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 diagram -example-...10 escription...11 ARVATS...13 Abbreviation ist...13 TT TRQU STAAR TS...14 Tightening Torque Table...14 R A RUTS A SAATS...15 Recommended hemical roducts and Sealants...15 TRY...16 SA 1930 Terminology ist...16 ATURS W...20 TAT RAT...20 odel Variation...20 dentification umber...22 imensions...24 Wheels & Tires...25 RAUT...26 RAUTS...26 escription...26 Supplemental Restraint System (SRS) "AR A" and "SAT T R-TSR"...26 ecessary for Steering Wheel Rotation After attery isconnect...26 rocedures without owl Top over...27 eneral recautions...27 Three Way atalyst...28 uel (Regular Unleaded asoline Recommended) QR25...29 uel (Unleaded remium asoline Required) VQ35...29 ultiport uel njection System or ngine ontrol System...29 oses...29 ngine ils...30 Air onditioning...31 T T...32 Special Service Tool...32 arage ack and Safety Stand...32 2-ole ift...33 oard-on ift...34 TW TRU TW...35 Tow Truck Towing...35 Vehicle Recovery (reeing a Stuck Vehicle)...35 AS ST...37 SRV RAT R TRA T...37 Work low...37 ontrol Units and lectrical arts...37 ow to heck Terminal...38 ntermittent ncident...41 ircuit nspection...44 SUT- SYST...49-1
escription... 49 unction and System Application... 49 SUT- ata ink onnector () ircuit... 50 Wiring iagram... 51-2
< W T US TS AUA > W T US TS AUA W T US TS AUA W T US TS AUA escription :0000000001547180 This volume explains Removal, isassembly, nstallation, nspection and Adjustment and Trouble iagnoses. Terms :0000000001547181 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 :0000000001547182 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 : 59-78 m (6.0-8.0 kg-m, 43-58 ft-lb) ontents rive Shaft nstallation olt : 44.3 m (4.5 kg-m, 33 ft-lb) :0000000001547183 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. -3
W T US TS AUA < W T US TS AUA > Relation between llustrations and escriptions :0000000001547184 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 :0000000001547185 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
< W T US TS AUA > W T US TS AUA 1. 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 SA2959 SAA0749-5
W T W TRU ASS < W T US TS AUA > W T W TRU ASS escription :0000000001547186 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 :0000000001547187 AA0021 1. 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
< W T US TS AUA > W T W TRU ASS ey to Symbols Signifying easurements or rocedures :0000000001547188 SAA1539-7
W T W TRU ASS < W T US TS AUA > SAA1540-8
< 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. :0000000001547189 ale and female terminals onnector guides for male terminals are shown in black and female terminals in white in wiring diagrams. SAA0257 S363-9
W T RA WR ARAS < W T US TS AUA > Sample/wiring diagram -example- :0000000001547190 or detail, refer to following -11, "escription". AWA0005-10
< W T US TS AUA > escription W T RA WR ARAS :0000000001547191 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 -58, "lectrical Units ocation", -33, "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: -11
W T RA WR ARAS < 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. S860 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. SAA0017-12
< W T US TS AUA > ARVATS Abbreviation ist ARVATS :0000000001547192 The following ARVATS are used: 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 -13
TT TRQU STAAR TS < W T US TS AUA > TT TRQU STAAR TS Tightening Torque Table :0000000001547193 4T 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 6 6.0 1.0 5.5 0.56 4 49 7 0.71 5 62 8 8.0 10 10.0 1.25 13.5 1.4 10 17 1.7 13 1.0 13.5 1.4 10 17 1.7 13 1.5 28 2.9 21 35 3.6 26 1.25 28 2.9 21 35 3.6 26 1.75 45 4.6 33 55 5.6 41 12 12.0 1.25 45 4.6 33 65 6.6 48 14 14.0 1.5 80 8.2 59 100 10 74 6 6.0 1.0 9 0.92 7 80 11 1.1 8 97 8 8.0 10 10.0 1.25 22 2.2 16 28 2.9 21 1.0 22 2.2 16 28 2.9 21 1.5 45 4.6 33 55 5.6 41 1.25 45 4.6 33 55 5.6 41 1.75 80 8.2 59 100 10 74 12 12.0 1.25 80 8.2 59 100 10 74 14 14.0 1.5 130 13 96 170 17 125 6 6.0 1.0 11 1.1 8 13.5 1.4 10 8 8.0 10 10.0 1.25 28 2.9 21 35 3.6 26 1.0 28 2.9 21 35 3.6 26 1.5 55 5.6 41 80 8.2 59 1.25 55 5.6 41 80 8.2 59 1.75 100 10 74 130 13 96 12 12.0 1.25 100 10 74 130 13 96 14 14.0 1.5 170 17 125 210 21 155 *: ominal diameter 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. 044A -14
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. :0000000001547194 1 2 3 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-A000 99998-50505 ermatex 81844 999-A001 99998-50503 ermatex 51813 and 51817 999-A002 999-A002 ermatex 56521 999-A003 (Ultra rey) 99998-50506 (Ultra rey) Threadlocker 999-A004 999-A004 Threadlocker (service tool removable) 999-A005 999-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, 24283 and 09178; Three ond 1322, 1322, 1324 &, 1333, 1361, 1364, 1370 and 1374-15
< W T US TS AUA > TRY SA 1930 Terminology ist TRY :0000000001547195 All emission related terms used in this publication in accordance with SA 1930 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 -16
< 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 -17
< 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 -18 TR ock-up cancel solenoid ock-up solenoid
< W T US TS AUA > TRY ***: ot applicable W TR W ARY / ARVAT TR 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 -19
TAT RAT < ATURS W > ATURS W TAT RAT odel Variation :0000000001329078 refix and suffix designations: osition haracter Qualifier efinition 1 ody type : ing ab : rew ab 2 3 ngine : V56 4 Axle : 2W : 4W 5 rive : R: X 6 T rade T: S U: R V: 7 Transmission : R5R05A (5A/T) 8 9 49 odel 49: 2008 Titan 10 11 ntake 12 U Zone : : V : anada U: USA and exico 13 quipment : Standard 14 15 16 XXXXX ption odes ption odes 17 18 2W odel ody ngine Transmission estination rade odel 50-State X S R-U T-U V56 R5R05A (5A/T) V-U ing ab anada X S R- T- X R-U V56 V R5R05A (5A/T) 50-State S T-U V-U -20
< ATURS W > TAT RAT rew ab 4W odel 2W odel ody ngine Transmission estination rade odel V56 R5R05A (5A/T) 50-State exico V56 V R5R05A (5A/T) 50-State X S X S X S R-U T-U V-U R-U T-U R-U T-U V-U ody ngine Transmission estination rade odel ing ab rew ab V56 R5R05A (5A/T) 50-State anada V56 V R5R05A (5A/T) 50-State V56 R5R05A (5A/T) 50-State anada exico V56 V R5R05A (5A/T) 50-State X S R S X S R X S R X S R R X S R R-U T-U U-U V-U T- V- R-U T-U U-U V-U R-U T-U U- V-U R- T- U- V- U-U V-U R-U T-U U-U V-U ody ngine Transmission estination rade odel ing ab (W) V56 R5R05A (5A/T) 50-State V56 V R5R05A (5A/T) 50-State X S X S 5R-U 5T-U 5V-U R-U 5R-U 5V-U -21
TAT RAT < ATURS W > ody ngine Transmission estination rade odel 50-State X S 5R-U 5T-U V56 R5R05A (5A/T) 5V-U rew ab (W) exico X S R-U T-U X 5R-U V56 V R5R05A (5A/T) 50-State S 5T-U 5V-U 4W odel ody ngine Transmission estination rade odel X 9R-U ing ab (W) V56 R5R05A (5A/T) 50-State S 9T-U 9V-U anada S 9T- X 9R-U V56 V R5R05A (5A/T) 50-State 50-State S X S R 9T-U 9V-U 9R-U 9T-U 9U-U V56 R5R05A (5A/T) 9V-U rew ab (W) anada X S 9R- 9T- 9V- X 9R-U V56 V R5R05A (5A/T) 50-State S R 9T-U 9U-U dentification umber 9V-U :0000000001329079 AA0047-22
< ATURS W > TAT RAT 1. mission control information label 2. Vacuum hose diagram 3. Tire placard 4. VSS certification label 5. Vehicle identification number plate V TAT UR ARRAT osition haracter Qualifier efinition 1 2 3 16 anufacturer 16: USA produced multi-purpose vehicle 4 A ngine type A: V56 ; V56 (lexible fuel vehicle) 5 A Vehicle line A: SSA Titan 6 0 odel change (0-9) 7 6 ody type 8 A SRA UR ross vehicle weight rating 6: Truck (ing ab) 7: Truck (rew ab) A: 2W, 4-wheel AS, lass : 4W, 4-wheel AS, lass 9 * heck digit (0 to 9 or X) The code for the check digit is determined by a mathematical computation. 10 8 odel year 2008 11 12 13 14 15 16 17 XXXXX anufacturing plant Vehicle serial number : anton ississippi hassis number AA0044 TRASR SRA UR A108-23
TAT RAT < ATURS W > AUTAT TRASSS UR AA0054 imensions :0000000001329080 Unit: mm (in) rive type 2W 4W verall length (Short ed) 5704 (224.6) verall length (ong ed) 6204 (244.2) verall width 2016 (79.4) verall height *1 1906.0 (75.0) 1945.8 (76.6) verall height *2 1915.0 (75.4) 1953.0 (76.9) 18 inch tire with offroad package 1725 (67.9) ront tread width *1: ing ab *2: rew ab 18 inch tire 1725 (67.9) 20 inch tire with alloy wheels 1729 (68.1) 18 inch tire with offroad package 1725 (67.9) Rear tread width 18 inch tire 1725 (67.9) 20 inch tire with alloy wheels 1729 (68.1) Wheelbase (Short ed) 3550 (139.8) Wheelbase (ong ed) 4050 (159.4) inimum Running round learance (at front suspension)*1 inimum Running round learance (at front suspension)*2 With standard undercover With offroad skid plate With oil pan skid plate With standard undercover With offroad skid plate With oil pan skid plate 247.2 (9.73) 286.1 (11.26) 242.2 (9.54) 281.1 (11.1) 286.4 (11.28) 251.5 (9.9) 291.5 (11.48) 246.5 (9.7) 286.4 (11.28) 291.3 (11.46) -24
< ATURS W > Wheels & Tires TAT RAT :0000000001329081 rive Type rade Road wheel Tire Spare tire size X 18X8 Steel 265/70R18 265/70R18 4x2 S 18X8 Alloy 265/70R18 265/70R18 20X8 Alloy 275/60R20 275/60R20 X 18X8 Steel 265/70R18 265/70R18 4x4 S 20X8 Alloy 265/70R18 265/70R18 20X8 Alloy 275/60R20 275/60R20 R-4X 18X8 Alloy 275/70R18 275/70R18-25
< RAUT > RAUT RAUTS escription RAUTS :0000000001547196 bserve the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section. Supplemental Restraint System (SRS) "AR A" and "SAT T R-TS- R" :0000000001547197 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 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. ecessary for Steering Wheel Rotation After attery isconnect :0000000001547198 T: efore removing and installing any control units, first turn the push-button ignition switch to the position, then disconnect both battery cables. After finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. Always use SUT- to perform self-diagnosis as a part of each function inspection after finishing work. f a T is detected, perform trouble diagnosis according to self-diagnosis results. This vehicle is equipped with a push-button ignition switch and a steering lock unit. f the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. f turning the steering wheel is required with the battery disconnected or discharged, 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. arry the ntelligent ey or insert it to the key slot and turn the push-button ignition switch to A position. (At this time, the steering lock will be released.) 3. isconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. 4. erform the necessary repair operation. 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from A position to position, then to position. (The steering wheel will lock when the push-button ignition switch is turned to position.) 6. erform self-diagnosis check of all control units using SUT-. -26
< RAUT > rocedures without owl Top over RAUTS When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. :0000000001547199 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. 3706 :0000000001547200 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. S289-27
< 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 leaks. S233 0190 efore servicing the vehicle: rotect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint. 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. Three Way atalyst :0000000001547201 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. -28
< RAUT > RAUTS o not place the vehicle on flammable material. eep flammable material off the exhaust pipe and the three way catalyst. uel (Regular Unleaded asoline Recommended) QR25 :0000000001547202 Use unleaded regular gasoline with an octane rating of at least 87 A (Anti-nock ndex) number (Research octane number 91). AUT: o not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. o not use -85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for -85 fuel (i.e. lexible uel Vehicle - V models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity. uel (Unleaded remium asoline Required) VQ35 :0000000001547203 Use 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, unleaded regular gasoline with an octane rating of at least 87 A number (Research octane number 91) can be used, but only under the following precautions: have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gasoline as soon as possible. avoid full throttle driving and abrupt acceleration. owever, for maximum vehicle performance, the use of unleaded premium gasoline is recommended. AUT: o not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. o not use -85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for -85 fuel (i.e. lexible uel Vehicle - V models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity. 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. :0000000001547204 oses S RVA A STAAT To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver. S787 :0000000001547205 SA019-29
< RAUT > RAUTS 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.) SA020 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. SA021 After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around. ngine ils SA022 :0000000001547206 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 -30
< RAUT > 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 :0000000001547207 Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to A section -134a (R-134a) Service rocedure. -31
< RAUT > T T Special Service Tool T T :0000000001547208 The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. Tool number (ent-oore o.) Tool name escription 4086-0200 ( - ) oard on attachment S-T001 4519-0000 ( - ) 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 transmission 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 transmission jack or equivalent. e careful not to smash or do anything that would affect piping parts. arage ack and Safety Stand :0000000001547209 WAR: ark the vehicle on a level surface when using the jack. ake sure 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. S-T002-32
< RAUT > T T ift at reinforced area of front suspension member where lower control arm attaches, staying in center line of wheels. WAA0035 2-ole ift :0000000001547210 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. -33
< RAUT > T T When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler. AA0018 oard-on ift :0000000001547211 AUT: ake sure vehicle is empty when lifting. The board-on lift attachment (4086-0200) 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. A016-34
< RAUT > TW TRU TW Tow Truck Towing TW TRU TW :0000000001547212 AUT: ever tow a VT model with the rear wheels raised and the front wheels on the ground. This may cause serious and expensive damage to the transaxle. f it is necessary to tow the vehicle with the rear wheels raised, always use towing dollies under the front wheels. ever tow an automatic transaxle model from the rear (that is backward) with four wheels on the ground. This may cause serious and expensive damage to the transaxle. SSA recommends that the vehicle be towed with the driving (front) wheels off the ground. AUT: Always release the parking brake when towing the vehicle with the front wheels raised with the rear wheels on the ground. When towing manual transaxle models with the front wheels on the ground (if a towing dolly is not used), turn the ignition key to the position, and secure the steering wheel in the 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. ove the shift lever to the (eutral) position. When the battery of a vehicle equipped with the ntelligent ey system is discharged, the vehicle should be towed with the front wheels on towing dollies or place the vehicle on a flat bed truck. Vehicle Recovery (reeing a Stuck Vehicle) :0000000001547213 RT Securely install the vehicle recovery hook stored with jacking tools. ake sure that the hook is properly secured in the storage place after use. WAR: Stand clear of a stuck vehicle. o not 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. o not 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 do not 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. VT S986 To tow a vehicle equipped with a VT, an appropriate vehicle dolly UST be placed under the towed vehicle's drive wheels. Always follow the dolly manufacture's recommendations when using their product. f the vehicle is stuck in sand, snow, mud, etc., use the following procedure: 1. Turn off the Vehicle ynamic ontrol System. -35
TW TRU TW < RAUT > 2. ake sure the area in front and behind the vehicle is clear of obstructions. 3. Turn the steering wheel right and left to clear an area around the front tires. 4. Slowly rock the vehicle forward and backward. Shift back and forth between R (reverse) and (drive). Apply the accelerator as little as possible to maintain the rocking motion. Release the accelerator pedal before shifting between R and. o not spin the tires above 35 m.p.h. (55 km/h). 5. f the vehicle can not be freed after a few tries, contact a professional towing service to remove the vehicle. -36
< AS ST > SRV RAT R TRA T AS ST SRV RAT R TRA T Work low WR W :0000000001547214 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. W System Symptoms, perating onditions (ther omponents nteraction). 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. ake sure you have not inadvertently created a new incident during your diagnosis or repair steps. :0000000001547215 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. -37
SRV RAT R TRA T < AS ST > 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. SAA0255 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. ow to heck Terminal S348 :0000000001547216 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. -38
< AS ST > SRV RAT R TRA T Tool number (ent-oore o.) Tool name - (38751-95) onnector and terminal pin kit (SSA) - (38751-95) onnector and terminal pin kit (T) - (42992-98T) and terminal repair kit - (42992-2000U) - 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 -39
SRV RAT R TRA T < AS ST > Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing. S266V A TRA arefully probe the contact surface of each terminal using a T pin. AUT: ot not bend terminal. 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: o not force the male terminal into the female terminal with your hands. S271V -40
< AS ST > SRV RAT R TRA T 4. While moving the connector, check whether the male terminal can be easily inserted or not. f the male terminal can be easily inserted into the female terminal, replace the female terminal. S272V 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, make sure 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. 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. S273V S275V ntermittent ncident S330V :0000000001547217 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- -41
SRV RAT R TRA T < AS ST > 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. 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 S839-42
< AS ST > SRV RAT R TRA T An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. f the wiring runs under seating areas, inspect wire routing for possible damage or pinching. AT SSTV The customer's concern may occur during hot weather or after car has sat for a short time. n such cases you will want to check for a heat sensitive condition. To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. AUT: o not heat components above 60 (140 ). f incident occurs while heating the unit, either replace or properly insulate the component. RZ The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. ake sure it will get cold enough to demonstrate his complaint. eave the car parked outside overnight. n the morning, do a quick and thorough diagnosis of those electrical components which could be affected. The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. f it occurs, repair or replace the component. WATR TRUS The incident may occur only during high humidity or in rainy/snowy weather. n such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash. AUT: o not spray water directly on any electrical components. S842 S843 TRA A The incident may be electrical load sensitive. erform diagnosis with all accessories (including A/, rear window defogger, radio, fog lamps) turned on. S844 R T START U n some occasions an electrical incident may occur only when the car is started cold, or it may occur when the car is restarted hot shortly after being turned off. n these cases you may have to keep the car overnight to make a proper diagnosis. -43 S845