30DDTi
Body type
T: Station Wagon K: Hardtop
Manufacturer
JN1: Japan produced vehicle

Dimensions
FOR THE MIDDLE EAST
Wagon

Hardtop

Overall length*1

mm (in)

5,080 (200.0)*2, *5
5,030 (198.0)*3, *6
5,075 (199.8)*4, *7

4,460 (175.6)*3, *6
4,505 (177.4)*4, *7

Overall width

mm (in)

1,840 (72.4)*3
1,940 (76.4)*2, *4

1,840 (72.4)*3
1,940 (76.4)*4

Overall height

mm (in)

1,855 (73.0)

1,840 (72.4)

Front tread

mm (in)

1,555 (61.2)*3
1,605 (63.2)*2, *4

1,555 (61.2)*3
1,605 (63.2)*4

Rear tread

mm (in)

1,575 (62.0)*3
1,625 (64.0)*2, *4

1,575 (62.0)*3
1,625 (64.0)*4

Wheelbase

mm (in)

2,970 (116.9)

2,400 (94.5)

*1: With winch, 15 mm (0.59 in) is added to the overall length. With front spoiler, 30 mm (1.18
in) is added.
*2: 275/70R16, 275/65R17 tires
*3: 235/80R16, 235/80R16LT tires
*4: 265/70R16, 265/70R16LT tires
*5: 15 mm (0.59 in) is added with pintle hook, and 50 mm (1.97 in) is added with spare tire
cover.
*6: 100 mm (3.94 in) is added with spare tire cover.
*7: 20 mm (0.79 in) is added with pintle hook, and 55 mm (2.17 in) is added with spare tire
cover.

FOR EUROPE
Wagon

Hardtop

Overall length

mm (in)

5,145 (202.6)*1, *4
5,045 (198.6)*2
5,095 (200.6)*3

4,525 (178.1)*1, *4
4,475 (176.2)*2
4,620 (181.9)*3

Overall width

mm (in)

1,940 (76.4)*1, *3
1,840 (72.4)*2

Overall height

mm (in)

1,855 (73.0)

1,840 (72.4)

Front tread

mm (in)

1,605 (63.2)*1, *3
1,555 (61.2)*2

Rear tread

mm (in)

1,625 (64.0)*1, *3
1,575 (62.0)*2

Wheelbase

mm (in)

2,970 (116.9)

2,400 (94.5)

*1:
*2:
*3:
*4:

For models equipped with 275/65R17 tires
For models equipped with 235/80R16 tires
For models equipped with 265/70R16 tires
50 mm (1.97 in) is added with spare tire cover.

GI-4008

IDENTIFICATION INFORMATION
Wheels & Tires
FOR THE MIDDLE EAST
Road wheel
Size
Offset

16 x 6JJ

16 x 8JJ*

17 x 8JJ

35 (1.38)

10 (0.39)

235/80R16 109S,
235/80R16LT

265/70R16 112S,
275/70R16,
265/70R16LT

275/65R17

16 x 6JJ

16 x 8JJ*

17 x 8JJ

35 (1.38)

10 (0.39)

235/80R16 109S

265/70R16 112S

275/65R17 114H

mm (in)

Tire size

*: Steel or Aluminum wheel

FOR EUROPE
Road wheel
Size
Offset
Tire size

mm (in)

*: Steel or Aluminum wheel

GI-4009

HEATER &
AIR CONDITIONER
SECTION

MODIFICATION NOTICE:
+ Wiring diagram has been changed.
+ Automatic A/C controller has been changed.
+ Front thermo amp. for auto A/C has been eliminated.

CONTENTS
AUTO
DESCRIPTION …………………………………………………..4002
Features (TB48 Engine Models) ………………………4002
REAR HEATER
TROUBLE DIAGNOSES …………………………………….4003
Wiring Diagram — R/HEAT —/LHD Models ………4003
Wiring Diagram — R/HEAT —/RHD Models………4004

Mode Door Motor……………………………………………4035
Air Mix Door Motor …………………………………………4036
Intake Door Motor…………………………………………..4037
Blower Motor………………………………………………….4038
Magnet Clutch………………………………………………..4039
Insufficient Cooling …………………………………………4052
Insufficient Heating …………………………………………4053
Self-diagnosis ………………………………………………..4054
REAR COOLER

MANUAL
TROUBLE DIAGNOSES …………………………………….4005
Wiring Diagram — A/C, M —/Wagon and
Hardtop Models with ZD Engine ………………………4005
AUTO
DESCRIPTION …………………………………………………..4007
Control Operation …………………………………………..4007
TROUBLE DIAGNOSES …………………………………….4008
Circuit Diagram — A/C, A —/TB48 Engine ………..4008
Wiring Diagram — A/C, A —/TB48 Engine ………..4009
Circuit Diagram — A/C, A —/TB45 Engine ………..4013
Wiring Diagram — A/C, A —/TB45 Engine ………..4014
Circuit Diagram — A/C, A —/TD Engine ……………4017
Wiring Diagram — A/C, A —/TD Engine ……………4018
Circuit Diagram — A/C, A —/ZD Engine ……………4021
Wiring Diagram — A/C, A —/ZD Engine ……………4022
Self-diagnosis ………………………………………………..4025
Operational Check ………………………………………….4032
A/C System……………………………………………………4034

TROUBLE DIAGNOSES …………………………………….4055
Wiring Diagram — R/COOL —/LHD Models with
Front Auto A/C ……………………………………………….4055
Wiring Diagram — R/COOL —/LHD Models with
Front Manual A/C Except for TB45E Engine ……..4057
Wiring Diagram — R/COOL —/LHD Models with
Front Manual A/C for TB45E Engine…………………4059
Wiring Diagram — R/COOL —/RHD Models with
Front Auto A/C ……………………………………………….4061
Wiring Diagram — R/COOL —/RHD Models with
Front Manual A/C……………………………………………4063
COOL BOX
TROUBLE DIAGNOSES …………………………………….4065
Wiring Diagram — COOL/B —/All Engines
Except TB48 and TB45E Wagon Models for the
Middle East ……………………………………………………4065
Wiring Diagram — COOL/B —/TB48 and TB45E
Engine Wagon Models for the Middle East………..4066

HA-4001

DESCRIPTION

AUTO

Features (TB48 Engine Models)
CAN COMMUNICATION SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many
electronic control units are equipped onto a vehicle, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected with
2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only.

SYSTEM CONSTRUCTION
Magnet clutch control

RHA408I

When A/C switch is pressed, turn fan control dial to ON or set mode control dial to DEF position, A/C auto
amp. inputs compressor ON signal to ECM.
ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant pressure sensor signal, throttle angle, etc.).
When sending compressor ON signal to ECM from A/C auto amp., ECM simultaneously sends compressor
feedback signal to unified meter C/U via CAN communication line.
Unified meter control unit sends compressor feedback signal to A/C auto amp. Then, A/C auto amp. uses input
compressor feedback signal to control air inlet.

HA-4002

TROUBLE DIAGNOSES

REAR HEATER

Wiring Diagram — R/HEAT —/LHD Models

THA185M

HA-4003

TROUBLE DIAGNOSES

REAR HEATER

Wiring Diagram — R/HEAT —/RHD Models

THA186M

HA-4004

TROUBLE DIAGNOSES

MANUAL

Wiring Diagram — A/C, M —/Wagon and
Hardtop Models with ZD Engine

THA187M

HA-4005

MANUAL
TROUBLE DIAGNOSES
Wiring Diagram — A/C, M —/Wagon and
Hardtop Models with ZD Engine (Cont’d)

THA188M

HA-4006

DESCRIPTION

AUTO

Control Operation

RHA371I

MODE CONTROL DIAL
Controls the air discharge outlets.
Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.
When shifting mode control dial to DEF under the following conditions compressor is turned ON. (A/C LED
ON)
+ FAN: ON
+ A/C: OFF

TEMPERATURE CONTROL DIAL (POTENTIO TEMPERATURE CONTROL)
Increase or decrease the set temperature.

FAN CONTROL DIAL
Automatically or Manually control the blower speed. Twenty-five speeds are available for manual control.
Shifting fan control dial to AUTO, compressor is turned ON automatically.

INTAKE SWITCH
+
+
+
+
+

When intake switch is ON, REC LED turns ON, and air inlet is fixed to REC.
When press intake switch again, FRE LED turns ON, and air inlet is fixed to FRE.
When intake switch is pressed for approximately 1.5 seconds or longer, REC and FRE LEDs blink twice.
Then, automatic control mode is entered. Inlet status is displayed even during automatic control.
Automatic control mode is entered when REC and FRE LEDs are turned OFF.
When shifting mode control dial to DEF position, FRE LED is turned ON, or when compressor is turned
from ON to OFF, FRE indicator is automatically turned OFF (fixed to FRE mode).
REC mode can be re-entered by pressing intake switch again. (Except DEF position)

A/C SWITCH
The compressor is ON or OFF.
(Pressing the A/C switch when the fan control dial is ON will turn off the A/C switch and compressor.)

HA-4007

TROUBLE DIAGNOSES

AUTO

Circuit Diagram — A/C, A —/TB48 Engine

THA189M

HA-4008

TROUBLE DIAGNOSES

AUTO

Wiring Diagram — A/C, A —/TB48 Engine

THA190M

HA-4009

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TB48 Engine
(Cont’d)

THA191M

HA-4010

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TB48 Engine
(Cont’d)

THA192M

HA-4011

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TB48 Engine
(Cont’d)

THA193M

HA-4012

TROUBLE DIAGNOSES

AUTO

Circuit Diagram — A/C, A —/TB45 Engine

THA194M

HA-4013

TROUBLE DIAGNOSES

AUTO

Wiring Diagram — A/C, A —/TB45 Engine

THA195M

HA-4014

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TB45 Engine
(Cont’d)

THA196M

HA-4015

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TB45 Engine
(Cont’d)

THA197M

HA-4016

TROUBLE DIAGNOSES

AUTO

Circuit Diagram — A/C, A —/TD Engine

THA198M

HA-4017

TROUBLE DIAGNOSES

AUTO

Wiring Diagram — A/C, A —/TD Engine

THA199M

HA-4018

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TD Engine (Cont’d)

THA200M

HA-4019

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/TD Engine (Cont’d)

THA201M

HA-4020

TROUBLE DIAGNOSES

AUTO

Circuit Diagram — A/C, A —/ZD Engine

THA202M

HA-4021

TROUBLE DIAGNOSES

AUTO

Wiring Diagram — A/C, A —/ZD Engine

THA203M

HA-4022

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/ZD Engine (Cont’d)

THA204M

HA-4023

AUTO
TROUBLE DIAGNOSES
Wiring Diagram — A/C, A —/ZD Engine (Cont’d)

THA205M

HA-4024

TROUBLE DIAGNOSES

AUTO

Self-diagnosis
INTRODUCTION AND GENERAL DESCRIPTION
The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line.
Self-diagnosis is step-1 to 7. There are two ways of changing method during self-diagnosis.
+ Switching to self-diagnosis step-1 to 4.
Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning
the ignition switch from OFF to ON) and pressing A/C switch for at least 5 seconds. The A/C switch must
be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system will be
canceled by either pressing intake switch or turning the ignition switch OFF. Shifting from one step to
another is accomplished be means of turning fan control dial, as required.
+ Switching to self-diagnosis step-5 to 7 (Auxiliary mechanism).
Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning
the ignition switch from OFF to ON) and pressing intake switch for at least 5 seconds. The intake switch
must be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system
will be canceled by either pressing A/C switch or turning the ignition switch OFF. Shifting from one step
to another is accomplished by means of turning fan control dial, as required.

HA-4025

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)

AUTO

RJIA2106E

CAUTION:
This A/C system cannot perform the setup of the FOOT position (Self-diagnosis: STEP-6).
LED of A/C switch illuminates. It means that it is fixed to the initial setting.

HA-4026

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
STEP-BY-STEP PROCEDURE
Set mode control dial to AUTO.
.

Set temperature control dial to 25°C.
.

Set fan control dial to OFF.
RHA409I

Turn ignition switch ON.
.

Set in self-diagnostic mode. Within 10 seconds after starting engine (ignition switch is
turned “ON”.), press A/C switch for at least
5 seconds.

STEP 1 — LEDs ARE CHECKED.
Do all LEDs illuminate?

No
c

Yes

Malfunctioning A/C switch
or LED.
Replace A/C auto amp.

Set fan control dial to AUTO.
.

Advance to self-diagnosis STEP 2?

No
c

Yes

Malfunctioning fan control
dial.
Replace A/C auto amp.

Set fan control dial to OFF.
.

Return to self-diagnosis STEP 1?
Yes
.

Set fan control dial to AUTO.
.

j
A
(Go to next page.)

HA-4027

No
c

Malfunctioning fan control
dial.
Replace A/C auto amp.

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
j
A

STEP 2 — SENSOR CIRCUITS ARE
CHECKED FOR OPEN OR SHORT
CIRCUIT.
Does LED of A/C switch illuminate?

Yes
RJIA1480E
.

Set fan control dial
to 1 — 12th step.

.
B
j
(Go to next page.)

Refer to the following chart.
MODE
position

Malfunctioning sensor
(including circuits)

Reference
page

VENT

Ambient sensor

HA-125*

B/L

In-vehicle sensor

HA-127*

FOOT

Sunload sensor*1

HA-129*

D/F

Intake sensor

HA-132*

DEF

Air mix door motor
(LCU) PBR

HA-101*

*: Refer to Y61 SERVICE MANUAL, Publication
No. SM7E-2Y61G1.
*1: Conduct self-diagnosis STEP 2 under sunshine.
When conducting indoors, aim a light (more than
60W) at sunload sensor, otherwise LED of A/C
switch will indicate despite that sunload sensor is
functioning properly.

HA-4028

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
j
B

STEP 3 — MODE DOOR POSITIONS
ARE CHECKED.
Does LED of A/C switch illuminate?

Yes
RHA372I

Set fan control dial
to 13 — 25th step.

Mode door motor is malfunctioning.
Result

j
C
(Go to next page.)

HA-4029

LED status

Mode door motor operates in good order

A/C: ON

Mode door motor is
malfunctioning

REC: ON

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
j
C
.

STEP 4 — OPERATION OF EACH ACTUATOR IS CHECKED.
Engine running.

Actuator test pattern
Mode door

Intake
door

Air mix
door

Blower
motor

Compressor

REC

Full
Cold

4 — 5V

REC

Full
Cold

9 — 11V

REC

Full
Cold

7 — 9V

OFF

FRE

Full
Hot

7 — 9V

OFF

FRE

Full
Hot

7 — 9V

FRE

Full
Hot

10 12V

VENT
AUTO

RHA654FF
VENT
VENT

B/L
B/L

FOOT
FOOT

D/F
D/F

DEF
DEF

OK
.

Turn ignition switch OFF or press intake
switch.

END

HA-4030

NG
c

+ Air outlet does not
change.
Go to HA-4035.
+ Intake door does not
change.
Go to HA-4037.
+ Discharge air temperature does not change.
Go to HA-4036.
+ Magnet clutch does not
engage.
Go to HA-4039.
+ Blower motor operation is
malfunctioning.
Go to HA-4038.

AUTO

TROUBLE DIAGNOSES
Self-diagnosis (Cont’d)
AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER

The trimmer compensates for differences in range of ±3°C between temperature setting (Temperature control
dial position) and temperature felt by driver.
Operating procedures for this trimmer are as follows:
1. Set temperature at 25°C.
2. Set fan control dial to OFF.
3. Turn ignition switch ON.
4. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press intake switch for at least 5 seconds.
5. Turn temperature control dial as desired. Temperature will change at a rate of 1°C each time a dial is
turned.
LED status of each switch
Setting temperature
FRE

REC

A/C

−3°C

−2°C

OFF

−1°C

OFF

0°C (Initial setting)

OFF

1°C

OFF

2°C

OFF

3°C

OFF

When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial
condition, i.e. 0°C.

AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER
CAUTION:
This A/C system cannot perform the setup of the FOOT position.
LED of A/C switch illuminates. It means that it is fixed to the initial setting.

AUXILIARY MECHANISM: INLET PORT MEMORY FUNCTION
When ignition switch is turned from OFF to ON, inlet port can be set to AUTO or manual.
Operating procedures for this trimmer are as follows:
1. Set fan control dial to 1st — 25th step.
2. Turn ignition switch ON.
3. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press intake switch for at least 5 seconds.
4. Press intake switch as desired.
LED status of intake switch

Setting status

FRE

REC

FRE

OFF

Manual REC status is
AUTO control (Initial setmemorized.
ting)
(Initial setting)

OFF

Manual FRE status is
memorized.

AUTO control

Manual FRE status is
memorized.

Manual REC status is
memorized.

OFF

AUTO control

HA-4031

REC

Setting changeover
method

Intake switch: ON

TROUBLE DIAGNOSES

AUTO

Operational Check
The purpose of the operational check is to confirm that the system
is as it should be. The systems which will be checked are the
blower, mode (discharge air), intake air, temperature decrease,
temperature increase and A/C switch.

CONDITIONS:
+

Engine running and at normal operating temperature.

PROCEDURE:
1. Check blower
1) Turn fan control dial to 1st speed. Blower should operate at low
speed.
2) Turn fan control dial to 2nd speed, and continue checking
blower speed until all speeds are checked.
3) Leave blower on MAX speed.

RHA373I

2. Check discharge air
1) Turn mode control dial to each position.

RHA374I

2) Confirm that discharge air comes out according to the air distribution table at left.
Refer to “Discharge Air Flow”, “DESCRIPTION” (HA-14) in Y61
SERVICE MANUAL, Publication No. SM7E-2Y61G1.
NOTE:
Confirm that the compressor clutch is engaged (sound or
visual inspection) and intake door position is at FRESH when
the DEF position is selected.
Intake door position is checked in the next step.

RHA654FF

HA-4032

TROUBLE DIAGNOSES
Operational Check (Cont’d)

AUTO

3. Check intake door
1) Press intake switch. Recirculation indicator should illuminate.
2) Press intake switch again. Fresh indicator should illuminate.
3) Listen for intake door position change (you should hear blower
sound change slightly).

RHA375I

4. Check temperature decrease
1) Turn temperature control dial until 18°C.
2) Check for cold air at discharge air outlets.

RHA376I

5. Check temperature increase
1) Turn temperature control dial until 32°C.
2) Check for hot air at discharge air outlets.

RHA377I

6. Check A/C switch
1) Turn fan control dial to AUTO position.
2) Press A/C switch. (LED will turn ON.)
Confirm that the compressor clutch engages (sound or visual
inspection).
(Discharge air and suction air will depend on ambient, in-vehicle and set temperatures.)

RHA378I

HA-4033

TROUBLE DIAGNOSES

AUTO

A/C System
TROUBLE DIAGNOSIS PROCEDURE FOR A/C SYSTEM
SYMPTOM:
+ A/C system does not come on.

Inspection flow

RHA379I

*1: HA-96 in Y61 SERVICE MANUAL,
Publication No. SM7E-2Y61G1

*2: HA-4032

HA-4034

AUTO

TROUBLE DIAGNOSES
Mode Door Motor
TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR MOTOR (LAN)
SYMPTOM:
+ Air outlet does not change.
+ Mode door motor does not operate normally.

Inspection flow

RHA380I

*1:
*2:
*3:
*4:
*5:

HA-14*
HA-4032
HA-4027
HA-4028
HA-4029

*6: HA-4030
*7: HA-125*
*8: HA-127*
*9: HA-129*
*10: HA-132*

*: Refer to Y61 SERVICE MANUAL, Publication No. SM7E-2Y61G1.

HA-4035

*11: HA-101*
*12: HA-87*
*13: HA-99*
*14: HA-91*

AUTO

TROUBLE DIAGNOSES
Air Mix Door Motor
TROUBLE DIAGNOSIS PROCEDURE FOR AIR MIX DOOR (LAN)
SYMPTOM:
+ Discharge air temperature does not change.
+ Air mix door motor does not operate.

Inspection flow

RHA381I

*5: HA-127*
*1: HA-4027
*6: HA-129*
*2: HA-4028
*7: HA-132*
*3: HA-4027 see STEP 4
*8: HA-101*
*4: HA-125*
*: Refer to Y61 SERVICE MANUAL, Publication No. SM7E-2Y61G1.

HA-4036

*9: HA-91*
*10: HA-100*
*11: HA-103*
*12: HA-4032

AUTO

TROUBLE DIAGNOSES
Intake Door Motor
TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR
SYMPTOM:
+ Intake door does not change.
+ Intake door motor does not operate normally.

Inspection flow

RHA382I

*1:
*2:
*3:
*4:

HA-4027
HA-4028
HA-4027 see STEP 4
HA-125*

*5:
*6:
*7:
*8:

*9: HA-107*
*10: HA-106*
*11: HA-4032
*12: HA-91*

HA-127*
HA-129*
HA-132*
HA-101*

*: Refer to Y61 SERVICE MANUAL, Publication No. SM7E-2Y61G1.

HA-4037

AUTO

Inspection flow

RHA383I

*1:
*2:
*3:
*4:

HA-4027
HA-4028
HA-4030
HA-111*

*8: HA-132*
*9: HA-91*
*10: HA-4032

*5: HA-125*
*6: HA-127*
*7: HA-129*

*: Refer to Y61 SERVICE MANUAL, Publication No. SM7E-2Y61G1.

HA-4038

TROUBLE DIAGNOSES

AUTO

Magnet Clutch
TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH
SYMPTOM:
+ Magnet clutch does not engage.

Inspection flow

RHA384I

*1:
*2:
*3:
*4:

HA-4027
HA-4027 see STEP 2
HA-4027 see STEP 4
HA-4040: TB48 engine
HA-4043: TB45 engine
HA-4046: TD engine
HA-4049: ZD engine

*5: HA-125 in Y61 SERVICE MANUAL,
publication No. SM7E-2Y61G1
*6: HA-132 in Y61 SERVICE MANUAL,
publication No. SM7E-2Y61G1
*7: HA-4032
*8: HA-91 in Y61 SERVICE MANUAL,
publication No. SM7E-2Y61G1

HA-4039

*9: HA-43 in Y61 SERVICE MANUAL,
publication No. SM7E-2Y61G1

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)

DIAGNOSTIC PROCEDURE (TB48 ENGINE EXCEPT
FOR THE MIDDLE EAST)
SYMPTOM: Magnet clutch does not engage when A/C switch
and fan control dial are ON.
CHECK INTAKE SENSOR CIRCUIT.
Refer to self-diagnosis (HA-4027) and
intake sensor circuit (HA-132 in Y61 SERVICE MANUAL, publication No. SM7E2Y61G1.)

Yes

CHECK POWER SUPPLY FOR COMPRESSOR.
Disconnect compressor harness connector.
Do approx. 12 volts exist between compressor harness connector terminal No. j
1 and
ground?

Check magnet clutch coil.
.

Replace magnet clutch.
Refer to HA-178 in Y61
SERVICE MANUAL (publication No. SM7E-2Y61G1).

No
.

Disconnect A/C relay.
Note

.
RHA385I

CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS CONNECTOR TERMINAL NO. j
3 AND COMPRESSOR HARNESS CONNECTOR TERMINAL NO. j
1 .
Continuity should exist.
If OK, check harness for short.
OK
.

SHA579F

CHECK POWER SUPPLY FOR A/C
RELAY.
Disconnect A/C relay.
Do approx. 12 volts exist between A/C
relay harness connector terminal Nos. j
1 ,
j
5 and ground?

No
c

Yes
.

CHECK A/C RELAY AFTER DISCONNECTING IT.
Refer to HA-41 in Y61 SERVICE MANUAL,
publication No. SM1E-Y61EG1.

Check power supply circuit
and 10A or 20A (No.
)
located in the fuse block
(J/B).
Refer to EL section (“Wiring
Diagram”, “POWER SUPPLY ROUTING”).

NG
c

Replace A/C relay.

. OK

j
A
(Go to next page.)
SHA580FC

Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

SHA581F

HA-4040

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
A
.

Reconnect A/C relay.
.

SHA582FB

CHECK COIL SIDE CIRCUIT OF A/C
RELAY.
Do approx. 12 volts exist between ECM
harness connector terminal No. j
24 and
ground?
Yes

Yes

M/T models . A/T models
j
B
(Go to next page.)

CHECK VOLTAGE FOR ECM.
Do approx. 12 volts exist between ECM
harness connector terminal No. j
86 and
ground?

Note

CHECK CIRCUIT CONTINUITY BETWEEN A/C
RELAY HARNESS CONNECTOR TERMINAL NO.
j
2 AND ECM HARNESS
CONNECTOR TERMINAL
NO. j
24 .
Continuity should exist.
If OK, check harness for
short.

SHA583F

Disconnect A/C relay.
Disconnect ECM harness
connector.

No
c

CHECK ECM. Refer to EC
section.

Yes

Disconnect ECM harness connector.
Disconnect auto amp. harness connector.
SHA584FB

Note

CHECK CIRCUIT CONTINUITY
BETWEEN ECM HARNESS CONNECTOR TERMINAL NO. j
86 AND AUTO AMP.
HARNESS CONNECTOR TERMINAL NO.
j
4 .
Continuity should exist.
If OK, check harness for short.
.
RHA386I

CHECK REFRIGERANT PRESSURE
SENSOR.
Refer to EC-498 (publication No.
SM2E-Y61FG1).
.

NG
c

Replace refrigerant pressure sensor.

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-4041

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
B

Note

CHECK VOLTAGE FOR COMBINATION
METER. (COMPRESSOR ON SIGNAL)
Do approx. 12V exist between combination meter harness connector terminal No.
j
42 and ground?

Yes
SHA693FA

CHECK CIRCUIT CONTIc
NUITY BETWEEN COMBINATION METER HARNESS CONNECTOR TERMINAL NO. j
42 AND ECM
HARNESS CONNECTOR
86 .
TERMINAL NO. j
Continuity should exist.
If OK, check harness for
short.
.

Replace ECM.
.

SHA694F

CHECK VOLTAGE FOR COMBINATION
METER. (FAN ON SIGNAL)
Do approx. 12V exist between combination meter harness connector terminal No.
j
43 and ground?
.

No
c

Replace combination
meter.

Replace refrigerant pressure sensor.

Yes

Disconnect combination meter and auto
amp. harness connector.

Note

RHA387I

CHECK CIRCUIT CONTINUITY
BETWEEN COMBINATION METER HARNESS CONNECTOR TERMINAL NO. j
43
AND AUTO AMP. HARNESS CONNECTOR TERMINAL NO. j
19 .
Continuity should exist.
If OK, check harness for short.
.

CHECK REFRIGERANT PRESSURE
SENSOR.
Refer to EC-498 (publication No. SM2EY61FG1).
.

Replace auto amp.

SHA697F

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-4042

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)

DIAGNOSTIC PROCEDURE (MODELS WITH TB45
ENGINE)
SYMPTOM: Magnet clutch does not engage when A/C switch
and fan control dial are ON.
Yes
CHECK POWER SUPPLY FOR COMPRESSOR.
Disconnect compressor harness connector.
Do approx. 12 volts exist between compressor harness connector terminal No. j
1 and
ground?

Check magnet clutch coil.
.

Replace magnet clutch.
Refer to HA-178 in Y61
SERVICE MANUAL, publication No. SM7E-2Y61G1.

No
.

Disconnect A/C relay.
Note

CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS CONNECTOR TERMINAL NO. j
3 AND COMPRESSOR HARNESS CONNECTOR TERMINAL NO. j
1 .
Continuity should exist.
If OK, check harness for short.
RHA388I

OK
.

CHECK POWER SUPPLY FOR A/C
RELAY.
Disconnect A/C relay.
Do approx. 12 volts exist between A/C
relay harness connector terminal Nos. j
1 ,
j
5 and ground?

No
c

Yes
.

RHA096GG

CHECK A/C RELAY AFTER DISCONNECTING IT.
Refer to HA-22 in Y61 SERVICE MANUAL,
publication No. SM1E-Y61EG1.

Check power supply circuit
and 10A or 20A (No.
)
located in the fuse block
(J/B).
Refer to EL section (“Wiring
Diagram”, “POWER SUPPLY ROUTING”).

NG
c

Replace A/C relay.

. OK

j
A
(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

SHA580FA

SHA581F

HA-4043

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
A
.

Reconnect A/C relay.

RHA655GC

CHECK COIL SIDE CIRCUIT OF A/C
RELAY.
Do approx. 12 volts exist between ECM
harness connector terminal No. j
9 and
ground?

Yes

RHA389I

Disconnect A/C relay.
Disconnect ECM harness
connector.

Note

CHECK CIRCUIT CONTINUITY BETWEEN A/C
RELAY HARNESS CONNECTOR TERMINAL NO.
j
2 AND ECM HARNESS
CONNECTOR TERMINAL
NO. j
9 .
Continuity should exist.
If OK, check harness for
short.

CHECK VOLTAGE FOR ECM.
Do approx. 12 volts exist between ECM
harness connector terminal No. j
46 and
ground?

No
c

CHECK ECM. Refer to EC
section.

Yes
.

Disconnect ECM harness connector.
Disconnect dual-pressure switch harness
connector.

RHA657GC

Note

CHECK CIRCUIT CONTINUITY
BETWEEN ECM HARNESS CONNECTOR TERMINAL NO. j
46 AND DUALPRESSURE SWITCH HARNESS CONNECTOR TERMINAL NO. j
2 .
Continuity should exist.
If OK, check harness for short.
OK
.

RHA390I

CHECK DUAL-PRESSURE SWITCH.
Refer to HA-119 in Y61 SERVICE
MANUAL, publication No. SM7E-2Y61G1.
.

NG
c

Replace dual-pressure
switch.

j
B
(Go to next page.)

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-4044

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)

AUTO

j
B

Note

Check circuit continuity between dual-pressure switch harness connector terminal No.
j
1 and auto amp. harness connector terminal No. j
4 .
Continuity should exist.
If OK, check harness for short.
RHA227IA

OK
.

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-4045

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
DIAGNOSTIC PROCEDURE (MODELS WITH TD
ENGINE)

SYMPTOM: Magnet clutch does not engage when A/C switch
and fan control dial are ON.
CHECK POWER SUPPLY FOR COMPRESSOR.
Disconnect compressor harness connector.
Do approx. 12 volts exist between compressor harness terminal No. j
1 and
ground?

Yes
c

Check magnet clutch coil.
NG
.

Replace magnet clutch.
Refer to HA-178 in Y61
SERVICE MANUAL, publication No. SM7E-2Y61G1.

No
.

Disconnect A/C cut relay.

Note

RHA392I

CHECK CIRCUIT CONTINUITY
BETWEEN A/C CUT RELAY HARNESS
CONNECTOR TERMINAL NO. j
3 AND
COMPRESSOR HARNESS CONNECTOR
TERMINAL NO. j
1 .
Continuity should exist.
If OK, check harness for short.
OK
.

CHECK A/C CUT RELAY.
Refer to HA-4051.

Replace A/C cut relay.

OK
Note

SHA579F

CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS CONNECTOR TERMINAL NO. j
7 AND A/C
CUT RELAY HARNESS CONNECTOR
4 .
TERMINAL NO. j
Continuity should exist.
If OK, check harness for short.
.

j
A
(Go to next page.)

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.
SHA580F

RHA393I

HA-4046

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
A
Note

CHECK CIRCUIT CONTINUITY
BETWEEN A/C CUT RELAY HARNESS
CONNECTOR TERMINAL NO. j
1 AND
GROUND.
OK
RHA394I

Note

CHECK CIRCUIT CONTINUITY
BETWEEN A/C CUT RELAY HARNESS
CONNECTOR TERMINAL NO. j
2 AND
ENGINE COOLANT TEMPERATURE
SWITCH-2 HARNESS CONNECTOR
TERMINAL NO. j
2 .
OK
.

CHECK ENGINE COOLANT TEMPERATURE SWITCH-2.
Refer to HA-4051.

NG
c

Replace engine coolant
temperature switch-2.

Check power supply circuit
and 10A or 20A (No. 6 )
located in the fuse block
(J/B).
Refer to EL section (“Wiring Diagram”, “POWER
SUPPLY ROUTING”).

OK
RHA395I
.

CHECK POWER SUPPLY FOR ENGINE
COOLANT TEMPERATURE SWITCH-2.
Do approx. 12 volts exist between engine
coolant temperature switch-2 harness connector terminal No. j
1 and ground?

Yes

m
.

RHA396I

CHECK POWER SUPPLY FOR A/C
RELAY.
Do approx. 12 volts exist between A/C
relay harness connector terminal Nos. j
1 ,
j
6 and ground?

Yes
Note

CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS CONNECTOR TERMINAL NO. j
2 AND DUALPRESSURE SWITCH HARNESS CONNECTOR TERMINAL NO. j
2 .
Continuity should exist.
If OK, check harness for short.
RHA397I

j
B
(Go to next page.)

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

RHA398I

HA-4047

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
B
.

CHECK DUAL-PRESSURE SWITCH.
Refer to HA-119 in Y61 SERVICE
MANUAL, publication No. SM7E-2Y61G1.

NG
c

Replace dual-pressure
switch.

OK
Note

RHA227IA

CHECK CIRCUIT CONTINUITY
BETWEEN DUAL-PRESSURE SWITCH
HARNESS CONNECTOR TERMINAL NO.
j
1 AND AUTO AMP. HARNESS CONNECTOR TERMINAL NO. j
4 .
Continuity should exist.
If OK, check harness for short.
OK
.

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-4048

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
DIAGNOSTIC PROCEDURE (MODELS WITH ZD
ENGINE)

SYMPTOM: Magnet clutch does not engage when A/C switch
and fan control dial are ON.
Yes
CHECK POWER SUPPLY FOR COMPRESSOR.
Disconnect compressor harness connector.
Do approx. 12 volts exist between compressor harness connector terminal No. j
1 and
ground?

Check magnet clutch coil.
.

Replace magnet clutch.
Refer to HA-178 in Y61
SERVICE MANUAL, publication No. SM7E-2Y61G1.

No
.

Disconnect A/C relay.
Note

CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS CONNECTOR TERMINAL NO. j
7 AND COMPRESSOR HARNESS CONNECTOR TERMINAL NO. j
1 .
Continuity should exist.
If OK, check harness for short.
RHA399I

OK
.

CHECK POWER SUPPLY FOR A/C
RELAY.
Disconnect A/C relay.
Do approx. 12 volts exist between A/C
relay harness connector terminal Nos. j
1 ,
j
6 and ground?

No
c

Yes
.

SHA579F

CHECK A/C RELAY AFTER DISCONNECTING IT.
Refer to HA-119 in Y61 SERVICE
MANUAL, publication No. SM7E-2Y61G1.

Check power supply circuit
and 10A or 20A (No.
)
located in the fuse block
(J/B).
Refer to EL section (“Wiring
Diagram”, “POWER SUPPLY ROUTING”).

NG
c

Replace A/C relay.

. OK

j
A
(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.

RHA653GA

RHA654G

HA-4049

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
A
.

Reconnect A/C relay.

RHA400I

CHECK COIL SIDE CIRCUIT OF A/C
RELAY.
Do approx. 12 volts exist between ECM
harness connector terminal No. j
15 and
ground?

Yes

RHA401I

Disconnect A/C relay.
Disconnect ECM harness
connector.

Note

CHECK CIRCUIT CONTINUITY BETWEEN A/C
RELAY HARNESS CONNECTOR TERMINAL NO.
j
2 AND ECM HARNESS
CONNECTOR TERMINAL
NO. j
15 .
Continuity should exist.
If OK, check harness for
short.

CHECK VOLTAGE FOR ECM.
Do approx. 12 volts exist between ECM
harness connector terminal No. j
21 and
ground?

No
c

CHECK ECM. Refer to EC
section.

Yes
.

Disconnect ECM harness connector.
Disconnect dual-pressure switch harness
connector.

RHA402I

Note

CHECK CIRCUIT CONTINUITY
BETWEEN ECM HARNESS CONNECTOR TERMINAL NO. j
21 AND DUALPRESSURE SWITCH HARNESS CONNECTOR TERMINAL NO. j
2 .
Continuity should exist.
If OK, check harness for short.
OK
.

RHA403I

CHECK DUAL-PRESSURE SWITCH.
Refer to HA-119 in Y61 SERVICE
MANUAL, publication No. SM7E-2Y61G1.
.

NG
c

Replace dual-pressure
switch.

j
B

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

HA-4050

AUTO

TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
j
B

Note

Yes
.

Replace auto amp.

Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector.

COMPONENT INSPECTION
A/C cut relay (TD engine models)
Check continuity between terminal Nos. j
4 and j
3 .
Conditions

Continuity

12V direct current supply between
terminal Nos. j
2 and j
1

No current supply

Yes

If NG, replace relay.
RHA404I

Engine coolant temperature switch-2 (TD engine
models)
Check engine coolant temperature switch-2 for proper operation.
Operating temperature °C (°F)

Operation

Increasing to 87 — 93 (189 — 199)

OFF → ON

Decreasing to 82 — 84 (180 — 183)

ON → OFF

OFF: Continuity does not exist.
ON: Continuity exists.

HA-4051

AUTO

TROUBLE DIAGNOSES
Insufficient Cooling
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING
SYMPTOM:
+ Insufficient cooling.

Inspection flow

RHA405I

*1:
*2:
*3:
*4:

HA-4032
HA-4027
HA-4028
HA-4030

*5:
*6:
*7:
*8:

*9: HA-111*
*10: HA-4039
*11: HA-41*

HA-101*
HA-41*
HA-4031
HA-100*

*: Refer to Y61 SERVICE MANUAL, Publication No. SM7E-2Y61G1.

HA-4052

AUTO

TROUBLE DIAGNOSES
Insufficient Heating
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING
SYMPTOM:
+ Insufficient heating.

Inspection flow

RHA406I

*1: HA-4032
*2: HA-4027
*3: HA-4028

*4: HA-4030
*5: HA-100*

*6: HA-111*
*7: HA-4036

*: Refer to Y61 SERVICE MANUAL, Publication No. SM7E-2Y61G1.

HA-4053

TROUBLE DIAGNOSES

AUTO

Self-diagnosis
TROUBLE DIAGNOSIS PROCEDURE FOR SELF-DIAGNOSIS
SYMPTOM:
+ Self-diagnosis cannot be performed.

Inspection flow

RHA407I

*1: HA-4032

*2: HA-96 in Y61 SERVICE MANUAL,
Publication No. SM7E-2Y61G1

HA-4054

*3: HA-91 in Y61 SERVICE MANUAL,
Publication No. SM7E-2Y61G1

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/LHD Models with
Front Auto A/C

THA206M

HA-4055

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/LHD Models with
Front Auto A/C (Cont’d)

THA207M

HA-4056

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/LHD Models with
Front Manual A/C Except for TB45E Engine

THA208M

HA-4057

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/LHD Models with
Front Manual A/C Except for TB45E Engine
(Cont’d)

THA209M

HA-4058

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/LHD Models with
Front Manual A/C for TB45E Engine

THA210M

HA-4059

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/LHD Models with
Front Manual A/C for TB45E Engine (Cont’d)

THA211M

HA-4060

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/RHD Models with
Front Auto A/C

THA212M

HA-4061

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/RHD Models with
Front Auto A/C (Cont’d)

THA213M

HA-4062

TROUBLE DIAGNOSES

REAR COOLER

Wiring Diagram — R/COOL —/RHD Models with
Front Manual A/C

THA214M

HA-4063

REAR COOLER
TROUBLE DIAGNOSES
Wiring Diagram — R/COOL —/RHD Models with
Front Manual A/C (Cont’d)

THA215M

HA-4064

TROUBLE DIAGNOSES

COOLBOX

Wiring Diagram — COOL/B —/All Engines
Except TB48 and TB45E Wagon Models for the
Middle East

THA216M

HA-4065

TROUBLE DIAGNOSES

COOLBOX

Wiring Diagram — COOL/B —/TB48 and TB45E
Engine Wagon Models for the Middle East

THA217M

HA-4066

ALPHABETICAL INDEX
SECTION

IDX-4001

IDX

ALPHABETICAL INDEX
Dome light — See Interior lamp ……………….EL-4088
DTRL — Wiring diagram ………………………….EL-4047

A
A/C operational check …………………………..HA-4032
A/C self-diagnoses (auto A/C)………………..HA-4025
A/C, A — Wiring diagram ………………………..HA-4009
A/CCUT — Wiring diagram ……………………..EC-4058
Air cleaner filter replacement…………………MA-4003
Air flow meter — See Mass air flow
sensor ……………………………………………..EC-4047
Air mix. door motor……………………………….HA-4036
Antenna……………………………………………….EL-4164
ASCD (automatic speed control
device)……………………………………………..EL-4233
ASCD — Wiring diagram …………………………EL-4234
A/T — Wiring diagram ……………………………..AT-4003
A/T trouble diagnoses ……………………………AT-4011
A/T Wiring diagram AT — NONDTC ………….AT-4012
Audio …………………………………………………..EL-4136
AUDIO — Wiring diagram………………………..EL-4137
Audio and A/C control removal and
installation — See Instrument panel ………BT-4006
Auto air conditioner — Wiring diagram ……..HA-4009
Automatic speed control system — See
ASCD ………………………………………………EL-4233
AV and NAVI control unit ……………………….EL-4164
B
Back-up lamp ……………………………………….EL-4055
BACK/L — Wiring diagram……………………….EL-4055
Blower motor ……………………………………….HA-4038
Bumper, front ……………………………………….BT-4002
Bumper, rear ………………………………………..BT-4005
C
Camshaft…………………………………………….EM-4003
CHIME — Wiring diagram………………………..EL-4113
Combination meter………………………………..EL-4095
Combination meter removal and installation — See Instrument panel………………BT-4006
Combination switch……………………………….EL-4034
COMPAS — Wiring diagram…………………….EL-4099
Console box — See Instrument panel……….BT-4006
CONSULT-II general information……………..GI-4002
Cruise control — See ASCD…………………….EL-4233
Cylinder head………………………………………EM-4016
D
Daytime light system……………………………..EL-4047
DEF — Wiring diagram ……………………………EL-4126
DEICER — Wiring diagram………………………EL-4125
Dimensions …………………………………………..GI-4008
D/LOCK — Wiring diagram………………………EL-4245

E
ECM input/output signal ………………………..EC-4040
Electrical load signal circuit …EC-4008, 4016, 4025
Electrical units location ………………………….EL-4300
Engine control circuit
diagram ………………………..EC-4003, 4005, 4013,
4022, 4037, 4059
Exhaust system ……………………………………FE-4008
Exterior………………………………………………..BT-4009
F
F/FOG — Wiring diagram ………………………..EL-4061
FICD — Wiring diagram ………………………….EC-4036
Fog lamp, front……………………………………..EL-4061
Fog lamp, rear ……………………………………..EL-4064
Front bumper ……………………………………….BT-4002
Front fog lamp………………………………………EL-4061
Front washer ………………………………………..EL-4117
Front wiper …………………………………………..EL-4117
Fuel gauge …………………………………………..EL-4095
Fuse……………………………………………………..Foldout
Fusible link…………………………………………….Foldout
G
Gauges………………………………………………..EL-4095
GLOW — Wiring diagram………………………..EC-4033
GPS antenna ……………………………………….EL-4164
Ground distribution………………………………..EL-4016
H
Harness layout…………………………….EL-4307, 4308
Headlamp…………………………………………….EL-4040
Headlamp washer …………………………………EL-4122
Heat up switch……………………………………..EC-4054
Heated seat………………………………………….EL-4231
HEATUP — Wiring diagram …………………….EC-4054
Height (Dimensions) ………………………………GI-4008
H/LAMP — Wiring diagram………………………EL-4040
HLC — Wiring diagram ……………………………EL-4122
Hood……………………………………………………BT-4002
Horn ……………………………………………………EL-4124
HORN — Wiring diagram…………………………EL-4124
HSEAT — Wiring diagram………………………..EL-4231
I
ILL — Wiring diagram ……………………………..EL-4080

IDX-4002

ALPHABETICAL INDEX
Illumination …………………………………………..EL-4079
Instrument panel …………………………………..BT-4006
Intake door motor …………………………………HA-4037
Interior lamp …………………………………………EL-4088

Q
Quick-glow system ……………………………….EC-4031

Keyless entry system — See Multi-remote control system…………………………..EL-4264
L
Length (Dimensions) ……………………………..GI-4008
License lamp………………………………………..EL-4049
Line pressure test (A/T) …………………………AT-4014
LOAD — Wiring diagram ………EC-4008, 4016, 4025
Location of electrical units ……………………..EL-4300
M
MAFS — Wiring diagram…………………………EC-4049
Magnet clutch ………………………………………HA-4039
Maintenance………………………………………..MA-4003
Maintenance (engine) …………………………..MA-4003
Major overhaul (Transfer) ……………..TF-4002, 4003
Mass air flow sensor (MAFS)…………………EC-4047
Meter …………………………………………………..EL-4095
METER — Wiring diagram……………………….EL-4097
MIRROR — Wiring diagram……………………..EL-4227
Mode door motor………………………………….HA-4035
Model variation ……………………………………..GI-4005
MULTI — Wiring diagram ……………….EL-4264, 4266
Multi-remote control system……………………EL-4264
N
NATS (Nissan anti-theft system) ……EL-4293, 4295
NATS — Wiring diagram ……….EL-4293, 4295, 4297
NAVI — Wiring diagram …………………………..EL-4175
Navigation System ………………………………..EL-4162
P
P/ANT — Wiring diagram…………………………EL-4159
Parking lamp ………………………………………..EL-4049
POWER — Wiring diagram………………………EL-4006
Power door lock ……………………………………EL-4244
Power supply routing …………………………….EL-4005
Power window………………………………………EL-4238
Pressure test (A/T)………………………………..AT-4014

Radio — See Audio…………………………………EL-4136
R/COOL — Wiring diagram (front auto
A/C)…………………………………………………HA-4055
R/COOL — Wiring diagram (front
manual A/C)……………………………………..HA-4057
Rear bumper ………………………………………..BT-4005
Rear seat …………………………………………….BT-4012
Rear seat belt………………………………………RS-4013
Rear window defogger…………………………..EL-4126
REMOTE — Wiring diagram…………………….EL-4155
R/FOG — Wiring diagram………………………..EL-4064
R/HEAT — Wiring diagram………………………HA-4003
Road wheel size ……………………………………GI-4009
Room lamp — See Interior lamp ………………EL-4088
ROOM/L — Wiring diagram ……………………..EL-4089
S
Seat belt, rear………………………………………RS-4013
Seat, rear …………………………………………….BT-4012
Seat, second (2nd) ……………………………….BT-4012
Second (2nd) seat ………………………………..BT-4012
Shift schedule……………………………………….AT-4014
SMJ (super multiple junction)…………………..Foldout
Speedometer………………………………………..EL-4095
SRS — Wiring diagram …………………………..RS-4003
STAB — Wiring diagram …………………………RA-4002
Stabilizer release device ……………………….RA-4002
Stabilizer release device — Wiring
diagram……………………………………………RA-4002
Stall test (A/T) ………………………………………AT-4014
S/TANK — Wiring diagram ………………………FE-4004
Steering switch……………………………………..EL-4036
Stop lamp…………………………………………….EL-4059
STOP/L — Wiring diagram……………………….EL-4059
Sub fuel tank control system ………………….FE-4002
Super lock ……………………………………………EL-4290
Supplemental restraint system — Wiring
diagram……………………………………………RS-4003
T
Tachometer ………………………………………….EL-4095
Tail lamp………………………………………………EL-4049
TAIL/L — Wiring diagram …………………………EL-4049
TCM circuit diagram ……………………..AT-4002, 4011
Telephone…………………………………………….EL-4161
THEFT — Wiring diagram ………………EL-4279, 4284
Theft warning system…………………………….EL-4278

IDX-4003

ALPHABETICAL INDEX
Tire size ……………………………………………….GI-4009
Tread-FR&RR (Dimensions)……………………GI-4008
TRQ/SG — Wiring diagram…………….EC-4015, 4024
TURN — Wiring diagram …………………………EL-4068
Turn signal lamp …………………………………..EL-4067
U
UNIFIED METER CONTROL UNIT
(TIME CONTROL SYSTEM)……………….EL-4292
V
Valve clearance……………………………………EM-4005
Valve lifter …………………………………………..EM-4003
Vehicle identification number…………………..GI-4007
Vehicle speed sensor (VSS) ………..EC-4004, 4007,
4053, 4060
Viscosity number (SAE)………………………..MA-4002

VSS — Wiring diagram …………EC-4004, 4053, 4060
W
WARN — Wiring diagram ………………………..EL-4102
Warning chime ……………………………………..EL-4113
Warning lamps ……………………………………..EL-4100
Washer, front ………………………………………..EL-4117
Water temperature gauge ………………………EL-4095
Wheel size ……………………………………………GI-4009
Wheelbase (Dimensions) ……………………….GI-4008
Width (Dimensions) ……………………………….GI-4008
WINDOW — Wiring diagram ……………………EL-4239
WIP/R — Wiring diagram …………………………EL-4118
WIPER — Wiring diagram………………………..EL-4117
Wiper deicer…………………………………………EL-4125
Wiper, front…………………………………………..EL-4117
Wiring Diagram (Cell code) list……………….EL-4347

IDX-4004

MAINTENANCE
SECTION

MODIFICATION NOTICE:
+
+

SAE Viscosity Number charts for engine oil have been revised for Europe.
Caution on the air cleaner filter installation for TB engine has been added.

CONTENTS
RECOMMENDED FLUIDS AND LUBRICANTS…….4002
SAE Viscosity Number ……………………………………4002

TB45E, TB48DE
ENGINE MAINTENANCE ……………………………………4003
Cleaning and Changing Air Cleaner Filter………….4003

MA-4001

RECOMMENDED FLUIDS AND LUBRICANTS
SAE Viscosity Number
DIESEL ENGINE
+ 5W-30 is preferable. If 5W-30 is not available, select the
viscosity from the chart, that is suitable for the outside
temperature range.

SMA204D

MA-4002

ENGINE MAINTENANCE

TB45E, TB48DE

Cleaning and Changing Air Cleaner Filter
To properly tighten wing nuts, position clamps at four
places and tighten wing nuts until they touch air cleaner.
Then tighten them three more turns by hand.
CAUTION:
Do not use pliers or any other tools to tighten wing nuts.
+ Clean inside air cleaner body when changing the element,
or cleaning for dry paper type.
+

SMA981C

MA-4003

MANUAL TRANSMISSION
SECTION

MODIFICATION NOTICE:
+
+

Transmission gear ratio has been changed based on the upgrade of ZD30DDTi engine.
Service Data and Specifications (SDS) have been changed.

CONTENTS
FS5R50B

General Specifications…………………………………….4002

SERVICE DATA AND SPECIFICATIONS ……………..4002

MT-4001

FS5R50B

SERVICE DATA AND SPECIFICATIONS
General Specifications
TB45E
Applied model

Pickup

Hardtop

TB48DE
Wagon

ZD30DDTi
Hardtop

TD42
Wagon

TD42Ti
Wagon & Pickup

4WD
Transmission

FS5R50B

Number of speed

Transmission control

Floor direct

Shift pattern

Synchromesh type

Warner

Gear ratio
1st

4.262

4.084

4.556

4.262

2nd

2.455

2.353

2.625

2.455

3rd

1.488

1.426

1.591

1.488

4th

1.000

0.850

0.880

0.836

0.850

Reverse

3.971

3.806

4.245

3.971

Drive

1st

2nd

3rd

Reverse

Drive

1st

2nd

3rd

Reverse

Number of teeth
Mainshaft

Countershaft

Reverse idler gear
Oil capacity

! (Imp pt)

3.5 (6-1/8)
1st, 2nd and 3rd double baulk ring type synchronizer

Remarks
Reverse synchronizer type

MT-4002

PROPELLER SHAFT &
DIFFERENTIAL CARRIER
SECTION

MODIFICATION NOTICE:
Service Data and Specifications have been changed.

CONTENTS
SERVICE DATA AND SPECIFICATIONS (SDS) ……4002

Final Drive……………………………………………………..4002

PD-4001

Standard

Diff. lock

Optional

Diff. lock

35/8

4.375

4-pinion

H260

Standard

35/8

4.375

4-pinion

Wagon

3.0 (5-1/4)

39/11

3.545

Diff. lock

Optional

5.4 (9-1/2)

39/11

3.545

2-pinion

H233B

Standard

5A/T

Standard

TB48DE

Oil capacity (Approx.)
2.4 (4-1/4) 2.1 (3-3/4) 3.0 (5-1/4) 4.7 (8-1/4) 3.7 (6-1/2) 2.4 (4-1/4)
! (Imp pt)

37/9

Number of teeth (Drive
gear/drive pinion)

LSD

4.111

4-pinion

H233B

Gear ratio

Rear final drive
[Grade]

5M/T

Optional

37/9

Number of teeth (Drive
gear/drive pinion)

Oil capacity (Approx.)
! (Imp pt)

4.111

TB45E

Gear ratio

Front final drive

Transmission

Engine

Body type

GENERAL SPECIFICATIONS

LSD

37/9

4.111

2.1 (3-3/4)

H233B

Standard

37/9

4.111

5M/T

Diff. lock

Optional

ZD30DDTi

3.0 (5-1/4)

35/8

4.375

Standard

35/8

4.375

4A/T

2.4 (4-1/4)

37/9

4.111

4-pinion

H233B

Standard

37/9

4.111

5M/T

TD42

SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive

PD-4002

Standard

5M/T

Transmission

Optional

Oil capacity (Approx.)
! (Imp pt)

2.4 (4-1/4)

3.0 (5-1/4)

37/9

Number of teeth (Drive
gear/drive pinion)

LSD
4.111

Diff. lock

Gear ratio

Rear final drive
[Grade]

4-pinion

37/9

Number of teeth (Drive
gear/drive pinion)

Oil capacity (Approx.)
! (Imp pt)

4.111

Gear ratio

Front final drive

TB45E

Engine

Body type

2.1 (3-3/4)

Standard

5M/T

Diff. lock

H233B

5.4 (9-1/2)

2-pinion

H233B

Standard

Hardtop

3.0 (5-1/4)

Optional

ZD30DDTi

3.0 (5-1/4)

35/8

4.375

Diff. lock

Standard

35/8

4.375

4A/T

SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont’d)

PD-4003

REAR AXLE &
REAR SUSPENSION
SECTION

MODIFICATION NOTICE:
+

Wiring diagrams have been changed.

CONTENTS
STABILIZER RELEASE DEVICE…………………………4002
Wiring Diagram ………………………………………………4002

RA-4001

STABILIZER RELEASE DEVICE
Wiring Diagram
LHD MODELS

TRA011M

RA-4002

STABILIZER RELEASE DEVICE
Wiring Diagram (Cont’d)
LHD MODELS

TRA012M

RA-4003

STABILIZER RELEASE DEVICE
Wiring Diagram (Cont’d)
RHD MODELS

TRA013M

RA-4004

STABILIZER RELEASE DEVICE
Wiring Diagram (Cont’d)
RHD MODELS

TRA014M

RA-4005

RESTRAINT SYSTEM
SECTION

MODIFICATION NOTICE:
+
+

Air bag system wiring diagrams have been changed.
Rear seat belt has been changed.

CONTENTS
TROUBLE DIAGNOSES — Supplemental
Restraint System (SRS) …………………………………….4002
Schematic ……………………………………………………..4002
Wiring Diagram — SRS — (LHD Models) …………4003

Wiring Diagram — SRS — (RHD Models)…………4008
SEAT BELTS …………………………………………………….4013
Rear Seat Belt ……………………………………………….4013

RS-4001

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Schematic

TRS081M

RS-4002

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (LHD Models)

TRS062M

RS-4003

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (LHD Models)
(Cont’d)

TRS082M

RS-4004

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (LHD Models)
(Cont’d)

TRS083M

RS-4005

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (LHD Models)
(Cont’d)
TD ENGINE MODELS WITH NATS

TRS084M

RS-4006

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (LHD Models)
(Cont’d)
EXCEPT FOR TD ENGINE MODELS WITH NATS

TRS085M

RS-4007

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (RHD Models)

TRS072M

RS-4008

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (RHD Models)
(Cont’d)

TRS086M

RS-4009

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (RHD Models)
(Cont’d)

TRS087M

RS-4010

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (RHD Models)
(Cont’d)
TD ENGINE MODELS WITH NATS

TRS088M

RS-4011

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)
Wiring Diagram — SRS — (RHD Models)
(Cont’d)
EXCEPT FOR TD ENGINE MODELS WITH NATS

TRS089M

RS-4012

SEAT BELTS
Rear Seat Belt
REMOVAL (WAGON)
Remove rear seat. Refer to “SEAT” in BT section for details.
Remove 3rd seat. Refer to BT-38 in Service Manual (Pub. No. SM7E-2Y61G1).
Slide side seat belt anchor cover.
Remove side seat belt anchor bolt.
Remove luggage upper and lower finishers. Refer to BT-17 in Service Manual (Pub. No. SM7E-2Y61G1).
Remove shoulder anchor bolt.
Remove headlining. Refer to BT-21 in Service Manual (Pub. No. SM7E-2Y61G1).
Remove the bolt and anchor bolt securing side seat belt retractor, then remove side seat belt and side
seat belt retractor.
j
9 Remove the bolt and anchor bolt securing center seat belt retractor, then remove center seat belt and
center seat belt retractor.

j
1
j
2
j
3
j
4
j
5
j
6
j
7
j
8

PIIB1985E

RS-4013

SEAT BELTS
Rear Seat Belt (Cont’d)
REMOVAL (HARDTOP)
Fold the rear seat forward.
Slide anchor cover.
Remove shoulder anchor cover.
Remove anchor bolt.
Remove shoulder anchor bolt.
Remove luggage upper and lower finishers. Refer to BT-17 in Service Manual. (Pub. No. SM7E-2Y61G1).
Remove headlining. Refer to BT-23 in Service Manual (Pub. No. SM7E-2Y61G1).
Remove anchor bolt securing side seat belt retractor, then remove side seat belt and side seat belt
retractor.
j
9 Remove anchor bolt securing center seat belt retractor, then remove center seat belt and center seat belt
retractor.

j
1
j
2
j
3
j
4
j
5
j
6
j
7
j
8

PIIB1986E

RS-4014

TRANSFER
SECTION

MODIFICATION NOTICE:
TX12A transfer model with gear component parts have been changed.

CONTENTS
MAJOR OVERHAUL ………………………………………….4002
Case Components ………………………………………….4002

Gear Components ………………………………………….4003

TF-4001

MAJOR OVERHAUL
Case Components

SMT098E

TF-4002

MAJOR OVERHAUL
Gear Components

SMT216E

TF-4003

AUTOMATIC TRANSMISSION

GI
MA

SECTION

MODIFICATION NOTICE:
I

EM
LC
EC

Wiring diagrams have been changed.

CONTENTS
RE4R03A
OVERALL SYSTEM ………………………………………………..2
Circuit Diagram ……………………………………………………2
Wiring Diagram — A/T —……………………………………..3
TROUBLE DIAGNOSES — A/T Shift Lock
System…………………………………………………………………11
Wiring Diagram — SHIFT —……………………………….11
RE5R05A
TROUBLE DIAGNOSIS………………………………………….12
Circuit Diagram ………………………………………………….12

DTC P0615 START SIGNAL CIRCUIT …………………….13
Wiring Diagram — AT — STSIG ………………………….13
DTC P1701 TRANSMISSION CONTROL MODULE
(POWER SUPPLY) ………………………………………………..14
Wiring Diagram — AT — POWER ……………………….14
DTC P1815 MANUAL MODE SWITCH ……………………16
Wiring Diagram — AT — MMSW …………………………16
TROUBLE DIAGNOSES FOR SYMPTOMS……………..17
Wiring Diagram — AT — NONDTC………………………17
A/T SHIFT LOCK SYSTEM…………………………………….19
Wiring Diagram — SHIFT —……………………………….19

CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX

AT-1

OVERALL SYSTEM

RE4R03A

Circuit Diagram

TAT160M

AT-2

OVERALL SYSTEM

RE4R03A

Wiring Diagram — A/T —

MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT161M

AT-3

IDX

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT162M

AT-4

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

GI
MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT163M

IDX

AT-5

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT164M

AT-6

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

GI
MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT165M

IDX

AT-7

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT166M

AT-8

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

GI
MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT167M

IDX

AT-9

OVERALL SYSTEM
Wiring Diagram — A/T — (Cont’d)

RE4R03A

TAT114M

AT-10

TROUBLE DIAGNOSES — A/T Shift Lock System

RE4R03A

Wiring Diagram — SHIFT —

MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT168M

AT-11

IDX

TROUBLE DIAGNOSIS

RE5R05A

Circuit Diagram

TAT152M

AT-12

DTC P0615 START SIGNAL CIRCUIT

RE5R05A

Wiring Diagram — AT — STSIG

MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT153M

AT-13

IDX

DTC P1701 TRANSMISSION CONTROL MODULE (POWER
RE5R05A
SUPPLY)
Wiring Diagram — AT — POWER

TAT154M

AT-14

DTC P1701 TRANSMISSION CONTROL MODULE (POWER
RE5R05A
SUPPLY)
Wiring Diagram — AT — POWER (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT155M

IDX

AT-15

DTC P1815 MANUAL MODE SWITCH

RE5R05A

Wiring Diagram — AT — MMSW

TAT156M

AT-16

TROUBLE DIAGNOSES FOR SYMPTOMS

RE5R05A

Wiring Diagram — AT — NONDTC

MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT157M

AT-17

IDX

RE5R05A
TROUBLE DIAGNOSES FOR SYMPTOMS
Wiring Diagram — AT — NONDTC (Cont’d)

TAT158M

AT-18

A/T SHIFT LOCK SYSTEM

RE5R05A

Wiring Diagram — SHIFT —

MA
EM
LC
EC
FE
CL
MT

TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TAT159M

AT-19

IDX

BRAKE SYSTEM

GI
MA

SECTION

MODIFICATION NOTICE:

EM
LC
EC

Wiring Diagrams have been changed.

CONTENTS
TROUBLE DIAGNOSES ………………………………………….2
Schematic …………………………………………………………..2

Wiring Diagram — ABS — ……………………………………3

CL
MT
AT
TF
PD
FA
RA

ST
RS
BT
HA
EL
SE
IDX

BR-1

TROUBLE DIAGNOSES
Schematic

TBR052M

BR-2

TROUBLE DIAGNOSES
GI

Wiring Diagram — ABS —

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA

ST
RS
BT
HA
EL
SE
TBR042M

BR-3

IDX

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR043M

BR-4

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA

ST
RS
BT
HA
EL
SE
TBR053M

IDX

BR-5

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)

TBR066M

BR-6

TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA

ST
RS
BT
HA
EL
SE
TBR067M

IDX

BR-7

ENGINE CONTROL SYSTEM

GI
MA

SECTION

EM
LC

MODIFICATION NOTICE:
Wiring diagrams have been modified.

CONTENTS
ZD30DDTi
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM…………………………………………………………………2
Circuit Diagram ……………………………………………………2
DTC 0102 MASS AIR FLOW SEN…………………………….3
Wiring Diagram ……………………………………………………3
DTC 0103 COOLANT TEMP SEN …………………………….4

Wiring Diagram ……………………………………………………4
DTC 0504 A/T COMM LINE ……………………………………..5
Wiring Diagram ……………………………………………………5
DTC 0905 TURBO PRESSURE ………………………………..6
Wiring Diagram ……………………………………………………6
ENGINE OIL PRESSURE SWITCH …………………………..7
Wiring Diagram ……………………………………………………7

CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX

EC-1

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ZD30DDTi

Circuit Diagram

TEC611M

EC-2

DTC 0102 MASS AIR FLOW SEN

ZD30DDTi

Wiring Diagram

MA
EM
LC

FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TEC603M

EC-3

IDX

DTC 0103 COOLANT TEMP SEN

ZD30DDTi

Wiring Diagram

TEC604M

EC-4

DTC 0504 A/T COMM LINE

ZD30DDTi

Wiring Diagram

MA
EM
LC

FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TEC605M

EC-5

IDX

DTC 0905 TURBO PRESSURE

ZD30DDTi

Wiring Diagram

TEC606M

EC-6

ENGINE OIL PRESSURE SWITCH

ZD30DDTi

Wiring Diagram

MA
EM
LC

FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
TEC607M

EC-7

IDX

ELECTRICAL SYSTEM

GI
MA

SECTION

EM
LC
EC

MODIFICATION NOTICE:
I
I
I

Wiring Diagrams have been changed.
NAVI C/U has been changed.
TMC tuner has been adopted.

CONTENTS
POWER SUPPLY ROUTING/WAGON AND
HARDTOP MODELS ……………………………………………….3
Schematic …………………………………………………………..3
Wiring Diagram — POWER —………………………………4
GROUND DISTRIBUTION/WAGON AND
HARDTOP MODELS ……………………………………………..14
Engine Room Harness/LHD Models …………………….14
Engine Room Harness/RHD Models…………………….16
Main Harness/LHD Models………………………………….18
Main Harness/RHD Models …………………………………21
Body Harness/LHD Models …………………………………24
Body Harness/RHD Models…………………………………26
Body No. 2 Harness/LHD Models ………………………..28
Body No. 2 Harness/RHD Models………………………..29
Back Door and Rear Window Defogger Harness/
LHD Models ………………………………………………………30
Back Door and Rear Window Defogger Harness/
RHD Models ……………………………………………………..31
STARTING SYSTEM/WAGON AND HARDTOP
MODELS ………………………………………………………………32
Wiring Diagram — START —/A/T Models with
TB48 Engine ……………………………………………………..32
Wiring Diagram — START —/A/T Models with
ZD30 Engine……………………………………………………..33
HEADLAMP/WAGON AND HARDTOP MODELS
— Daytime Light System — ………………………………….34
Wiring Diagram — DTRL — ………………………………..34
TURN SIGNAL AND HAZARD WARNING LAMPS/
WAGON AND HARDTOP MODELS ………………………..36
Wiring Diagram — TURN — ……………………………….36
ILLUMINATION/WAGON AND HARDTOP
MODELS ………………………………………………………………38
Schematic …………………………………………………………38
Wiring Diagram — ILL — ……………………………………39

METER AND GAUGES/WAGON AND HARDTOP
MODELS ………………………………………………………………47
Combination Meter …………………………………………….47
Schematic …………………………………………………………48
Wiring Diagram — METER —……………………………..49
WARNING LAMPS/WAGON AND HARDTOP
MODELS ………………………………………………………………52
Schematic …………………………………………………………52
Wiring Diagram — WARN — ………………………………54
A/T INDICATOR/WAGON AND HARDTOP
MODELS ………………………………………………………………65
Wiring Diagram — AT/IND —/TB48 Engine
Models with A/T …………………………………………………65
REAR WIPER AND WASHER/WAGON AND
HARDTOP MODELS ……………………………………………..66
Wiring Diagram — WIP/R —……………………………….66
CIGARETTE LIGHTER/WAGON AND HARDTOP
MODELS ………………………………………………………………68
Wiring Diagram — CIGAR —/RHD Models …………..68
REAR WINDOW DEFOGGER/WAGON AND
HARDTOP MODELS ……………………………………………..69
Wiring Diagram — DEF —/LHD Models ……………….69
Wiring Diagram — DEF —/RHD Models ………………71
AUDIO/WAGON AND HARDTOP MODELS……………..73
Schematic/LHD Models with Sub-harness …………….73
Wiring Diagram — AUDIO —/LHD Models with
Sub-harness………………………………………………………74
Schematic/RHD Models with Sub-harness ……………77
Wiring Diagram — AUDIO —/RHD Models with
Sub-harness………………………………………………………78
Schematic/LHD Models without Sub-harness ………..81
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness …………………………………………..82
Schematic/RHD Models without Sub-harness ……….86

EL-1

MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX

CONTENTS
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness …………………………………………..87
NAVIGATION SYSTEM ………………………………………….91
Traffic Information (RDS-TMC)…………………………….91
Component Parts Location ………………………………….91
Schematic …………………………………………………………92
Wiring Diagram — NAVI —/LHD Models ………………93
Wiring Diagram — NAVI —/RHD Models ……………100
Terminals and Reference Value for NAVI Control
Unit…………………………………………………………………107
Terminals and Reference Value for Display …………109
Terminals and Reference Value for NAVI Switch ….110
Terminals and Reference Value for Transfer Unit …110
Terminals and Reference Value for TMC Tuner……112
Terminals and Reference Value for Voice
Change Relay ………………………………………………….113
Special Note for Trouble Diagnosis…………………….114
On Board Self-Diagnosis Function ……………………..114
Self Diagnosis Mode…………………………………………115
Confirmation/Adjustment Mode ………………………….119
All Images Are Not Displayed…………………………….126
Vehicle Mark Is Not Displayed Properly………………134
Tint Is Strange for The RGB Image ……………………135
RGB Image Is Rolling……………………………………….137
Values for All Items in the Drive Computer
Screen Do Not Change …………………………………….138
Values for Items, “Driving Distance” and
“Average Speed” Do Not Change ………………………138
Voice Guidance Is Not Heard…………………………….138
RDS-TMC (Traffic Information) Is Not Received…..142
Example of Symptoms Judged Not Malfunction …..143
HEATED SEAT/WAGON AND HARDTOP
MODELS …………………………………………………………….146

(Cont’d)

Wiring Diagram — HSEAT —…………………………….146
AUTOMATIC SPEED CONTROL DEVICE (ASCD)/
WAGON AND HARDTOP MODELS ………………………148
Schematic ……………………………………………………….148
Wiring Diagram — ASCD — ……………………………..149
POWER WINDOW/WAGON AND HARDTOP
MODELS …………………………………………………………….153
Schematic ……………………………………………………….153
Wiring Diagram — WINDOW — ………………………..154
CAN SYSTEM/TB48 ENGINE MODELS WITH A/T …159
Wiring Diagram — CAN —………………………………..159
LOCATION OF ELECTRICAL UNITS/WAGON
AND HARDTOP MODELS ……………………………………160
Passenger Compartment — LHD Models……………160
Passenger Compartment — RHD Models …………..162
HARNESS LAYOUT …………………………………………….165
How to Read Harness Layout ……………………………165
HARNESS LAYOUT/WAGON AND HARDTOP
MODELS …………………………………………………………….166
Main Harness/LHD Models………………………………..166
Main Harness/RHD Models ……………………………….170
Engine Room Harness/LHD Models …………………..174
Engine Room Harness/RHD Models…………………..176
Body Harness/RHD Models……………………………….178
Body No. 2 Harness/LHD Models ………………………182
Body No. 2 Harness/RHD Models………………………184
Engine Harness ……………………………………………….186
WIRING DIAGRAM CODES (CELL CODES)………….187
Wiring Diagram Codes (Cell Codes) …………………..187
FUSE AND FUSIBLE LINK BOX/WAGON AND
HARDTOP MODELS ………………………………………Foldout
Terminal Arrangement………………………………….Foldout

EL-2
Z 05.9.5/Y61 Euro sup9X

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
GI

Schematic

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL190N

EL-3

IDX

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER —
BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

TEL191N

EL-4

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL192N

IDX

EL-5

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL964M

EL-6

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL193N

IDX

EL-7

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL966M

EL-8

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
GI

ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON”

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL194N

EL-9

IDX

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START”

TEL195N

EL-10

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL969M

IDX

EL-11

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)

TEL970M

EL-12

POWER SUPPLY ROUTING/WAGON AND HARDTOP MODELS
Wiring Diagram — POWER — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL971M

IDX

EL-13

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models

CEL606M

EL-14

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL556M

IDX

EL-15

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models

CEL607M

EL-16

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL608M

IDX

EL-17

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models

CEL591M

EL-18

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL609M

IDX

EL-19

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

CEL610M

EL-20

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
GI

Main Harness/RHD Models

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL611M

EL-21

IDX

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

CEL612M

EL-22

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL613M

IDX

EL-23

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/LHD Models

CEL565M

EL-24

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/LHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL566M

IDX

EL-25

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/RHD Models

CEL567M

EL-26

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL614M

IDX

EL-27

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models

CEL615M

EL-28

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
GI

Body No. 2 Harness/RHD Models

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL570M

EL-29

IDX

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
Back Door and Rear Window Defogger
Harness/LHD Models

CEL571M

EL-30

GROUND DISTRIBUTION/WAGON AND HARDTOP MODELS
GI

Back Door and Rear Window Defogger
Harness/RHD Models

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX
CEL572M

EL-31

STARTING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — START —/A/T Models with
TB48 Engine

TEL196N

EL-32

STARTING SYSTEM/WAGON AND HARDTOP MODELS
Wiring Diagram — START —/A/T Models with
ZD30 Engine

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX
TEL197N

EL-33

HEADLAMP/WAGON AND HARDTOP MODELS — Daytime Light System —
Wiring Diagram — DTRL —

TEL198N

EL-34

HEADLAMP/WAGON AND HARDTOP MODELS — Daytime Light System —
Wiring Diagram — DTRL — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL199N

IDX

EL-35

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN —

TEL200N

EL-36

TURN SIGNAL AND HAZARD WARNING LAMPS/WAGON AND HARDTOP
MODELS
Wiring Diagram — TURN — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL201N

IDX

EL-37

ILLUMINATION/WAGON AND HARDTOP MODELS
Schematic

TEL202N

EL-38

ILLUMINATION/WAGON AND HARDTOP MODELS
GI

Wiring Diagram — ILL —

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL011N

EL-39

IDX

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL012N

EL-40

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL013N

IDX

EL-41

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL014N

EL-42

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL203N

IDX

EL-43

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL204N

EL-44

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL017N

IDX

EL-45

ILLUMINATION/WAGON AND HARDTOP MODELS
Wiring Diagram — ILL — (Cont’d)

TEL018N

EL-46

METER AND GAUGES/WAGON AND HARDTOP MODELS
GI

Combination Meter

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL587M

EL-47

IDX

METER AND GAUGES/WAGON AND HARDTOP MODELS
Schematic

TEL022N

EL-48

METER AND GAUGES/WAGON AND HARDTOP MODELS
GI

Wiring Diagram — METER —

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL023N

EL-49

IDX

METER AND GAUGES/WAGON AND HARDTOP MODELS
Wiring Diagram — METER — (Cont’d)

TEL205N

EL-50

METER AND GAUGES/WAGON AND HARDTOP MODELS
NOTE

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX

EL-51

WARNING LAMPS/WAGON AND HARDTOP MODELS
Schematic

TEL899M

EL-52

WARNING LAMPS/WAGON AND HARDTOP MODELS
Schematic (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL251N

EL-53

IDX

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN —

TEL206N

EL-54

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL207N

IDX

EL-55

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL903M

EL-56

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL904M

IDX

EL-57

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL905M

EL-58

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL906M

IDX

EL-59

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL208N

EL-60

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL252N

IDX

EL-61

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)

TEL209N

EL-62

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
GI

LHD MODELS

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL910M

EL-63

IDX

WARNING LAMPS/WAGON AND HARDTOP MODELS
Wiring Diagram — WARN — (Cont’d)
RHD MODELS

TEL026N

EL-64

A/T INDICATOR/WAGON AND HARDTOP MODELS
GI

Wiring Diagram — AT/IND —/TB48 Engine
Models with A/T

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX
TEL210N

EL-65

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R —
LHD MODELS

TEL211N

EL-66

REAR WIPER AND WASHER/WAGON AND HARDTOP MODELS
Wiring Diagram — WIP/R — (Cont’d)
GI

LHD MODELS

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL033N

EL-67

IDX

CIGARETTE LIGHTER/WAGON AND HARDTOP MODELS
Wiring Diagram — CIGAR —/RHD Models

TEL212N

EL-68

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
GI

Wiring Diagram — DEF —/LHD Models

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL213N

EL-69

IDX

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/LHD Models (Cont’d)

TEL214N

EL-70

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
GI

Wiring Diagram — DEF —/RHD Models

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL215N

EL-71

IDX

REAR WINDOW DEFOGGER/WAGON AND HARDTOP MODELS
Wiring Diagram — DEF —/RHD Models (Cont’d)

TEL216N

EL-72

AUDIO/WAGON AND HARDTOP MODELS
GI

Schematic/LHD Models with Sub-harness

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL217N

EL-73

IDX

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models with
Sub-harness

TEL218N

EL-74

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models with
Sub-harness (Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL050N

EL-75

IDX

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models with
Sub-harness (Cont’d)

TEL051N

EL-76

AUDIO/WAGON AND HARDTOP MODELS
GI

Schematic/RHD Models with Sub-harness

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL219N

EL-77

IDX

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models with
Sub-harness

TEL220N

EL-78

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models with
Sub-harness (Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL055N

EL-79

IDX

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models with
Sub-harness (Cont’d)

TEL056N

EL-80

AUDIO/WAGON AND HARDTOP MODELS
Schematic/LHD Models without Sub-harness

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL221N

EL-81

IDX

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness

TEL222N

EL-82

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness (Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL059N

EL-83

IDX

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness (Cont’d)

TEL060N

EL-84

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/LHD Models
without Sub-harness (Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL223N

EL-85

IDX

AUDIO/WAGON AND HARDTOP MODELS
Schematic/RHD Models without Sub-harness

TEL224N

EL-86

AUDIO/WAGON AND HARDTOP MODELS
GI

Wiring Diagram — AUDIO —/RHD Models
without Sub-harness

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX
TEL225N

EL-87

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness (Cont’d)

TEL064N

EL-88

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness (Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL065N

EL-89

IDX

AUDIO/WAGON AND HARDTOP MODELS
Wiring Diagram — AUDIO —/RHD Models
without Sub-harness (Cont’d)

TEL066N

EL-90

NAVIGATION SYSTEM
GI

Traffic Information (RDS-TMC)
SYSTEM DESCRIPTION
Refer to owner’s manual or navigation system owner’s manual for the system operation.
The Traffic Information broadcast allows to you to avoid delays due to traffic incidents.
Traffic jams, roadwork, closed roads around your current location, etc. are represented graphically on the map
by icons depicting the nature of the event.
Incidents on the route are automatically brought to your attention when they are approached.
The Traffic Information feature gives you the opportunity to forecast traffic incidents, determine how serious
they are and, via the guidance mode, allows you to detour around traffic incidents.
The navigation system receives traffic information from best available sources and enables the RDS-TMC
(Radio Data System-Traffic Message Channel) to inform and guide you.
The RDS-TMC broadcast is fed by a dedicated FM tuner so that you can still tune your radio station while
Traffic Information is being broadcasted.

Component Parts Location

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT

PKIC6342E

SE
IDX

EL-91

NAVIGATION SYSTEM
Schematic

TEL226N

EL-92

NAVIGATION SYSTEM
GI

Wiring Diagram — NAVI —/LHD Models

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL227N

EL-93

IDX

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/LHD Models
(Cont’d)

TEL228N

EL-94

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/LHD Models
(Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL229N

IDX

EL-95

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/LHD Models
(Cont’d)

TEL230N

EL-96

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/LHD Models
(Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL231N

IDX

EL-97

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/LHD Models
(Cont’d)

TEL232N

EL-98

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/LHD Models
(Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL233N

EL-99

IDX

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/RHD Models

TEL234N

EL-100

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/RHD Models
(Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL235N

IDX

EL-101

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/RHD Models
(Cont’d)

TEL236N

EL-102

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/RHD Models
(Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL237N

IDX

EL-103

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/RHD Models
(Cont’d)

TEL238N

EL-104

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/RHD Models
(Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL239N

IDX

EL-105

NAVIGATION SYSTEM
Wiring Diagram — NAVI —/RHD Models
(Cont’d)

TEL240N

EL-106

NAVIGATION SYSTEM
GI

Terminals and Reference Value for NAVI
Control Unit
Terminal No.
(Wire color)

MA
Item

(+)

(-)

1 (B)

Ground

2 (R/G)

Ground

Battery
power supply

5
(L/OR)

Ground

ACC power
supply

14 (BR)

Voice guidance signal

Signal
input/
output

Condition
Reference value

Example of symptom

Ignition
switch

Operation

—

Approx. 0 V

Input

OFF

—

Battery voltage

System does not work
properly.

Input

ACC

—

Battery voltage

System does not work
properly.

EM
—

LC
EC
FE

12 (Y)

Output

Only route guidance and
operation guidance are
not heard.

Press the “VOICE”
switch.

SKIB3597E

44 (R)

—

Ground

Shield

RGB signal
(R: red)

—

Output

—

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

—

MT
AT

RGB screen looks bluish.

TF
SKIB7360E

PD
45 (G)

Ground

RGB signal
(G: green)

Output

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

RGB screen looks reddish.

FA
RA

SKIB7361E

BR
46 (B)

Ground

RGB signal
(B: blue)

Output

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

RGB screen looks yellowish.

SKIB7362E

—

Shield

—

ST
RS
BT

48 (W)

Ground

RGB synchronizing
signal

Output

—

RGB screen is rolling.

HA
SKIB3603E

50 (R)

61 (L/B)

Ground

RGB area
(YS) signal

Ground

Illumination
signal

Output

Input

—

Approx. 5 V

Lighting switch position 1st or 2nd

Approx. 12 V

Lighting switch position OFF

Approx. 0 V

RGB screen is not
shown.
Night illumination for
switches does not illuminate.

SE
IDX

EL-107

NAVIGATION SYSTEM
Terminals and Reference Value for NAVI
Control Unit (Cont’d)
Terminal No.
(Wire color)

Item

(+)

(-)

63
(R/W)

Ground

IGN signal

Ground

Reverse
signal

65 (Y)

Signal
input/
output
Input

Input

Condition
Ignition
switch

Operation

—

Reference value

Example of symptom

Battery voltage.

Vehicle information setting is not possible.

Select R-position

Approx.12 V

Other position

Approx. 0 V

The navigation currentlocation mark moves
strangely when the
vehicle is moving backwards.

NOTE:
Maximum voltage may be 5 V due to
specifications (connected units).

66
(R/W)

Ground

Vehicle
speed signal
(8-pulse)

Input

When vehicle speed
is approx. 40 km/h
(25 MPH)

Navigation current-location mark does not indicate the correct position.

PKIA1935E

—

69
(W)

Ground

Shield

Communication signal
(+)

—

Input/
Output

—

System does not work
properly.

SKIB7378E

70 (B)

Ground

Communication signal
(-)

Input/
Output

System does not work
properly.

—

SKIB7379E

71 (R)

Ground

Communication signal
(+)

Input/
Output

System does not work
properly.

—

SKIB7378E

72 (G)

Ground

Communication signal
(-)

Input/
Output

System does not work
properly.

—

SKIB7379E

Ground

—

GPS
antenna signal
Shield

Input

—

Connector is not
connected.
—

EL-108

Approx. 5 V
—

GPS correction is not
possible.
—

NAVIGATION SYSTEM

Terminal No.
(Wire color)
(+)

Item

(-)

Signal
input/
output

Ignition
switch

Terminals and Reference Value for Display

Condition

Reference value

Example of symptom

Operation

EM
1 (R)

Ground

RGB signal
(R: red)

Input

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

RGB screen looks bluish.

SKIB7360E

2 (G)

RGB signal
Ground
(G: green)

Input

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

RGB screen looks reddish.

CL
SKIB7361E

MT
3 (B)

Ground

—

RGB signal
(B: blue)

Input

Select “Color bar” of
CONFIRMATION/
ADJUSTMENT function.

—

RGB screen looks yellowish.

SKIB7362E

Shield

—

PD
RGB synchronizing signal

7 (W)

Ground

8 (R)

RGB area (YS)
Ground
signal

Input

—

RGB screen is rolling.

SKIB3603E

Input

—

RGB screen is not
shown.

Approx. 5 V

BR
15 (OR)

Communication
Ground signal
(DISP-SW)

Output

System does not work
properly.

—

SKIB3606E

16 (B)

Communication
Ground signal
(NAVI-DISP)

BT
Input

System does not work
properly.

—

HA
SKIB3607E

17
19
(L/OR)
21
(R/G)
22 (B)
23
(R/G)
24 (B)

—
Ground
Ground
Ground
Ground
Ground

Shield
ACC power
supply
Battery power
supply
Ground
Battery power
supply
Ground

—

Input

ACC

—

Battery voltage

Input

OFF

—

Battery voltage

—

Approx. 0 V

Input

—

Battery voltage

—

Approx. 0 V

EL-109

—
System does not work
properly.
System does not work
properly.
—
System does not work
properly.
—

SE
IDX

NAVIGATION SYSTEM
Terminals and Reference Value for NAVI Switch
Terminal No.
(Wire color)

Item

Signal
input/
output

(+)

(-)

1
(L/OR)

Ground

ACC power
supply

3 (B)

Illumination
signal

Input

Communication signal
(DISP-SW)

Input

2 (L/B)

4 (OR)

Ground

Input

Condition
Reference value

Ignition
switch

Operation

ACC

—

Battery voltage

Lighting switch position 1st or 2nd

Approx. 12 V

Lighting switch position OFF

Approx. 0 V

OFF

Example of symptom

All operations do not
work.
Night illumination for
switches does not illuminate.

System does not work
properly.

—

SKIB3606E

5 (L/W)

Ground

Communication signal
(SW-NAVI)

Output

System does not work
properly.

—

SKIB3611E

6
7 (B)

—
Ground

Shield
Ground

—
—

—
ON

—
—

—

—
All operations do not
work.

Approx. 0 V

Terminals and Reference Value for Transfer
Unit
Terminal No.
(Wire color)
(+)

(-)

1 (L)

2 (PU)

Item

Voice guidance signal

Signal
input/
output

Output

Condition
Ignition
switch

Reference value

Example of symptom

Operation

Only route guidance and
operation guidance are
not heard.

Press the “VOICE”
switch.

SKIB3609E

6 (BR)

4 (R)

Voice
change
relay ON
signal

Output

Only route guidance and
operation guidance are
not heard.

Press the “VOICE”
switch.

SKIB3610E

—

Shield

—

EL-110

—

NAVIGATION SYSTEM
Terminals and Reference Value for Transfer
Unit (Cont’d)
Terminal No.
(Wire color)
(+)

Item

(-)

Signal
input/
output

Condition
Ignition
switch

Reference value

Example of symptom

GI
MA

Operation

EM
8 (Y)

10 (BR)

Voice guidance signal

Input

Only route guidance and
operation guidance are
not heard.

Press the “VOICE”
switch.

SKIB3597E

—

Shield

—

FE
11
(W)

Ground

Communication signal
(+)

Input/
Output

System does not work
properly.

—

CL
MT

SKIB7378E

AT
13 (B)

Ground

Communication signal
(-)

Input/
Output

—

System does not work
properly.

—

SKIB7379E

—

Shield

—

TF
PD
FA

18
(L/W)

Ground

Communication signal
(SW-NAVI)

Input

System does not work
properly.

—

SKIB3611E

—

Shield

—

RA
BR
ST

20 (B)

Ground

Communication signal
(NAVI-DISP)

Output

System does not work
properly.

—

SKIB3607E

25 (B)

Ground

—

Approx. 0 V

27 (B)

—

Approx. 0 V

—

Ground

29
(L/OR)

Ground

ACC power
supply

Input

ACC

—

Battery voltage

System does not work
properly.

31
(R/G)

Ground

Battery
power supply

Input

OFF

—

Battery voltage

System does not work
properly.

32
(R/G)

Ground

Battery
power supply

Input

OFF

—

Battery voltage

System does not work
properly.

—

SE
IDX

EL-111

NAVIGATION SYSTEM
Terminals and Reference Value for TMC Tuner
Terminal No.
(Wire color)

Item

(+)

(-)

1 (R)

Ground

Communication signal
(+)

Signal input/
output

Input/Output

Condition

Reference value

Ignition switch

Operation

—

SKIB7378E

2 (G)

Ground

Communication signal
(-)

Input/Output

—

SKIB7379E

—

Shield

5 (R/G)

Ground

Battery
power supply

7 (L/OR)

Ground

ACC power
supply

8 (B)

Ground

—

Input

OFF

—

Battery voltage

Input

ACC

—

Battery voltage

—

Approx. 0 V

EL-112

NAVIGATION SYSTEM
Terminals and Reference Value for Voice
Change Relay
Terminal No.
(Wire color)
(+)

2 (BR)

MA
Item

(-)

1 (R)

Voice
change
relay ON
signal

Signal
input/
output

Condition
Ignition
switch

Reference value

Example of symptom

Operation

LC
Input

Only route guidance and
operation guidance are
not heard.

Press the “VOICE”
switch.

SKIB3610E

FE
3 (OR)

5 (G)

Audio sound
signal
(driver side)

Input

No sound from door
speaker and tweeter
(driver side).

Receive audio signal.

CL
MT

SKIB3609E

AT
4
(L)*1
(BR)*2

8
(B/W)*1
(B/R)*2

Voice guidance signal

Output

Only route guidance and
operation guidance are
not heard.

Press the “VOICE”
switch.

SKIB3609E

6 (L)

7 (PU)

Voice guidance signal

Input

PD
Only route guidance and
operation guide are not
heard.

Press the “VOICE”
switch.

FA
RA

SKIB3609E

*1: LHD models.
*2: RHD models.

BR
ST
RS
BT
HA

SE
IDX

EL-113

NAVIGATION SYSTEM
Special Note for Trouble Diagnosis
Prior to perform trouble diagnosis, make sure there are no corresponding description in the “Example of
Symptoms Possible No Malfunction”. Refer to EL-143, “Example of Symptoms Judged Not Malfunction”.

On Board Self-Diagnosis Function
DESCRIPTION
I
I
I

Trouble diagnosis function of navigation system has a Self Diagnosis mode by automatic operation and a
Confirmation/Adjustment mode by manual operation.
Self Diagnosis mode checks for connections between the units constituting this system, analyzes each
individual unit at the same time, and displays the results on the display.
Confirmation/Adjustment mode displays trouble diagnosis that require an operation and a judgment by a
human (auto-decision cannot be performed by the system), confirmation of preset value, and an error history.

DIAGNOSIS ITEM
Mode

Description
I NAVI Control unit diagnosis (DVD-ROM drive will not be diagnosed when no
DVD-ROM is in it.).
I Analyzes connection between the NAVI control unit and the GPS antenna, connection between the NAVI control unit and each unit, and operation of each
unit.

Self Diagnosis

Display Diagnosis

Color tone and shading of the screen can be checked by the display of a color
bar and a gray scale.

Vehicle Signals

Diagnosis of signals that are input to NAVI control unit can be performed for
Vehicle speed, Lights, Ignition and Reverse.
Steering Angle This mode is used to correct difference between actual turning angle of a vehicle
Adjustment
and turning angle of the vehicle mark on the display.

Navigation
Confirmation/
Adjustment

Under ordinary conditions, the navigation system distance measuring function will
automatically compensate for minute decreases in wheel and tire diameter
Speed Calibracaused by tire wear or low-pressure. Speed Calibration can immediately restore
tion
system accuracy in cases such as when distance calibration is needed because
of the use of tire chains.

Error History

Malfunctions that occurred in the past are displayed, along with the number of
times each has occurred. Time and location when/where the errors occurred are
also displayed.

Delete Unit Connection Log

Erase the connection history of unit and error history.

Feature Restriction Setting

Operations of navigation system that are performed while driving can be
restricted by using this function.

EL-114

NAVIGATION SYSTEM
GI

Self Diagnosis Mode
OPERATION PROCEDURE
1. Start the engine.
” buttons simultaneously for 5
2. Press and hold “MAP” and “
seconds or more.
I
Shifting from current screen to previous screen is performed by pressing “BACK” button.

MA
EM
LC

PKIB1537E

3. The initial trouble diagnosis screen will be shown, and items
“Self Diagnosis” and “Confirmation/Adjustment” will become
selective.

EC
FE
CL
MT

SKIB6971E

4. Perform self-diagnosis by selecting the “Self Diagnosis”.
I
Self-diagnosis screen is displayed, and then self-diagnosis
starts.
I
The bar graph visible below self-diagnosis screen displays
progress of the diagnosis.

AT
TF
PD
FA
RA

SKIB6972E

5. On the diagnosis results screen, each unit name and connection line will be colored according to the diagnosis result, as
follows.
Diagnosis results

Unit

Connection
line

Normal

Green

Connection malfunction

Gray

Yellow

DVD-ROM drive undiagnosed

Gray

Green

DVD-ROM and DVD-ROM drive malfunction

Yellow

Green

Unit returned an error

Red

Green

SKIB7631E

NOTE:
I Control unit = NAVI control unit
I Converter = Transfer unit
I Switch = NAVI switch
I TMC BB = TMC tuner
I Only Control unit (NAVI control unit) is displayed in red.
I If multiple malfunctions occur at the same time for a single unit,
the screen switch colors are determined according to the following order of priority: red > yellow > gray.

EL-115

BR
ST
RS
BT
HA

SE
IDX

NAVIGATION SYSTEM
Self Diagnosis Mode (Cont’d)
6. Select a switch on the diagnosis results screen, and comments
for the diagnosis results will be shown.

SKIB3659E

EL-116

NAVIGATION SYSTEM
Self Diagnosis Mode (Cont’d)
GI

SELF-DIAGNOSIS RESULT
Check the applicable display in the following table, and then repair the malfunctioning parts.

Quick Reference Table
Self-diagnosis result screen

Possible cause

Action to take

EM
LC

NAVI control unit malfunction is
detected.

Replace NAVI control unit.

EC
FE

SKIB7632E

I Malfunction is detected on DVDROM drive pickup lens in NAVI
control unit.
I There is dirt and damage on the
DVD-ROM.

SKIB7633E

1. Check if the inserted DVD-ROM is
specified for this navigation
system, and the DVD-ROM is dirty,
scratched or warped.
2. If the results from the above
checkup show no malfunction,
insert the same DVD-ROM, and
then restart self-diagnosis.
3. If self-diagnosis results still show
any malfunction, replace NAVI
control unit.

MT
AT
TF
PD
FA
RA

DVD-ROM not inserted is detected.

Insert DVD-ROM.

BR
ST

SKIB7634E

GPS antenna connection malfunction
is detected.

1. Check if GPS antenna feeder line
is snapped or pinched.
2. If the results from the above
checkup show no malfunction,
replace GPS antenna, and then
restart self-diagnosis.
3. If self-diagnosis results still show
any malfunction, replace NAVI
control unit.

RS
BT
HA

SKIB7635E

SE
IDX

EL-117

NAVIGATION SYSTEM
Self Diagnosis Mode (Cont’d)
Self-diagnosis result screen

Possible cause

Action to take

I TMC tuner power supply and
ground circuit malfunction is
detected.
I Malfunction is detected on communication signal between NAVI control unit and TMC tuner.

1. Check TMC tuner power supply
and ground circuit.
2. Check communication circuit
between NAVI control unit and
TMC tuner.
3. If the results from the above
checkup show no malfunction,
replace either TMC tuner or NAVI
control unit, and then start selfdiagnosis.
4. If self-diagnosis results still show
any malfunction, replace the other
unit.

SKIB7636E

EL-118

NAVIGATION SYSTEM
Confirmation/Adjustment Mode

OPERATION PROCEDURE
1. Start the engine.
” buttons simultaneously for 5
2. Press and hold “MAP” and “
seconds or more.
I
Shifting from current screen to previous screen is performed by pressing “BACK” button.

MA
EM
LC

PKIB1537E

3. The initial trouble diagnosis screen will be shown, and items
“Self Diagnosis” and “Confirmation/Adjustment” will become
selective.

EC
FE
CL
MT

SKIB6974E

4. Each diagnosis is shown by selecting each screen switch on
Confirmation/Adjustment screen.

AT
TF
PD
FA
RA

SKIB6975E

BR
ST
RS
BT
HA

SE
IDX

EL-119

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
DISPLAY DIAGNOSIS

SKIB6976E

If RGB signal is malfunctioning, the tint of the color bar display is as follows.
R (red) signal error: Light blue (Cyan) tint
G (green) signal error: Purple (Magenta) tint
B (blue) signal error: Yellow tint

VEHICLE SIGNALS
A comparison check can be made of each actual vehicle signal and
the signals recognized by the NAVI control unit.

SKIB6977E

Diagnosis item

Vehicle speed

Display

Condition

When vehicle speed is more than 0 km/h (0 MPH)

OFF

When vehicle speed is 0 km/h (0 MPH)

—

Ignition switch in ACC position

Lighting switch ON

OFF

Lighting switch OFF

Ignition switch ON

OFF

Ignition switch ACC position

Selector lever in R position

OFF

Selector lever in any position other than R position

Remarks
Changes in indication may be
delayed. This is normal.

Lights

—

Ignition

Reverse

—

Changes in indication may be
delayed. This is normal.

Ignition switch in ACC position

NOTE:
If ignition signal is NG, each vehicle signal of vehicle speed and reverse is not displayed.

EL-120

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
NAVIGATION

Steering Angle Adjustment
The steering angle output value detected by the gyroscope can be
adjusted.

MA
EM
LC

SKIB3684E

Speed Calibration
Usually the automatic distance correction function adjusts the malfunction in distance caused by the tires wearing down or the tire
pressure change. If prompt adjustment is necessary when the tire
chains are installed etc., perform this procedure.

EC
FE
CL
MT

SKIB3685E

AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX

EL-121

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
ERROR HISTORY
Diagnosis results of self-diagnosis depend on if any error occurred during the time after selecting “Self Diagnosis” until self-diagnosis results are displayed.
Meanwhile, when an error occurs before selecting “Self Diagnosis”, and if an error does not occur until selfdiagnosis results are displayed, a diagnosis result is judged as normal.
Consequently, a diagnosis needs to be performed with “Error History” for the past error that is not available
with self-diagnosis.
“Error History” displays the time and place of the most recent occurrence of that error. However, take note of
the following points.
I Correct time of the error occurrence may not be displayed when the GPS antenna substrate within the
NAVI control unit has malfunctioned.
I Place of the error occurrence is represented by the position of the vehicle mark at the time when the error
occurred. If the vehicle mark has deviated from the correct position, then the place of the error occurrence
may not be located correctly.
I When the ignition switch is turned ON if the error is detected, the counter increases 1. Even if it is normal when the ignition switch is turned ON the next time, the counter does not decrease.
I The upper limit of the counter is 50. 51 or more is displayed as 50. It can be reset to 0 by “Delete log”
switch.

SKIB6978E

EL-122

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
GI

Diagnosis by Error History
I

When having a difficulty on the investigation of cause due to multiple errors with a reproducible
malfunction, turn ON the ignition switch from OFF mode after making a memo of the item and number of
time (or delete “Error History”). Check “Error History” again after the malfunction was reproduced, and then
perform diagnosis focusing on the item of which number of time increased.
DVD-ROM error history may be restored because DVD-ROM cannot be temporarily read. (Driving on rough
road etc.) Then, erase the error history. (This is not a malfunction.) Perform service in “Action to take” if
error history are repeatedly indicated again.
Error item

GPS Antenna Error

Possible cause

GPS antenna connection malfunction is
detected.

FLASH-ROM Error Of Control Unit
NAVI control unit malfunction is detected.
Connection Of Gyro

Action to take
1. Start self-diagnosis, and make sure of
the result.
2. If any error is found, GO TO 3. If any
error is not found, delete the error history and end the diagnosis. (This is not
a malfunction.)
3. Check if GPS antenna feeder line is
snapped or pinched.
4. If the results from the above checkup
show no malfunction, replace GPS
antenna, and then restart self-diagnosis.
5. If self-diagnosis results still show any
malfunction, replace NAVI control unit.
1. Start self-diagnosis, and make sure of
the result.
2. If any error is found, replace NAVI control unit. If any error is not found, delete
the error history and end the diagnosis.
(This is not a malfunction.)

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD

GPS Communication Error
Transmission error: GPS-Main CPU
Receive error: GPS-Main CPU
GPS malfunction is detected.
GPS ROM Error
GPS RAM Error

If the symptoms such as the GPS receipt
malfunction occur, intermittent malfunction
caused by strong radio interference may
be detected.
If the malfunction always occurs, replace
NAVI control unit.

GPS RTC Error

FA
RA
BR

DVD-ROM Mechanism not Detected
DVD-ROM Communication Error

DVD-ROM Mechanism Error
DVD-ROM Focus Error
DVD-ROM TOC Error
DVD-ROM Disc Error
DVD-ROM Seek Error
DVD-ROM Error Correction Error

I Malfunction is detected on DVD-ROM
drive pickup lens in NAVI control unit.
I There is dirt and damage on the DVDROM.

DVD-ROM Read Error
DVD-ROM Data Transfer Error

1. Check if the inserted DVD-ROM is
specified for this navigation system,
and the DVD-ROM is dirty, scratched
or warped.
2. If the results from the above checkup
show no malfunction, insert the same
DVD-ROM, and then restart self-diagnosis.
3. If self-diagnosis results still show any
malfunction, replace NAVI control unit.

RS
BT
HA

DVD-ROM Data Error
DVD-ROM Loading/Eject Error

DVD-ROM Time-out

IDX

EL-123

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
Error item

Converter Connection Error

RDS-TMC Error

Possible cause

Action to take

I Transfer unit power supply and ground
circuit malfunction is detected.
I Malfunction is detected on communication signal between NAVI control unit
and transfer unit.

1. Delete the error history, and turn OFF
ignition switch.
2. Turn ON ignition switch, and make sure
of the error history.
3. If the error item listed left is displayed
again, GO TO 4. If the error item is not
displayed, end the diagnosis. (This is
not a malfunction.)
4. Check transfer unit power supply and
ground circuit.
5. Check communication circuit between
NAVI control unit and transfer unit.
6. If the results from the above checkup
show no malfunction, replace either
transfer unit or NAVI control unit, and
then start self-diagnosis.
7. If self-diagnosis results still show any
malfunction, replace the other unit.

I TMC tuner power supply and ground
circuit malfunction is detected.
I Malfunction is detected on communication signal between NAVI control unit
and TMC tuner.

1. Start self-diagnosis, and make sure of
the result.
2. If any error is found, GO TO 3. If any
error is not found, delete the error history and end the diagnosis. (This is not
a malfunction.)
3. Check TMC tuner power supply and
ground circuit.
4. Check communication circuit between
NAVI control unit and TMC tuner.
5. If the results from the above checkup
show no malfunction, replace either
TMC tuner or NAVI control unit, and
then start self-diagnosis.
6. If self-diagnosis results still show any
malfunction, replace the other unit.

EL-124

NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont’d)
DELETE UNIT CONNECTION LOG

Erase the connection history of unit and error history that is
recorded in NAVI control unit (clear the connection history of the
removed unit).

MA
EM
LC

SKIB6979E

FEATURE RESTRICTION SETTING
Operations of navigation system that are performed while driving
can be restricted by using this function.
CAUTION:
Once operational restrictions are imposed, they cannot be
cancelled even when the software is updated or the languageswitching program is loaded.

EC
FE
CL
MT

SKIB6980E

AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX

EL-125

NAVIGATION SYSTEM
All Images Are Not Displayed
Symptom: All images are not displayed. (Navigation system does
not start.)
1.

CHECK CONDITION

1. Turn ignition switch ON.
2. Press and hold “MAP” and “

” buttons simultaneously for 5 seconds or more.
Does NAVI switch sound a beep twice?

YES

GO TO 2.

GO TO 5.

CHECK NAVI CONTROL UNIT POWER SUPPLY AND GROUND CIRCUIT

1. Check voltage between NAVI control unit harness connector terminals and ground.

SKIB7018E

Terminals
(+)
Connector

Terminal
2

M179

OFF

(-)
Ground

ACC

Battery voltage

2. Turn ignition switch OFF.
3. Disconnect NAVI control unit connector.
4. Check continuity between NAVI control unit harness connector M179 terminal 1 and ground.
1 — Ground: Continuity should exist.

SKIB7019E

OK or NG
OK

GO TO 3.

Repair harness or connector.

EL-126

NAVIGATION SYSTEM
All Images Are Not Displayed (Cont’d)
3.

CHECK HARNESS

1. Disconnect NAVI control unit and transfer unit connectors.
2. Check continuity between NAVI control unit harness connector (A) M180 terminals 69, 70 and transfer unit harness
connector (B) M173 terminals 11, 13.
69 — 11: Continuity should exist.
70 — 13: Continuity should exist.
3. Check continuity between NAVI control unit harness connector (A) M180 terminals 69, 70 and ground.
69, 70 — Ground: Continuity should not exist.

MA
EM
LC
EC
FE
CL

SKIB7020E

OK or NG
OK

GO TO 4.

Repair harness or connector.

CHECK NAVI CONTROL UNIT AND TRANSFER UNIT

1. Replace NAVI control unit or transfer unit.
2. Turn ignition switch ON.
3. Check if an image is displayed on the screen.
Is an image displayed on the screen?
YES

INSPECTION END

Replace the other unit.

MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX

EL-127

NAVIGATION SYSTEM
All Images Are Not Displayed (Cont’d)
5.

CHECK POWER SUPPLY CIRCUIT

Check voltage between the following harness connector terminals and ground.

SKIB7021E

Terminals
Unit

(+)
Connector

(A) NAVI switch

M169

(B) Display

M170

M173

OFF

ACC

Battery voltage

21, 23

Battery voltage

Terminal

(-)

Ground

31, 32

Battery voltage

OK or NG
OK

GO TO 6.

Repair harness or connector.

EL-128

NAVIGATION SYSTEM
All Images Are Not Displayed (Cont’d)
6.

CHECK GROUND CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect NAVI switch, display and transfer unit connectors.
3. Check continuity between the following harness connector terminals and ground.

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
SKIB7022E

ST
Terminals
Unit

(+)
Connector

Terminal

(A) NAVI switch

M169

(B) Display

M170

22, 24

M173

25, 27

(-)

Ground

Continuity

Yes

BT
HA

OK or NG
OK

GO TO 7.

Repair harness or connector.

SE
IDX

EL-129

NAVIGATION SYSTEM
All Images Are Not Displayed (Cont’d)
7.

CHECK HARNESS

1. Check continuity between transfer unit harness connector (A) M173 terminal 20 and display harness connector (B)
M170 terminal 16.
20 — 16: Continuity should exist.
2. Check continuity between transfer unit harness connector (A) M173 terminal 20 and ground.
20 — Ground: Continuity should not exist.

SKIB7023E

OK or NG
OK

GO TO 8.

Repair harness or connector.

CHECK COMMUNICATION SIGNAL (NAVI-DISP)

1. Connect NAVI switch, display and transfer unit connectors.
2. Turn ignition switch ON.
3. Check voltage waveform between transfer unit harness connector M173 terminal 20 and ground using CONSULT-ll or
oscilloscope.
20 — Ground:

SKIB3607E

SKIB7024E

OK or NG
OK

GO TO 9.

Replace transfer unit.

EL-130

NAVIGATION SYSTEM
All Images Are Not Displayed (Cont’d)
9.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect display and NAVI switch connectors.
3. Check continuity between display harness connector (A) M170 terminal 15 and NAVI switch harness connector (B)
M169 terminal 4.
15 — 4: Continuity should exist.
4. Check continuity between display harness connector (A) M170 terminal 15 and ground.
15 — Ground: Continuity should not exist.

MA
EM
LC
EC
FE
CL

SKIB7025E

OK or NG
OK

GO TO 10.

Repair harness or connector.

10.

MT
AT

CHECK COMMUNICATION SIGNAL (DISP-SW)

1. Connect display and NAVI switch connectors.
2. Turn ignition switch ON.
3. Check voltage waveform between display harness connector M170 terminal 15 and ground using CONSULT-ll or oscilloscope.
15 — Ground:

TF
PD
FA
RA

SKIB3606E

BR
ST
RS
BT

SKIB7026E

OK or NG
OK

GO TO 11.

Replace display.

SE
IDX

EL-131

NAVIGATION SYSTEM
All Images Are Not Displayed (Cont’d)
11.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect NAVI switch and transfer unit connectors.
3. Check continuity between NAVI switch harness connector (A) M169 terminal 5 and transfer unit harness connector (B)
M173 terminal 18.
5 — 18: Continuity should exist.
4. Check continuity between NAVI switch harness connector (A) M169 terminal 5 and ground.
5 — Ground: Continuity should not exist.

SKIB7027E

OK or NG
OK

GO TO 12.

Repair harness or connector.

12.

CHECK COMMUNICATION SIGNAL (SW-NAVI)

1. Connect NAVI switch and transfer unit connectors.
2. Turn ignition switch ON.
3. Check voltage waveform between NAVI switch harness connector M169 terminal 5 and ground using CONSULT-ll or
oscilloscope.
5 — Ground:

SKIB3611E

SKIB7028E

OK or NG
OK

GO TO 13.

Replace NAVI switch.

EL-132

NAVIGATION SYSTEM
All Images Are Not Displayed (Cont’d)
13.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit and display connectors.
3. Check continuity between NAVI control unit harness connector (A) M180 terminal 50 and display harness connector (B)
M170 terminal 8.
50 — 8: Continuity should exist.
4. Check continuity between NAVI control unit harness connector (A) M180 terminal 50 and ground.
50 — Ground: Continuity should not exist.

MA
EM
LC
EC
FE
CL

SKIB6983E

OK or NG

GO TO 14.

Repair harness or connector.

14.

CHECK RGB AREA (YS) SIGNAL

1. Connect NAVI control unit and display connectors.
2. Turn ignition switch ON.
3. Check voltage waveform between NAVI control unit harness connector M180 terminal 50 and ground using CONSULT-ll or oscilloscope.

TF
PD
FA
RA
BR

SKIB6984E

ST
RS

Terminal
(+)

(-)

Ground

Condition

Reference value

When displaying RGB image

Approx. 5 V

OK or NG
OK

Replace display.

Replace NAVI control unit.

BT
HA

SE
IDX

EL-133

NAVIGATION SYSTEM
Vehicle Mark Is Not Displayed Properly
Symptom: Vehicle mark is not displayed at the vehicle driving position properly.
1.

NAVIGATION SYSTEM ADJUSTMENT

1. Select “Navigation” in Confirmation/Adjustment mode, and adjust items, “Steering Angle Adjustment” and “Speed Calibration”.
2. Check symptom with driving.
Is any malfunction observed?
YES

GO TO 2.

INSPECTION END

SELF-DIAGNOSIS

Start self-diagnosis, and check any malfunction related to GPS.
Is any malfunction related to GPS observed?
YES

Repair malfunctioning part by diagnostic results.

GO TO 3.

CHECK VEHICLE SIGNAL

Select “Vehicle Signals” in Confirmation/Adjustment mode, and check the vehicle speed signal and reverse signal inputting
to NAVI control unit.
OK or NG
OK

Limit of position detection capacity.

I Check NAVI control unit vehicle speed signal circuit, and repair malfunctioning part.
I Check NAVI control unit reverse signal circuit, and repair malfunctioning part.

EL-134

NAVIGATION SYSTEM
GI

Tint Is Strange for The RGB Image
Symptom: Tint of RGB image is strange.
1.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit and display connectors.
3. Check the malfunctioning circuit according to the symptoms.
I Light blue (Cyan) tinged screen
Check continuity between NAVI control unit harness connector (A)
M180 terminal 44 and display harness connector (B) M170 terminal 1.
44 — 1: Continuity should exist.
Check continuity between NAVI control unit harness connector (A)
M180 terminal 44 and ground.
44 — Ground: Continuity should not exist.

EM
LC
EC
FE
CL
SKIB6994E

I Purple (Magenta) tinged screen
Check continuity between NAVI control unit harness connector (A)
M180 terminal 45 and display harness connector (B) M170 terminal 2.
45 — 2: Continuity should exist.
Check continuity between NAVI control unit harness connector (A)
M180 terminal 45 and ground.
45 — Ground: Continuity should not exist.

MT
AT
TF
PD
SKIB6995E

I Yellow tinged screen
Check continuity between NAVI control unit harness connector (A)
M180 terminal 46 and display harness connector (B) M170 terminal 3.
46 — 3: Continuity should exist.
Check continuity between NAVI control unit harness connector (A)
M180 terminal 46 and ground.
46 — Ground: Continuity should not exist.

FA
RA
BR
ST
SKIB6996E

OK or NG
OK

GO TO 2.

Repair harness or connector.

RS
BT
HA

SE
IDX

EL-135

NAVIGATION SYSTEM
Tint Is Strange for The RGB Image (Cont’d)
2.

CHECK RGB SIGNAL

1. Connect NAVI control unit and display connectors.
2. Turn ignition switch ON.
3. Start Confirmation/Adjustment mode.
4. Display color bar by selecting “Color Spectrum bar” on Display Diagnosis screen.
5. Check the malfunctioning circuit according to the symptoms.
I Light blue (Cyan) tinged screen
Check voltage waveform between NAVI control unit harness connector
M180 terminal 44 and ground using CONSULT-ll or oscilloscope.
44 — Ground:

SKIB7360E
SKIB6997E

I Purple (Magenta) tinged screen
Check voltage waveform between NAVI control unit harness connector
M180 terminal 45 and ground using CONSULT-ll or oscilloscope.
45 — Ground:

SKIB7361E
SKIB6998E

I Yellow tinged screen
Check voltage waveform between NAVI control unit harness connector
M180 terminal 46 and ground using CONSULT-ll or oscilloscope.
46 — Ground:

SKIB7362E
SKIB6999E

OK or NG
OK

Replace display.

Replace NAVI control unit.

EL-136

NAVIGATION SYSTEM
GI

RGB Image Is Rolling
Symptom: RGB image such as a map screen is rolling.
1.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit and display connectors.
3. Check continuity between NAVI control unit harness connector (A) M180 terminal 48 and display harness connector (B)
M170 terminal 7.
48 — 7: Continuity should exist.
4. Check continuity between NAVI control unit harness connector (A) M180 terminal 48 and ground.
48 — Ground: Continuity should not exist.

EM
LC
EC
FE
CL
MT

SKIB7000E

OK or NG
OK

GO TO 2.

Repair harness or connector.

AT
TF

CHECK RGB SYNCHRONIZING SIGNAL

1. Connect NAVI control unit and display connectors.
2. Turn ignition switch ON.
3. When displaying RGB image, check voltage waveform between NAVI control unit harness connector M180 terminal 48
and ground using CONSULT-ll or oscilloscope.
48 — Ground:

PD
FA
RA
BR

SKIB3603E

ST
RS
BT
HA

SKIB7001E

OK or NG
OK

Replace display.

Replace NAVI control unit.

SE
IDX

EL-137

NAVIGATION SYSTEM
Values for All Items in the Drive Computer
Screen Do Not Change
Symptom: Values for items, “Elapsed Time”, “Driving Distance” and “Average Speed” in the Drive Computer
screen do not change.
1.

CHECK NAVI CONTROL UNIT IGNITION SIGNAL

Select “Vehicle Signals” in Confirmation/Adjustment mode, and check the ignition signal inputting to NAVI control unit.
OK or NG
OK

Replace NAVI control unit.

Check NAVI control unit ignition signal circuit, and repair malfunctioning part.

Values for Items, “Driving Distance” and
“Average Speed” Do Not Change
Symptom: Values for Items, “Driving Distance” and “Average Speed” do not change. (The Value for “Elapsed
Time” Changes.)
1.

CHECK NAVI CONTROL UNIT VEHICLE SPEED SIGNAL

Select “Vehicle Signals” in Confirmation/Adjustment mode, and check the vehicle speed signal inputting to NAVI control
unit.
OK or NG
OK

Replace NAVI control unit.

Check NAVI control unit vehicle speed signal circuit, and repair malfunctioning part.

Voice Guidance Is Not Heard
Symptom: Voice guidance does not sound at route guidance.
1.

CHECK CONDITION

Turn audio system ON, and check if any sound can be heard from front door speaker (driver side).
OK or NG
OK

GO TO 2.

Repair malfunctioning part.

CHECK CONDITION

Turn audio system ON, and check if front door speaker (driver side) is muted when pressing “VOICE” button during sounding from front door speaker (driver side).
Is front door speaker (driver side) muted?
YES

GO TO 3.

GO TO 7.

EL-138

NAVIGATION SYSTEM
Voice Guidance Is Not Heard (Cont’d)
3.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect NAVI control unit and transfer unit connectors.
3. Check continuity between NAVI control unit harness connector (A) M179 terminals 12, 14 and transfer unit harness
connector (B) M173 terminals 8, 10.
12 — 8: Continuity should exist.
14 — 10: Continuity should exist.
4. Check continuity between NAVI control unit harness connector (A) M179 terminals 12, 14 and ground.
12, 14 — Ground: Continuity should not exist.

MA
EM
LC
EC
FE
CL

SKIB7002E

OK or NG
OK

GO TO 4.

Repair harness or connector.

MT
AT
TF

CHECK VOICE GUIDANCE SIGNAL

1. Connect NAVI control unit and transfer unit connectors.
2. Turn ignition switch ON.
3. When pressing “VOICE” button, check voltage waveform between NAVI control unit harness connector M179 terminals
12 and 14 using CONSULT-ll or oscilloscope.
12 — 14:

PD
FA
RA
BR

SKIB3597E

ST
RS
BT
HA
SKIB7003E

OK or NG
OK

GO TO 5.

Replace NAVI control unit.

SE
IDX

EL-139

NAVIGATION SYSTEM
Voice Guidance Is Not Heard (Cont’d)
5.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect transfer unit and voice change relay connectors.
3. Check continuity between transfer unit harness connector (A) M173 terminals 1, 2 and voice change relay harness connector (B) M174 terminals 6, 7.
1 — 6: Continuity should exist.
2 — 7: Continuity should exist.
4. Check continuity between transfer unit harness connector (A) M173 terminals 1, 2 and ground.
1, 2 — Ground: Continuity should not exist.

SKIB7004E

OK or NG
OK

GO TO 6.

Repair harness or connector.

CHECK VOICE GUIDANCE SIGNAL

1. Connect transfer unit and voice change relay connectors.
2. Turn ignition switch ON.
3. When pressing “VOICE” button, check voltage waveform between transfer unit harness connector M173 terminals 1
and 2 using CONSULT-ll or oscilloscope.
1 — 2:

SKIB3609E

SKIB7005E

OK or NG
OK

Replace voice change relay.

Replace transfer unit.

EL-140

NAVIGATION SYSTEM
Voice Guidance Is Not Heard (Cont’d)
7.

CHECK HARNESS

1. Turn ignition switch OFF.
2. Disconnect transfer unit and voice change relay connectors.
3. Check continuity between transfer unit harness connector (A) M173 terminals 4, 6 and voice change relay harness connector (B) M174 terminals 1, 2.
4 — 1: Continuity should exist.
6 — 2: Continuity should exist.
4. Check continuity between transfer unit harness connector (A) M173 terminal 6 and ground.
6 — Ground: Continuity should not exist.

MA
EM
LC
EC
FE
CL

SKIB7006E

OK or NG
OK

GO TO 8.

Repair harness or connector.

MT
AT
TF

CHECK VOICE GUIDANCE ON SIGNAL

PD
FA
RA
BR

SKIB3610E

ST
RS
BT
HA
SKIB7007E

OK or NG
OK

Replace voice change relay.

Replace transfer unit.

SE
IDX

EL-141

NAVIGATION SYSTEM
RDS-TMC (Traffic Information) Is Not Received
1.

CHECK SELF-DIAGNOSIS

Perform self-diagnosis.
Is self-diagnosis result normal?
YES

GO TO 2.

Refer to EL-117.

CHECK CONDITION

Turn ignition switch ON, and audio unit ON.
Does audio unit receive radiobroadcast?
YES

Replace TMC tuner.

Check antenna and antenna feeder.

EL-142

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction GI
MA

BASIC OPERATIONS
Symptom
No image comes on.

No map comes on the screen.

Possible cause

Remedy

The brightness adjustment is at the lowest
setting.

Adjust to brighter setting.

No map DVD-ROM is inserted, or it is
inserted upside down.

Insert the DVD-ROM correctly.

The map display mode is switched off.

Press the “MAP” button.

No voice guidance is available. or
The volume is not high enough.

The volume is not set correctly or it is turned
off.

Adjust the volume correctly.

The screen is too dim. The movement is slow.

The temperature in the vehicle is low.

Wait for the temperature to rise.

There are darker or brighter dots in
the display.

It is inherent to LC displays.

This is not malfunction.

LC
EC
FE
CL

VEHICLE MARKS
Symptom

Possible cause

Remedy

The location names differ between
PLAN VIEW and BIRDVIEW.

This is because the displayed information is
reduced so that the screen does not become
too crowded. There is also a chance that
names of the roads or locations will be
repeatedly displayed. The name appearing
on the screen may be different because of
the processing procedure.

It should not be regarded as malfunction.

The vehicle mark is not shown correctly.

The vehicle might have moved with the ignition off, for example on a ferry boat or car
transporter.

Drive the vehicle with GPS on for some distance.

The screen does not switch to night
mode even after turning the headlights on.

The last time the lights were turned on, your
setting was in daytime mode.

Turn the headlights on again, go to DISPLAY
SETTINGS screen and set it to the night
mode.

The map does not scroll even when
the vehicle is traveling.

The display is not switched to the map
screen.

Press the “MAP” button.

The vehicle mark does not show up.

The display is not switched to the map
screen.

Press the “MAP” button.

Move the vehicle outdoors with a clear view
of the sky.

GPS signals are not received because the
vehicle is indoors or in the shade of buildGPS indicator on the screen remains ings.
gray.
GPS satellites are in poor locations.
Driving on slippery road surface
Driving on slanted area

The location of the vehicle mark
does not match the actual position.

AT
TF

Wait for the satellites to move to better locations.
If the vehicle mark does not move to the correct position even after the vehicle has been
driven for approximately 10 km (6 miles),
adjust the current location. If necessary,
adjust the moving speed of the vehicle.

Rough or violent driving.

If the position maker does not move to the
correct position even after the vehicle has
been driven for approximately 10 km (6
miles), adjust the current location.

GPS indicator remains gray.

Please check the GPS indicator on the
screen to see if it remains gray.

Errors (gain or loss) result in calculating the
speed from the speed pulse because the
vehicle has tire chains on, or the system was
transferred to a different vehicle.

It will move by driving the vehicle for 30 minutes [in case it is running at 30 km/h (19
MPH)]. If you still notice errors, adjust moving
speed.

The map data has an error or is incomplete
(if the location error always happens in the
same area).

Please wait for the updated Map.

PD
FA

ST
RS
BT
HA

SE
IDX

EL-143

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
MAP DVD-ROM
Symptom
The message “Error” appears after
operation.

Possible cause
Map DVD-ROM is soiled or partially damaged.

Remedy
Check the DVD-ROM and wipe it clean with
a soft cloth.
In case you see any damage, replace the
DVD-ROM.

DESTINATION, WAYPOINTS OR MENU CONTENTS CANNOT BE CHOSEN OR SET
Symptom

Turn list is not displayed.

In re-routing, the waypoints are not
included in the calculation.

Route information is not displayed.

Possible cause

Remedy

Route calculation has not yet been
requested.

Set the destination and request route calculation.

The vehicle mark is not on the suggested
route.

Please drive the vehicle along the suggested
route.

Route guidance is off.

Turn the route guidance on.

The system has judged that the vehicle has
already passed the point.

If you want to go to that point again, edit the
route again.

Route calculation has not yet been
requested.

Set the destination and request route calculation.

The vehicle mark is not on the suggested
route.

Please drive the vehicle along the suggested
route.

Route guidance is off.

Turn the route guidance on.

Enter the route that can be calculated from.
The vehicle is not running on a route that can Alternatively, you can calculate the route
Route is not calculated automatically.
manually. In this case, the entire route will be
be calculated from.
calculated again.
It is impossible to request a detour.

Your vehicle is not running on the suggested
route.

Restart route calculation or join the suggested route.

The detour found is the same as the
previous suggestion.

The system took many conditions into
consideration, but the same result was
obtained.

This is not malfunction.

It is impossible to set the waypoints.

The number of waypoints exceeds 5.

It is impossible to set more than 5 waypoints.
Please divide them in groups to find them all.

VOICE GUIDANCE
Symptom

Possible cause

Remedy

Voice guidance is only available at certain
intersections marked with . In some cases,
System is not malfunction.
the guidance is not available even when the
vehicle should make a turn.
The voice guidance is not available.

The guidance content does not correspond to the actual condition.

The vehicle is off the suggested route.

Return to the recommended route or
re-search the route.

Voice guidance is set off.

Turn the voice guidance on.

Route guidance is set off.

Turn the route guidance on.

The content of the voice guidance may vary,
depending on the types of junctions to make
turns on.

Follow the actual rules and regulations.

EL-144

NAVIGATION SYSTEM
Example of Symptoms Judged Not Malfunction
(Cont’d)
GI
ROUTE CALCULATION
Symptom

Possible cause

Although the system is set with the
moving direction as the preference, it
There is no route found in that direction.
does not find the route by matching
the preference.

Route is not indicated.

There is no road close to the destination that
can be found by this system.

Remedy
This is not malfunction.
Reset the destination close to the road displayed with orange, or wider ones. Especially
with roads which have separate lanes for
opposite directions, be careful in setting the
destination or waypoints on it, as results may
differ depending on the lane you choose.

The starting point to the destination is too
close.

Set more distant destinations.

The route is not displayed continuously at waypoints that are for
example not calculated routes from
the vehicle’s current position.

Suggested routes may be displayed discontinuously near waypoints as route calculation
is done at each waypoint.

This is not malfunction.

The suggested route the vehicle has
travelled is erased.

Suggested routes are stored in memory by
the blocks; if the vehicle travels past waypoint 1, the former data will be erased.

This is not malfunction.

A very detoured route is suggested.

If there are restrictions (such as one-way trafTry slightly moving the starting point or destific) on roads close to the starting point or
nation.
destination, the system may suggest a
detoured route.

The landmark description does not
correspond to the actual one.

It may be caused by insufficient or incorrect
data on the DVD-ROM.

Please wait for the update Map DVD-ROM.

There is no data for route calculation closer
to these points.

Set these points on the main road displayed
in thick orange. Please note that in some
cases even main roads lack the data for
route calculation.

The suggested route does not
exactly connect to the starting point,
waypoints, or destination.

MA
EM
LC
EC
FE
CL

NOTE:
Except for the ordinance-designated cities and the prefectural capitals. (Applicable areas may be changed in
the updated map disc.)

MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX

EL-145

HEATED SEAT/WAGON AND HARDTOP MODELS
Wiring Diagram — HSEAT —

TEL241N

EL-146

HEATED SEAT/WAGON AND HARDTOP MODELS
Wiring Diagram — HSEAT — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL671A

IDX

EL-147

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Schematic

TEL242N

EL-148

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
GI

Wiring Diagram — ASCD —

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL569M

EL-149

IDX

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Wiring Diagram — ASCD — (Cont’d)

TEL243N

EL-150

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Wiring Diagram — ASCD — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL244N

IDX

EL-151

AUTOMATIC SPEED CONTROL DEVICE (ASCD)/WAGON AND HARDTOP
MODELS
Wiring Diagram — ASCD — (Cont’d)

TEL090N

EL-152

POWER WINDOW/WAGON AND HARDTOP MODELS
GI

Schematic

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL245N

EL-153

IDX

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW —

TEL246N

EL-154

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL092N

IDX

EL-155

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW — (Cont’d)

TEL093N

EL-156

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW — (Cont’d)
GI

LHD WAGON MODELS

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL094N

EL-157

IDX

POWER WINDOW/WAGON AND HARDTOP MODELS
Wiring Diagram — WINDOW — (Cont’d)
RHD WAGON MODELS

TEL095N

EL-158

CAN SYSTEM/TB48 ENGINE MODELS WITH A/T
GI

Wiring Diagram — CAN —

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL247N

EL-159

IDX

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — LHD Models

CEL616M

EL-160

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — LHD Models
(Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL617M

EL-161

IDX

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — RHD Models

CEL618M

EL-162

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
Passenger Compartment — RHD Models
(Cont’d)

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
CEL619M

EL-163

IDX

LOCATION OF ELECTRICAL UNITS/WAGON AND HARDTOP MODELS
NOTE

EL-164

HARNESS LAYOUT
How to Read Harness Layout
Example:
G2

GI
MA

B/6

: ASCD ACTUATOR

EM
Connector color / Cavity
Connector number

Grid reference

The following Harness Layouts use a map style grid to help locate connectors on the drawings:
I Main Harness
I Engine Room Harness
I Body Harness

To
1)
2)
3)
4)
5)

MT
AT

CONNECTOR SYMBOL
Main symbols of connector (in Harness Layout) are indicated in the below.
Water proof type

Standard type

Connector type
Male

Female

Male

I Cavity: Less than 4
I Relay connector

I Ground terminal etc.

PD
FA

I Cavity: From 5 to 8
I Cavity: More than 9

Female

—

—
—

BR
ST
RS
BT
HA

SE
IDX

EL-165

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models

TEL125V

EL-166

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL126V

IDX

EL-167

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/LHD Models (Cont’d)

TEL127V

EL-168

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
NOTE

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX

EL-169

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models

TEL128V

EL-170

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL129V

IDX

EL-171

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Main Harness/RHD Models (Cont’d)

TEL130V

EL-172

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
NOTE

GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
IDX

EL-173

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models
PASSENGER COMPARTMENT

TEL131V

EL-174

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/LHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL132V

IDX

EL-175

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models
PASSENGER COMPARTMENT

TEL133V

EL-176

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Room Harness/RHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL134V

IDX

EL-177

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models
WAGON

TEL136V

EL-178

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL137V

IDX

EL-179

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)
HARDTOP

TEL138V

EL-180

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body Harness/RHD Models (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL139V

IDX

EL-181

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models
WAGON

TEL140V

EL-182

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/LHD Models (Cont’d)
GI

HARDTOP

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL141V

EL-183

IDX

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/RHD Models
WAGON

TEL142V

EL-184

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Body No. 2 Harness/RHD Models (Cont’d)
GI

HARDTOP

MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SE
TEL143V

EL-185

IDX

HARNESS LAYOUT/WAGON AND HARDTOP MODELS
Engine Harness
ZD ENGINE

TEL147V

EL-186

WIRING DIAGRAM CODES (CELL CODES)
Wiring Diagram Codes (Cell Codes)

Use the chart below to find out what each wiring diagram code
stands for.
Refer to the wiring diagram code in the alphabetical index to find
the location (Page number) of each wiring diagram.

MA
EM

Code

Section

Wiring Diagram Name

A/T

ABS

Anti-lock Brake System

ASCD

Automatic Speed Control Device

AT/C

A/T Control

AT/IND

A/T Indicator Lamp

AUDIO

Audio

BOOST

Turbo Charger Boost Sensor

CAN

CAN Communication Line

CIGAR

Cigarette Lighter

DEF

Rear Window Defogger

DIFF/L

Differential Lock

DTRL

Headlamp — Daytime Light System

ECTS

Engine Coolant Temperature Sensor

FUELB1

Fuel Injection System Function
(Bank 1)

FUELB2

Fuel Injection System Function
(Bank 2)

HSEAT

Heated Seat

ILL

Illumination

INJECT

Injector

MAFS

Mass Air Flow Sensor

METER

Meter and Gauges

MMSW

Manual Mode Switch

NAVI

Navigation System

NONDTC

Non-detective Items

OILP/W

Engine Oil Pressure Warning System

POWER

Transmission Control Module (Power
Supply)

POWER

Power Supply Routing

R/HEAT

Rear Heater System

SHIFT

A/T Shift Lock System

STAB

Stabilizer Release Device

START

Starting System

STSIG

Start Signal Circuit

TURN

Turn Signal and Hazard Warning
Lamps

WARN

Warning Lamps

WINDOW

Power Window

WIP/R

Rear Wiper and Washer

LC
EC
FE
CL
MT
AT

FA
RA
BR

BT
HA

SE
IDX

EL-187

FUSE AND FUSIBLE LINK BOX/WAGON AND HARDTOP MODELS
Terminal Arrangement

CEL620M

EL-188

Edition: November 2005
Release: November 2005 (01)
Publication No.: SM5E00-1Y61E0E
Reference No.: 7711347682

QUICK REFERENCE INDEX

GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL

PATROL GR

ENGINE LUBRICATION &
COOLING SYSTEMS

MODEL Y61 SERIES

ENGINE CONTROL SYSTEM

ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEM

CLUTCH

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

TRANSFER

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

FRONT AXLE & FRONT SUSPENSION

REAR AXLE & REAR SUSPENSION

BRAKE SYSTEM

STEERING SYSTEM

RESTRAINT SYSTEM

BODY & TRIM

HEATER & AIR CONDITIONER

ELECTRICAL SYSTEM

ALPHABETICAL INDEX

IDX

NISSAN EUROPE S.A.S.
© 2005 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.

NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

GENERAL INFORMATION
MA

SECTION

OUTLINE OF MODIFICATIONS:
I
I

EM
LC
EC

Navigation system has been adopted for Europe.
Exterior design has been changed.

APPLIED FROM:
For Europe:

FE
For Israel:

JN1TESY61U0150001
JN1KESY61U0145001
JN1TFSY61U0011001

JN1TESY61*6X806501
JN1KESY61*6X806501

CL
MT

CONTENTS

AT
TF

CONSULT-II CHECKING SYSTEM ……………………………2
Function and System Application …………………………..2
Nickel Metal Hydride Battery Replacement……………..2
Checking Equipment…………………………………………….3

CONSULT-II Data Link Connector (DLC) Circuit ……..3
IDENTIFICATION INFORMATION……………………………..5
Model Variation ……………………………………………………5
Identification Number……………………………………………6

PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX

GI-1

CONSULT-II CHECKING SYSTEM
Function and System Application
Diagnostic test mode

Function

ENGINE

A/T

ABS

AIR
BAG

NATS*1

SMART
ENTRANCE

x*2

x*4

—

Work support

This mode enables a technician to adjust
some devices faster and more accurate by
following the indications on CONSULT-II.

Self-diagnostic results

Self-diagnostic results can be read and
erased quickly.

—

Trouble diagnostic
record

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

—

ECU discriminated
No.

Classification number of a replacement ECU
can be read to prevent an incorrect ECU
from being installed.

—

Data monitor

Input/Output data in the ECU can be read.

—

DTC work support

The operating condition to confirm Diagnosis
Trouble Codes can be selected.

—

Active test

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

—

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

—

Control unit initialization

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

—

Self-function check

ECM checks its own NATS communication
interface.

—

x*3

—

DTC confirmation

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

x*2

—

A maximum of four IDs (identifications) can
REMO CONT ID SET be registered in the memory using the
remote controller. These IDs can be also be
UP
confirmed and erased as required.

—

This mode can show results of self-diagnosis of ECU with either “OK” or “NG”. For
engine, more practical tests regarding
sensors/switches and/or actuators are available.

—

Function test

x: Applicable
*1: NATS (Nissan Anti-Theft System)
*2: Not available for diesel engine models.
*3: Except for ZD30DDTi engine models.
*4: RE4R03A models only

Nickel Metal Hydride Battery Replacement
CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following:
WARNING:
Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another battery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if
mistreated. Do not recharge, disassemble or dispose of in fire.
Keep the battery out of reach of children and discard used battery conforming to the local regulations.

GI-2

CONSULT-II CHECKING SYSTEM
Checking Equipment
When ordering the below equipment, contact your NISSAN distributor.

MA
Tool name

Description

NISSAN CONSULT-II
q
1 CONSULT-II unit (Tester
internal software: Resident version 3.3.0) and
accessories
q
2 Program card AED01C
and AEN00A or AEN00B
(For NATS)

EM
LC
EC
FE

SGI100A

NOTE:
I The CONSULT-II must be used in conjunction with a program card.
CONSULT-II does not require loading (Initialization) procedure.
I Be sure the CONSULT-II is turned off before installing or removing a program card.

CONSULT-II Data Link Connector (DLC) Circuit
(For ECM equipped models except TD42Ti engine and TD engine with NATS)

MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA

TGI006M

EL
SE
IDX

GI-3

CONSULT-II CHECKING SYSTEM
CONSULT-II Data Link Connector (DLC) Circuit
(Cont’d)
INSPECTION PROCEDURE
If the CONSULT-II cannot diagnose the system properly, check the following items.
Symptom

Check item

CONSULT-II cannot access any
system.

I CONSULT-II DLC power supply circuit (Terminal and ground circuit (Terminal 4)
(For detailed circuit, refer to EC section, “MIL & DATA LINK CONNECTORS”.)
I CONSULT-II (DDL) cable

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

I CONSULT-II program card (Check the appropriate CONSULT-II program card for the system.
Refer to “Checking Equipment” above.)
I Power supply and ground circuit for the control unit of the system
(For detailed circuit, refer to wiring diagram for each system.)
I Open or short circuit between the system and CONSULT-II DLC
(For detailed circuit, refer to wiring diagram for each system.)

GI-4

IDENTIFICATION INFORMATION
Model Variation
WAGON AND HARDTOP MODELS
Model

Rear seat arrangement
Destination

Steering
position

Hardtop

Station Wagon

2nd seat

2nd center split bench seat

Forward facing

3rd seat

Side facing or Seatless

Forward facing

Engine
Front differential

Transfer

FS5R50B

RHD

RE4R03A
FS5R50B

FS5R50B
ZD30DDTi

Europe

FS5R50B

KWSSREFY61UEA

—

TWSSREFY61UEA

KWSSRFFY61UEA

—

TWSSRFFY61UEA

KWSSRFAY61UEA

—

TWSSRFAY61UEA

—

TWSSRHFY61UEA

—

TWSSRHAY61UEA

KWSSLEFY61UGA

KWSSLEFY61USP

TWSSLEFY61UGA

KWSSLFFY61UGA

—

TWSSLFFY61UGA

—

TWSSLFFY61USA

KWSSLFAY61UGA

—

TWSSLFAY61UGA

—

TWSSLFAY61USA

—

TWSSLHFY61UGA

—

TWSSLHFY61USA

—

TWSSLHAY61UGA

—

TWSSLHAY61USA

—

TGPSLHNY61ESA

RE4R03A

TX12A

RE4R03A
LHD
FS5R50B
SE

RE4R03A
TB48DE

H233B/H260

Grade
S

FS5R50B

RE5R05A

EC
FE
CL
MT
AT
TF

PREFIX AND SUFFIX DESIGNATIONS
T

H233B

Rear differential
Transmission

Y61

A
A: 3rd/2nd seat forward facing
P: 3rd/2nd seat seatless

E: RHD for Europe
G: Central/South Europe
S: North Europe
E: Multiport fuel injection system engine
U: Turbocharger engine
F: 5-speed floor shift manual transmission
A: 4-speed floor shift automatic transmission
N: 5-speed floor shift automatic transmission
E: GL (SGL), ST, S F: SGL, TI, SAFARI, SE
H: GRX, S-SAFARI, SE
L: LH drive R: RH drive

PD
FA
RA
BR
ST
RS
BT

S: Long wheelbase

WS: ZD30DDTi engine GP: TB48DE engine
T: Station Wagon
K: Hardtop

EL
SE
IDX

GI-5

IDENTIFICATION INFORMATION
Identification Number
VEHICLE IDENTIFICATION NUMBER (Chassis number)
Prefix and suffix designations
For Europe (Except for Israel)
JN1

Y61

XXXXXX
Vehicle serial number

0: Stopgap (no meaning)
U: Europe
S: Long wheelbase (4WD)
Engine type
E: ZD30DDTi F: TB48DE
Body type
T: Station Wagon K: Hardtop
Manufacturer
JN1: Japan produced vehicle

For Israel
JN1

Y61

XXXXXX
Vehicle serial number

Manufacturing plant
X: Hiratsuka
Model year
6: 2006 model year
7: 2007 model year
S: Long wheelbase (4WD)
Engine type
E: ZD30DDTi
Body type
T: Station Wagon K: Hardtop
Manufacturer
JN1: Japan produced vehicle

GI-6

HEATER &
AIR CONDITIONER

GI
MA

SECTION

MODIFICATION NOTICE:
I Wiring diagram has been changed.

EM
LC
EC
FE

CONTENTS
REAR HEATER

Wiring Diagram — R/HEAT —/LHD Models ……………2

TROUBLE DIAGNOSES ………………………………………….2

MT
AT
TF
PD
FA
RA
BR
ST
RS
BT

EL
SE
IDX

HA-1

TROUBLE DIAGNOSES

REAR HEATER

Wiring Diagram — R/HEAT —/LHD Models

THA221M

HA-2

ALPHABETICAL INDEX

GI
MA

SECTION

IDX

EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE

IDX-1

ALPHABETICAL INDEX
Engine control circuit diagram……………………..EC-2
Engine coolant temperature sensor
(ECTS)………………………………………………….EC-4

A
ABS — Wiring diagram ………………………………..BR-3
Air flow meter — See Mass air flow
sensor …………………………………………………..EC-3
Anti-lock brake system — Wiring
diagram…………………………………………………BR-2
ASCD (automatic speed control
device)……………………………………………….EL-148
ASCD — Wiring diagram …………………………..EL-149
A/T — Wiring diagram …………………………………..AT-3
A/T control ………………………………………………..EC-5
A/T IND — Wiring diagram ………………………….EL-65
A/T indicator…………………………………………….EL-65
A/T shift lock system …………………………………AT-11
A/T shift lock system — Wiring diagram ………..AT-19
A/T trouble diagnoses ……………………………….AT-12
A/T Wiring diagram AT — MMSW…………………AT-16
A/T Wiring diagram AT — NONDTC ……………..AT-17
A/T Wiring diagram AT — POWER……………….AT-14
A/T Wiring diagram AT — STSIG………………….AT-13
AT/C — Wiring diagram………………………………..EC-5
Audio ………………………………………………………EL-73
AUDIO — Wiring diagram……………………………EL-74
Automatic speed control system — See
ASCD ………………………………………………..EL-148

F
Fluids……………………………………………………….MA-2
Fuel gauge ………………………………………………EL-47
Fuse……………………………………………………..Foldout
Fusible link…………………………………………….Foldout
G
Gauges……………………………………………………EL-47
Grease …………………………………………………….MA-2
Ground distribution……………………………………EL-14
H
Harness layout………………………………..EL-165, 166
Heated seat……………………………………………EL-146
HSEAT — Wiring diagram………………………….EL-146
I

B
BOOST — Wiring diagram ……………………………EC-6

ILL — Wiring diagram …………………………………EL-39
Illumination ………………………………………………EL-38
L

C
CAN (Controller Area Network) ………………..EL-159
CAN — Wiring diagram……………………………..EL-159
CAN communication ……………………………….EL-159
Charge air pressure sensor ………………………..EC-6
Cigarette lighter………………………………………..EL-68
Combination meter……………………………………EL-47
CONSULT-II general information…………………..GI-2
Controller Area Network (CAN) ………………..EL-159
Cruise control — See ASCD………………………EL-148
D

Location of electrical units ……………………….EL-160
Lubricants…………………………………………………MA-2
M
MAFS — Wiring diagram………………………………EC-3
Mass air flow sensor (MAFS)………………………EC-3
Meter ………………………………………………………EL-47
METER — Wiring diagram…………………………..EL-49
Model variation …………………………………………..GI-5
N

Daytime light system…………………………………EL-34
DEF — Wiring diagram ……………………………….EL-69
Differential lock — Wiring diagram…………………PD-2
DTRL — Wiring diagram ……………………………..EL-34

NAVI — Wiring diagram ………………………………EL-93
Navigation System ……………………………………EL-91

ECTS — Wiring diagram ………………………………EC-4
Electrical units location ……………………………EL-160

Oil change (capacity) …………………………………MA-2

IDX-2

ALPHABETICAL INDEX
P

POWER — Wiring diagram……………………………EL-4
Power supply routing ………………………………….EL-3
Power window………………………………………..EL-153

Tachometer ……………………………………………..EL-47
TCM circuit diagram………………………………AT-2, 12
Turn signal lamp ………………………………………EL-36

Radio — See Audio…………………………………….EL-73
Rear window defogger………………………………EL-69
R/HEAT — Wiring diagram……………………………HA-2

Vehicle identification number………………………..GI-6
Viscosity number (SAE)……………………………..MA-3

MA
EM
LC
EC

WARN — Wiring diagram ……………………………EL-54
Warning lamps …………………………………………EL-52
Water temperature gauge ………………………….EL-47
WINDOW — Wiring diagram ……………………..EL-154
WIP/R — Wiring diagram…………………………….EL-66

S
SHIFT — Wiring diagram ……………………….AT-11, 19
Speedometer……………………………………………EL-47
STAB — Wiring diagram ………………………………RA-2
Stabilizer release device …………………………….RA-2
Stabilizer release device — Wiring
diagram…………………………………………………RA-2
Starting system ………………………………………..EL-32

MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE

IDX-3

MAINTENANCE
SECTION

MODIFICATION NOTICE:
I
I

EM
LC
EC

SAE Viscosity Number charts for engine oil have been revised for Europe.
Specifications of recommended fluids and lubricants have been rivised.

CONTENTS
RECOMMENDED FLUIDS AND LUBRICANTS………….2
Fluids and Lubricants …………………………………………..2

SAE Viscosity Number …………………………………………3

FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX

MA-1

RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants
Capacity (Approximate)
Imp meaLiter
sure
Engine oil (Refill)
With oil filter

Without oil filter

Recommended Fluids/Lubricants
Gasoline engine: Genuine NISSAN engine oil
API SE, SF, SG, SH, SJ or
SL*1
ILSAC grade GF-I, GF-II, GFIII or SG+*1
Diesel engine: ZD30 for Europe:
Genuine NISSAN engine oil
API CF-4, ACEA B3 or B3/E3,
JASO DH-1*1, *5

TB48DE

6.8

6 qt

ZD30DDTi

8.2

7-1/4 qt

TB48DE

6.5

5-3/4 qt

ZD30DDTi

7.7

6-3/4 qt

13.2
13.0
13.0
13.2
12.5
12.0
14.1
13.9
14.1
14.3

11-5/8 qt
11-1/2 qt
11-1/2 qt
11-5/8 qt
11 qt
10-5/8 qt
12-3/8 qt
12-1/4 qt
12-3/8 qt
12-5/8 qt

3.5

6-1/8 qt

API GL-4, Viscosity SAE 75W-90 only

2.4
3.0

4-1/4 qt
5-1/4 qt

API GL-5*1

2.1

3-3/4 qt

1.9

1-5/8 qt

Cooling system (with reservoir tank)
With front heater
RHD
TB48DE
LHD
RHD
ZD30DDTi
LHD
Without front
TB48DE
heater
ZD30DDTi
With rear heater
RHD
TB48DE
LHD
RHD
ZD30DDTi
LHD
Manual transmission oil
FS5R50B
Differential carrier gear oil (without limited slip differential)
Without diff. lock
With diff. lock
Differential carrier gear oil (with limited slip differential)
Except Europe
Transfer fluid
TX12A
Automatic transmission fluid
RE5R05A
RE4R03A
Power steering fluid
Brake and clutch fluid
Multi-purpose grease
Propeller shaft grease
Air conditioning system refrigerant
Air conditioning system lubricants

For Europe
Genuine NISSAN Anti-freeze Coolant (L250) or
equivalent*6

Gear Oil Hypoid LSD (Part No.: KLD311400203) or equivalent*2
Genuine NISSAN ATF Matic Fluid D or equivalent*4 or API GL-4*1

9-1/8 — 9-3/8
Genuine NISSAN ATF Matic Fluid J*3
qt
Genuine NISSAN ATF Matic Fluid D or equiva11.8
10-3/8 qt
lent*4
Refill to the proper oil level
Genuine NISSAN PSF or equivalent*8
according to the instructions in
the “Maintenance and do-ityourself” section of the owner’s For Europe: DOT 3 or DOT 4 (U.S. FMVSS No.
116)*7
manual.
—
—
NLGI No. 2 (Lithium soap base)
NLGI No. 2 (Molybdenum disulphide lithium
soap base)
—
—
HFC-134a (R-134a)
Nissan A/C System Oil Type S or
—
—
equivalent
10.4 — 10.7

*1: For further details, see “SAE viscosity number”.
*2: API GL-5, SAE 140 and 10% volume of LSD Friction Modifier (Part No.: 38469-C6000) is an equivalent.
*3: Using automatic transmission fluid other than Genuine NISSAN ATF Matic Fluid J will cause deterioration in driveability and automatic
transmission durability, and may damage the automatic transmission, which is not covered by the warranty.
*4: For more information regarding suitable fluids, contact a Nissan dealer for correct brands of DEXRONTMIII/MERCONTM Automatic Transmission Fluid.
*5: Never use API CG-4.
*6: Use Genuine NISSAN Anti-freeze Coolant (L250) or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling
system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be covered by
the warranty even if such incidents occurred during the warranty period.
*7: Never mix DOT 3 & DOT 4.
*8: DEXRONTMIII type ATF can be used.

MA-2

RECOMMENDED FLUIDS AND LUBRICANTS
SAE Viscosity Number
I
I

For cold and warm areas:
10W-30 is preferable for ambient temperatures above
−20°C (−4°F).
5W-30 will positively improve fuel economy.

EM
LC
EC
FE
CL
MT
SMA203D

DIESEL ENGINE
I 5W-30 is preferable. If 5W-30 is not available, select the
viscosity from the chart, that is suitable for the outside
temperature range.

AT
TF
PD
FA
RA
BR
ST
RS
BT

SMA204D

HA
EL
SE
IDX

MA-3

PROPELLER SHAFT &
DIFFERENTIAL CARRIER

GI
MA

SECTION

MODIFICATION NOTICE:

EM
LC
EC

Wiring Diagrams have been changed.

CONTENTS
DIFFERENTIAL LOCK …………………………………………….2

Wiring Diagram — DIFF/L — ………………………………..2

CL
MT
AT
TF

FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX

PD-1

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —

TPD016M

PD-2

DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF

FA
RA
BR
ST
RS
BT
HA
EL
SE
TPD020M

IDX

PD-3

REAR AXLE &
REAR SUSPENSION

GI
MA

SECTION

MODIFICATION NOTICE:
I

EM
LC
EC

Wiring diagrams have been changed. (For RHD models)

CONTENTS
STABILIZER RELEASE DEVICE………………………………2

Wiring Diagram ……………………………………………………2

CL
MT
AT
TF
PD
FA

BR
ST
RS
BT
HA
EL
SE
IDX

RA-1

STABILIZER RELEASE DEVICE
Wiring Diagram
RHD MODELS

TRA018M

RA-2

STABILIZER RELEASE DEVICE
Wiring Diagram (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA

BR
ST
RS
BT
HA
EL
SE
TRA019M

IDX

RA-3

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram

ZD30DDTi

To ESM

FOR EUROPE

TEC485M

EC-3002a

EC-3002b

EC-3002c

EC-3002d

EC-3002e

EC-3002f

EC-3002g

EC-3002h

EC-3002i

(Supplement-III:SM4E00-1Y61E0E)

EC-3002j

EC-3002k

EC-3002l

(Supplement-III:SM4E00-1Y61E0E)

EC-3002m

To ESM

DOUBLE MASS FLYWHEEL INSPECTION
CAUTION:
I Do not disassemble double mass flywheel.
I Resurfacing may cause malfunction of the flywheel due to
machining debris invasion on springs and bearing.

To ESM

Flywheel Deflection
I
I
I

Measure deflection of flywheel contact surface to clutch with a
dial gauge.
Measure deflection at diameter C. (See the table below for C.)
Standard: D or less (See the table below for D.)
Limit: E or less (See the table below for E.)
When measured value exceeds the limit, replace flywheel with
a new one.

PBIC0683E

Movement Amount in Rotational Direction
I
1.
I
2.
SBIA0288E

3.
4.
I

Check the movement amount in the following procedure Installing the front side disk (flywheel mass) to the crankshaft.
Install a hexagon head bolt to clutch cover mounting bolt hole,
and place a torque wrench on the extended line of the flywheel
center line.
Tighten bolt at a force of 9.8 N⋅m (1 kg-m, 87 in-lb) to keep it
from loosening.
Put a mating mark on the peripheral surface of the front and
rear flywheel masses without applying any load (Measurement
standard points).
Apply a force of 9.8 N⋅m (1 kg-m, 87 in-lb) in each direction, and
mark the movement amount of the rear flywheel mass with the
front mass fixed.
Measure dimension of movement amounts A and B of the rear
flywheel mass.
Standard: F or less (See the table below for F.)
When measured value is outside the standard, replace flywheel.

Appearance of Rear flywheel Mass Surface
I
I

Heat spot: It is acceptable if the deflection is within the specification.
Subtle crack: It is acceptable if judder does not occur.

Specification Table
Unit: mm (in)
Deflection
Model

S15

Engine

Movement amount in rotational direction

Measured at
diameter C

Standard D

Limit E

Standard F

SR20DET

210 (8.27)

0.45 (0.0177)

0.8 (0.031)

35.4 (1.394)

RD28ETi

225 (8.86)

0.3 (0.012)

0.7 (0.028)

13.9 (0.547)

ZD30DDTi

250 (9.84)

0.3 (0.012)

0.7 (0.028)

5.9 (0.232)

Y61

—2—

DOUBLE MASS FLYWHEEL INSPECTION
CAUTION:
I Do not disassemble double mass flywheel.
I Resurfacing may cause malfunction of the flywheel due to
machining debris invasion on springs and bearing.

To ESM

Flywheel Deflection
I
I
I

PBIC0683E

Movement Amount in Rotational Direction
I
1.
I
2.
SBIA0288E

3.
4.
I

Appearance of Rear flywheel Mass Surface
I
I

Heat spot: It is acceptable if the deflection is within the specification.
Subtle crack: It is acceptable if judder does not occur.

Specification Table
Unit: mm (in)
Deflection
Model

S15

Engine

Movement amount in rotational direction

Measured at
diameter C

Standard D

Limit E

Standard F

SR20DET

210 (8.27)

0.45 (0.0177)

0.8 (0.031)

35.4 (1.394)

RD28ETi

225 (8.86)

0.3 (0.012)

0.7 (0.028)

13.9 (0.547)

ZD30DDTi

250 (9.84)

0.3 (0.012)

0.7 (0.028)

5.9 (0.232)

Y61

—2—

To ESM

CHARGING SYSTEM
Disassembly (For LR190-752)
• When removing alternator pulley, use
(KV10118200).

To ESM
PKIA1240E

EL-48

special service tool

CHASSIS AND BODY MAINTENANCE
Checking A/T Fluid
— RE5R05A —
To ESM
NOTE:
Use only service part of A/T fluid level gauge: Part No. 31086 VC200
1. Warm up engine.
2. Check for fluid leakage.
3. Remove the oil charging pipe cap.
4. Insert A/T fluid level gauge.
5. Before driving, fluid level can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD”
range on A/T fluid level gauge.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear position. Leave selector lever in “P” position.
c. Check fluid level with engine idling.
d. Remove A/T fluid level gauge and wipe clean with lint-free paper.
e. Re-insert A/T fluid level gauge into oil charging pipe as far as it will go.
CAUTION:
Insert A/T fluid level gauge securely.
f. Remove A/T fluid level gauge and note reading. If reading is at low side of range, add fluid to the oil
charging pipe.
Do not overfill.
6. Drive vehicle for approximately 5 minutes in urban areas.
7. Make the fluid temperature approximately 65°C (149°F).
NOTE:
Fluid level will be greatly affected by temperature as shown in figure. Therefore, be certain to perform
operation while checking data with CONSULT-II.

SMA174D

a.
b.
c.
8.

Connect CONSULT-II to data link connector.
Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
Read out the value of “ATF TEMP 1”.
Re-check fluid level at fluid temperature of approximately 65°C (149°F) using “HOT” range on A/T fluid
level gauge.

MA-20

CHASSIS AND BODY MAINTENANCE
Checking A/T Fluid (Cont’d)
CAUTION:
Insert A/T fluid level gauge securely into the position shown
in the figure.

SMA175D

9. Check fluid condition.
I If fluid is very dark or smells burned, refer to AT section for checking operation of A/T. Flush cooling system after repair of A/T.
I If A/T fluid contains frictional material (clutches, bands, etc.), replace radiator and flush cooler line using
cleaning solvent and compressed air after repair of A/T.
10. Make sure A/T fluid level gauge is removed then install the oil charging pipe cap.
Bolt: 4.4 — 5.8 N⋅m (0.45 — 0.59 kg-m, 39.1 — 51.2 in-lb)

MA-21

CATALYST AND TURBOCHARGER
Removal and Installation

To ESM

YEM075

REMOVAL
1.
쐌
쐌
쐌
쐌
쐌
SEM296G

쐌

Remove the following parts.
Undercover
Under guard
Drain engine coolant (for engine produced before “ZD104114A”)
Refer to MA section, “Changing Engine Coolant”.
Battery (on left side) (for cold areas)
Exhaust front tube
Refer to FE section, “Removal and Installation”, “EXHAUST
SYSTEM”.
Remove wires, harnesses, tubes and pipes.

EM-1014

CATALYST AND TURBOCHARGER
Removal and Installation (Cont’d)
2. Remove catalyst.
CAUTION:
Do not disassemble catalyst.

INSTALLATION (engine produced after “ZD-104114A”)
1. Install catalyst.
: 29 — 39 N⋅m (2.9 — 3.3 kg-m, 21 — 23 ft-lb)
Place the protruding area of the gasket between the turbocharger
and the exhaust outlet upwards, and install the lipped side to the
turbocharger side. Refer to the figure, EM-1014.
2. Install in the reverse order of removal.

INSTALLATION (engine produced before “ZD-104114A”)
1. Install catalyst.
: 29 — 39 N⋅m (2.9 — 3.3 kg-m, 21 — 23 ft-lb)
Place the protruding area of the gasket between the turbocharger
and the exhaust outlet upwards, and install the lipped side to the
turbocharger side. Refer to the figure, EM-1014.
2. Plug engine coolant outlet on oil cooler housing and engine
coolant return hole on gear case by using plugs and gaskets
which are installed to turbocharger for service.
3. Install in the reverse order of removal.

EM-1015

ENGINE LUBRICATION SYSTEM
Oil Jet (Cont’d)
OIL FILTER

The oil filter is an element type. Refer to “Changing Oil Filter” in MA
section.

Oil Cooler

To ESM

YLC072

REMOVAL AND INSTALLATION
Removal

JLC381B

1. Drain engine oil and coolant.
Remove catalyst and turbocharger. Refer to “CATALYST AND
TURBOCHARGER” in EM section.
2. Remove bolts A to C then remove oil cooler assembly.
쐌 Do not remove “D” nuts when removing oil cooler assembly.
Bolt length:
A: 20 mm (0.79 in)
B: 45 mm (1.77 in)
C: 65 mm (2.56 in)

Installation (engine produced after “ZD-104114A”)
1. Installation is in the reverse order of removal.
쐌 Do not spill coolant on the drive belt.

Installation (engine produced before “ZD-104114A”)
1. Plug engine coolant outlet on oil cooler housing and engine
coolant return hole on gear case by using plugs and gaskets
which are installed to turbocharger for service.
2. Assemble air cooled turbocharger assembly.
쐌 Do not spill coolant on the drive belt.

LC-1007a

ENGINE LUBRICATION SYSTEM
Oil Cooler (Cont’d)

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

LC-1007b

CYLINDER BLOCK

To ESM

SEM210H

EM-1067a

CYLINDER BLOCK

Assembly
OIL PRESSURE SWITCH (FOR EUROPE AND
AUSTRALIA)
I

Install oil pressure switch adapter with aligning pin with the
boss on cylinder block.

SEM211H

EM-1084a

SERVICE DATA AND SPECIFICATIONS (SDS)
Valve

To ESM

VALVE CLEARANCE
Unit: mm (in)
Items

Cold*

Intake and exhaust

0.30 — 0.40 (0.012 — 0.016)

*: Approximately 20 C (68 F)

AVAILABLE SHIMS
Thickness mm (in)

Identification mark

2.35 (0.0925)

2.35

2.40 (0.0945)

2.40

2.45 (0.0965)

2.45

2.50 (0.0984)

2.50

2.55 (0.1004)

2.55

2.60 (0.1024)

2.60

2.65 (0.1043)

2.65

2.70 (0.1063)

2.70

2.75 (0.1083)

2.75

2.80 (0.1102)

2.80

2.85 (0.1122)

2.85

2.90 (0.1142)

2.90

2.95 (0.1161)

2.95

3.00 (0.1181)

3.00

3.05 (0.1201)

3.05

JEM184G

VALVE LIFTER
Unit: mm (in)
Valve lifter outer diameter

34.450 — 34.465 (1.3563 — 1.3569)

Lifter guide inner diameter

34.495 — 34.515 (1.3581 — 1.3589)

Clearance between lifter and lifter guide

0.030 — 0.065 (0.0012 — 0.0026)

EM-1086a

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
To ESM

System Description/LHD Models for Europe
(Sweden), The Middle East and South Africa

FUNCTION
Remote control system has the following function.
쐌 Door lock
쐌 Door unlock
쐌 Hazard reminder

LOCK OPERATION
To lock door by remote controller, the following two signals must be received.
쐌 Key switch OFF (when ignition key is not in ignition key cylinder.)
쐌 All door switches CLOSED
When the LOCK signal is input to multi-remote control unit (the antenna of the system is combined with multiremote control unit), ground is supplied
쐌 through multi-remote control unit terminal 쎻
5
쐌 to combination meter terminal 쎻
22 .
Then combination meter supplies power and ground to each door lock actuator except driver side.

UNLOCK OPERATION
To unlock door by remote controller, the following signal must be received.
쐌 Key switch OFF (when ignition key is not in ignition key cylinder)
When the UNLOCK signal is input to multi-remote control unit (the antenna of the system is combined with
multi-remote control unit), ground is supplied
쐌 through multi-remote control unit terminal 쎻
6
쐌 to combination meter terminal 쎻
23 .
Then combination meter supplies power and ground to each door lock actuator except driver side.

HAZARD REMINDER
When the doors are locked or unlocked by remote controller, power is supplied
쐌 through multi-remote control unit terminals 쎻
3 and 쎻
8
쐌 to the hazard warning lamps
Then hazard warning lamp flash as follows.
쐌 Lock operation: Flash once
쐌 Unlock operation: Flash twice

REMOTE CONTROLLER ID CODE ENTRY
A maximum of four remote controllers can be entered. Any attempt to enter a remote controller will erase all
ID codes previously entered. Therefore, be sure to receive all remote controllers from the vehicle owner when
any ID code entry is performed.
To enter ID code entry, the following signals must be input to the multi-remote control unit.
쐌 Driver side LOCKED signal (from driver side door unlock sensor)
쐌 Door switch CLOSED signal
쐌 Ignition switch ON signal
쐌 Battery power supply
쐌 Signal from remote controller
For detailed procedure, refer to “ID Code Entry Procedure” in EL-6.

Page 1

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Trouble Diagnoses/LHD Models for Europe
(Sweden), The Middle East and South Africa
SYMPTOM CHART
Symptom
No doors can be locked or unlocked by remote control operation. (See NOTE.)

Possible cause

Diagnoses/service order

1. Check power door lock operation.
2. Check remote controller battery. Refer to EL-7.
3. Check harness for open or short between multi-remote
control unit and combination meter.
Ignition power supply circuit for 4. Make sure battery voltage is present at terminal 쎻
4 of
multi-remote control unit
multi-remote control unit while ignition switch is in ON
position.
Power supply circuit for multi-re- 5. Make sure battery voltage is present at terminal
쎻
mote control unit
2 of multi-remote control unit.
Ground circuit for multi-remote 6. Check continuity between terminal 쎻
1 of multi-remote
control unit
control unit and ground.
Remote controller
7. Replace remote controller. Refer to EL-6.

1. Power door lock system
2. Remote controller battery
3. Door lock/unlock circuit
4.

5.
6.
7.

Hazard reminder does not operate 1. Hazard reminder output to haz- 1. Check hazard reminder output to hazard warning
properly.
ard warning lamps
lamps at terminals 쎻
3 and 쎻
8 of multi-remote control
unit.
2. Hazard reminder circuit
2. Check the harness for open or short between hazard
warning lamps and multi-remote control unit.
3. Check driver’s door unlock sensor signal at terminal
3. Driver’s door unlock sensor
쎻
7 of multi-remote control unit.
The new ID of remote controller
cannot be entered.

1. Remote controller battery
2. Ignition power supply circuit
for multi-remote control unit
3. Driver’s door unlock sensor
4. Remote controller

1. Check remote controller battery. Refer to EL-7.
2. Make sure battery voltage is present at terminal 쎻
4 of
multi-remote control unit while ignition switch is in ON
position.
3. Check driver’s door unlock sensor signal at terminal
쎻
7 of multi-remote control unit.
4. Replace remote controller. Refer to EL-6.

Refer to “MULTI-REMOTE CONTROL UNIT INSPECTION TABLE” on next page to check the control unit signals.
NOTE:
쐌 The lock operation of multi-remote control system does not activate with the ignition key ON position.

Page 2

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Trouble Diagnoses/LHD Models for Europe
(Sweden), The Middle East and South Africa
(Cont’d)
MULTI-REMOTE CONTROL UNIT INSPECTION TABLE
Terminal
No.

Connections

Condition

Voltage (V)
(approximate
values)

Ground

—

Power source (BAT)

—

Hazard warning lamp RH

Ignition power supply

Remote controller LOCK/UNLOCK button is pushed
(All doors are closed and key is not in ignition key cylinder.)

Other than above condition

0
OFF

ON or START

Ignition switch

Lock signal

Unlock signal

Driver side door unlock sensor

Hazard warning lamp LH

Remote controller LOCK button is pushed
(All doors are closed and key is not in ignition key cylinder.)

Other than above condition

Remote controller UNLOCK button is pushed
(Key is not in ignition key cylinder.)

Other than above condition

5
Locked

Unlocked

Driver side door
Remote controller LOCK/UNLOCK button is pushed
(All doors are closed and key is not in ignition key cylinder.)

Other than above condition

SEL147X

Page 3

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Trouble Diagnoses/LHD Models for Europe
(Sweden), The Middle East and South Africa
(Cont’d)
REMOTE CONTROLLER BATTERY CHECK
Remove battery and measure voltage across battery positive and
negative terminals, 䊝 and 䊞.
Measuring terminal

SEL672U

䊝

䊞

Battery positive terminal
䊝

Battery negative terminal
䊞

Standard value

2.5 — 3.0V

Note:
Remote controller does not function if battery is not set correctly.

Page 4

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
ID Code Entry Procedure/LHD Models for
Europe (Sweden), The Middle East and South
Africa

SEL497XA

Page 5

MULTI-REMOTE CONTROL SYSTEM/WAGON AND HARDTOP MODELS
Remote Controller Battery Replacement/LHD
Models for Europe (Sweden), The Middle East
and South Africa

SEL241X

Page 6

INSPECTION AND ADJUSTMENT
Adjusting Clutch Pedal
1. Adjust pedal full stroke “S” with pedal stopper bolt or clutch
switch (with ASCD).
Pedal full stroke “S”:
147 — 157 mm (5.79 — 6.18 in)
Pedal height “H*” (Reference):
200 — 210 mm (7.87 — 8.27 in)
*: Measured from surface of dash reinforcement panel to
pedal pad
2. Adjust pedal free play with master cylinder push rod or clutch
booster input rod. Then tighten lock nut.
Pedal free play “A”:
1.0 — 3.0 mm (0.039 — 0.118 in)

To ESM

SCL934

CL-1002a

HYDRAULIC CLUTCH CONTROL
Clutch Booster
ADJUSTMENT
Adjust input rod length with clutch booster input rod.
Then tighten lock nut.
Input rod length:
Length “B”
131.4 — 132.4 mm (5.17 — 5.21 in)

SCL136A

To ESM

CL-1003a

Источник

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  - СЕЗОННОЕ ХРАНЕНИЕ ШИН И КОЛЕСНЫХ ДИСКОВ В NISSAN «У СЕРВИС +»
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  - Встречают по одежке! Идеальный кузов Вашего NISSAN круглый год
- Услуги и сервисы
  - Руководство по эксплуатации Nissan
  - Техническое обслуживание Nissan в «У Сервис+»
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Здесь собраны руководства по эксплуатации автомобилей NISSAN. Даже если Ваш Ниссан уже снят с производства, Вы найдете здесь всю необходимую информацию о его возможностях и уходе за ним. Для просмотра руководства выберите модель Вашего NISSAN. Если соответствующего руководства по автомобилю Ниссан не нашлось, мы всегда рады проконсультировать Вас по телефону.

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Руководство по эксплуатации NISSAN Patrol

Руководство по эксплуатации NISSAN Qashqai

Источник

Мультимедийное руководство на английском языке по техническому обслуживанию и ремонту автомобиля Nissan Note серии E11.

Рекомендуем перед началом ремонта или обслуживания изучить руководство, это позволит избежать проблем при эксплуатации и узнать о всех функциях и особенностях автомобиля.

Автор: –

Издательство: Nissan

Год издания: 2006

Страниц: –

Формат: –

Размер: 60,5 Mb

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