ON-VEHICLE SERVICE
AT-219
< SERVICE INFORMATION >
D
E
F
G
H
I
J
K
L
MA
B
AT
N
O
P
1. Install A/T fluid temperature sensor 2 to bracket.
2. Install A/T fluid temperature sensor 2 (with bracket) in control
valve with TCM. Tighten A/T fluid temperature sensor 2 bolt to
the specified torque. Refer to AT-228, "
Component".
CAUTION:
Adjust bolt hole of bracket to bolt hole of control valve with
TCM.
3. Connect A/T fluid temperature sensor 2 connector (A).
4. Securely fasten A/T fluid temperature sensor 2 harness with ter-
minal clip.
• : Terminal clip
5. Install oil pan to transmission case. Refer to AT-209, "
Oil Pan".
6. Connect the negative battery terminal
7. Refill the A/T with fluid and check fluid level and for fluid leakage. Refer to AT-13, "
Changing Automatic
Transmission Fluid (ATF)".
CAUTION:
After completing installation, check for A/T fluid leakage and fluid level. Refer to AT-13, "
Changing
Automatic Transmission Fluid (ATF)", AT-13, "Checking Automatic Transmission Fluid (ATF)".
Rear Oil SealINFOID:0000000003532479
REMOVAL AND INSTALLATION
Removal
SCIA5264E
SCIA5253E
SCIA8125E
AT-220
< SERVICE INFORMATION >
ON-VEHICLE SERVICE
1. Remove rear propeller shaft. Refer to PR-8, "Removal and
Installation".
2. Remove transfer from transmission (4WD models). Refer to TF-
128, "Removal and Installation".
3. Remove rear oil seal using suitable tool.
CAUTION:
Be careful not to scratch rear extension assembly (2WD
models) or adapter case assembly (4WD models).
Installation
1. Install new rear oil seal until it is flush with component face into
the extension case (2WD models) using Tool, or adapter case
(4WD models) using suitable tool.
CAUTION:
• Apply ATF to rear oil seal.
• Do not reuse rear oil seal.
2. Install transfer to transmission (4WD models). Refer to TF-128,
"Removal and Installation".
3. Install rear propeller shaft. Refer to PR-8, "
Removal and Installa-
tion".
CAUTION:
After completing installation, check for A/T fluid leakage and
fluid level. Refer to AT-13, "
Changing Automatic Transmission
Fluid (ATF)" and AT-13, "Checking Automatic Transmission
Fluid (ATF)".
SCIA5254E
Tool number : ST33400001 (J-26082)
SCIA5583E
TRANSMISSION ASSEMBLY
AT-225
< SERVICE INFORMATION >
D
E
F
G
H
I
J
K
L
MA
B
AT
N
O
P
• When installing transmission to the engine, attach the bolts as shown.
NOTE:
*: No.2 bolt also secures air breather vent.
CAUTION:
• When replacing an engine or transmission you must make
sure the dowels are installed correctly during re-assembly.
• Improper alignment caused by missing dowels may cause
vibration, oil leaks or breakage of drivetrain components.
• Align the positions of bolts for drive plate with those of the torque
converter, and temporarily tighten the bolts. Then tighten the bolts
with the specified torque.
CAUTION:
• When turning crankshaft, turn it clockwise as viewed from the
front of the engine.
• After converter is installed to drive plate, rotate crankshaft
several turns and check to be sure that transmission rotates
freely without binding.
• Install crankshaft position sensor (POS).
• After completing installation check fluid leakage, fluid level and the
positions of A/T. Refer to AT-13, "
Checking Automatic Transmis-
sion Fluid (ATF)", AT-208, "Checking of A/T Position" and AT-208, "Adjustment of A/T Position".
Removal and Installation (4WD)INFOID:0000000003532482
COMPONENTS
Transmission to engine bolts : 113 N·m (12 kg-m,
83 ft-lb)
LCIA0371E
LCIA0335E
AWDIA0441GB
TRANSMISSION ASSEMBLY
AT-227
< SERVICE INFORMATION >
D
E
F
G
H
I
J
K
L
MA
B
AT
N
O
P
17. Plug any openings such as the fluid charging pipe hole.
18. Remove A/T assembly to engine bolts using power tool.
19. Remove A/T assembly with transfer from vehicle.
CAUTION:
• Secure torque converter to prevent it from dropping.
• Secure A/T assembly to transmission jack.
20. Remove transfer from A/T assembly. Refer to TF-128, "
Removal and Installation".
INSPECTION
Installation and Inspection of Torque Converter
• After inserting a torque converter to a transmission, be sure to
check dimension A to ensure it is within specifications.
INSTALLATION
Installation of the remaining components is in the reverse order of removal, while paying attention to the fol-
lowing:
• When installing transmission to the engine, attach the bolts as shown.
NOTE:
*: No.2 bolt also secures air breather vent.
CAUTION:
• When replacing an engine or transmission you must make
sure the dowels are installed correctly during re-assembly.
• Improper alignment caused by missing dowels may cause
vibration, oil leaks or breakage of drivetrain components.
• Align the positions of bolts for drive plate with those of the torque
converter, and temporarily tighten the bolts. Then tighten the bolts
with the specified torque.
CAUTION:
• When turning crankshaft, turn it clockwise as viewed from the
front of the engine.
• After converter is installed to drive plate, rotate crankshaft
several turns and check to be sure that transmission rotates
freely without binding.
• Install crankshaft position sensor (POS).
• After completing installation, check fluid leakage, fluid level, and
the positions of A/T. Refer to AT-13, "
Checking Automatic Trans-
mission Fluid (ATF)", AT-208, "Checking of A/T Position" and AT-208, "Adjustment of A/T Position". Dimension A : 24.0 mm (0.94 in) or more
SAT017B
Transmission to engine bolts : 113 N·m (12 kg-m,
83 ft-lb)
LCIA0371E
LCIA0335E
ATC-16
< SERVICE INFORMATION >
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
Refrigerant CycleINFOID:0000000003533229
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the front and rear evaporators, and back to the compressor. The refrigerant evaporation through the
evaporator coils are controlled by front and rear exter nally equalized expansion valves, located inside the front
and rear evaporator cases.
Refrigerant System ProtectionINFOID:0000000003533230
REFRIGERANT PRESSURE SENSOR
The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sen-
sor, located on the condenser. If the system pressure rise s above or falls below the specifications, the refriger-
ant pressure sensor detects the pressure inside t he refrigerant line and sends a voltage signal to the ECM.
The ECM de-energizes the A/C relay to disengage the magnetic compressor clutch when pressure on the high
pressure side detected by refrigerant pressu re sensor is over about 2,746 kPa (28 kg/cm
2, 398 psi), or below
about 120 kPa (1.22 kg/cm
2, 17.4 psi).
PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrigerant in the system incr eases to an abnormal level [more than 2,990 kPa (30.5 kg/
ATC-108
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS
Insufficient Heating
INFOID:0000000003533261
SYMPTOM: Insufficient heating
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPER ATIONAL CHECK - TEMPERATURE INCREASE
1. Press the AUTO switch.
2. Turn the temperature control dial (driver) clockwise until 32 ° C (90 ° F) is displayed.
3. Check for hot air at discharge air outlets.
Can this symptom be duplicated?
YES >> GO TO 2.
NO >> Perform complete system operational check. Refer to ATC-50, "
Operational Check (Front)" .
2.CHECK FOR SERVICE BULLETINS
Check for any service bulletins.
>> GO TO 3.
3.PERFORM SELF-DIAGNOSIS
Perform self-diagnosis. Refer to ATC-48, "
A/C System Self-Diagnosis Function" .
OK or NG
OK >> GO TO 4.
NG >> Refer to ATC-48, "
A/C System Self-Diagnosis Function" .
4.CHECK ENGINE COOLING SYSTEM
1. Check for proper engine coolant level. Refer to CO-9, "
Inspection".
2. Check hoses for leaks or kinks.
3. Check radiator cap. Refer to CO-9, "
Inspection" .
4. Check for air in cooling system.
>> GO TO 5.
5.CHECK AIR MIX DOOR OPERATION
Check the operation of the air mix door.
OK or NG
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side becomes nega-
tive. Liquid tank or front/rear side of
expansion valve′s pipe is frost-
ed or dewed. High-pressure side is closed
and refrigerant does not flow.
↓
Expansion valve or liquid tank
is frosted. Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
• If water is the cause, initially
cooling is okay. Then the wa-
ter freezes causing a block-
age. Drain water from
refrigerant or replace refrig-
erant.
• If due to foreign particles, re-
move expansion valve and
remove the particles with dry
and compressed air (not
shop air).
• If either of the above meth- ods cannot correct the mal-
function, replace expansion
valve.
• Replace liquid tank.
• Check oil for contamination.
AC362A
ATC-158
< SERVICE INFORMATION >
REFRIGERANT LINES
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engag-
ing and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.
Removal and Installation for Low-Pressure Flexible HoseINFOID:0000000003533295
REMOVAL
1. Remove the engine room cover using power tools.
2. Remove the engine air cleaner and air ducts. Refer to EM-15
.
3. Remove the cowl top extension. Refer to EI-17
.
4. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
5. Remove the low-pressure flexible hose.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-152, "
Component".
CAUTION:
• Replace the O-ring of the low-pr essure flexible hose with a new one, then apply compressor oil to it
when installing it.
• After charging refrigerant, check for leaks.
Removal and Installation for High-pressure Flexible HoseINFOID:0000000003533296
REMOVAL
1. Remove the engine under cover.
2. Remove the engine air cleaner and air ducts. Refer to EM-15
.
3. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
4. Remove the high-pressure flexible hose. CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-152, "
Component".
CAUTION:
• Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to it
when installing it.
• After charging refrigerant, check for leaks.
Removal and Installation for High-pressure PipeINFOID:0000000003533297
REMOVAL
1. Remove the cowl top extension. Refer to EI-17.
2. Disconnect the battery negative terminal and positive battery terminal.
3. Reposition the IPDM E/R aside.
4. Remove the front right wheel and tire assembly. Refer to WT-7, "
Rotation".
5. Position aside the front floor insulator.
6. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
7. Remove the low-pressure pipe. Refer to ATC-159, "
Removal and Installation for Low-Pressure Pipe".
8. Remove the high-pressure pipe. CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
DI-1
ELECTRICAL
C
DE
F
G H
I
J
L
M
SECTION DI
A
B
DI
N
O P
CONTENTS
DRIVER INFORMATION SYSTEM
SERVICE INFORMATION .. ..........................3
PRECAUTION ................................................ .....3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
3
PREPARATION ...................................................4
Commercial Service Tool .................................... ......4
COMBINATION METERS ...................................5
Component Parts and Harness Connector Loca-
tion ...................................................................... ......
5
System Description ...................................................5
Arrangement of Combination Meter ..........................7
Internal Circuit ...........................................................8
Wiring Diagram - METER - .......................................9
Combination Meter Harness Connector Terminal
Layout .....................................................................
11
Terminal and Reference Value for Combination
Meter .......................................................................
11
Self-Diagnosis Mode of Combination Meter ........ ....12
How to Proceed with Trouble Diagnosis ............. ....15
Preliminary Check ...................................................15
Symptom Chart .......................................................16
Power Supply and Ground Circuit Inspection .........16
Vehicle Speed Signal Inspection .............................17
Engine Oil Pressure Signal Inspection ....................17
Water Temperature Signal Inspection .....................18
Engine Speed Signal Inspection ......................... ....18
Fuel Level Sensor Unit Inspection ...................... ....18
Fuel Gauge Fluctuates, Indicates Wrong Value, or
Varies .................................................................. ....
20
Fuel Gauge Does Not Move to Full-position ...........20
Electrical Component Inspection ......................... ....21
Removal and Installation of Combination Meter .....21
COMPASS AND THERMOMETER ................ ....22
System Description ............................................. ....22
Wiring Diagram - COMPAS - ..................................23
Trouble Diagnosis ............................................... ....23
Calibration Procedure for Compass .................... ....24
WARNING LAMPS ............................................26
Schematic ............................................................ ....26
Wiring Diagram - WARN - .......................................27
Oil Pressure Warning Lamp Stays Off (Ignition
Switch ON) .......................................................... ....
32
Oil Pressure Warning Lamp Does Not Turn Off
(Oil Pressure Is Normal) ...................................... ....
33
A/T INDICATOR ................................................34
Wiring Diagram - AT/IND - .......................................34
A/T Indicator Does Not Illuminate ............................34
WARNING CHIME .............................................36
Component Parts and Harness Connector Loca-
tion ....................................................................... ....
36
System Description ..................................................36
CAN Communication System Description ...............37
Wiring Diagram - CHIME - .......................................38
Terminal and Reference Value for BCM ..................39
Terminal and Reference Value for Combination
Meter ................................................................... ....
39
How to Proceed with Trouble Diagnosis ..................40
Preliminary Check ............................................... ....40
CONSULT-II Function (BCM) ..................................40
All Warning Chimes Do Not Operate .......................41
Key Warning Chime and Light Warning Chime Do
Not Operate (Seat Belt Warning Chime Does Op-
erate) .......................................................................
41
Key Warning Chime Does Not Operate ...................42
Light Warning Chime Does Not Operate .................44
Seat Belt Warning Chime Does Not Operate ..........44
REAR SONAR SYSTEM ...................................46
Component Parts and Harness Connector Loca-
tion ....................................................................... ....
46
System Description ..................................................46
Wiring Diagram - SONAR - ......................................48
Sonar Control Unit Harness Connector Terminal
Layout ......................................................................
50