
NEL664
Electrical Components InspectionNLEL0051FUEL WARNING LAMP OPERATION CHECKNLEL0051S011. Turn ignition switch ªOFFº.
2. Disconnect fuel level sensor unit harness connector B38.
3. Connect a resistor (80W) between fuel level sensor unit har-
ness connector terminals 4 and 1.
4. Turn ignition switch ªONº.
The fuel warning lamp should come on.
NOTE:
For models with E-OBD system Only
ECM might store the DTC P0180 during this inspection. If the DTC
is stored in ECM memory, erase the DTC after reconnecting the
fuel level sensor unit and fuel pump harness connector. Refer to
EC-69, EC-597 ªHOW TO ERASE EMISSION-RELATED DIAG-
NOSTIC INFORMATIONº, ªEmission-related Diagnostic
Informationº, ªON BOARD DIAGNOSTIC SYSTEM DESCRIP-
TIONº.
MEL425F
OIL PRESSURE SWITCH CHECKNLEL0051S02
Oil pressure
kPa (bar, kg/cm2, psi)Continuity
Engine runningMore than 10 - 20
(0.10 - 0.20, 0.1 - 0.2,
1-3)No
Engine not runningLess than 10 - 20
(0.10 - 0.20, 0.1 - 0.2,
1-3)Ye s
Check the continuity between the terminals of oil pressure switch
and body ground.
SEL901F
DIODE CHECKNLEL0051S03+Check continuity using an ohmmeter.
+Diode is functioning properly if test results are as shown in the
figure at left.
+Check diodes at the combination meter harness connector
instead of on the combination meter assembly. Refer to
EL-156, ªWARNING LAMPº wiring diagrams.
NOTE:
Specification may vary depending on the type of tester. Before
performing this inspection, be sure to refer to the instruction
manual for the tester to be used.
WARNING LAMPS
Electrical Components Inspection
EL-164

ComponentsNLEM0023
NEM347
1. Oil level gauge guide
2. Cylinder block
3. Rear oil seal retainer
4. Rear oil seal
5. Rear plate
6. Flywheel
7. Drain plug
8. Buffle plate
9. Top ring10. 2nd ring
11. Oil ring
12. Piston
13. Snap ring
14. Piston pin
15. Connecting rod
16. Connecting rod bearing
17. Connecting rod cap18. Key
19. Main bearing
20. Thrust bearing
21. Crankshaft
22. Main bearing cap
23. Knock sensor
24. Crankshaft position sensor (POS)
25. Signal plate
CYLINDER BLOCKQG
Components
EM-52

SEM019G
1. Oil level gauge
2. Generator adjusting bar
3. A/C compressor bracket4. Alternator bracket
5. Water outlet
6. Cylinder block drain plug7. Exhaust manifold (With three way
catalyst)
8. Exhaust manifold cover
9. Heated oxygen sensor
OUTER COMPONENT PARTSSR
Removal and Installation (Cont'd)
EM-84

Trouble Diagnosis of Turbocharger=NLEM0104S0206Preliminary check:
+Check that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.)
+Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
+Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
+If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection item meets
each inspection result)
Oil leak-
ageSmoke NoiseInsuffi-
cient
power/
accelera-
tion failure
Turbine wheelOil leaks.n
nn
Carbon is accumulated.n
jj
Friction with housing.nj
j
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously con-
taminated by oil.jj
Friction with housing.njj
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play.There is resistance when the rotor
shaft is rotated by your fingertips.nnj
The rotor shaft sometimes does
not rotate by your fingertips.
There is too much play in the
bearing.nnjn
Oil return portCarbon or sludge is accumulated
in the waste oil hole.n
nn
Operation of Waste gate actuator+The actuator does not operate
smoothly when vacuum pres-
sure is gradually applied.
+Stroke amount is not in compli-
ance with the vacuum pressure.j
: Large possibility
j: Medium possibility
n: Small possibility
EXHAUST MANIFOLD, TURBOCHARGERYD
Inspection (Cont'd)
EM-197

crankshaft position sensor (TDC sensor) from the assem-
bly.
+Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNLEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-59, ªChanging Engine Coolantº.
3. Remove the following parts:
+Battery
+RH and LH front wheels
+RH and LH splash covers (combined with undercover)
+Auxiliary belts
+Alternator
+Alternator brackets
+Radiator and cooling fan
+Engine cover
+Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
+Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
SEM499G
14. Install engine slingers to cylinder head.
: 30 - 37 N´m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
+Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont'd)
EM-219

SEM189G
+Make sure that support is stable with the use of safety
blocks.
16. Install hooks of lifting chain into engine slingers and tighten
chain so that engine still remains on transmission jacks with-
out being lifted up.
17. Remove engine mount insulator RH.
18. Remove through-bolt of engine mount insulator LH.
19. Remove bolts securing center member at front and rear.
JEM190G
20. Carefully lower transmission jacks in accordance with the low-
ering pace of the hoist, and remove engine and transaxle
assembly from vehicle.
+While working, check that no parts of engine assembly
interfere with adjacent parts on the vehicle.
+While working, make sure that parts requiring disconnec-
tion are not left connected, and that no parts interfere with
vehicle.
+To prevent vehicle from falling down, perform operation
carefully so that the center of gravity of the vehicle will not
shift.
21. Remove center member.
+Before starting removal operation, first place the assem-
bly on a level surface and securely support the bottom
surface with wood blocks. Using a hoist, lift engine
slingers, and make sure the assembly is stable.
22. Separate engine and transaxle.
INSTALLATIONNLEM0069S02Install in the reverse order of removal, observing the following:
+While installing, be careful to keep mount insulators free of oil
smear and damage.
+When parts require specified installation directions/positions,
install by using the identifying marks indicating up or front.
+While keeping the mount insulators free of twists or distortions,
start tightening from the through-bolt on the engine mount
insulator LH. This mount is used as the reference position.
ENGINE ASSEMBLYYD
Removal and Installation (Cont'd)
EM-220

Refrigeration System
REFRIGERATION CYCLENLHA0121Refrigerant FlowNLHA0121S01The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil
is controlled by an externally equalized expansion valve, located inside the heater & cooling unit.
Freeze ProtectionNLHA0121S02The compressor cycles go on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the com-
pressor operation. When the evaporator coil temperature rises above the specification, the thermo control
amplifier allows compressor operation.
Refrigerant System ProtectionNLHA0121S03Refrigerant Pressure SensorNLHA0121S0303The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure
sensor, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the
refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the
ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side
detected by refrigerant pressure sensor is over about 2,746 kPa (27.5 bar, 28 kg/cm
2, 398 psi) or below about
137 kPa (1.37 bar, 1.4 kg/cm2, 20 psi).
Dual-pressure Switch
NLHA0121S0304The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,
located on the liquid tank. If the pressure falls out of specifications, the switch opens to interrupt compressor
operation.
Pressure Relief Valve
NLHA0121S0302The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compres-
sor. When the pressure of refrigerant in the system increases to an abnormal level [more than 3,727 kPa (37.3
bar, 38 kg/cm
2, 540 psi)], the release port on the pressure relief valve automatically opens and releases
refrigerant into the atmosphere.
RHA682H
DESCRIPTION
Refrigeration System
HA-12

A
A/C HFC134a (R134a) system precaution . HA-2
A/C HFC134a (R134a) system service
procedure .............................................. HA-85
A/C HFC134a (R134a) system service
tools ....................................................... HA-10
A/C HFC134a system service equip-
ment precaution ....................................... HA-6
A/C air flow ............................................... HA-19
A/C component layout .............................. HA-17
A/C compressor clutch removal and
installation .............................................. HA-90
A/C compressor precaution ........................ HA-5
A/C compressor special service tool .......... HA-9
A/C control linkage adjustment
(manual A/C) ......................................... HA-48
A/C control operation (manual A/C) .......... HA-18
A/C diagnostic work flow (manual
A/C) ...................................................... HA-40
A/C harness layout (manual A/C) ............. HA-21
A/C lubricant (R134a) ............................... HA-87
A/C operational check ............................... HA-41
A/C performance chart .............................. HA-78
A/C performance test diagnoses .............. HA-76
A/C relay ................................................... HA-73
A/C service data specification ................ HA-104
A/C switch ................................................. HA-74
A/C, M - Wiring diagram ........................... HA-27
A/CCUT - Wiring diagram ..................... EC-1301
A/T - Wiring diagram - AT - BA/FTS ........ AT-172
A/T - Wiring diagram - AT - ENG SS ........ AT-91,
177
A/T - Wiring diagram - AT - FTS ................ AT-75
A/T - Wiring diagram - AT - LPSV ... AT-101, 159
A/T - Wiring diagram - AT - MAIN ............. AT-62
A/T - Wiring diagram - AT - PNP/SW ........ AT-68
A/T - Wiring diagram - AT - SSV/A .......... AT-147
A/T - Wiring diagram - AT - TCV ....... AT-96, 166
A/T - Wiring diagram - AT - TPS ..... AT-106, 139
A/T - Wiring diagram - AT - VSS/AT .. AT-86, 128
A/T - Wiring diagram - AT -
VSSMTR .............................................. AT-134
A/T control ............................................. EC-1012
A/T diagnosis communication line .......... EC-928
A/T shift lock system - Wiring
diagram ................................................ AT-196
A/T shift lock system ................................ AT-195
A/T trouble diagnoses .......................... AT-41, 46
AAC/V - Wiring diagram . EC-345, 468, 865, 997
ABS (anti-lock brake system) ................... BR-42
ABS - Wiring diagram ............................... BR-48
ABS sensor rotor ....................................... AX-23
APS - Wiring diagram ........................... EC-1155
AT/C - Wiring diagram .......................... EC-1013
ATDIAG - Wiring diagram ....................... EC-929
Accelerator control system .................... FE-3, 14
Accelerator position sensor ................... EC-1155
Air bag disposal ........................................ RS-30Air bag precautions .................................. GI-3
Air bag ....................................................... RS-16
Air bleeding (hydraulic clutch) ................... CL-10
Air bleeding for brake system ..................... BR-8
Air conditioner cut control ....... EC-38, 572, 1081
Air flow meter - See Mass air flow
sensor ................................ EC-154, 679, 1143
Air mix door control linkage
adjustment ............................................. HA-50
Air spoiler, rear .......................................... BT-38
Alternator ................................................... SC-28
Angular tightening application ...... EM-5, 76, 158
Antenna - See Power antenna ................ EL-233
Anti-lock brake system - Wiring
diagram .................................................. BR-48
Audio and A/C control removal and
installation - See Instrument panel ........ BT-22
Audio ........................................................ EL-208
Automatic transaxle number ...................... GI-40
Auxiliary air control (AAC) valve .... EC-343, 466,
863, 995
B
Back-up lamp switch (M/T) ....................... MT-16
Back-up lamp ............................................. EL-93
Ball joint (front) .......................................... SU-13
Basic inspection ...................... EC-99, 623,1111
Battery ......................................................... SC-3
Baulk ring (M/T) .................................. MT-25, 63
Blower motor ............................................. HA-61
Blower resistor .......................................... HA-61
Board-on lift ................................................ GI-42
Body alignment .......................................... BT-65
Brake booster ............................................ BR-16
Brake fluid change ...................................... BR-7
Brake fluid level and line check .................. BR-7
Brake hydraulic line .................................... BR-9
Brake pedal ............................................... BR-11
Bulb specifications ................................... EL-524
Bumper, front .............................................. BT-7
Bumper, rear .............................................. BT-10
C
CHARGE - Wiring diagram ....................... SC-25
CHIME - Wiring diagram ......................... EL-166
CIGAR - Wiring diagram ......................... EL-195
CKPS - Wiring diagram . EC-297, 440, 821, 911,
970, 1166
CMPS - Wiring diagram .................. EC-304, 828
CONSULT for ABS .................................... BR-58
CONSULT for engine .............. EC-82, 607, 1102
COOL/F - Wiring diagram ..... EC-376, 885, 1201
Camshaft inspection ................. EM-36, 114, 204
Camshaft position sensor (CMPS) . EC-302, 825
Camshaft position sensor (PHASE) ........ EC-302
ALPHABETICAL INDEX
IDX-2