323F BJ Service Manual (2002 ).pdf
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GENERAL INFORMATION
00-00
ENGINE
01
ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (ZM)
01-02A
ON-BOARD DIAGNOSTIC [ENGINE CONTROL SYSTEM (FS)]
01-02B
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM]
01-02C
SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM
(ZM)]
01-03A
SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM
(FS)]
01-03B
MECHANICAL [ZM]
01-10A
MECHANICAL [FS]
01-10B
LUBRICATION
01-11
COOLING SYSTEM
01-12
INTAKE-AIR SYSTEM [ZM]
01-13A
INTAKE-AIR SYSTEM [FS]
01-13B
FUEL SYSTEM
01-14
EXHAUST SYSTEM
01-15
EMISSION SYSTEM
01-16
CHARGING SYSTEM
01-17
IGNITION SYSTEM
01-18
STARTING SYSTEM
01-19
CRUISE CONTROL SYSTEM
01-20
CONTROL SYSTEM [ZM]
01-40A
CONTROL SYSTEM [FS]
01-40B
TECHNICAL DATA
01-50
SERVICE TOOLS
01-60
SUSPENSION
02
GENERAL PROCEDURES
02-10
WHEEL ALIGNMENT
02-11
FRONT SUSPENSION
02-13
REAR SUSPENSION
02-14
TECHNICAL DATA
02-50
SERVICE TOOLS
02-60
DRIVELINE / AXLE
03
GENERAL PROCEDURES
03-10
FRONT AXLE
03-11
REAR AXLE
03-12
DRIVE SHAFT
03-13
TECHNICAL DATA
03-50
SERVICE TOOLS
03-60
BRAKES
04
ON-BOARD DIAGNOSTIC
04-02
SYMPTOM TROUBLESHOOTING
04-03
GENERAL PROCEDURES
04-10
CONVENTION BRAKE SYSTEM
04-11
PARKING BRAKE SYSTEM
04-12
ANTI-LOCK BRAKE SYSTEM
04-13
TECHNICAL DATA
04-50
SERVICE TOOLS
04-60
TRANSMISSION / TRANSAXLE
05
ON-BOARD DIAGNOSTIC
05-02
SYMPTOM TROUBLESHOOTING
05-03
CLUTCH
05-10
MANUAL TRANSAXLE [F25M-R]
05-15A
MANUAL TRANSAXLE [G15M-R]
05-15B
MANUAL TRANSAXLE SHIFT MECHANISM
05-16
AUTOMATIC TRANSAXLE
05-17
AUTOMATIC TRANSAXLE SHIFT MECHANISM
05-18
TECHNICAL DATA
05-50
SERVICE TOOLS
05-60
STEERING
06
GENERAL PROCEDURES
06-10
ENGINE SPEED SENSING POWER STEERING
06-12
TECHNICAL DATA
06-50
SERVICE TOOLS
06-60
HEATER, VENTILATION & AC
07
SYMPTOM TROUBLESHOOTING
07-03
REFRIGERANT SYSTEM
07-10
BASIC SYSTEM
07-11
CONTROL SYSTEM
07-40
TECHNICAL DATA
07-50
SERVICE TOOLS
07-60
RESTRAINTS
08
ON-BOARD DIAGNOSTIC
08-02
SYMPTOM TROUBLESHOOTING
08-03
AIR BAG SYSTEM
08-10
SEAT BELT
08-11
SERVICE TOOLS
08-60
BODY & ACCESSORIES
09
ON-BOARD DIAGNOSTIC (POWER DOOR LOCK SYSTEM)
09-02A
ON-BOARD DIAGNOSTIC (AUDIO)
09-02B
SYMPTOM TROUBLESHOOTING
09-03
BODY PANELS
09-10
DOORS AND LIFT GATE
09-11
GLASS / WINDOWS / MIRRORS
09-12
SEATS
09-13
SECURITY AND LOCKS
09-14
SUNROOF
09-15
EXTERIOR TRIM
09-16
INTERIOR TRIM
09-17
LIGHTING SYSTEMS
09-18
WIPER / WASHER SYSTEM
09-19
ENTERTAINMENT
09-20
POWER SYSTEMS
09-21
INSTRUMENTATION / DRIVER INFO
09-22
TECHNICAL DATA
09-50
SERVICE TOOLS
09-60
GENERAL INFORMATION
00
SECTION
00–00
GENERAL INFORMATION . . . . 00-00
Toc of SCT
00–00 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00–00–1
Range of Topics
. . . . . . . . . . . . . . . . . . 00–00–1
Service Procedure
. . . . . . . . . . . . . . . . . 00–00–2
Symbols
. . . . . . . . . . . . . . . . . . . . . . . . 00–00–3
Advisory Messages
. . . . . . . . . . . . . . . . 00–00–4
Troubleshooting Procedure
. . . . . . . . . . 00–00–5
Procedures for Use
. . . . . . . . . . . . . . . . 00–00–6
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–11
Conversion to SI Units (Système International
d'Unités)
. . . . . . . . . . . . . . . . . . . . . . . 00–00–11
Rounding Off
. . . . . . . . . . . . . . . . . . . . . 00–00–11
Upper and Lower Limits
. . . . . . . . . . . . 00–00–11
FUNDAMENTAL PROCEDURES . . . . . . 00–00–11
Protection of the Vehicle
. . . . . . . . . . . . 00–00–11
Preparation of Tools and Measuring
Equipment
. . . . . . . . . . . . . . . . . . . . . . 00–00–12
Special Service Tools
. . . . . . . . . . . . . . 00–00–12
Oil Leakage Inspection
. . . . . . . . . . . . . 00–00–12
Disconnection of the Negative Battery
Cable
. . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–13
Removal of Parts
. . . . . . . . . . . . . . . . . . 00–00–13
Disassembly
. . . . . . . . . . . . . . . . . . . . . 00–00–13
Inspection During Removal,
Disassembly
. . . . . . . . . . . . . . . . . . . . 00–00–13
Arrangement of Parts
. . . . . . . . . . . . . . 00–00–14
Cleaning of Parts
. . . . . . . . . . . . . . . . . . 00–00–14
Reassembly
. . . . . . . . . . . . . . . . . . . . . 00–00–14
Adjustment
. . . . . . . . . . . . . . . . . . . . . . 00–00–15
Rubber Parts and Tubing
. . . . . . . . . . . 00–00–15
Hose Clamps
. . . . . . . . . . . . . . . . . . . . . 00–00–15
Torque Formulas
. . . . . . . . . . . . . . . . . . 00–00–15
Vise
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–16
Dynamometer
. . . . . . . . . . . . . . . . . . . . 00–00–16
INSTALLATION OF RADIO SYSTEM. . . 00–00–16
ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–16
Electrical Parts
. . . . . . . . . . . . . . . . . . . 00–00–16
Wiring Harness
. . . . . . . . . . . . . . . . . . . 00–00–17
Connectors
. . . . . . . . . . . . . . . . . . . . . . 00–00–17
Terminals
. . . . . . . . . . . . . . . . . . . . . . . 00–00–18
Sensors, Switches, and Relays
. . . . . . 00–00–19
Wiring Harness
. . . . . . . . . . . . . . . . . . . 00–00–19
Fuse
. . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–19
Electrical Troubleshooting Tools
. . . . . 00–00–20
Precautions Before Welding
. . . . . . . . 00–00–20
JACKING POSITIONS. . . . . . . . . . . . . . . 00–00–21
Front
. . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–21
Rear
. . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–21
VEHICLE LIFT (2 SUPPORTS) AND SAFETY
STAND (RIGID RACK) POSITION . . . . 00–00–22
Vehicle Lift Positions
. . . . . . . . . . . . . . 00–00–22
Safety Stand Positions
. . . . . . . . . . . . . 00–00–22
TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–22
Tiedown Hooks
. . . . . . . . . . . . . . . . . . 00–00–23
IDENTIFICATION NUMBER LOCATIONS00–00–24
Vehicle Identification Number (VIN)
. . . 00–00–24
Chassis Number
. . . . . . . . . . . . . . . . . . 00–00–24
Engine Identification Number
. . . . . . . . 00–00–24
SAE STANDARDS . . . . . . . . . . . . . . . . . 00–00–25
ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–26
PRE-DELIVERY INSPECTION . . . . . . . . 00–00–27
Pre-Delivery Inspection Table
. . . . . . . 00–00–27
SCHEDULED MAINTENANCE . . . . . . . . 00–00–29
Scheduled Maintenance Table
. . . . . . 00–00–29
End of Toc
HOW TO USE THIS MANUAL
A3U000000001W01
Range of Topics
•
This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
00–00–1
Toc of SCT
GENERAL INFORMATION
Service Procedure
Inspection, adjustment
•
Inspection and adjustment procedures are
divided into steps. Important points regarding the
location and contents of the procedures are
explained in detail and shown in the illustrations.
ZLU0000W208
00–00–2
GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
00–00
YLU000WA0
Symbols
•
There are eight symbols indicating oil, grease, fluids, sealant, ane the use of
SST
or equivalent. use. These
symbols show application points or use of these ma
terials during service.
Symbol
Meaning
Kind
Apply oil
New appropriate
engine oil or gear
oil
00–00–3
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