GENERAL INFORMATION SECTION GI CONTENTS GENERAL INFORMATION GI-1 HOW TO USE THIS MANUAL... 3 PRECAUTION...36 BASIC INSPECTION...47

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1 RA RAT ST RA RAT TTS W T US TS AUA... 3 W T US TS AUA... 3 escription...3 Terms...3 Units...3 ontents...3 omponent...3 ow to ollow Trouble iagnosis...4 ow to Read Wiring iagram...8 Abbreviations...15 W T W TRU ASS...17 escription...17 ow to ollow Test roups in Trouble iagnosis...17 ey to Symbols Signifying easurements or rocedures...18 W T RA WR ARAS...20 onnector symbols...20 Sample/wiring diagram -example escription...22 ARVATS...24 Abbreviation ist...24 TT TRQU STAAR TS...25 Tightening Torque Table...25 R A RUTS A SAATS...26 Recommended hemical roducts and Sealants...26 TRY...27 S Terminology ist...27 TT TRQU STAAR TS...31 Tightening Torque Table...31 ATURS W...32 TAT RAT...32 odel Variation...32 dentification umber...33 imensions...34 Wheels & Tires...35 RAUT...36 ATTRY ST...36 Required rocedure After attery isconnection...36 RAUTS...37 escription...37 recaution for Supplemental Restraint System (SRS) "AR A" and "SAT T R-T- SR"...37 recaution for ATS (SSA AT-TT SYST)...37 recaution ecessary for Steering Wheel Rotation After attery isconnect...37 eneral recaution...38 recaution for All ode 4 4 System...39 recaution for Three Way atalyst...39 recaution for uel...40 recaution for ultiport uel njection System or ngine ontrol System...40 recaution for Turbocharger (f quipped)...40 recaution for oses...40 recaution for ngine ils...41 recaution for Air onditioning...42 T T...43 antograph ack...43 arage ack and Safety Stand ole ift...43 TW TRU TW...45 Tow Truck Towing...45 Vehicle Recovery (reeing a Stuck Vehicle)...46 AS ST

2 SRV RAT R TRA T Work low ontrol Units and lectrical arts ow to heck Terminal ntermittent ncident ircuit nspection SUT- SYST escription unction and System Application SUT- ata ink onnector () ircuit Wiring iagram

3 < W T US TS AUA > W T US TS AUA W T US TS AUA W T US TS AUA escription : This volume explains Removal, isassembly, nstallation, nspection and Adjustment and Trouble iagnoses. Terms : The captions WAR and AUT warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WAR indicates the possibility of personal injury if instructions are not followed. AUT indicates the possibility of component damage if instructions are not followed. TY STATTS except WAR and AUT give you helpful information. Standard value:tolerance at inspection and adjustment. imit value:the maximum or minimum limit value that should not be exceeded at inspection and adjustment. Units : The UTS given in this manual are primarily expressed as the S UT (nternational System of Unit), and alternatively expressed in the metric system and in the yard/pound system. Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the standard tightening torque. xample Range uter Socket ock ut : m ( kg-m, ft-lb) Standard ontents : AATA X is provided at the end of this manual so that you can rapidly find the item and page you are searching for. A QU RR X, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab. T TTS are listed on the first page of each section. T TT is indicated on the upper portion of each page and shows the part or system. T A UR of each section consists of two or three letters which designate the particular section and a number (e.g. R-5 ). T SA USTRATS 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. omponent rive Shaft nstallation olt : 44.3 m (4.5 kg-m, 33 ft-lb) : T AR USTRATS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the ARTS ATA (e.g. S. 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 ARTS ATA. omponents shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration. -3

4 W T US TS AUA < W T US TS AUA > SA Union bolt 2. opper washer 3. rake hose 4. ap 5. leed valve 6. Sliding pin bolt 7. iston seal 8. iston 9. iston boot 10. ylinder body 11. Sliding pin 12. Torque member mounting bolt 13. Washer 14. Sliding pin boot 15. ushing 16. Torque member 17. nner shim cover 18. nner shim 19. nner pad 20. ad retainer 21. ad wear sensor 22. uter pad 23. uter shim 24. uter shim cover 1: (oly utyl uprysil) grease or silicone-based grease 2: Rubber grease : rake fluid Refer to section for additional symbol definitions. SYS ow to ollow Trouble iagnosis SAA0749 : SRT T: Trouble diagnoses indicate work procedures required to diagnose problems effectively. bserve the following instructions before diagnosing. 1. efore performing trouble diagnoses, read the reliminary heck, the Symptom hart or the Work low. 2. After repairs, re-check that the problem has been completely eliminated. -4

5 < W T US TS AUA > W T US TS AUA 3. Refer to omponent arts and arness onnector ocation for the Systems described in each section for identification/location of components and harness connectors. 4. Refer to the ircuit iagram for quick pinpoint check. f you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring iagram in each individual section and arness ayout in section for identification of harness connectors. 5. When checking circuit continuity, ignition switch should be. 6. efore checking voltage at connectors, check battery voltage. 7. After accomplishing the iagnostic rocedures and lectrical omponents nspection, make sure that all harness connectors are reconnected as they were. W T W TST RUS TRU ASS 1. Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups. 2. Questions and required results Questions and required results are indicated in bold type in test group. The meaning of are as follows: a. attery voltage 11-14V or approximately 12V b. Voltage : Approximately 0V ess than 1V 3. Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. efore diagnosing a problem, familiarize yourself with each symbol. Refer to "onnector Symbols" in Section and "Y T SY- S SY ASURTS R RURS" below. 4. Action items ext action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group. ARSS WR R A TR UR AT There are two types of harness wire color and connector number indication. TY 1: arness Wire olor and onnector umber are Shown in llustration -5 SAA0256

6 W T US TS AUA < W T US TS AUA > etter designations next to test meter probe indicate harness wire color. onnector numbers in a single circle (e.g. 33) indicate harness connectors. onnector numbers in a double circle (e.g. 211) indicate component connectors. A070 TY 2: arness Wire olor and onnector umber are Shown in Text S144A -6

7 W T US TS AUA < W T US TS AUA > Y T SYS SY ASURTS R RURS SAA0750-7

8 W T US TS AUA < W T US TS AUA > ow to Read Wiring iagram SAA0751 : TR SYS ost of connector symbols in wiring diagrams are shown from the terminal side. -8

9 < W T US TS AUA > W T US TS AUA onnector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. onnector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. ertain systems and components, especially those related to, may use a new style slide-locking type harness connector. or description and how to disconnect, refer to section, escription, ARSS TR. SAA0257 ale and female terminals onnector guides for male terminals are shown in black and female terminals in white in wiring diagrams. SA/WR ARA - XA - S363-9

10 W T US TS AUA < W T US TS AUA > or detail, refer to following SRT. S091A -10

11 < W T US TS AUA > ptional Splice W T US TS AUA SRT umber tem escription 1 ower condition This shows the condition when the system receives battery positive voltage (can be operated). 2 usible link 3 usible link/fuse location S942 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. This shows the location of the fusible link or fuse in the fusible link or fuse box. or arrangement, refer to section, WR SUY RUT. 4 use 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 urrent rating This shows the current rating of the fusible link or fuse. 6 onnectors This shows that connector 3 is female and connector 1 is male. The /R wire is located in the 1A terminal of both connectors. Terminal number with an alphabet (1A, 5, etc.) indicates that the connector is S connector. Refer to section, S (SUR UT UT). 7 ptional splice The open circle shows that the splice is optional depending on vehicle application. 8 Splice The shaded circle shows that the splice is always on the vehicle. 9 age 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 ommon connector The dotted lines between terminals show that these terminals are part of the same connector. 11 ption abbreviation This shows that the circuit is optional depending on vehicle application. 12 Relay This shows an internal representation of the relay. or details, refer to section, STA- ARZ RAY. 13 onnectors This shows that the connector is connected to the body or a terminal with bolt or nut. -11

12 W T US TS AUA < W T US TS AUA > umber 14 Wire color This shows a code for the color of the wire. = lack W = White R = Red = reen = lue Y = Yellow = ight reen R = rown R or = range = ink U or V (Violet) = urple Y or R = ray S = Sky lue = ark rown = ark reen When the wire color is striped, the base color is given first, followed by the stripe color as shown below: xample: /W = lue with White Stripe 15 ption description This shows a description of the option abbreviation used on the page. 16 Switch This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. ontinuity exists between terminals 1 and 3 when the switch is in the position. 17 Assembly parts onnector terminal in component shows that it is a harness incorporated assembly. 18 ell code 19 urrent flow arrow 20 System branch This identifies each page of the wiring diagram by section, system and wiring diagram page number. Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow. A double arrow operation. shows that current can flow in either direction depending on circuit This shows that the system branches to another system identified by cell code (section and system). 21 age crossing This arrow shows that the circuit continues to another page identified by cell code. The will match with the on another page within the system other than the next or preceding pages. 22 Shielded line The line enclosed by broken line circle shows shield wire. 23 tem omponent 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. 24 omponent name This shows the name of a component. 25 onnector number 26 round () This shows the connector number. The letter shows which harness the connector is located in. xample: : main harness. or detail and to locate the connector, refer to section "ain arness", arness ayout. A coordinate grid is included for complex harnesses to aid in locating connectors. The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector. 27 round () This shows the ground connection. or detailed ground distribution information, refer to "round istribution" in section. 28 onnector views This area shows the connector faces of the components in the wiring diagram on the page. 29 ommon component 30 onnector color escription onnectors enclosed in broken line show that these connectors belong to the same component. This shows a code for the color of the connector. or code meaning, refer to wire color codes, umber 14 of this chart. 31 usible link and fuse box 32 Reference area This shows the arrangement of fusible link(s) and fuse(s), used for connector views of "W- R SUY RUT" in section. The open square shows current flow in, and the shaded square shows current flow out. This shows that more information on the Super ultiple unction (S) and oint onnectors (/) exists on the section. Refer to "Reference Area" for details. arness ndication -12

13 < W T US TS AUA > W T US TS AUA etter designations next to test meter probe indicate harness (connector) wire color. onnector numbers in a single circle 33 indicate harness connectors. omponent ndication onnector numbers in a double circle 211 indicate component connectors. Switch ositions 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, doors, hood and trunk lid/back door are closed, pedals are not depressed, and parking brake is released. A070 etectable ines and on-etectable ines n some wiring diagrams, two kinds of lines, representing wires, with different weight are used. S860-13

14 W T US TS AUA < W T US TS AUA > A line with regular weight (wider line) represents a detectable line for T (iagnostic Trouble ode). A detectable line for T is a circuit in which can detect its malfunctions with the on board diagnostic system. A line with less weight (thinner line) represents a non-detectable line for T. A non-detectable line for T is a circuit in which cannot detect its malfunctions with the on board diagnostic system. S862- ultiple 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. S875 Reference Area -14

15 < W T US TS AUA > W T US TS AUA The Reference Area of the wiring diagram contains references to additional electrical reference pages at the end of the manual. f connector numbers and titles are shown in the Reference Area of the wiring diagram, these connector symbols are not shown in the onnector Area. Abbreviations The following ARVATS are used: S092A : ARVAT A/ Air onditioner SRT A/T Automatic Transaxle/Transmission AT 1 Automatic Transmission luid rive range 1st gear 2 rive range 2nd gear 3 rive range 3rd gear 4 rive range 4th gear R, RR ront, Rear -15

16 W T US TS AUA < W T US TS AUA > ARVAT, R eft-and, Right-and /T anual Transaxle/Transmission verdrive /S ower Steering SA Society of Automotive ngineers, nc. SS Service ata and Specifications SST Special Service Tools 2W 2-Wheel rive 22 2nd range 2nd gear 21 2nd range 1st gear 12 1st range 2nd gear 11 1st range 1st gear SRT -16

17 < W T US TS AUA > W T W TRU ASS W T W TRU ASS escription : T: Trouble diagnoses indicate work procedures required to diagnose problems effectively. bserve the following instructions before diagnosing. efore performing trouble diagnoses, read the Work low in each section. After repairs, re-check that the problem has been completely eliminated. Refer to omponent arts and arness onnector ocation for the Systems described in each section for identification/location of components and harness connectors. When checking circuit continuity, ignition switch should be. Refer to the ircuit iagram for quick pinpoint check. f you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring iagram in each individual section and arness ayout in section for identification of harness connectors. efore checking voltage at connectors, check battery voltage. After accomplishing the iagnosis rocedures and lectrical omponents nspection, make sure that all harness connectors are reconnected as they were. ow to ollow Test roups in Trouble iagnosis : AA Test group number and test group title Test group number and test group title are shown in the upper portion of each test group. 2. Work and diagnosis procedure Start to diagnose a problem using procedures indicated in enclosed test groups. 3. Questions and results Questions and required results are indicated in test group. 4. Action ext action for each test group is indicated based on result of each question. -17

18 W T W TRU ASS < W T US TS AUA > ey to Symbols Signifying easurements or rocedures : SAA

19 < W T US TS AUA > W T W TRU ASS SAA

20 W T RA WR ARAS < W T US TS AUA > W T RA WR ARAS onnector symbols : ost of connector symbols in wiring diagrams are shown from the terminal side. onnector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. onnector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. ertain systems and components, especially those related to, may use a new style slide-locking type harness connector. or description and how to disconnect, refer to section, escription, ARSS TR. SAA0257 ale and female terminals onnector guides for male terminals are shown in black and female terminals in white in wiring diagrams. S363-20

21 < W T US TS AUA > Sample/wiring diagram -example- or detail, refer to following -22, "escription". W T RA WR ARAS : AWA

22 W T RA WR ARAS < W T US TS AUA > escription : umber tem escription 1 ower supply This means the power supply of fusible link or fuse. 2 usible link X means the fusible link. 3 umber of fusible link/ fuse This means the number of fusible link or fuse location. 4 use / means the fuse. 5 urrent rating of fusible link/fuse This means the current rating of the fusible link or fuse. 6 ptional splice The open circle shows that the splice is optional depending on vehicle application. 7 onnector number The letter shows which harness the connector is located in. xample : main harness. or detail and to locate the connector, refer to -64, "lectrical Units ocation", -37, "arness ayout". 8 Splice The shaded circle means the splice. 9 age crossing This circuit continues to an adjacent page. 10 ption abbreviation This means the vehicle specifications which layouts the circuit between. 11 Relay This shows an internal representation of the relay. 12 ption description This shows a description of the option abbreviation used on the page. 13 Switch This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. ontinuity exists between terminals 1 and 3 when the switch is in the position. 14 ircuit (Wiring) This means the wiring. 15 System branch This shows that the circuit is branched to other systems. 16 Shielded line The line enclosed by broken line circle shows shield wire. 17 omponent name This shows the name of a component. 18 round () This shows the ground connection. 19 onnector This means the connector information. This unit-side is described by the connector symbols. 20 onnectors This means that a transmission line bypasses two connectors or more. 21 Wire color This shows a code for the color of the wire. = lack W = White R = Red = reen = lue Y = Yellow = ight reen R = rown R or = range = ink U or V (Violet) = urple Y or R = ray S = Sky lue = ark rown = ark reen When the wire color is striped, the base color is given first, followed by the stripe color as shown below: xample: /W = lue with White Stripe 22 Terminal number This means the terminal number of a connector. SWT STS Switches are shown in wiring diagrams as if the vehicle is in the normal condition. A vehicle is in the normal condition when: -22

23 < W T US TS AUA > ignition switch is, doors, hood and trunk lid/back door are closed, pedals are not depressed, and parking brake is released. W T RA WR ARAS UT SWT 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. S860 SAA

24 < W T US TS AUA > ARVATS Abbreviation ist The following ARVATS are used: ARVATS : ARVAT A/ Air onditioner A/T Automatic Transaxle/Transmission AT Automatic Transmission luid AW All wheel drive 1 rive range 1st gear 2 rive range 2nd gear 3 rive range 3rd gear 4 rive range 4th gear R, RR ront, Rear, R eft-and, Right-and verdrive /S ower Steering SA Society of Automotive ngineers, nc. SS Service ata and Specifications SST Special Service Tools 2W 2-Wheel rive 22 2nd range 2nd gear 21 2nd range 1st gear 12 1st range 2nd gear 11 1st range 1st gear SRT -24

25 < W T US TS AUA > TT TRQU STAAR TS TT TRQU STAAR TS Tightening Torque Table : T 7T 9T rade olt size olt diameter * mm itch mm Tightening torque (Without lubricant) exagon head bolt exagon flange bolt m kg-m ft-lb in-lb m kg-m ft-lb in-lb *: ominal diameter 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. 044A -25

26 R A RUTS A SAATS < W T US TS AUA > R A RUTS A SAATS Recommended hemical roducts and Sealants : Refer to the following chart for help in selecting the appropriate chemical product or sealant roduct escription Rear View irror Adhesive Anaerobic iquid asket igh erformance Thread Sealant 4 Silicone RTV 5 6 igh Temperature, igh Strength Thread ocking Sealant (Red) edium Strength Thread ocking Sealant (lue) urpose Used to permanently remount rear view mirrors to windows. or metal-to-metal flange sealing. an fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications. rovides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.) o not use on plastic. asket aker asket aker for axima/ Quest 5-speed automatic transmission (R522A) issan orth America art o. (USA) issan anada art o. (anada) Aftermarket rossreference art os. 999-A ermatex A ermatex and A A002 ermatex A003 (Ultra rey) (Ultra rey) Threadlocker 999-A A004 Threadlocker (service tool removable) 999-A A005 ermatex Ultra rey 82194; Three ond 1207,1215, 1216, 1217, 1217 and 1217 issan RTV art o. 999-A7007 Three ond 1281 or exact equivalent in its quality ermatex 27200; Three ond 1360, 1360, 1305 &, 1307, 1335, 1335, 1363, 1377, 1386, & and 1388 octite 648 ermatex 24200, 24206, 24240, and 09178; Three ond 1322, 1322, 1324 &, 1333, 1361, 1364, 1370 and

27 < W T US TS AUA > TRY S Terminology ist TRY : All emission related terms used in this publication in accordance with S are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart. W TR W ARY / ARVAT TR Air cleaner A Air cleaner arometric pressure AR *** arometric pressure sensor- ARS- amshaft position *** amshaft position sensor S rank angle sensor anister *** anister arburetor AR arburetor harge air cooler A ntercooler losed loop losed loop losed throttle position switch T switch dle switch lutch pedal position switch switch lutch switch ontinuous fuel injection system system *** ontinuous trap oxidizer system TX system *** rankshaft position *** rankshaft position sensor S *** ata link connector *** ata link connector for SUT- for SUT- iagnostic connector for SUT- iagnostic test mode T iagnostic mode iagnostic test mode selector T selector iagnostic mode selector iagnostic test mode T ode iagnostic test mode T ode iagnostic trouble code T alfunction code irect fuel injection system system *** istributor ignition system system gnition timing control arly fuel evaporation-mixture heater -mixture heater ixture heater arly fuel evaporation system system ixture heater control lectrically erasable programmable read only memory R *** lectronic ignition system system gnition timing control ngine control *** ngine control module S control unit ngine coolant temperature T ngine temperature ngine coolant temperature sensor TS ngine temperature sensor ngine modification *** ngine speed R ngine speed rasable programmable read only memory R *** vaporative emission canister VA canister anister vaporative emission system VA system anister control solenoid valve xhaust gas recirculation valve R valve R valve -27

28 < W T US TS AUA > TRY W TR W ARY / ARVAT TR xhaust gas recirculation control-t valve R-T valve T valve xhaust gas recirculation control-solenoid valve R-solenoid valve R control solenoid valve xhaust gas recirculation temperature sensor RT sensor xhaust gas temperature sensor R temperature sensor lash electrically erasable programmable read only memory R *** lash erasable programmable read only memory R *** lexible fuel sensor S *** lexible fuel system system *** uel pressure regulator *** ressure regulator uel pressure regulator control solenoid valve *** RVR control solenoid valve uel trim T *** eated xygen sensor 2S xhaust gas sensor dle air control system A system dle speed control dle air control valve-air regulator AV-air regulator Air regulator dle air control valve-auxiliary air control valve AV-AA valve Auxiliary air control (AA) valve dle air control valve- solenoid valve AV- solenoid valve solenoid valve dle air control valve-idle up control solenoid valve AV-idle up control solenoid valve dle up control solenoid valve dle speed control- pot S- pot pot dle speed control system S system *** gnition control *** gnition control module *** ndirect fuel injection system system *** ntake air A Air ntake air temperature sensor AT sensor Air temperature sensor nock *** etonation nock sensor S etonation sensor alfunction indicator lamp heck engine light anifold absolute pressure A *** anifold absolute pressure sensor AS *** anifold differential pressure *** anifold differential pressure sensor S *** anifold surface temperature ST *** anifold surface temperature sensor STS *** anifold vacuum zone VZ *** anifold vacuum zone sensor VZS *** ass air flow sensor AS Air flow meter ixture control solenoid valve solenoid valve Air-fuel ratio control solenoid valve ultiport fuel injection System system uel injection control -28

29 < W T US TS AUA > TRY W TR onvolatile random access memory VRA *** n board diagnostic system system Self-diagnosis pen loop pen loop xidation catalyst atalyst xidation catalytic converter system system *** xygen sensor 2S xhaust gas sensor ark position switch *** ark switch ark/neutral position switch switch ark/neutral switch nhibitor switch eutral position switch eriodic trap oxidizer system TX system *** ositive crankcase ventilation V ositive crankcase ventilation ositive crankcase ventilation valve V valve V valve owertrain control module *** rogrammable read only memory R *** ulsed secondary air injection control solenoid valve AR solenoid valve AV control solenoid valve ulsed secondary air injection system AR system Air induction valve (AV) control ulsed secondary air injection valve AR valve Air induction valve Random access memory RA *** Read only memory R *** Scan tool ST *** Secondary air injection pump AR pump *** Secondary air injection system AR system *** Sequential multiport fuel injection system S system Sequential fuel injection Service reminder indicator SR *** Simultaneous multiport fuel injection system *** Simultaneous fuel injection Smoke puff limiter system S system *** Supercharger S *** Supercharger bypass S *** System readiness test SRT *** Thermal vacuum valve TVV Thermal vacuum valve Three way catalyst TW atalyst Three way catalytic converter system TW system *** Three way + oxidation catalyst TW + atalyst Three way + oxidation catalytic converter system TW + system *** Throttle body T Throttle chamber S body Throttle body fuel injection system T system uel injection control Throttle position T Throttle position Throttle position sensor TS Throttle sensor Throttle position switch T switch Throttle switch Torque converter clutch solenoid valve T solenoid valve W ARY / ARVAT TR ock-up cancel solenoid ock-up solenoid -29

30 < W T US TS AUA > TRY Transmission control module T A/T control unit Turbocharger T Turbocharger Vehicle speed sensor VSS Vehicle speed sensor Volume air flow sensor VAS Air flow meter Warm up oxidation catalyst WU- atalyst Warm up oxidation catalytic converter system WU- system *** Warm up three way catalyst WU-TW atalyst Warm up three way catalytic converter system WU-TW system *** Wide open throttle position switch WT switch ull switch ***: ot applicable W TR W ARY / ARVAT TR -30

31 < W T US TS AUA > TT TRQU STAAR TS TT TRQU STAAR TS Tightening Torque Table : T 7T 9T rade olt size olt diameter * mm itch mm Tightening torque (Without lubricant) exagon head bolt exagon flange bolt m kg-m ft-lb in-lb m kg-m ft-lb in-lb *: ominal diameter 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. 044A -31

32 TAT RAT < ATURS W > ATURS W TAT RAT odel Variation : osition haracter Qualifier efinition 1 ody type : Wagon 2 3 ngine : VQ40 : V56 4 Z Axle U: 2W Z: 4W art Time W: 4W ull Time 5 rive : R: S 6 R rade T: S U: ff Road V: 7 Transmission : 5-speed automatic transmission odel 44: athfinder ntake : 12 Zone : anda U: ederal 13 A quipment A: Standard XXXXX ption odes ption odes W odel ody ngine Transmission estination rade odel S UR-UA Wagon VQ40 R5R05A (5A/T) U.S.A. S(V6) S (V8) UT-UA UT-UA (V6) UV-UA (V8) UV-UA anada S (V8) WT-UA exico S (V6) UT-UA 4W odel ody ngine Transmission estination rade odel S ZR-U -32

33 < ATURS W > TAT RAT Wagon VQ40 R5R05A (5A/T) dentification umber S (V6) ZT-UA S (V8) WT-UA U.S.A. S-R ZU-UA (V6) WV-UA (V8) WV-UA S (V6) WR-A anada S (V6) WT-A S (V8) WT-A (V6) WV-A (V8) WV-A exico (V6) UV-UA S (V6) UT-UA : AA mission control information label 2. Vacuum hose diagram 3. Vehicle identification number plate 4. Tire placard certification plate V TAT UR ARRAT osition haracter Qualifier efinition anufacturer 51: USA produced multi-purpose vehicle 4 A ngine type A: VQ40 : V56 5 R Vehicle line R: R51 SSA athfinder 6 1 odel change (0-9) 7 8 ody type 8: 4 oor wagon 8 A ross vehicle weight rating 9 * heck digit A: 2W, 4-wheel AS, lass : 4W, 4-wheel AS, lass U: 2W, 4- wheel AS, lass (0 to 9 or X) The code for the check digit is determined by a mathematical computation. -33

34 TAT RAT < ATURS W > osition haracter Qualifier efinition 10 8 odel year XXXXX SRA UR anufacturing plant Vehicle serial number : Smyrna Tennessee hassis number AA0055 TRASR SRA UR A108 AUTAT TRASSS UR AA0054 imensions : Unit: mm (in) verall length 4884 (192.3) verall width (excludes mirrors) 1850 (72.8) -34

35 < ATURS W > TAT RAT S* (72.0) S* (72.6) S-R 1858 (73.1) verall height S/ (V6)* (72.2) S/ (V6)* (72.6) S/ (V8)* (72.3) S/ (V8)* (72.7) ront tread width 1570 (61.8) Rear tread width 1570 (61.8) Wheelbase 2850 (112.2) *1: With roof rack *2: Without roof rack 2W odel inimum Running round learance (with standard tires) S (8.7) S (V6) (8.6) S (V8) (8.7) (V6) (8.6) (V8) (87) 4W odel S (9.0) S (V6) (8.9) inimum Running round learance (with standard tires) S (V8) (9.0) S-R (9.0) (V6) (8.9) (V8) (9.0) Wheels & Tires : rive Type rade Road wheel Tire Spare tire size S 16 X 7 Aluminum Alloy 245/75R16 245/75R16* S (V6) 16 X 7 Aluminum Alloy 265/65R17 265/65R17* All S (V8) 17 X 7.5 Aluminum Alloy 265/60R18 265/60R18 S-R 16 X 7 Aluminum Alloy 265/75/R16 265/75/R16* (V6) 17 X 7.5 Aluminum Alloy 265/65/R17 265/65/R17* (V8) 18 X 8 Aluminum Alloy 265/60/R18 265/60/R18 * Steel wheel -35

36 < RAUT > RAUT ATTRY ST ATTRY ST Required rocedure After attery isconnection : SYST T RR /SA/V/TS/AS Steering angle sensor neutral position R-137 V/TS/AS Steering angle sensor neutral position R-12 Automatic drive positioner Automatic drive positioner system initialization Refer to wner s anual -36

37 < RAUT > RAUTS escription RAUTS : bserve the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section. recaution for Supplemental Restraint System (SRS) "AR A" and "SAT T R-TSR" : The Supplemental Restraint System such as AR A and SAT T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. nformation necessary to service the system safely is included in the SR and S section of this Service anual. WAR: 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 SSA/T dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and Air ag odule, see the SR section. o not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. recaution for ATS (SSA AT-TT SYST) -37 : ATS will immobilize the engine if someone tries to start it without the registered key of ATS. oth of the originally supplied ignition key s have been ATS registered. The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is functioning. Therefore, ATS warns outsiders that the vehicle is equipped with the anti-theft system. When ATS detects trouble, the security indicator lamp lights up while ignition switch is in "" position. This lighting up indicates that the anti-theft is not functioning, so prompt service is required. When servicing ATS (trouble diagnoses, system initialization and additional registration of other ATS ignition key s), SUT- hardware and SUT- ATS software is necessary. Regarding the procedures of ATS initialization and ATS ignition key registration, refer to SUT- operation manual, ATS. Therefore, SUT- ATS software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function. When servicing ATS (trouble diagnoses, system initialization and additional registration of other ATS ignition key s), it may be necessary to re-register original key identification. Therefore, be sure to receive all keys from vehicle owner. A maximum of four or five key s can be registered into ATS. When failing to start the engine first time using the key of ATS, start as follows. 1. eave the ignition key in "" position for approximately 5 seconds. 2. Turn ignition key to "" or "" position and wait approximately 5 seconds. 3. Repeat step 1 and 2 again. 4. Restart the engine while keeping the key separate from any others on key-chain. recaution ecessary for Steering Wheel Rotation After attery isconnect : T: This rocedure is applied only to models with ntelligent ey system and ATS (SSA AT-TT SYS- T). Remove and install all control units after disconnecting both battery cables with the ignition knob in the position. Always use SUT- to perform self-diagnosis as a part of each function inspection after finishing work. f T is detected, perform trouble diagnosis according to self-diagnostic results. or models equipped with the ntelligent ey system and ATS, an electrically controlled steering lock mechanism is adopted on the key cylinder.

38 < RAUT > RAUTS or this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible. f steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation. RAT RUR 1. onnect both battery cables. T: Supply power using jumper cables if battery is discharged. 2. Use the ntelligent ey or mechanical key to turn the ignition switch to the A position. At this time, the steering lock will be released. 3. isconnect both battery cables. The steering lock will remain released and the steering wheel can be rotated. 4. erform the necessary repair operation. 5. When the repair work is completed, return the ignition switch to the position before connecting the battery cables. (At this time, the steering lock mechanism will engage.) 6. erform a self-diagnosis check of all control units using SUT-. eneral recaution o not operate the engine for an extended period of time without proper exhaust ventilation. eep 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. o not smoke while working on the vehicle. : S285 efore 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 them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. S231 efore starting repairs which do not require battery power: Turn off ignition switch. isconnect the negative battery terminal. f the battery terminals are disconnected, recorded memory of radio and each control unit is erased. S289-38

39 < RAUT > RAUTS To prevent serious burns: Avoid contact with hot metal parts. o not remove the radiator cap when the engine is hot. ispose of drained oil or the solvent used for cleaning parts in an appropriate manner. o not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. ontinued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire. lean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. Replace oil seals, gaskets, packings, -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. o not touch the terminals of electrical components which use microcomputers (such as ). 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. efore servicing the vehicle: rotect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint. S233 S234 WAR: To prevent from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and T (transmission control module) system. The connectors should be disconnected only when working according to the WR W of TRU ASS in and AT sections. recaution for All ode 4 4 System : ven if the 2W mode is selected, the All mode 4 4 system occasionally changes from 2W to 4W automatically depending on the driving conditions. When spinning the front wheels by running the engine with the front wheels jacked up or mounted on the free rollers / or a chassis dynamometer, be careful because the vehicle may suddenly move due to the driving force from the rear wheels. To avoid personal injury and vehicle damage, use one of the following methods when working with the front wheels drive force and spinning freely. Remove the propeller shaft. Use free rollers / chassis dynamometer designed for 4W vehicles. recaution for Three Way atalyst : f a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions. Use unleaded gasoline only. eaded gasoline will seriously damage the three way catalyst. When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. o not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst. -39

40 < RAUT > RAUTS o not place the vehicle on flammable material. eep flammable material off the exhaust pipe and the three way catalyst. recaution for uel : AS Use unleaded gasoline with an octane rating of at least 91 (R). AUT: o not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity. S iesel fuel of at least 50 cetane. f two types of diesel fuel are available, use summer or winter fuel properly according to the following temperature conditions. Above 7 (20 )... Summer type diesel fuel. elow 7 (20 )... Winter type diesel fuel. AUT: o not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of those can cause engine damage. o not use summer fuel at temperatures below 7 (20 ). The cold temperatures will cause wax to form in the fuel. As a result, it may prevent the engine from running smoothly. o not add gasoline or other alternate fuels to diesel fuel. recaution for ultiport uel njection System or ngine ontrol System efore connecting or disconnecting any harness connector for the multiport fuel injection system or : Turn ignition switch to position. isconnect negative battery terminal. therwise, there may be damage to. efore disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure. e careful not to jar components such as and mass air flow sensor. : recaution for Turbocharger (f quipped) S787 : The turbocharger turbine revolves at extremely high speeds and becomes very hot. Therefore, it is essential to maintain a clean supply of oil flowing through the turbocharger and to follow all required maintenance instructions and operating procedures. Always use the recommended oil. ollow the instructions for proper time to change the oil and proper oil level. Avoid accelerating engine to a high rpm immediately after starting. f engine had been operating at high rpm for an extended period of time, let it idle for a few minutes prior to shutting if off. recaution for oses S292 : S RVA A STAAT -40

41 < RAUT > RAUTS To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver. To reinstall the rubber hose securely, make sure that hose insertion length and orientation is correct. (f tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.) SA019 S A f old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). f there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position. iscard old clamps; replace with new ones. SA020 SA021 After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around. recaution for ngine ils SA022 : rolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. f skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. AT RTT RAUTS Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. o not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil. -41

42 < RAUT > RAUTS eavily soiled clothing and oil-impregnated footwear should not be worn. veralls must be cleaned regularly. irst 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). reparations containing lanolin replace the natural skin oils which have been removed. o not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin. f skin disorders develop, obtain medical advice without delay. Where practical, degrease components prior to handling. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. recaution for Air onditioning : Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to AT/T section -134a (R-134a) Service rocedure, RRRAT S for specific instructions. -42

43 < RAUT > T T antograph ack T T : WAR: ever 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. lace wheel chocks at both front and back of the wheels on the ground. arage ack and Safety Stand : AUT: lace a wooden or rubber block between safety stand and vehicle body when the supporting body is flat. AA ole ift WAA0028 : WAR: 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. -43

44 < RAUT > T T When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, or fuel lines. WAA

45 < RAUT > TW TRU TW Tow Truck Towing TW TRU TW : WAR: ever 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. lace wheel chocks at both front and back of the wheels on the ground. AUT: All applicable local laws regarding the towing operation must be obeyed. t is necessary to use proper towing equipment to avoid possible damage during towing operation. Towing is in accordance with Towing rocedure anual at dealer. Always attach safety chains before towing. When towing, make sure that the transmission, steering system and powertrain are in good order. f any unit is damaged, dollies must be used. ever tow an automatic transmission model from the rear (i.e., backward) with four wheels on the ground as this may cause serious and expensive damage to the transmission. WAA0030 SSA does not recommend towing automatic transmission equipped vehicles with the drive wheels on the ground. AUT: When towing with the front wheels on the ground or rear wheels on the ground (f you do not use towing dollies): Set the free-running hubs to the free position and move the transfer case shift lever into the 2 position. When towing with the front on the ground: Turn the ignition key to the position and secure the steering wheel in a straight ahead position with a rope or similar device. ever place the ignition key in the position. This will result in damage to the steering lock mechanism. bserve the following restricted towing speeds and distances. Speed istance : elow 50 km/h (30 ) : ess than 65 km (40 miles) TW T AUT: WAA

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