GENERAL INFORMATION SECTION GI CONTENTS GENERAL INFORMATION GI-1 HOW TO USE THIS MANUAL... 3 PREPARATION...36 VEHICLE INFORMATION...37 PRECAUTION...

Transcription

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 Relation between llustrations and escriptions...4 omponents...4 W T W TRU ASS... 6 escription...6 ow to ollow Test roups in Trouble iagnosis...6 ey to Symbols Signifying easurements or rocedures...7 W T RA WR ARAS... 9 onnector Symbols...9 Sample/Wiring iagram -xample onnector nformation...12 ow to Repair Aluminum Wires...13 ARVATS...16 Abbreviation ist...16 TT TRQU STAAR TS...21 escription...21 Tightening Torque Table (ew Standard ncluded)...21 R A RUTS A SAATS...24 Recommended hemical roducts and Sealants...24 RAUT...25 RAUTS...25 escription...25 recaution for Supplemental Restraint System (SRS) "AR A" and "SAT T R-T- SR"...25 recaution for rocedure without owl Top over...25 recautions for Removing of attery Terminal...26 eneral recautions...26 Three Way atalyst...27 ultiport uel njection System or ngine ontrol System...28 recaution for Turbocharger...28 oses...28 ngine ils...29 Air onditioning...29 uel...30 T T...31 ommercial Service Tools...31 arage ack and Safety Stand and 2-ole ift...31 oard-n ift...32 TW TRU TW...33 Tow Truck Towing...33 Vehicle Recovery (reeing a Stuck Vehicle)...34 RARAT...36 RARAT...36 Special Service Tools...36 ommercial Service Tools...36 Repair arts...36 V RAT...37 TAT RAT...37 odel Variation...37 nformation About dentification or odel ode...38 imensions...41 Wheels & Tires...41 AS ST...42 SRV RAT R TRA T...42 Work low...42 ontrol Units and lectrical arts

2 ow to heck Terminal ntermittent ncident ircuit nspection SUT/ST SYST escription SUT unction and System Application* SUT/ST ata ink onnector () ircuit Wiring iagram - SUT/ST SYST ST A AUSTT ATA SRV W RV AT- TRY ATV TRA ATA SRV W RV ATTRY ATV TRA : Required rocedure After attery isconnection

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 Standard uter Socket ock ut : m ( kg-m, ft-lb) ontents rive Shaft nstallation olt : 44.3 m (4.5 kg-m, 33 ft-lb) : 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. -3

4 W T US TS AUA < W T US TS AUA > Relation between llustrations and escriptions : The following sample explains the relationship between the part description in an illustration, the part name in the text and the service procedures. omponents SAA0519 : 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. -4

5 < W T US TS AUA > W T US TS AUA A ap 2. leeder valve 3. ylinder body 4. iston seal 5. iston 6. iston boot 7. Sliding pin 8. Sliding pin boot 9. ushing 10. Torque member : Apply rubber grease. : Apply brake fluid. : m (kg-m, in-lb) :Always replace after every disassembly. SYS SAA0749-5

6 W T W TRU ASS < W T US TS AUA > 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, check 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. -6

7 < W T US TS AUA > W T W TRU ASS ey to Symbols Signifying easurements or rocedures : AA0982-7

8 W T W TRU ASS < W T US TS AUA > SAA1461-8

9 < W T US TS AUA > W T RA WR ARAS onnector Symbols W T RA WR ARAS 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. : ale and female terminals onnector guides for male terminals are shown in black and female terminals in white in wiring diagrams. SAA0257 S363-9

10 W T RA WR ARAS < W T US TS AUA > Sample/Wiring iagram -xample- : ach section includes wiring diagrams. AWA0150 escription umber tem escription 1 ower supply This means the power supply of fusible link or fuse. 2 use / means the fuse. 3 4 urrent rating of fusible link/fuse umber of fusible link/ fuse This means the current rating of the fusible link or fuse. This means the number of fusible link or fuse location. 5 usible link X means the fusible link. 6 onnector number 7 Switch Alphabetic characters show to which harness the connector is placed. umeric characters show the identification number of connectors. 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. 8 ircuit (Wiring) This means the wiring. -10

11 < W T US TS AUA > W T RA WR ARAS umber tem escription 9 Shielded line The line enclosed by broken line circle shows shield wire. 10 onnectors This means that a transmission line bypasses two connectors or more. 11 ption abbreviation This means the vehicle specifications which layouts the circuit between. 12 Relay This shows an internal representation of the relay. 13 ptional splice The open circle shows that the splice is optional depending on vehicle application. 14 Splice The shaded circle means the splice. 15 System branch This shows that the circuit is branched to other systems. 16 age crossing This circuit continues to an adjacent page. 17 omponent name This shows the name of a component. 18 Terminal number This means the terminal number of a connector. 19 round () This shows the ground connection. 20 xplation of option description This shows a description of the option abbreviation used on the page. 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: ignition switch is doors, hood and trunk lid/back door are closed pedals are not depressed parking brake is released UT SWT The continuity of multiple switch is described in two ways as shown below. The switch chart is used in schematic diagrams. S860-11

12 W T RA WR ARAS < W T US TS AUA > The switch diagram is used in wiring diagrams. SAA0017 onnector nformation : W T US TR RAT AWA

13 < W T US TS AUA > W T RA WR ARAS escription umber tem escription 1 onnector number Alphabetic characters show to which harness the connector is placed. umeric characters show the identification number of connectors. 2 onnector type 1: onnector model 2: avity 3: ale () and female () terminals 4: onnector color 5: Special type 3 Terminal number This means the terminal number of a connector. 4 Wire color 5 onnector ow to Repair Aluminum Wires : RAUTS R T A AUU WRS f an aluminum wire is damaged (e.g. broken), never perform the repair method for copper wires (soldering). ever perform electrotap for connecting broken aluminum wires. To secure the wire fixing strength (a force to protect aluminum wire from being disconnected from crimp terminal) and electrical conductivity, always use the dedicated harness repair kit and caulking tool [SST: V ] when repairing broken wires. W T STUS AUU WRS Wiring color: avender (olor code: A) This shows a code for the color of the wire. = lack W = White R = Red = reen = lue Y = Yellow = ight reen or = eige A = avender W T RAR R WRS 1. nsert heat shrinkable tube (2) into the target aluminum wire (1) beforehand. 2. Strip wire terminal approximately 10 mm and insert it into crimp terminal (3). AUT: heck wire size and use appropriate crimp terminal. 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 This means the connector information. This unit-side is described by the connector symbols. A0113 SAA2961ZZ -13

14 W T RA WR ARAS < W T US TS AUA > 3. Set crimp terminal to the die (tooth) of caulking tool [SST: V ]. AUT: Use appropriate die (tooth) of caulking tool [SST: V ] according to the crimp terminal size. SAA2963ZZ 4. Apply load until the handle of caulking tool [SST: V ] is released. T: The handle of the specified caulking tool [SST: V ] is not opened until crimping is completed. SAA2962ZZ 5. After crimping both sides, pull wire at both ends to check that they are not disconnected from crimp terminals. SAA2964ZZ 6. over the crimp terminal with heat shrinkable tube (1) and heat the tube with industrial dryer (A). SAA2965ZZ 7. After heating heat shrinkable tube (1), check that adhesive (A) is squeezed out from both ends of tube to the entire perimeter. SAA2966ZZ -14

15 < W T US TS AUA > W T RA WR ARAS 8. Wind insulating tape (A) around heat shrinkable tube for the purpose of waterproof and anticorrosion. W T XT WRS When repairing a broken aluminum wire, it can be extended by connecting aluminum wire (2) with copper wire (3) by using crimp terminal (1). SAA2967ZZ SAA3100ZZ -15

16 < W T US TS AUA > ARVATS Abbreviation ist The following ARVATS are used: ARVATS : A ARVAT A/ A/ A/ sensor A/T AS AS A A A AT AV AW ARVAT AR S SW Air conditioner Air conditioning Air fuel ratio sensor Automatic transaxle/transmission Anti-lock braking system Advance climate control system Air cleaner Accelerator pedal Accelerator pedal position Automatic transmission fluid Audio visual All wheel drive arometric pressure ack-up collision intervention ody control module rake limited slip differential rake pedal position lind spot warning SRT SRT ARVAT T VT SRT rankshaft position losed loop amshaft position lutch pedal position losed throttle position ontinuously variable transaxle/transmission ARVAT A S T rive range first gear rive range second gear rive range third gear rive range fourth gear istance control assist ownhill drive support irect fuel injection system ata link connector iagnostic trouble code SRT -16

17 < W T US TS AUA > ARVATS ARVAT SRT /T xhaust temperature lectric brake force distribution ngine control ngine coolant level ngine control module T ngine coolant temperature V lectrical control valve R lectrically erasable programmable read only memory T ngine fuel temperature R xhaust gas recirculation RT xhaust gas recirculation temperature T xhaust gas temperature ngine oil pressure xhaust pressure R xhaust pressure regulator S lectronically controlled power steering S lectronic stability program system VA canister vaporative emission canister VS lectric vehicle supply equipment X xhaust control ARVAT SRT an control W orward collision warning orward emergency braking uel injector control uel pump R ront R uel rail pressure RT uel rail temperature T uel tank pressure TT uel tank temperature ARVAT SRT round S ST lobal positioning system eneric scan tool ARVAT SRT ydraulic body-motion control system ard disk drive 2S eated oxygen sensor eated oxidation catalyst ybrid power train control module -17

18 < W T US TS AUA > ARVATS ARVAT SRT / nspection and maintenance A ntake air A dle air control AT ntake air temperature A ntelligent brake assist gnition control ntelligent cruise control gnition control module /R ntelligent power distribution module engine room S dle speed control SS nput shaft speed ARVAT S ARVAT U W ARVAT /T A A U ARVAT X ARVAT 2 2S SS nock sensor i-ion battery controller iquid crystal display ocal control unit ane departure prevention ane departure warning ight emitting diode eft-hand ocal interconnect network anual transaxle/transmission ass airflow anifold absolute pressure ulti display unit alfunction indicator alfunction indicator lamp itrogen oxides xygen xygen sensor n board diagnostic xidation catalytic converter verdrive pen loop utput shaft speed SRT SRT SRT SRT SRT -18

19 < W T US TS AUA > ARVATS ARVAT SRT /S ower steering R otentio balance resistor V ositive crankcase ventilation W redictive forward collision warning ark/eutral position S ower steering pressure T ositive temperature coefficient T ower takeoff W ulse width modulation R ARVAT SRT RA Random access memory RAS Rear active steer R Right-hand R R Read only memory ngine speed RR Rear S ARVAT SRT SA S Society of Automotive ngineers, nc. Serial clock SS Service ata and Specifications SRT SST System readiness test Special Service Tools T ARVAT SRT T Turbocharger T TS Transmission control module Traction control system TU Telematics communication unit T TS Throttle position Tire pressure monitoring system TSS TW Turbine shaft speed Three way catalytic converter U ARVAT USS Uphill start support SRT V ARVAT V Vehicle control module SRT V Vehicle dynamics control system V Vehicle identification number VSS Vehicle speed sensor -19

20 < W T US TS AUA > W ARVAT WT Wide open throttle ARVATS SRT 1 2 ARVAT 11 1st range first gear 12 1st range second gear 1R irst gear ARVAT 21 2nd range first gear 22 2nd range second gear 2R Second gear 2W 2-wheel drive SRT SRT ARVAT 3R ARVAT 4R 4WAS 4W ARVAT 5R ARVAT 6R ARVAT 7R Third gear ourth gear our wheel active steer our wheel drive ifth gear Sixth gear Seventh gear SRT SRT SRT SRT SRT -20

21 < W T US TS AUA > TT TRQU STAAR TS TT TRQU STAAR TS escription : This vehicle has both new standard based on S* and previous standard bolts/nuts. There are some differences between these two types of bolts/ nuts; shape of the head, grade of strength, hexagonal width across flats and the standard tightening torque. or guidance in discriminating, refer to -21, "Tightening Torque Table (ew Standard ncluded)". The new standard machine screws and tapping screws have a head of S standard torx recess. f the tightening torque is not described in the description or figure, refer to -21, "Tightening Torque Table (ew Standard ncluded)". *S: nternational rganization for Standardization Tightening Torque Table (ew Standard ncluded) : AUT: The special parts are excluded. The bolts/nuts in these tables have a strength (discrimination) number/symbol assigned to the head or the like. As to the relation between the strength grade in these tables and the strength (discrimination) number/symbol, refer to SRAT TS A UTS. RVUS STAAR rade (Strength grade) 4T 7T 9T olt size olt diameter mm exagonal width across flats mm itch mm exagon head bolt Tightening torque (Without lubricant) exagon flange bolt m kg-m ft-lb in-lb m kg-m ft-lb in-lb AUT: -21

22 TT TRQU STAAR TS < W T US TS AUA > The parts with aluminum or the cast iron washer surface/thread surface are excluded. W STAAR AS S rade (Strength grade) olt size olt diameter mm exagonal width across flats mm itch mm Tightening torque exagon head bolt exagon flange bolt m kg-m ft-lb in-lb m kg-m ft-lb in-lb (Without lubricant) (With lubricant) (With lubricant) (With lubricant) AUT: 1. Use tightening torque with lubricant for the new standard bolts/nuts in principle. riction coefficient stabilizer is applied to the new standard bolts/nuts. 2. owever, use tightening torque without lubricant for the following cases. riction coefficient stabilizer is not applied to the following bolts/nuts. - rade 4.8, 6 size bolt, onical spring washer installed - aint removing nut (Size 6 and 8) for fixing with weld bolt -22

23 TT TRQU STAAR TS < W T US TS AUA > SRAT TS A UTS SAA

24 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

25 < RAUT > 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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SRS AR A and SAT T of this Service anual. WAR: Always observe the following items for preventing accidental activation. To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that 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 SRS AR A. ever 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. RAUTS W US WR TS (AR R TR) A ARS WAR: Always observe the following items for preventing accidental activation. When working near the Air ag iagnosis Sensor Unit or other Air ag System sensors with the ignition or engine running, never use air or electric power tools or strike near the sensor(s) with a hammer. eavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. When using air or electric power tools or hammers, always switch the ignition, disconnect the battery, and wait at least 3 minutes before performing any service. recaution for rocedure without owl Top over When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc to prevent damage to windshield. :

26 < RAUT > RAUTS recautions for Removing of attery Terminal : When removing the 12V battery terminal, turn the ignition switch and wait at least 30 seconds. T: U may be active for several tens of seconds after the ignition switch is turned. f the battery terminal is removed before U stops, then a T detection error or U data corruption may occur. or vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning the ignition switch. T: f the ignition switch is turned with any one of the terminals of main battery and sub battery disconnected, then T may be detected. After installing the 12V battery, always check "Self iagnosis Result" of all Us and erase T. T: The removal of 12V battery may cause a T detection error. eneral recautions 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. S289 : 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. or vehicles with two batteries, be sure to remove both batteries when instructed to remove 12V battery in the service manual. f specified as main battery or sub battery, then do as instructed. S289-26

27 < 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 hand tools, power tools (disassembly only) 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 leakage. S233 efore servicing the vehicle: rotect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint. AA0335ZZ S234 WAR: To prevent from storing the diagnostic trouble codes, never 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 T sections. 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. -27

28 < RAUT > RAUTS o not place the vehicle on flammable material. eep flammable material off the exhaust pipe and the three way catalyst. 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 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. oses S292 : S RVA A STAAT To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver. SA019 To reinstall the rubber hose securely, check 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.) SA020 S A -28

29 < RAUT > RAUTS 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. After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around. SA021 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. 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. VRTA RTT RAUTS ispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. f in doubt, contact the local authority for advice on disposal facilities. t is illegal to pour used oil on to the ground, down sewers or drains, or into water sources. The regulations concerning pollution vary between regions. Air onditioning : Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to A section RRRAT for specific instructions. -29

30 < RAUT > uel RAUTS : SSA recommends the use of unleaded premium gasoline with an octane rating of at least 91 A (Anti- nock ndex) number (Research octane number 96). f unleaded premium gasoline is not available, may use unleaded regular gasoline with an octane rating of at least 87 A number (Research octane number 91), can be used. n such case, engine performance may be decrease. AUT: Using a fuel other than that specified could adversely affect the emission control system, and may also affect warranty coverage. Under no circumstances should a leaded gasoline be used, because this will damage the three-way catalyst. o not use -15 or -85 fuel in the vehicle. The vehicle is not designed to run on -15 or -85 fuel. Using -15 or -85 fuel in a vehicle not specifically designed for -15 or -85 fuel can adversely affect the emission control devices and systems of the vehicle. amage caused by such fuel is not covered by the SSA new vehicle limited warranty. U.S. government regulations require ethanol dispensing pumps to be identified by a small, square, orange and black label with the common abbreviation or the appropriate percentage for that region. -30

31 < RAUT > T T ommercial Service Tools T T : Tool name escription oard on attachment S-T001 Safety stand attachment AUT: very time the vehicle is lifted up, maintain the complete vehicle curb condition. Since the vehicle's center of gravity changes when removing main parts on the front side (engine, transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission jack or equivalent. Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle, suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equivalent. e careful not to smash or never do anything that would affect piping parts. arage ack and Safety Stand and 2-ole ift : WAR: ark the vehicle on a level surface when using the jack. heck to avoid damaging pipes, tubes, etc. under the vehicle. ever get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehicle. lace wheel chocks at both front and back of the wheels on the ground. 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, never allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler. S-T002-31

32 < RAUT > T T AA0291ZZ 1. Safety stand point and lift up point (front) 2. Safety stand point and lift up point (rear) 4. arage jack point (rear) (2W) 5. arage jack point (rear) (AW) AUT: There is canister just behind arage jack point rear. ack up carefully. oard-n ift AUT: heck vehicle is empty when lifting. The board-on lift attachment (A) set at front end of vehicle should be set on the front of the sill under the front door opening. osition attachments at front and rear ends of board-on lift. 3. arage jack point (front) : : Vehicle front AA0004ZZ -32

33 < RAUT > TW TRU TW Tow Truck Towing TW TRU TW : AUT: All applicable state or rovincial (in anada) laws and local laws regarding the towing operation must be obeyed. t is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing rocedure anual at dealer. Always attach safety chains before towing. When towing, check that the transmission, steering system and powertrain are in good order. f any unit is damaged, dollies must be used. ever tow a VT model from the rear (that is backward) with four wheels on the ground. This may cause serious and expensive damage to the transmission. 2W S AA0068ZZ SSA recommends that vehicle be towed with the driving (front) wheels off the ground or that a dolly be used as illustrated. AUT: ever tow VT models with the front wheels on the ground or four wheels on the ground (forward or backward), as this may cause serious and expensive damage to the transmission. f it is necessary to tow the vehicle with the rear wheels raised, always use towing dollies under the front wheels. When towing VT models with the front wheels on towing dollies: - Turn the ignition switch to the position, and secure the steering wheel in a straight ahead position with a rope or similar device. ever secure the steering wheel by turning the ignition switch to the position. This may damage the steering lock mechanism. - ove the selector lever to the (eutral) position. When the battery of vehicle equipped with the ntelligent ey system is discharged, your vehicle should be towed with the front wheels on towing dollies or place the vehicle on a flat bed truck. When towing two wheel drive VT model with the rear wheels on the ground (if you do not use towing dollies): Always release the parking brake. -33

34 < RAUT > AW S TW TRU TW AA0069ZZ SSA recommends that a dolly be used as illustrated when towing AW models. AUT: ever tow AW models with any of the wheels on the ground as this may cause serious and expensive damage to the powertrain. Vehicle Recovery (reeing a Stuck Vehicle) : RT Securely install the vehicle recovery hook stored with jacking tools. heck that the hook is properly secured in the stored place after use. WAR: Stand clear of a stuck vehicle. ever spin your tires at high speed. This could cause them to explode and result in serious injury. arts of your vehicle could also overheat and be damaged. AUT: Tow chains or cables must be attached only to the vehicle recovery hooks or main structural members of the vehicle. therwise, the vehicle body will be damaged. AA0260ZZ ever use the vehicle tie downs to free a vehicle stuck in sand, snow, mud, etc. ever tow the vehicle using the vehicle tie downs or recovery hooks. Always pull the cable straight out from the front of the vehicle. ever pull on the hook at an angle. ulling devices should be routed so they never touch any part of the suspension, steering, brake or cooling systems. ulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery. RAR Securely install the vehicle recovery hook stored with jacking tools. 2W AA0261ZZ -34

35 < RAUT > TW TRU TW AW AA0293ZZ -35

36 < RARAT > RARAT RARAT Special Service Tools RARAT : Tool number Tool name V aulking tool escription rimping terminals ommercial Service Tools SAA2959ZZ : Tool name ndustrial dryer escription eating heat shrinkable tube Repair arts SAA3281ZZ : art name arness repair kit A: eat shrinkable tube : rimp terminal (or harness with the diameter of 1.00 or less) : rimp terminal (or harness with the diameter of 1.25 or more) escription onnecting aluminum wires SAA2960ZZ -36

37 < V RAT > V RAT TAT RAT odel Variation TAT RAT : estination ody ngine Axle andle Transmission rade odel USA (xcept for alifornia) alifornia anada 4-door atchback R16T 2W AW 2W AW 2W AW 6T -VT 6T -VT 6T -VT SV S S S SV S S SV S S SV S S S SV S S SV S S S SV S S SV S SV S AUY-UUA AVY-UUA AWY-UUA ARW-UUA AUW-UUA AVW-UUA RW-UUA UW-UUA VW-UUA WW-UUA AUY-UVA AVY-UVA AWY-UVA ARW-UVA AUW-UVA AVW-UVA RW-UVA UW-UVA VW-UVA WW-UVA ARY-UA AUY-UA AWY-UA ARW-UA AUW-UA RW-UA UW-UA WW-UA -37

38 < V RAT > odel variation code (refix and suffix designations) TAT RAT SAA2862 nformation About dentification or odel ode : TAT UR AA Air conditioner specification label 2. mission control information label 3. Vehicle identification number (hassis number) 4. Vehicle identification number plate 5. VSS certification label (or USA) VSS certification label (or anada) 6. Tire and loading information label -38

39 TAT RAT < V RAT > V TAT UR ARRAT RTAT A VSS certification label SAA3275 SAA2499ZZ 1. R onth / Year 2. ross vehicle weight rating 3. ross axle weight rating (ront) 4. Tire size 5. Wheel size 6. Tire inflation pressure 7. ross axle weight rating (Rear) 8. Vehicle identification number 9. Verification model code 10. ody color number 11. Trim color number 12. Transmission type 13. Axle type 14. ngine type 15. ngine displacement 16. V bar code VSS certification label -39

40 < V RAT > TAT RAT SAA2500ZZ 1. R onth / Year 2. ross vehicle weight rating 3. ross axle weight rating (ront) 4. Tire size 5. Wheel size 6. Tire inflation pressure 7. ross axle weight rating (Rear) 8. Vehicle identification number 9. Verification model code 10. ody color number 11. Trim color number 12. Transmission type 13. Axle type 14. ngine type 15. ngine displacement 16. V bar code SRA UR : Vehicle front VT UR SAA1341 : Vehicle front AUA TRASAX UR SAA

41 < V RAT > TAT RAT : Vehicle front imensions verall length verall width *1: With front license plate bracket *2: Without front license plate bracket *3: With front license plate bracket (S models) *4: Without front license plate bracket (S models) *5: S models *6: 2W models *7: AW models Wheels & Tires 4,135 (162.8) *1 4,125 (162.4) *2 4,165 (164.0) *3 4,160 (163.8) *4 1,765 (69.5) 1,770 (69.7) *5 verall height 1,570 (61.8) ront tread 1,525 (60.0) Rear tread 1,525 (60.0) *6 1,505 (59.3) *7 Wheelbase 2,530 (99.6) SAA1338 : Unit: mm (in) : onventional 17 inch 18 inch Tire Road wheel (Aluminum) Tire Road wheel (Aluminum) Size nset Size nset 215/55R17 93V mm (1.85 in) 225/45R18 95Y mm (1.85 in) Spare Tire Road wheel (Steel) Size nset T135/ *1 T135/ *2 16 4T 30 mm (1.18 in) *1: 2W models *2: AW models -41

42 SRV RAT R TRA T < AS ST > AS ST SRV RAT R TRA T Work low : WR W S838 ST ST 1 ST 2 ST 3 ST 4 ST 5 ST 6 ontrol Units and lectrical arts SRT et 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: WAT Vehicle odel, ngine, Transmission/Transaxle and the System (i.e. Radio). W ate, Time of ay, Weather onditions, requency. WR Road onditions, Altitude and Traffic Situation. System Symptoms, perating onditions (ther omponents nteraction). W Service istory and if any After arket Accessories have been installed. perate the system, road test if necessary. Verify the parameter of the incident. f the problem cannot be duplicated, refer to ncident Simulation Tests. et the proper diagnosis materials together including: ower Supply Routing System peration escriptions Applicable Service anual Sections heck for any Service ulletins dentify where to begin diagnosis based upon your knowledge of the system operation and the customer comments. nspect the system for mechanical binding, loose connectors or wiring damage. etermine which circuits and components are involved and diagnose using the ower Supply Routing and arness ayouts. Repair or replace the incident circuit or component. perate the system in all modes. Verify the system works properly under all conditions. heck you have not inadvertently created a new incident during your diagnosis or repair steps. RAUTS ever reverse polarity of battery terminals. nstall only parts specified for a vehicle. efore replacing the control unit, check the input and output and functions of the component parts. o not apply excessive force when disconnecting a connector. :

43 < AS ST > SRV RAT R TRA T o not apply excessive shock to the control unit by dropping or hitting it. e careful to prevent condensation in the control unit due to rapid temperature changes and do not let water or rain get on it. f water is found in the control unit, dry it fully and then install it in the vehicle. e careful not to let oil to get on the control unit connector. Avoid cleaning the control unit with volatile oil. o not disassemble the control unit, and do not remove the upper and lower covers. When using a, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting. When checking input and output signals of the control unit, use the specified check adapter. SAA0255 ow to heck Terminal S348 : TR A TRA T Use the connector and terminal pin kits listed below when replacing connectors or terminals. The connector and terminal pin kits contain some of the most commonly used SSA/T connectors and terminals. or detailed connector and terminal pin replacement procedures, refer to the latest SSA/ T TR A TRA SRV AUA. -43

44 SRV RAT R TRA T < AS ST > Tool number (ent-oore o.) Tool name - ( ) onnector and terminal pin kit (SSA) - ( ) onnector and terminal pin kit (T) - ( T) and terminal repair kit - ( U) - onnector it Update WAA0004 escription W T R TRS onnector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. The probe of a digital multimeter () may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a T pin. or the best contact grasp the T pin using an alligator clip. robing from arness Side Standard type (not waterproof type) connector should be probed from harness side with T pin. f the connector has a rear cover such as a connector, remove the rear cover before probing the terminal. o not probe waterproof connector from harness side. amage to the seal between wire and connector may result. WAA0005 robing from Terminal Side A TRA There is a small notch above each female terminal. robe each terminal with the T pin through the notch. o not insert any object other than the same type male terminal into female terminal. S841 S265V -44

45 < AS ST > SRV RAT R TRA T Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing. A TRA arefully probe the contact surface of each terminal using a T pin. AUT: ever bend terminal. S266V ow to heck nlarged ontact Spring of Terminal An enlarged contact spring of a terminal may create intermittent signals in the circuit. f 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. T: Use a male terminal which matches the female terminal. 2. isconnect the suspected faulty connector and hold it terminal side up. S267V S270V 3. While holding the wire of the male terminal, try to insert the male terminal into the female terminal. AUT: ever force the male terminal into the female terminal with your hands. S271V -45

46 SRV RAT R TRA T < AS ST > 4. While moving the connector, check whether the male terminal can be easily inserted or not. S272V f the male terminal can be easily inserted into the female terminal, replace the female terminal. S273V Waterproof onnector nspection f water enters the connector, it can short interior circuits. This may lead to intermittent problems. heck the following items to maintain the original waterproof characteristics. RUR SA ST ost waterproof connectors are provided with a rubber seal between the male and female connectors. f 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, check the rubber seal is properly installed on either side of male or female connector. WR SA ST The wire seal must be installed on the wire insertion area of a waterproof connector. e sure that the seal is installed properly. S275V Terminal ock nspection heck for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit. ntermittent ncident S330V : SRT Sometimes the symptom is not present when the vehicle is brought in for service. f possible, re-create the conditions present at the time of the incident. oing so may help avoid a o Trouble ound iagnosis. The fol- -46

47 < AS ST > SRV RAT R TRA T lowing 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 eat sensitive reezing Water intrusion lectrical load old or hot start up et a thorough description of the incident from the customer. t is important for simulating the conditions of the problem. V VRAT The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/ on). n such a case, you will want to check for a vibration related condition. Refer to the following illustration. onnector & arness etermine which connectors and wiring harness would affect the electrical system you are inspecting. ently 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. int onnectors can be exposed to moisture. t is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. f the problem occurs intermittently, perhaps the problem is caused by corrosion. t is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. Sensor & Relay ently 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. S839 ngine ompartment There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: onnectors 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. oose, 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 round nspection described later.) irst 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. ehind the nstrument anel 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 -47