Nissan Patrol (Y61) Workshop Manual / Repair Manual

NISSAN PATROL Y61 - SERVICE MANUAL - REPAIR MANUAL

- English Workshop Manual to vehicles NISSAN PATROL MODELS Y61.

INDEX:

-First Edition
-Supplement I
-Supplement II
-Supplement III Diesel
-Supplement III Petrol
-Supplement IV


INDEX

FIRST EDITION

BR
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Precautions for Brake System
Commercial Service Tools
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
CHECK AND ADJUSTMENT
Checking Brake Fluid Level
Checking Brake Line
Changing Brake Fluid
Bleeding Brake System
BRAKE HYDRAULIC LINE/CONTROL VALVE
Brake Hydraulic Line
Load Sensing Valve
BRAKE PEDAL AND BRACKET
Removal and Installation
Inspection
Adjustment
MASTER CYLINDER
Removal
Disassembly
Inspection
Assembly
Installation
BRAKE BOOSTER
Brake Booster
VACUUM PIPING (LHD models)
Vacuum Hose
VACUUM PIPING (RHD models)
Vacuum Hose
VACUUM PIPING
VACUUM PUMP
Removal and Installation
FRONT DISC BRAKE
Pad Replacement
Removal
Disassembly
Inspection - Caliper
Inspection - Rotor
Assembly
Installation
REAR DISC BRAKE
Pad Replacement
Removal
Disassembly
Inspection - Caliper
Inspection - Rotor
Assembly
Installation
PARKING CENTER BRAKE CONTROL
Removal
Inspection
Installation
Adjustment
PARKING CENTER BRAKE
Removal and Installation
Inspection - Drum
Inspection - Lining
ANTI-LOCK BRAKE SYSTEM
Purpose
Operation
ABS Hydraulic Circuit
System Components
System Description
Removal and Installation
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Preliminary Check
Component Parts and Harness Connector Location
Circuit Diagram for Quick Pinpoint Check
Wiring Schematics - ABS -
Self-diagnoses
CONSULT
CONSULT Inspection Procedure
Ground Circuit Check
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 1 (Wheel sensor or rotor)
Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay)
Diagnostic Procedure 3 (Motor relay or motor)
Diagnostic Procedure 4 (Low voltage)
Diagnostic Procedure 5 (G sensor)
Diagnostic Procedure 6 (Control unit)
TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 7 (ABS works frequently.)
Diagnostic Procedure 8 (Unexpected pedal action)
Diagnostic Procedure 9 (Long stopping distance)
Diagnostic Procedure 10 (ABS does not work.)
Diagnostic Procedure 11 (Pedal vibration and noise)
Diagnostic Procedure 12 (Warning lamp does not come on when ignition switch is turned ON.)
Diagnostic Procedure 13 (Warning lamp stays on when ignition switch is turned ON.)
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
SUPER MULTIPLE JUNCTION (SMJ)
FUSE BLOCK - Junction Box (J/B)
FUSE AND FUSIBLE LINK BOX
ELECTRICAL UNITS
JOINT CONNECTOR (J/C)
SUPPLEMENT-I
BT
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS
Service Notice
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
GENERAL SERVICING
Clip and Fastener
BODY END
Body Front End
Body Rear End and Opener
DOOR
Front Door
Rear Door
INSTRUMENT PANEL




INTERIOR TRIM
Side and Floor Trim
Door Trim
Roof Trim
Back Door Trim
EXTERIOR
SEAT
Front Seat
Heated Seat
Rear Seat
3rd Seat
SUNROOF
WINDSHIELD AND WINDOWS
Windshield
Rear Side Window
Back Door Window
MIRROR
Door Mirror
CAB BODY
Body Mounting
BODY ALIGNMENT
Engine Compartment
Underbody
SUPPLEMENT-I
CL
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS AND PREPARATION
Precautions
Special Service Tools
Commercial Service Tools
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
CLUTCH SYSTEM
INSPECTION AND ADJUSTMENT
Adjusting Clutch Pedal
Air Bleeding Procedure
HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder
Clutch Operating Cylinder
Clutch Booster

CLUTCH RELEASE MECHANISM
CLUTCH DISC AND CLUTCH COVER
Clutch Disc
Clutch Cover and Flywheel
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
SUPPLEMENT-I
EC
QUICK REFERENCE INDEX
CONTENTS
DIAGNOSTIC TROUBLE CODE INDEX
Alphabetical & Numerical Index for DTC
PRECAUTIONS AND PREPARATION
Special Service Tools
Commercial Service Tool
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Engine Fuel & Emission Control System
Precautions
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
ECCS-D Component Parts Location
Circuit Diagram
System Diagram
Vacuum Hose Drawing
System Chart
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection System
Fuel Injection Timing System
Air Conditioning Cut Control
Fuel Cut Control (at no load & high engine speed)
CRANKCASE VENTILATION SYSTEM
Description
Inspection
INJECTION NOZZLE
Removal and Installation
Disassembly (No. 2 - 4 nozzles)

Inspection (No. 2 - 4 nozzles)
Cleaning (No. 2 - 4 nozzles)
Assembly (No. 2 - 4 nozzles)
Test and Adjustment
ELECTRONIC FUEL INJECTION PUMP
Removal
Installation
Disassembly and Assembly
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
DTC and MIL Detection Logic
Diagnostic Trouble Code (DTC)
Malfunction Indicator Lamp (MIL)
CONSULT
TROUBLE DIAGNOSIS - Introduction
Introduction
Diagnostic Worksheet
TROUBLE DIAGNOSIS - Work Flow
Work Flow
Description for Work Flow
TROUBLE DIAGNOSIS - Basic Inspection
Basic Inspection
TROUBLE DIAGNOSIS - General Description
Symptom Matrix Chart
CONSULT Reference Value in Data Monitor Mode
Major Sensor Reference Graph in Data Monitor Mode
ECM Terminals and Reference Value
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
TROUBLE DIAGNOSIS FOR "CAM POS SEN (PUMP)" (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
TROUBLE DIAGNOSIS FOR "MASS AIR FLOW SEN" (DTC 12)
Mass Air Flow Sensor (MAFS)
TROUBLE DIAGNOSIS FOR "COOLANT TEMP SEN" (DTC 13)
Engine Coolant Temperature (ECT) Sensor
TROUBLE DIAGNOSIS FOR "VEHICLE SPEED SEN" (DTC 14)
Vehicle Speed Sensor (VSS)
TROUBLE DIAGNOSIS FOR "CONT SLEEV POS SEN" (DTC 15)
Control Sleeve Position Sensor (CSPS)
TROUBLE DIAGNOSIS FOR "ADJUST RESISTOR" (DTC 17)
Adjustment Resistor
TROUBLE DIAGNOSIS FOR "F/INJ F/B 2" (DTC18), "F/INJ F/B" (DTC 22), "ELECTRIC GOV" (DTC 25)
Electric Governor
TROUBLE DIAGNOSIS FOR "F/INJ TIMG F/B" (DTC 21)
Injection Timing Control Valve
TROUBLE DIAGNOSIS FOR "ACCEL POS SW (F/C)" (DTC 23)
Accelerator Switch (F/C)
TROUBLE DIAGNOSIS FOR "ECM 1" (DTC 27), "ECM 2 " (DTC 31)
Engine Control Module (ECM)-ECCS-D Control Module
TROUBLE DIAGNOSIS FOR "OVER HEAT" (DTC 28)
Cooling Fan (Overheat)
TROUBLE DIAGNOSIS FOR "I/C INT/A TEMP SEN" (DTC 33)
Charge Air Temperature Sensor
TROUBLE DIAGNOSIS FOR "NEEDLE LIFT SEN" (DTC 34)
Needle Lift Sensor (NLS)
TROUBLE DIAGNOSIS FOR "FUEL CUT S/V 1" (DTC 36), "FCV SHORT" (DTC 37), "FUEL CUT S/V 2" (DTC 38)
Fuel Cut Solenoid Valve
TROUBLE DIAGNOSIS FOR "FUEL TEMP SENSOR" (DTC 42)
Fuel Temperature Sensor (FTS)
TROUBLE DIAGNOSIS FOR "ACCEL POS SENSOR" (DTC 43)
Accelerator Position Sensor
TROUBLE DIAGNOSIS FOR "CRANK POS SEN (TDC)" (DTC 47)
Crankshaft Position Sensor (TDC)
TROUBLE DIAGNOSIS FOR "GOV CUT CIRCUIT" (DTC 48)
Governor Cut Circuit
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Glow Control System
EGRC-Solenoid Valve A, B and Throttle Control Solenoid Valve
Start Signal
Accelerator Position Switch
Park/Neutral Position Switch
A/T Control
Charge Air Cooler Fan Control
Heat up Switch
Air Conditioner Control
MIL & Data Link Connectors
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Injection Nozzle
Inspection and Adjustment
SUPER MULTIPLE JUNCTION (SMJ)
FUSE BLOCK - Junction Box (J/B)
FUSE AND FUSIBLE LINK BOX
ELECTRICAL UNITS
JOINT CONNECTOR (J/C)
SUPPLEMENT-I
EL
QUICK REFERENCE INDEX
CONTENTS
PRECAUTION
Supplemental Restraint System (SRS) "AIR BAG" and SEAT BELT PRE-TENSIONER"
HARNESS CONNECTOR
Description
STANDARDIZED RELAY
Description
POWER SUPPLY ROUTING
Schematic
Wiring Schematics-POWER-
Fuse
Fusible Link
Circuit Breaker Inspection
GROUND DISTRIBUTION/LHD MODELS
Engine Room Harness
Main Harness
Body Harness
Body No. 2 Harness
Back Door and Rear Window Defogger Harness
Room Lamp Harness
GROUND DISTRIBUTION/RHD MODELS
Engine Room Harness

Main Harness
Body Harness
Body No. 2 Harness
Back Door and Rear Window Defogger Harness
Room Lamp Harness
BATTERY
How to Handle Battery
Battery Test and Charging Chart
Service Data and Specifications (SDS)
STARTING SYSTEM
Wiring diagram-START-
Trouble Diagnoses
Construction
Removal and Installation
Inspection
Assembly
Service Data and Specifications (SDS)
CHARGING SYSTEM
Wiring Schematics -CHARGE-
Trouble Diagnoses
Construction
Removal and Installation
Disassembly

Inspection
Assembly
Service Data and Specifications (SDS)
COMBINATION SWITCH
Check
Replacement
STEERING SWITCH
Check
HEADLAMP - Conventional Type -
Wiring Schematics - H/LAMP -
Trouble Diagnoses
Bulb Replacement
Aiming Adjustment

HEADLAMP - Daytime Light System -
System description
Wiring Schematics - DTRL -
Trouble Diagnoses
Bulb Replacement
Aiming Adjustment
HEADLAMP - Headlamp Aiming Control -
System Description
Wiring Schematics - H/AIM -
PARKING, LICENSE AND TAIL LAMPS
Wiring Schematics - TAIL/L -/Type A
Wiring Schematics - TAIL/L -/Type B
STOP LAMP
Wiring Schematics -STOP/L -/Type A
BACK-UP LAMP
Wiring Schematics - BACK/L -/LHD Models
Wiring Schematics - BACK/L -/RHD Models
REAR FOG LAMP
Wiring Schematics - R/FOG -

TURN SIGNAL AND HAZARD WARING LAMPS
Wiring Schematics - TURN -/Type A
Wiring Schematics - TURN -/Type B
Trouble Diagnoses
Electrical Components Inspection
ILLUMINATION
Schematic
Wiring Schematics - ILL -
INTERIOR ROOM LAMP - With Timer -
System Description
Schematic
Wiring Schematics - ROOM/L -/LHD Models
Wiring Schematics - ROOM/L -/RHD Models
Trouble Diagnoses
MAP AND VANITY MIRROR LAMPS
Wiring Schematics-INT/L-
METER AND GAUGES
System Description
Combination Meter
Wiring Schematics - METER -/LHD Models
Wiring Schematics - METER -/RHD Models
Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode
Flexible Print Circuit (FPC)
Trouble Diagnoses
Electrical Components Inspection
COMPASS AND THERMOMETER
System Description
Wiring Schematics - COMPAS -
Trouble Diagnoses
Calibration Procedure For Compass
WARNING LAMPS
Schematic
Wiring Schematics - WARN -
Electrical Components Inspection
WARNING CHIME
System Description
Wiring Schematics - CHIME -/LHD Models
Wiring Schematics - CHIME -/RHD Models
Trouble Diagnoses
Electrical Components Inspection
FRONT WIPER AND WASHER
System Description
Wiring Schematics - WIPER- /With Intermittent Wiper
Removal and Installation
Washer Nozzle Adjustment
Washer Tube Layout
REAR WIPER AND WASHER
System Description
Wiring Schematics - WIP/R -/LHD Models
Wiring Schematics - WIP/R -/RHD Models
Trouble Diagnoses
Removal and Installation
Washer Nozzle Adjustment
Washer Tube Layout
Check Valve
HEADLAMP WIPER AND WASHER
Wiring Schematics - HLC -
Electrical Components Inspection
Removal and Installation
Washer Tube Layout
Check Valve
HORN
Wiring Schematics - HORN -
CIGARETTE LIGHTER
Wiring Schematics - CIGAR -
CLOCK
Wiring Schematics - CLOCK -
REAR WINDOW DEFOGGER
System Description
Wiring Schematics - DEF -/LHD Models
Wiring Schematics - DEF -/RHD Models
Trouble Diagnoses
Electrical Components Inspection
Filament Check
Filament Repair
WIPER DEICER
System Description
Wiring Schematics - DEICER -
AUDIO
Wiring Schematics - AUDIO -/LHD Models
Wiring Schematics - AUDIO -/RHD Models
Trouble Diagnoses
CATS (Code) System/RHD
NATS Audio Link/LHD
AUDIO - CD AUTO CHANGER -
Wiring Schematics - CD/CHG -/LHD Wagon
Wiring Schematics - CD/CHG -/LHD Hardtop
Wiring Schematics - CD/CHG -/RHD Wagon
Wiring Schematics - CD/CHG -/RHD Hardtop
Trouble Diagnoses
AUDIO ANTENNA
Wiring Schematics - P/ANT -/LHD Models
Wiring Schematics - P/ANT -/RHD Models
Trouble Diagnoses
Location of Antenna
Antenna Rod Replacement
Window Antenna Repair
ELECTRIC SUNROOF
Wiring Schematics - SROOF -
POWER DOOR MIRROR
Wiring Schematics - MIRROR -/LHD Models
Wiring Schematics - MIRROR -/RHD Models
POWER SEAT
Wiring Schematics - SEAT -/LHD Models
Wiring Schematics - SEAT -/RHD Models
HEATED SEAT
Wiring Schematics - HSEAT -
POWER WINDOW
System Description
Schematic
Wiring Schematics - WINDOW -
Trouble Diagnoses
POWER DOOR LOCK
System Description
Wiring Schematics - D/LOCK -
Trouble Diagnoses
POWER DOOR LOCK - Super Lock -
Component Parts and Harness Connector Location
System Description
Schematic
Wiring Schematics - S/LOCK -/LHD Models
Wiring Schematics - S/LOCK -/RHD Models
Trouble Diagnoses
MULTI-REMOTE CONTROL SYSTEM
System Description
Wiring Schematics - MULTI -/LHD Models
Trouble Diagnoses
IP Code Entry Procedure
NATS (Nissan Anti-Theft System)/LHD MODELS
System Description
System Composition
Wiring Schematics - NATS -
CONSULT
Trouble Diagnoses

How to Replace NATS IMMU
NATS (Nissan Anti-Theft System)/RHD MODELS
Componenet Parts and Harness Connector Location
System Description
System Composition
Wiring Schematics-NATS-
CONSULT
Trouble Diagnoses
LOCATION OF ELECTRICAL UNITS
Engine Compartment
Passenger Compartment - LHD Models
Passenger Compartment - RHD Models
HARNESS LAYOUT
How to Read Harness Layout
Outline/LHD Models
Outline/RHD Models
Main Harness/LHD Models
Main Harness/RHD Models
Engine Room Harness/LHD Models
Engine Room Harness/RHD Models
Engine Harness
Engine Control Harness and Alternator
Body Harness/LHD Models
Body Harness/RHD Models
Body No. 2 Harness/LHD Models
Body No. 2 Harness/RHD Models
Chassis Harness
Room Lamp Harness
Front Door Harness (Driver side)
Front Door Harness (Passenger side)
Rear Door Harness
Back Door Harness and Rear Window Defogger Harness
BULB SPECIFICATIONS
Headlamp
Exterior Lamp
Interior Lamp
WIRING DIAGRAM CODES (CELL CODES)
SUPER MULTIPLE JUNCTION (SMJ)
FUSE BLOCK - Junction Box (J/B)
FUSE AND FUSIBLE LINK BOX
ELECTRICAL UNITS
JOINT CONNECTOR (J/C)
SUPPLEMENT-I
EM
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS
Parts Requiring Angular Tightening
Liquid Gasket Application Procedure
PREPARATION
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart - Engine Noise
OUTER COMPONENT PARTS
COMPRESSION PRESSURE
Measurement of compression Pressure
OIL PAN
Removal
Installation
TIMING BELT
Removal
Inspection
Installation
OIL SEAL REPLACEMENT
TURBOCHARGER
Removal and Installation
Inspection
CHARGE AIR COOLERS
CYLINDER HEAD
Removal
Disassembly
Inspection
Assembly
Installation
VALVE CLEARANCE
Checking
Adjusting

ENGINE REMOVAL
Removal
Installation
CYLINDER BLOCK
Disassembly
Inspection
Assembly
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
SUPPLEMENT-I
FA
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS AND PREPARATION
Precautions
Special Service Tools
Commercial Service Tools
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
FRONT AXLE AND FRONT SUSPENSION
ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts
Front Wheel Bearing
Front Wheel Alignment
FRONT AXLE - Drive Flange and Free-running Hub
FRONT AXLE - Manual-lock Free-running Hub
Removal
Installation
Inspection
FRONT AXLE - Auto-lock Free-running Hub
Removal
Installation
FRONT AXLE - Wheel Hub and Rotor Disc
Removal and Installation
Inspection
Assembly
FRONT AXLE - Knuckle Flange
Removal
Inspection
Installation
Knuckle Flange Grease Seal
FRONT AXLE - Drive Shaft
Inspection
Installation
FRONT SUSPENSION
Shock Absorber
Stabilizer Bar
Coil Spring
Leading Arm
Panhard Rod
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
SUPPLEMENT-I
FE
QUICK REFERENCE INDEX
CONTENTS
ACCELERATOR CONTROL SYSTEM
Accelerator Control System
FUEL SYSTEM
EXHAUST SYSTEM
SUPPLEMENT-I
GI
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and SEAT BELT PRE-TENSIONER"
General Precautions
Precautions for Multiport Fuel Injection System or ECCS Engine
Precautions for Three Way Catalyst (If so equipped)
Precautions for Engine Oils
Precautions for Fuel
Precautions for Air Conditioning
HOW TO USE THIS MANUAL
HOW TO READ WIRING SCHEMATICS
Sample/Wiring Schematics - EXAMPL -
Description
HOW TO CHECK TERMINAL
How to Probe Connectors
How to Check Enlarged Contact Spring of Terminal
Waterproof Connector Inspection
Terminal Lock Inspection
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Work Flow
Incident Simulation Tests
Circuit Inspection
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
How to Follow This Flow Chart
CONSULT CHECKING SYSTEM
Function and System Application
Lithium Battery Replacement
Checking Equipment
Loading Procedure
CONSULT Data Link Connector (DLC) Circuit
IDENTIFICATION INFORMATION
Model Variation
Identification Number
Dimensions
Wheels & Tires
LIFTING POINTS AND TOW TRUCK TOWING
Screw Jack
Garage Jack and Safety Stand
2-Pole Lift
Tow Truck Towing
SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List
SUPPLEMENT-I
HA
QUICK REFERENCE INDEX
CONTENTS
MANUAL AND AUTO
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Precautions for Working with AFC-134a (R-134a)
General Refrigerant Precautions
Precautions for Refrigerant Connection
Precautions for Servicing Compressor
Special Service Tools
HFC-134a (R-134a) Service Tools and Equipment
Precautions for Service Equipment
DESCRIPTION
Refrigeration Cycle
Component Layout
Discharge Air Flow
REAR HEATER
TROUBLE DIAGNOSES
Wiring Schematics - R/HEAT -/LHD Models
Wiring Schematics -R/HEAT -/RHD Models

MANUAL
DESCRIPTION
System Description
Control Operation
TROUBLE DIAGNOSES
Component Location
Wiring Schematics - A/C, M -
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Operational Check
Intake Door Motor
Blower Motor

Insufficient Cooling
Trouble Diagnoses for Abnormal Pressure
Insufficient Heating
Air Outlet
Magnet Clutch
Noise
AUTO
DESCRIPTION
Introduction
Features
Overview of Control System
Control Operation
TROUBLE DIAGNOSES
Component Location
Circuit Diagram
Wiring Schematics - A/C, A -
Auto Amp. Terminals and Reference Value
Self-diagnosis
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Operational Check
A/C System
Mode Door Motor
Air Mix Door Motor
Intake Door Motor

Blower Motor
Magnet Clutch
Insufficient Cooling
Insufficient Heating
Noise
Self-diagnosis
Memory Function
Ambient Sensor
In-vehicle Sensor
Sunload Sensor
Intake Sensor
MANUAL AND AUTO
SERVICE PROCEDURES
HFC-134a (R-134-s) Service Procedure
Maintenance of Lubricant Quantity in Compressor
Ventiliation Air Filter
Refrigerant Lines
Checking Refrigerant Leaks
Compressor Mounting
Compressor - KDS-17CH
Compressor Clutch
SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifacations
Inspection and Adjustment
SUPER MULTIPLE JUNCTION (SMJ)
FUSE BLOCK - Junction Box (J/B)
FUSE AND FUSIBLE LINK BOX
ELECTRICAL UNITS
JOINT CONNECTOR (J/C)
SUPPLEMENT-I
LC
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS AND PREPARATION
Liquid Gasket Application Procedure
Special Service Tools
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Oil Pressure Check
Oil Pump
Oil Cooler
Oil Jet
Turbocharger
ENGINE COOLING SYSTEM
Cooling Circuit
System Check
Water Pump
Thermostat
Radiator
Refilling Engine Coolant
Cooling Fan (Crankshaft driven)
Cooling Fan (Motor driven)
Radiator (Aluminium type)
Overheating Cause Analysis
SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Lubrication System
Engline Cooling System
SUPPLEMENT-I
MA
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Special Service Tools
PRE-DELIVERY INSPECTION ITEMS
GENERAL MAINTENANCE
PERIODIC MAINTENANCE
Engine Oil & Minor Service
Engine and Emission Control Service
Chassis and Body Services
Maintenance Under Severe Driving Conditions
RECOMMENDED FLUIDS AND LUBRICANTS
Fluid and lubricants
SAE Viscosity Number

Anti-freeze Coolant Mixture Ratio
ENGINE MAINTENANCE
Checking Tightening Torque
Checking Drive Belt
Changing Engine Oil
Changing Engine Oil Filter
Changing Engine Coolant
Checking Cooling System
Checking and Replacing Fuel Filter and Draining Water
Checking Fuel Lines
Cleaning and Replacing Air Cleaner Filter
Checking Injection Nozzle
Checking Idle Speed
Timing Belt Replacement
CHASSIS AND BODY MAINTENANCE
Checking Exhaust System
Checking Clutch Fluid Level and Leaks
Checking Clutch System
Checking M/T Oil Level and Leaks
Changing M/T Oil
Checking Water Entry
Checking Transfer Fluid Level
Changing Transfer Fluid
Checking Propeller Shaft
Greasing Nipples of Propeller Shafts
Checking Differential Gear Oil
Changing Differential Gear Oil
Checking Front Wheel Bearing Grease
Repacking Front Wheel Bearing and Axle Joint Grease
Checking Free-running Hub Grease
Checking Water Entry in Knuckle Flange
Checking Brake Fluid Level Leaks
Checking Brake System
Changing Brake Fluid
Checking Brake Booster, Vacuum Hoses, Connections and Check Valve
Checking Disc Brake
Balancing Wheels
Tire Rotation
Checking Power Steering Fluid and Lines
Checking Steering Damper
Checking Steering Gear Box and Linkage
Lubricating Locks, Hinges and Hood Latches
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters
Checking Body Corrosion
SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Maintenance
Chassis and Body Maintenance
SUPPLEMENT-I
MT
QUICK REFERENCE INDEX
CONTENTS
PREPARATION
Special Service Tools
Commercial Service Tools
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
ON-VEHICLE SERVICE
Replacing Rear Oil Seal
Position Switch Check
REMOVAL AND INSTALLATION
Removal
Installation
DESCRIPTION
Cross-sectional View
AIR BREATHER
Air Breather Piping
MAJOR OVERHAUL
Case Components
Gear Components
Shift Control Components
DISASSEMBLY
Case Components
Shift Control Components
Gear Components
INSPECTION
Shift Control Components
Gear Components
ASSEMBLY
Gear Components
Shift Control Components
Case Components
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
SUPPLEMENT-I
PD
QUICK REFERENCE INDEX
CONTENTS
PREPARATION
Special Service Tools
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
PROPELLER SHAFT
Front Propeller Shaft
Rear Propeller Shaft
On-vehicle Service
Removal and Installation
Inspection
Disassembly
Assembly
ON-VEHICLE SERVICE (Final Drive)
Front Oil Seal Replacement
REMOVAL AND INSTALLATION
Removal
Installation
FRONT FINAL DRIVE
REAR FINAL DRIVE
DISASSEMBLY
Pre-inspection
Differential Carrier
Differential Case
INSPECTION
Ring Gear and Drive Pinion
Differential Case Assembly
Bearing
LIMITED SLIP DIFFERENTIAL
Preparation for Disassembly
Disassembly
Inspection
Adjustment
Assembly
ADJUSTMENT

Drive Pinion Height
Tooth Contact
ASSEMBLY
Differential Case - 4-pinion type -
Differential Case - 2-pinion type -
Differential Carrier
DIFFERENTIAL LOCK
Actuator and Fork
Disassembly
Inspection
Assembly
System Description
Componant Parts Location
Wiring Schematics - DIFF/L -/LHD Models
Wiring Schematics - DIFF/L -RHD Models
Electrical Components Inspection
SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft
Final Drive
SUPER MULTIPLE JUNCTION (SMJ)

FUSE BLOCK - Junction Box (J/B)
FUSE AND FUSIBLE LINK BOX
ELECTRICAL UNITS
JOINT CONNECTOR (J/C)
SUPPLEMENT-I
RA
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS AND PREPARATION
Precautions
Special Service Tools
Commercial Service Tools
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
REAR AXLE AND REAR SUSPENSION
ON-VEHICLE SERVICE
Rear Axle and Rear Suspension Parts
Rear Wheel Bearing
REAR AXLE
Components
Removal
Inspection
Installation
REAR SUSPENSION
Removal and Installation
Coil Spring and Shock Absorber
Upper Link, Lower Link and Panhard Rod
Stabilizer Bar
STABILIZER RELEASE DEVICE
System Components
System Description
Removal and Installation
Wiring Schematics
Trouble Diagnoses
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspections and Adjustment
SUPPLEMENT-I
RS
QUICK REFERENCE INDEX
CONTENTS
PRECAUTION
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
SEAT BELTS
Front Seat Belt
Rear Seat Belt
3rd Seat Belt
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Precautions for SRS "AIR BAG" and "Seat Belt Pre-tensioner" Service
Special Service Tools
Description
SRS Component Parts Location
Maintenance Items
Removal and Installation - Diagnosis Sensor Unit and Seat Belt Pre-tensioner
Removal and Installation - Air Bag Module and Spiral Cable
Removal - Air Bag Module and Spiral Cable
Removal - Front Passenger Air Bag Module
Installation - Air Bag Module and Spiral Cable
Installation - Front Passenger Air Bag Module
Disposal of Air Bag Module and Seat Belt Pre-tensioner
TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Trouble Diagnoses Introduction
How to Perfrom Trouble Diagnoses for Quick and Accurate Repair
Schematic
Wiring Schematics - SRS -
SRS Operation Check
Trouble Diagnoses with CONSULT
Trouble Diagnoses without CONSULT
Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off
Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On
Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch
COLLISION DIAGNOSIS
SUPER MULTIPLE JUNCTION (SMJ)
FUSE BLOCK - Junction Box (J/B)
FUSE AND FUSIBLE LINK BOX
ELECTRICAL UNITS
JOINT CONNECTOR (J/C)

SUPPLEMENT-I
ST
QUICK REFERENCE INDEX
CONTENTS
PRECAUTIONS AND PREPARATION
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Precautions for Steering System
Special Service Tools
NOISE, VIBRATIONS AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
ON-VEHICLE SERVICE
Checking Steering Wheel Play
Checking Neutral Position on Steering Wheel
Front Wheel Turning Angle
Checking and Adjusting Drive Belts
Checking Fluid Level
Checking Fluid Leakage
Bleeding Hydraulic System
Checking Steering Wheel Turning Force
Checking Hydraulic System
STEERING WHEEL AND STEERING COLUMN
Removal and Installation
Disassembly and Assembly
Inspection
POWER STEERING SYSTEM (Model: PB69K)
Description
POWER STEERING GEAR (Model: PB69K)
Removal and Installation
Inspection
POWER STEERING OIL PUMP
Removal and Installation
Disassembly and Assembly
Pre-disassembly Inspection
Inspection
Disassembly
Assembly
STEERING LINKAGE
Removal and Installation
Disassembly
Inspection
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
SUPPLEMENT-I
TF
QUICK REFERENCE INDEX
CONTENTS
PREPARATION
Special Service Tools
Commercial Service Tools
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
DESCRIPTION
Cross-sectional View
ON-VEHICLE SERVICE
Replacing Oil Seal
Checking Position Switch
REMOVAL AND INSTALLATION
Removal
Installation
TRANSFER GEAR CONTROL
MAJOR OVERHAUL
Case Components
Gear Components
Shift Control Components
DISASSEMBLY
REPAIR FOR COMPONENT PARTS
Mainshaft
Front Drive Shaft
Counter Gear
Main Gear
Front Case
Front Case Cover

Center Case
Bearing Retainer
Rear Case
Shift Control Components
ASSEMBLY
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
SUPPLEMENT-I
FOLDOUT
QUICK REFERENCE INDEX
SUPER MULTIPLE JUNCTION (SMJ)
Terminal Arrangement
FUSE BLOCK - Junction Box (J/B)
Terminal Arrangement
FUSE AND FUSIBLE LINK BOX
Terminal Arrangement
ELECTRICAL UNITS
Terminal Arrangement
JOINT CONNECTOR (J/C)
Terminal Arrangement
SUPPLEMENT 01
AT
QUICK REFERENCE INDEX
CONTENTS
PREPARATION AND PRECAUTIONS
Special Service Tools
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Precautions
Service Notice or Precautions
OVERALL SYSTEM
A/T Electrical Parts Location
Circuit Diagram
Wiring Schematics - A/T -
Cross-sectional View
Hydraulic Control Circuits
Shift Mechanism
Control System
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Self-diagnosis
Diagnosis by CONSULT-II
TROUBLE DIAGNOSIS - Introduction
Introduction
Diagnostic Worksheet
Work Flow
TROUBLE DIAGNOSIS - Basic Inspection
A/T Fluid Check
Stall Test
Line Pressure Test
Road Test
TROUBLE DIAGNOSIS - General Description
Symptom Chart
TCM Terminals and Reference Value

TROUBLE DIAGNOSIS FOR VHCL SPEED SEN.A/T
Vehicle Speed Sensor.A/T (Revolution sensor)
TROUBLE DIAGNOSIS FOR VHCL SPEED SEN.MTR
Vehicle Speed Sensor.MTR
TROUBLE DIAGNOSIS FOR THROTTLE POSI SEN
Accelerator Position Sensor
TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V A
Shift Solenoid Valve A
TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V B
Shift Solenoid Valve B
TROUBLE DIAGNOSIS FOR OVERRUN CLUTCH S/V
Overrun Clutch Solenoid Valve
TROUBLE DIAGNOSIS FOR T/C CLUTCH SOL/V
Torque Converter Clutch Solenoid Valve
TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP SEN
A/T Fluid Temperature Sensor and TCM Power Source
TROUBLE DIAGNOSIS FOR ENGINE SPEED SIG
Engine Speed Signal
TROUBLE DIAGNOSIS FOR LINE PRESSURE S/V
Line Pressure Solenoid Valve
TROUBLE DIAGNOSIS FOR CONTROL UNIT (RAM), CONTROL UNIT (ROM)
Description
Diagnostic Procedure
TROUBLE DIAGNOSIS FOR CONTROL UNIT (EFP ROM)
Description
Diagnostic Procedure
TROUBLE DIAGNOSIS FOR NON.DETECTABLE ITEMS
PNP, Overdrive Control, A/T Mode or Accelerator Position Switches
DIAGNOSTIC PROCEDURES FOR SYMPTOMS
1. SPORT Indicator Lamp Does Not Come On
2. SPORT Indicator Lamp Does Not Come On
3. O/D OFF Indicator Lamp Does Not Come On
4. SPORT Indicator Lamp Does Not Come On
5. Engine Cannot Be Started In "P" and "N" Position
6. In "P" Position, Vehicle Moves Forward Or Backward When Pushed
7. In "N" Position, Vehicle Moves
8. Large Shock. "N" -> "R" Position
9. Vehicle Does Not Creep Backward In "R" Position
10. Vehicle Does Not Creep Forward In "D", "2" Or "1" Position
11. Vehicle Cannot Be Started From D1
12. A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2
13. A/T Does Not Shift: D2 -> D3
14. A/T Does Not Shift: D3 -> D4
15. A/T Does Not Perform Lock-up
16. A/T Does Not Hold Lock-up Condition
17. Lock-up Is Note Released
18. Engine Speed Does Not Return To Idle (Light Braking D4 -> D3)
19. Vehicle Does Not Start From D1
20. A/T Does Not Shift: D2 -> D1 When Depressing Accelerator Pedal
21. A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch "ON" -> "OFF"
22. A/T Does Not Shift: D3 -> 2-2, When Selector Lever "D2" -> "2" Position
23. A/T Does Not Shift: 2-2 -> 1-1, When Selector Lever "2" -> "1" Position
24. Vehicle Does Not Decelerate By Engine Brake
TROUBLE DIAGNOSES - A/T Shift Lock System
Description
Wiring Schematics - SHIFT -
Diagnostic Procedure
Key Interlock Cable
Component Check
ON-VEHICLE SERVICE
Control Valve Assembly and Accumulators
Revolution Sensor Replacement
Rear Oil Seal Replacement
Parking Pawl Components Inspection
PNP Switch Adjustment
Manual Control Linkage Adjustment
REMOVAL AND INSTALLATION
Removal
Installation
MAJOR OVERHAUL
Oil Channel
Locations of Needle Bearings, Thrust Washers and Snap Rings
DISASSEMBLY
REPAIR FOR COMPONENT PARTS
Oil Pump
Control Valve Assembly
Control Valve Upper Body
Control Valve Lower Body
Reverse Clutch
High Clutch
Forward and Overrun Clutches
Low & Reverse Brake
Forward Clutch Drum Assembly
Rear Internal Gear and Forward Clutch Hub
Band Servo Piston Assembly
Parking Pawl Components
ASSEMBLY
Assembly (1)
Adjustment
Assembly (2)
A/T FLUID COOLER SYSTEM
A/T Fluid Cooler
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Specifications and Adjustment
FUSE BLOCK - Junction Box (J/B)
FUSE AND FUSIBLE LINK BOX
ELECTRICAL UNITS
SUPPLEMENT-II
BR
QUICK REFERENCE INDEX
FIRST EDITION
CONTENTS
TROUBLE DIAGNOSES
Schematic
Wiring Schematics - ABS -

Self-diagnosis
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
FUSE BLOCK - Junction Box (J/B)
FUSE AND FUSIBLE LINK BOX
ELECTRICAL UNITS
SUPPLEMENT-II
BT
QUICK REFERENCE INDEX
FIRST EDITION
CONTENTS
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
DOOR
Front Door Limit Switch Reset (Driver side only)
INTERIOR TRIM
Door Trim
SEAT
Front Seat
MIRROR
Door Mirror
SUPPLEMENT-II

CL
QUICK REFERENCE INDEX
FIRST EDITION
CONTENTS
CLUTCH SYSTEM
HYDRAULIC CLUTCH CONTROL
Clutch Operating Cylinder
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Inspection and Adjustment
SUPPLEMENT-II
EC
QUICK REFERENCE INDEX
FIRST EDITION
CONTENTS
ZD30DDTi
PRECAUTIONS AND PREPARATION
Special Service Tool
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
TROUBLE DIAGNOSIS - INDEX
Alphabetical & Numerical Index for DTC
PRECAUTIONS
Precautions
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
ECCS-D Component Parts Location
Circuit Diagram
System Diagram
Vacuum Hose Drawing
System Chart
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection Control System
Fuel Injection Timing Control System
Air Conditioning Cut Control
Fuel Cut Control (at no load & high engine speed)
Crankcase Ventilation System
BASIC SERVICE PROCEDURE
Injection Tube and Injection Nozzle
Electronic Control Fuel Injection Pump
Air Bleeding

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
DTC and MI Detection Logic
Diagnostic Trouble Code (DTC)
Malfunction Indicator (MI)
CONSULT-II
TROUBLE DIAGNOSIS - INTRODUCTION
Introduction
Work Flow
TROUBLE DIAGNOSIS - BASIC INSPECTION
Basic Inspection
TROUBLE DIAGNOSIS - GENERAL DESCRIPTION
Symptom Matrix Chart
CONSULT-II Reference Value in Data Monitor Mode
Major Sensor Reference Graph in Data Monitor Mode
ECM Terminals and Reference Value
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
Description
Diagnostic Procedure
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
DTC 0102 MASS AIR FLOW SEN
Component Description
CONSULT-II Reference Value in Data Monitor Mode
ESM Terminals and Reference Value
On Board Diagnosis Logic
DTC Confirmation Procedure
Wiring Schematics
Diagnostic Procedure
DTC 0103 COOLANT TEMP SEN
Description
On Board Diagnosis Logic
DTC Confirmation Procedure
Wiring Schematics
Diagnostic Procedure
DTC 0104 VEHICLE SPEED SEN
Description
ECM Terminals and Reference Value
On Board Diagnosis Logic
Overall Function Check
Wiring Schematics
Diagnostic Procedure
DTC 0203 ACCEL POS SW (F/C)
Description &l