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Description
2013 NISSAN XTERRA N50 Series Service Manual PDF DOWNLOAD
FILE DETAILS:
2013 NISSAN XTERRA N50 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 3762
Downloadable : Yes
File Type: PDF
IMAGES PREVIEW OF THE MANUAL:
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DESCRIPTION:
2013 NISSAN XTERRA N50 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedure for the 2013 NISSAN XTERRA.
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
IMPORTANT SAFETY NOTICE:
-
The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.
-
The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
-
Service varies with the procedures used, the skills of the technician and the tools and parts available.
-
Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.
TABLE OF CONTENTS:
2013 NISSAN XTERRA N50 Series Service Manual PDF DOWNLOAD
GI...................................................................................................................................................................................... 1 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 1 HOW TO USE THIS MANUAL.......................................................................................................................................................... 3 HOW TO USE THIS MANUAL...................................................................................................................................................... 3 Description............................................................................................................................................................. 3 Terms................................................................................................................................................................... 3 Units................................................................................................................................................................... 3 Contents................................................................................................................................................................ 3 Relation between Illustrations and Descriptions......................................................................................................................... 4 Component............................................................................................................................................................... 4 SYMBOLS............................................................................................................................................................. 5 HOW TO FOLLOW TROUBLE DIAGNOSES............................................................................................................................................. 6 Description............................................................................................................................................................. 6 How to Follow Test Groups in Trouble Diagnosis.......................................................................................................................... 6 Key to Symbols Signifying Measurements or Procedures.................................................................................................................... 7 HOW TO READ WIRING DIAGRAMS................................................................................................................................................. 9 Connector symbols....................................................................................................................................................... 9 Sample/wiring diagram -example-......................................................................................................................................... 10 Description............................................................................................................................................................. 11 SWITCH POSITIONS ................................................................................................................................................... 11 MULTIPLE SWITCH..................................................................................................................................................... 12 ABBREVIATIONS............................................................................................................................................................... 13 Abbreviation List....................................................................................................................................................... 13 TIGHTENING TORQUE OF STANDARD BOLTS......................................................................................................................................... 14 Description............................................................................................................................................................. 14 Tightening Torque Table (New Standard Included)......................................................................................................................... 14 PREVIOUS STANDARD................................................................................................................................................... 14 NEW STANDARD BASED ON ISO........................................................................................................................................... 15 DISCRIMINATION OF BOLTS AND NUTS.................................................................................................................................... 16 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.................................................................................................................................. 17 Recommended Chemical Products and Sealants.............................................................................................................................. 17 TERMINOLOGY................................................................................................................................................................. 18 ISO 15031-2 Terminology List............................................................................................................................................ 18 FEATURES OF NEW MODEL........................................................................................................................................................... 22 IDENTIFICATION INFORMATION.................................................................................................................................................. 22 Model Variation......................................................................................................................................................... 22 Identification Number................................................................................................................................................... 23 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT........................................................................................................................... 23 ENGINE SERIAL NUMBER................................................................................................................................................ 24 TRANSFER SERIAL NUMBER.............................................................................................................................................. 24 AUTOMATIC TRANSMISSION NUMBER....................................................................................................................................... 24 MANUAL TRANSMISSION NUMBER.......................................................................................................................................... 24 Dimensions.............................................................................................................................................................. 24 Wheels & Tires.......................................................................................................................................................... 25 PRECAUTION...................................................................................................................................................................... 26 PRECAUTIONS................................................................................................................................................................. 26 Description............................................................................................................................................................. 26 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 26 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 26 Precaution for NATS (NISSAN ANTI-THEFT SYSTEM).......................................................................................................................... 26 General Precaution...................................................................................................................................................... 27 Precaution for Three Way Catalyst....................................................................................................................................... 28 Precaution for Fuel..................................................................................................................................................... 28 GASOLINE ENGINE..................................................................................................................................................... 28 Precaution for Multiport Fuel Injection System or Engine Control System................................................................................................. 28 Precaution for Hoses.................................................................................................................................................... 29 HOSE REMOVAL AND INSTALLATION....................................................................................................................................... 29 HOSE CLAMPING....................................................................................................................................................... 29 Precaution for Engine Oils.............................................................................................................................................. 29 HEALTH PROTECTION PRECAUTIONS ...................................................................................................................................... 29 Precaution for Air Conditioning......................................................................................................................................... 30 LIFTING POINT............................................................................................................................................................... 31 Pantograph Jack......................................................................................................................................................... 31 Garage Jack and Safety Stand............................................................................................................................................ 31 2-Pole Lift............................................................................................................................................................. 31 TOW TRUCK TOWING............................................................................................................................................................ 33 Tow Truck Towing........................................................................................................................................................ 33 2WD MODEL........................................................................................................................................................... 33 4WD MODEL........................................................................................................................................................... 33 Towing Point.................................................................................................................................................... 34 Vehicle Recovery (Freeing a stuck vehicle).............................................................................................................................. 34 WIRING DIAGRAM.................................................................................................................................................................. 35 CONSULT CHECKING SYSTEM..................................................................................................................................................... 35 Wiring Diagram.......................................................................................................................................................... 35 BASIC INSPECTION................................................................................................................................................................ 36 SERVICE INFORMATION FOR ELECTRICAL INCIDENT................................................................................................................................. 36 Work Flow............................................................................................................................................................... 36 WORK FLOW........................................................................................................................................................... 36 Control Units and Electrical Parts...................................................................................................................................... 36 PRECAUTIONS......................................................................................................................................................... 36 How to Check Terminal................................................................................................................................................... 37 CONNECTOR AND TERMINAL PIN KIT...................................................................................................................................... 37 HOW TO PROBE CONNECTORS............................................................................................................................................. 38 Probing from Harness Side ...................................................................................................................................... 38 Probing from Terminal Side ..................................................................................................................................... 38 How to Check Enlarged Contact Spring of Terminal................................................................................................................ 39 Waterproof Connector Inspection ................................................................................................................................ 40 Terminal Lock Inspection ....................................................................................................................................... 40 Intermittent Incident................................................................................................................................................... 40 DESCRIPTION......................................................................................................................................................... 40 VEHICLE VIBRATION................................................................................................................................................... 41 Connector & Harness............................................................................................................................................. 41 Hint............................................................................................................................................................ 41 Sensor & Relay.................................................................................................................................................. 41 Engine Compartment.............................................................................................................................................. 41 Behind the Instrument Panel..................................................................................................................................... 41 Under Seating Areas............................................................................................................................................. 41 HEAT SENSITIVE...................................................................................................................................................... 42 FREEZING ........................................................................................................................................................... 42 WATER INTRUSION..................................................................................................................................................... 42 ELECTRICAL LOAD .................................................................................................................................................... 42 COLD OR HOT START UP ............................................................................................................................................... 42 Circuit Inspection...................................................................................................................................................... 43 DESCRIPTION ........................................................................................................................................................ 43 TESTING FOR “OPENS” IN THE CIRCUIT.................................................................................................................................. 43 Continuity Check Method......................................................................................................................................... 43 Voltage Check Method............................................................................................................................................ 43 TESTING FOR “SHORTS” IN THE CIRCUIT................................................................................................................................. 44 Resistance Check Method......................................................................................................................................... 44 Voltage Check Method............................................................................................................................................ 44 GROUND INSPECTION .................................................................................................................................................. 44 VOLTAGE DROP TESTS ................................................................................................................................................. 45 Measuring Voltage Drop - Accumulated Method..................................................................................................................... 45 Measuring Voltage Drop - Step-by-Step........................................................................................................................... 46 CONTROL UNIT CIRCUIT TEST .......................................................................................................................................... 46 CASE 1.......................................................................................................................................................... 46 CASE 2.......................................................................................................................................................... 47 CONSULT CHECKING SYSTEM..................................................................................................................................................... 48 Description............................................................................................................................................................. 48 Function and System Application......................................................................................................................................... 48 CONSULT Data Link Connector (DLC) Circuit............................................................................................................................... 48 INSPECTION PROCEDURE................................................................................................................................................ 48 acc..................................................................................................................................................................................... 50 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 50 PRECAUTION...................................................................................................................................................................... 51 PRECAUTIONS................................................................................................................................................................. 51 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 51 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 51 UNIT REMOVAL AND INSTALLATION................................................................................................................................................... 52 ACCELERATOR CONTROL SYSTEM.................................................................................................................................................. 52 Component............................................................................................................................................................... 52 Removal and Installation................................................................................................................................................ 52 REMOVAL............................................................................................................................................................. 52 INSTALLATION........................................................................................................................................................ 52 INSPECTION AFTER INSTALLATION....................................................................................................................................... 52 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................................................................... 54 SERVICE DATA AND SPECIFICATIONS (SDS)....................................................................................................................................... 54 Accelerator Control..................................................................................................................................................... 54 ACCELERATOR PEDAL................................................................................................................................................... 54 AV...................................................................................................................................................................................... 55 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 55 BASE AUDIO...................................................................................................................................................................... 60 BASIC INSPECTION............................................................................................................................................................ 60 DIAGNOSIS AND REPAIR WORKFLOW........................................................................................................................................... 60 Work Flow........................................................................................................................................................... 60 OVERALL SEQUENCE................................................................................................................................................ 60 DETAILED FLOW................................................................................................................................................... 60 SYSTEM DESCRIPTION.......................................................................................................................................................... 62 AUDIO SYSTEM............................................................................................................................................................ 62 System Diagram...................................................................................................................................................... 62 System Description.................................................................................................................................................. 62 AUDIO SYSTEM.................................................................................................................................................... 62 Component Parts Location............................................................................................................................................ 63 Component Description............................................................................................................................................... 63 DTC/CIRCUIT DIAGNOSIS....................................................................................................................................................... 64 POWER SUPPLY AND GROUND CIRCUIT......................................................................................................................................... 64 AUDIO UNIT.......................................................................................................................................................... 64 AUDIO UNIT : Diagnosis Procedure................................................................................................................................ 64 FRONT DOOR SPEAKER...................................................................................................................................................... 65 Description......................................................................................................................................................... 65 Diagnosis Procedure................................................................................................................................................. 65 FRONT TWEETER........................................................................................................................................................... 67 Description......................................................................................................................................................... 67 Diagnosis Procedure................................................................................................................................................. 67 REAR DOOR SPEAKER....................................................................................................................................................... 69 Description......................................................................................................................................................... 69 Diagnosis Procedure................................................................................................................................................. 69 ECU DIAGNOSIS INFORMATION................................................................................................................................................... 71 AUDIO UNIT.............................................................................................................................................................. 71 Reference Value..................................................................................................................................................... 71 TERMINAL LAYOUT................................................................................................................................................. 71 PHYSICAL VALUES................................................................................................................................................. 71 WIRING DIAGRAM.............................................................................................................................................................. 73 BASE AUDIO SYSTEM....................................................................................................................................................... 73 Wiring Diagram...................................................................................................................................................... 73 SYMPTOM DIAGNOSIS........................................................................................................................................................... 79 AUDIO SYSTEM............................................................................................................................................................ 79 Symptom Table....................................................................................................................................................... 79 AUDIO SYSTEM.................................................................................................................................................... 79 NORMAL OPERATING CONDITION.............................................................................................................................................. 81 Description......................................................................................................................................................... 81 NOISE........................................................................................................................................................... 81 Type of Noise and Possible Cause............................................................................................................................ 81 PRECAUTION.................................................................................................................................................................. 82 PRECAUTIONS............................................................................................................................................................. 82 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................................................... 82 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................ 82 Precaution for Procedure without Cowl Top Cover..................................................................................................................... 82 Precaution for Work................................................................................................................................................. 82 PREPARATION................................................................................................................................................................. 84 PREPARATION............................................................................................................................................................. 84 Special Service Tool................................................................................................................................................ 84 Commercial Service Tools............................................................................................................................................ 84 REMOVAL AND INSTALLATION.................................................................................................................................................... 85 AUDIO UNIT.............................................................................................................................................................. 85 Removal and Installation............................................................................................................................................ 85 REMOVAL......................................................................................................................................................... 85 INSTALLATION.................................................................................................................................................... 86 FRONT TWEETER........................................................................................................................................................... 87 Removal and Installation............................................................................................................................................ 87 REMOVAL......................................................................................................................................................... 87 INSTALLATION.................................................................................................................................................... 87 FRONT DOOR SPEAKER...................................................................................................................................................... 88 Removal and Installation............................................................................................................................................ 88 REMOVAL......................................................................................................................................................... 88 INSTALLATION.................................................................................................................................................... 88 REAR DOOR SPEAKER....................................................................................................................................................... 89 Removal and Installation............................................................................................................................................ 89 REMOVAL......................................................................................................................................................... 89 INSTALLATION.................................................................................................................................................... 89 AUDIO ANTENNA........................................................................................................................................................... 90 Location of Audio Antenna System Component.......................................................................................................................... 90 Removal and Installation............................................................................................................................................ 90 REMOVAL......................................................................................................................................................... 90 INSTALLATION.................................................................................................................................................... 90 DISPLAY AUDIO WITHOUT AMPLIFIER................................................................................................................................................. 91 SYSTEM DESCRIPTION.......................................................................................................................................................... 91 COMPONENT PARTS......................................................................................................................................................... 91 Component Parts Location............................................................................................................................................ 91 Component Description............................................................................................................................................... 91 SYSTEM.................................................................................................................................................................. 93 System Diagram...................................................................................................................................................... 93 System Description.................................................................................................................................................. 93 AUDIO SYSTEM.................................................................................................................................................... 93 SATELLITE RADIO SYSTEM.......................................................................................................................................... 93 HANDS-FREE PHONE SYSTEM......................................................................................................................................... 93 System Operation............................................................................................................................................ 93 Bluetooth................................................................................................................................................... 94 Steering Wheel Audio Control Switches....................................................................................................................... 94 Microphone.................................................................................................................................................. 94 Audio Unit.................................................................................................................................................. 94 DIAGNOSIS SYSTEM (AUDIO UNIT)........................................................................................................................................... 95 Description......................................................................................................................................................... 95 On Board Diagnosis Function......................................................................................................................................... 95 SELF DIAGNOSIS MODE............................................................................................................................................. 95 Audio Unit Self Diagnosis................................................................................................................................... 95 Audio Unit Self Diagnosis Results........................................................................................................................... 96 Audio Unit Confirmation/Adjustment.......................................................................................................................... 96 Display Diagnosis........................................................................................................................................... 97 Vehicle Signals............................................................................................................................................. 97 Speaker Test................................................................................................................................................ 97 Error History............................................................................................................................................... 97 AV COMM Diagnosis........................................................................................................................................... 98 Delete Unit Connection Log.................................................................................................................................. 99 Initialize Settings......................................................................................................................................... 99 ECU DIAGNOSIS INFORMATION................................................................................................................................................... 100 AUDIO UNIT.............................................................................................................................................................. 100 Reference Value..................................................................................................................................................... 100 TERMINAL LAYOUT................................................................................................................................................. 100 PHYSICAL VALUES................................................................................................................................................. 100 BLUETOOTH® CONTROL UNIT................................................................................................................................................. 103 Reference Value..................................................................................................................................................... 103 TERMINAL LAYOUT................................................................................................................................................. 103 PHYSICAL VALUES................................................................................................................................................. 103 WIRING DIAGRAM.............................................................................................................................................................. 105 DISPLAY AUDIO WITHOUT AMPLIFIER......................................................................................................................................... 105 Wiring Diagram...................................................................................................................................................... 105 BASIC INSPECTION............................................................................................................................................................ 118 DIAGNOSIS AND REPAIR WORKFLOW........................................................................................................................................... 118 Work Flow........................................................................................................................................................... 118 OVERALL SEQUENCE................................................................................................................................................ 118 DETAILED FLOW................................................................................................................................................... 118 DTC/CIRCUIT DIAGNOSIS....................................................................................................................................................... 120 POWER SUPPLY AND GROUND CIRCUIT......................................................................................................................................... 120 AUDIO UNIT.......................................................................................................................................................... 120 AUDIO UNIT : Diagnosis Procedure................................................................................................................................ 120 BLUETOOTH® CONTROL UNIT............................................................................................................................................. 120 BLUETOOTH® CONTROL UNIT : ...................................................................................................................................... 120 MICROPHONE.......................................................................................................................................................... 121 MICROPHONE : Diagnosis Procedure................................................................................................................................ 121 FRONT DOOR SPEAKER...................................................................................................................................................... 123 Diagnosis Procedure................................................................................................................................................. 123 FRONT TWEETER........................................................................................................................................................... 125 Diagnosis Procedure................................................................................................................................................. 125 REAR DOOR SPEAKER....................................................................................................................................................... 127 Diagnosis Procedure................................................................................................................................................. 127 STEERING SWITCH......................................................................................................................................................... 129 Diagnosis Procedure................................................................................................................................................. 129 MICROPHONE SIGNAL CIRCUIT............................................................................................................................................... 131 Diagnosis Procedure................................................................................................................................................. 131 USB CONNECTOR........................................................................................................................................................... 133 Diagnosis Procedure................................................................................................................................................. 133 SYMPTOM DIAGNOSIS........................................................................................................................................................... 134 AUDIO SYSTEM............................................................................................................................................................ 134 Symptom Table....................................................................................................................................................... 134 RELATED TO AUDIO................................................................................................................................................ 134 RELATED TO HANDS-FREE PHONE..................................................................................................................................... 135 Check Compatibility......................................................................................................................................... 135 NORMAL OPERATING CONDITION.............................................................................................................................................. 137 Description......................................................................................................................................................... 137 RELATED TO NOISE................................................................................................................................................ 137 Type of Noise and Possible Cause............................................................................................................................ 137 RELATED TO HANDS-FREE PHONE..................................................................................................................................... 137 PRECAUTION.................................................................................................................................................................. 139 PRECAUTIONS............................................................................................................................................................. 139 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................................................... 139 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................ 139 Precaution for Trouble Diagnosis.................................................................................................................................... 139 AV COMMUNICATION SYSTEM......................................................................................................................................... 139 Precaution for Harness Repair....................................................................................................................................... 139 AV COMMUNICATION SYSTEM......................................................................................................................................... 139 Precaution for Work................................................................................................................................................. 140 PREPARATION................................................................................................................................................................. 141 PREPARATION............................................................................................................................................................. 141 Special Service Tools............................................................................................................................................... 141 Commercial Service Tools............................................................................................................................................ 141 REMOVAL AND INSTALLATION.................................................................................................................................................... 142 AUDIO UNIT.............................................................................................................................................................. 142 Removal and Installation............................................................................................................................................ 142 REMOVAL......................................................................................................................................................... 142 INSTALLATION.................................................................................................................................................... 142 FRONT TWEETER........................................................................................................................................................... 143 Removal and Installation............................................................................................................................................ 143 REMOVAL......................................................................................................................................................... 143 INSTALLATION.................................................................................................................................................... 143 FRONT DOOR SPEAKER...................................................................................................................................................... 144 Removal and Installation............................................................................................................................................ 144 REMOVAL......................................................................................................................................................... 144 INSTALLATION.................................................................................................................................................... 144 REAR DOOR SPEAKER....................................................................................................................................................... 145 Removal and Installation............................................................................................................................................ 145 REMOVAL......................................................................................................................................................... 145 INSTALLATION.................................................................................................................................................... 145 STEERING SWITCH......................................................................................................................................................... 146 Removal and Installation............................................................................................................................................ 146 REMOVAL......................................................................................................................................................... 146 INSTALLATION.................................................................................................................................................... 146 BLUETOOTH CONTROL UNIT.................................................................................................................................................. 147 Removal and Installation............................................................................................................................................ 147 REMOVAL......................................................................................................................................................... 147 INSTALLATION.................................................................................................................................................... 148 MICROPHONE.............................................................................................................................................................. 149 Removal and Installation............................................................................................................................................ 149 REMOVAL......................................................................................................................................................... 149 INSTALLATION.................................................................................................................................................... 149 AUDIO ANTENNA........................................................................................................................................................... 150 Location of Antenna................................................................................................................................................. 150 Removal and Installation............................................................................................................................................ 150 REMOVAL......................................................................................................................................................... 150 INSTALLATION.................................................................................................................................................... 151 SATELLITE RADIO ANTENNA................................................................................................................................................. 152 Removal and Installation............................................................................................................................................ 152 REMOVAL......................................................................................................................................................... 152 INSTALLATION.................................................................................................................................................... 152 USB CONNECTOR........................................................................................................................................................... 153 Removal and Installation............................................................................................................................................ 153 REMOVAL......................................................................................................................................................... 153 INSTALLATION.................................................................................................................................................... 153 DISPLAY AUDIO WITH AMPLIFIER.................................................................................................................................................... 154 SYSTEM DESCRIPTION.......................................................................................................................................................... 154 COMPONENT PARTS......................................................................................................................................................... 154 Component Parts Location............................................................................................................................................ 154 Component Description............................................................................................................................................... 154 SYSTEM.................................................................................................................................................................. 156 System Diagram...................................................................................................................................................... 156 System Description.................................................................................................................................................. 156 AUDIO SYSTEM.................................................................................................................................................... 156 SATELLITE RADIO SYSTEM.......................................................................................................................................... 156 HANDS-FREE PHONE SYSTEM......................................................................................................................................... 156 System Operation............................................................................................................................................ 156 Bluetooth................................................................................................................................................... 157 Steering Wheel Audio Control Switches....................................................................................................................... 157 Microphone.................................................................................................................................................. 157 Audio Unit.................................................................................................................................................. 157 DIAGNOSIS SYSTEM (AUDIO UNIT)........................................................................................................................................... 158 Description......................................................................................................................................................... 158 On Board Diagnosis Function......................................................................................................................................... 158 METHOD OF STARTING.............................................................................................................................................. 158 SELF DIAGNOSIS MODE............................................................................................................................................. 158 Audio Unit Self Diagnosis................................................................................................................................... 158 Audio Unit Self Diagnosis Results........................................................................................................................... 159 Audio Unit Confirmation/Adjustment.......................................................................................................................... 159 Display Diagnosis........................................................................................................................................... 160 Vehicle Signals............................................................................................................................................. 160 Speaker Test................................................................................................................................................ 160 Error History............................................................................................................................................... 161 AV COMM Diagnosis........................................................................................................................................... 162 Delete Unit Connection Log.................................................................................................................................. 162 Initialize Settings......................................................................................................................................... 162 ECU DIAGNOSIS INFORMATION................................................................................................................................................... 163 AUDIO UNIT.............................................................................................................................................................. 163 Reference Value..................................................................................................................................................... 163 TERMINAL LAYOUT................................................................................................................................................. 163 PHYSICAL VALUES................................................................................................................................................. 163 AUDIO AMP............................................................................................................................................................... 166 Reference Value..................................................................................................................................................... 166 TERMINAL LAYOUT................................................................................................................................................. 166 PHYSICAL VALUES................................................................................................................................................. 166 BLUETOOTH CONTROL UNIT.................................................................................................................................................. 169 Reference Value..................................................................................................................................................... 169 TERMINAL LAYOUT................................................................................................................................................. 169 PHYSICAL VALUES................................................................................................................................................. 169 WIRING DIAGRAM.............................................................................................................................................................. 171 DISPLAY AUDIO WITH AMPLIFIER............................................................................................................................................ 171 Wiring Diagram...................................................................................................................................................... 171 BASIC INSPECTION............................................................................................................................................................ 186 DIAGNOSIS AND REPAIR WORKFLOW........................................................................................................................................... 186 Work Flow........................................................................................................................................................... 186 OVERALL SEQUENCE................................................................................................................................................ 186 DETAILED FLOW................................................................................................................................................... 186 DTC/CIRCUIT DIAGNOSIS....................................................................................................................................................... 188 POWER SUPPLY AND GROUND CIRCUIT......................................................................................................................................... 188 AUDIO UNIT.......................................................................................................................................................... 188 AUDIO UNIT : Diagnosis Procedure................................................................................................................................ 188 AUDIO AMP........................................................................................................................................................... 188 AUDIO AMP. : Diagnosis Procedure................................................................................................................................ 188 BLUETOOTH CONTROL UNIT.............................................................................................................................................. 189 BLUETOOTH CONTROL UNIT : Diagnosis Procedure.................................................................................................................... 189 MICROPHONE.......................................................................................................................................................... 190 MICROPHONE : Diagnosis Procedure................................................................................................................................ 190 FRONT DOOR SPEAKER...................................................................................................................................................... 192 Diagnosis Procedure................................................................................................................................................. 192 FRONT TWEETER........................................................................................................................................................... 195 Diagnosis Procedure................................................................................................................................................. 195 REAR DOOR SPEAKER....................................................................................................................................................... 198 Diagnosis Procedure................................................................................................................................................. 198 REAR TWEETER............................................................................................................................................................ 201 Diagnosis Procedure................................................................................................................................................. 201 SUBWOOFER............................................................................................................................................................... 204 Diagnosis Procedure................................................................................................................................................. 204 AMP. ON SIGNAL CIRCUIT.................................................................................................................................................. 207 Diagnosis Procedure................................................................................................................................................. 207 STEERING SWITCH......................................................................................................................................................... 208 Diagnosis Procedure................................................................................................................................................. 208 MICROPHONE SIGNAL CIRCUIT............................................................................................................................................... 210 Diagnosis Procedure................................................................................................................................................. 210 USB CONNECTOR........................................................................................................................................................... 212 Diagnosis Procedure................................................................................................................................................. 212 SYMPTOM DIAGNOSIS........................................................................................................................................................... 213 AUDIO SYSTEM............................................................................................................................................................ 213 Symptom Table....................................................................................................................................................... 213 RELATED TO AUDIO................................................................................................................................................ 213 RELATED TO HANDS-FREE PHONE..................................................................................................................................... 215 Check Compatibility......................................................................................................................................... 215 NORMAL OPERATING CONDITION.............................................................................................................................................. 217 Description......................................................................................................................................................... 217 RELATED TO NOISE................................................................................................................................................ 217 Type of Noise and Possible Cause............................................................................................................................ 217 RELATED TO HANDS-FREE PHONE..................................................................................................................................... 217 PRECAUTION.................................................................................................................................................................. 219 PRECAUTIONS............................................................................................................................................................. 219 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................................................... 219 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................ 219 Precaution for Trouble Diagnosis.................................................................................................................................... 219 AV COMMUNICATION SYSTEM......................................................................................................................................... 219 Precaution for Harness Repair....................................................................................................................................... 219 AV COMMUNICATION SYSTEM......................................................................................................................................... 219 Precaution for Work................................................................................................................................................. 220 PREPARATION................................................................................................................................................................. 221 PREPARATION............................................................................................................................................................. 221 Special Service Tools............................................................................................................................................... 221 Commercial Service Tools............................................................................................................................................ 221 REMOVAL AND INSTALLATION.................................................................................................................................................... 222 AUDIO UNIT.............................................................................................................................................................. 222 Removal and Installation............................................................................................................................................ 222 REMOVAL......................................................................................................................................................... 222 INSTALLATION.................................................................................................................................................... 222 AUDIO AMP............................................................................................................................................................... 223 Removal and Installation............................................................................................................................................ 223 REMOVAL......................................................................................................................................................... 223 INSTALLATION.................................................................................................................................................... 223 FRONT TWEETER........................................................................................................................................................... 224 Removal and Installation............................................................................................................................................ 224 REMOVAL......................................................................................................................................................... 224 INSTALLATION.................................................................................................................................................... 224 FRONT DOOR SPEAKER...................................................................................................................................................... 225 Removal and Installation............................................................................................................................................ 225 REMOVAL......................................................................................................................................................... 225 INSTALLATION.................................................................................................................................................... 225 REAR DOOR SPEAKER....................................................................................................................................................... 226 Removal and Installation............................................................................................................................................ 226 REMOVAL......................................................................................................................................................... 226 INSTALLATION.................................................................................................................................................... 226 REAR TWEETER............................................................................................................................................................ 227 Removal and Installation............................................................................................................................................ 227 REMOVAL......................................................................................................................................................... 227 INSTALLATION.................................................................................................................................................... 227 SUBWOOFER............................................................................................................................................................... 228 Removal and Installation............................................................................................................................................ 228 REMOVAL......................................................................................................................................................... 228 INSTALLATION.................................................................................................................................................... 228 STEERING SWITCH......................................................................................................................................................... 229 Removal and Installation............................................................................................................................................ 229 REMOVAL......................................................................................................................................................... 229 INSTALLATION.................................................................................................................................................... 229 BLUETOOTH CONTROL UNIT.................................................................................................................................................. 230 Removal and Installation............................................................................................................................................ 230 REMOVAL......................................................................................................................................................... 230 INSTALLATION.................................................................................................................................................... 231 MICROPHONE.............................................................................................................................................................. 232 Removal and Installation............................................................................................................................................ 232 REMOVAL......................................................................................................................................................... 232 INSTALLATION.................................................................................................................................................... 232 AUDIO ANTENNA........................................................................................................................................................... 233 Location of Antenna................................................................................................................................................. 233 Removal and Installation............................................................................................................................................ 233 REMOVAL......................................................................................................................................................... 233 INSTALLATION.................................................................................................................................................... 234 SATELLITE RADIO ANTENNA................................................................................................................................................. 235 Removal and Installation............................................................................................................................................ 235 REMOVAL......................................................................................................................................................... 235 INSTALLATION.................................................................................................................................................... 235 USB CONNECTOR........................................................................................................................................................... 236 Removal and Installation............................................................................................................................................ 236 REMOVAL......................................................................................................................................................... 236 INSTALLATION.................................................................................................................................................... 236 NAVIGATION...................................................................................................................................................................... 237 SYSTEM DESCRIPTION.......................................................................................................................................................... 237 COMPONENT PARTS......................................................................................................................................................... 237 Component Parts Location............................................................................................................................................ 237 Component Description............................................................................................................................................... 238 SYSTEM.................................................................................................................................................................. 239 System Diagram...................................................................................................................................................... 239 System Description.................................................................................................................................................. 239 NAVIGATION SYSTEM FUNCTION...................................................................................................................................... 239 Description................................................................................................................................................. 239 POSITION DETECTION PRINCIPLE................................................................................................................................ 239 MAP-MATCHING................................................................................................................................................ 240 GPS (Global Positioning System)............................................................................................................................. 241 SATELLITE RADIO FUNCTION........................................................................................................................................ 241 AUXILIARY INPUT FUNCTION........................................................................................................................................ 241 REAR VIEW MONITOR FUNCTION...................................................................................................................................... 241 Camera Image Operation Principle............................................................................................................................ 241 USB CONNECTION FUNCTION......................................................................................................................................... 241 SPEED SENSITIVE VOLUME SYSTEM................................................................................................................................... 242 HANDS-FREE PHONE SYSTEM......................................................................................................................................... 242 When A Call Is Originated................................................................................................................................... 242 When Receiving A Call....................................................................................................................................... 242 DIAGNOSIS SYSTEM (AV CONTROL UNIT)...................................................................................................................................... 243 Description......................................................................................................................................................... 243 On Board Diagnosis Function......................................................................................................................................... 243 METHOD OF STARTING.............................................................................................................................................. 243 CONSULT Function.................................................................................................................................................... 244 CONSULT FUNCTIONS............................................................................................................................................... 244 ECU IDENTIFICATION.............................................................................................................................................. 244 SELF DIAGNOSTIC RESULT.......................................................................................................................................... 244 DATA MONITOR.................................................................................................................................................... 244 CONFIGURATION................................................................................................................................................... 244 CAN DIAG SUPPORT MNTR........................................................................................................................................... 244 ECU DIAGNOSIS INFORMATION................................................................................................................................................... 245 AV CONTROL UNIT......................................................................................................................................................... 245 Reference Value..................................................................................................................................................... 245 TERMINAL LAYOUT................................................................................................................................................. 245 PHYSICAL VALUES................................................................................................................................................. 245 DTC Index........................................................................................................................................................... 247 AUDIO AMP............................................................................................................................................................... 249 Reference Value..................................................................................................................................................... 249 TERMINAL LAYOUT................................................................................................................................................. 249 PHYSICAL VALUES................................................................................................................................................. 249 WIRING DIAGRAM.............................................................................................................................................................. 252 NAVIGATION SYSTEM....................................................................................................................................................... 252 Wiring Diagram...................................................................................................................................................... 252 BASIC INSPECTION............................................................................................................................................................ 269 DIAGNOSIS AND REPAIR WORKFLOW........................................................................................................................................... 269 Work Flow........................................................................................................................................................... 269 OVERALL SEQUENCE................................................................................................................................................ 269 DETAILED FLOW................................................................................................................................................... 269 INSPECTION AND ADJUSTMENT............................................................................................................................................... 271 ADDITIONAL SERVICE WHEN REPLACING AV CONTROL UNIT................................................................................................................... 271 ADDITIONAL SERVICE WHEN REPLACING AV CONTROL UNIT : Description................................................................................................. 271 BEFORE REPLACEMENT.......................................................................................................................................... 271 AFTER REPLACEMENT........................................................................................................................................... 271 ADDITIONAL SERVICE WHEN REPLACING AV CONTROL UNIT : Work Procedure.............................................................................................. 271 CONFIGURATION (AV CONTROL UNIT)..................................................................................................................................... 271 CONFIGURATION (AV CONTROL UNIT) : Description................................................................................................................... 272 CONFIGURATION (AV CONTROL UNIT) : Work Procedure................................................................................................................ 272 CONFIGURATION (AV CONTROL UNIT) : Configuration List............................................................................................................ 273 DTC/CIRCUIT DIAGNOSIS....................................................................................................................................................... 274 U1000 CAN COMM CIRCUIT.................................................................................................................................................. 274 DTC Logic........................................................................................................................................................... 274 DTC DETECTION LOGIC............................................................................................................................................. 274 Diagnosis Procedure................................................................................................................................................. 274 U1010 CONTROL UNIT (CAN)................................................................................................................................................ 275 DTC Logic........................................................................................................................................................... 275 DTC DETECTION LOGIC............................................................................................................................................. 275 U1217 AV CONTROL UNIT................................................................................................................................................... 276 DTC Logic........................................................................................................................................................... 276 DTC DETECTION LOGIC............................................................................................................................................. 276 U1229 AV CONTROL UNIT................................................................................................................................................... 277 DTC Logic........................................................................................................................................................... 277 DTC DETECTION LOGIC............................................................................................................................................. 277 U122F AV CONTROL UNIT................................................................................................................................................... 278 DTC Logic........................................................................................................................................................... 278 DTC DETECTION LOGIC............................................................................................................................................. 278 U1244 GPS ANTENNA....................................................................................................................................................... 279 DTC Logic........................................................................................................................................................... 279 DTC DETECTION LOGIC............................................................................................................................................. 279 Diagnosis Procedure................................................................................................................................................. 279 U1258 SATELLITE RADIO ANTENNA........................................................................................................................................... 280 DTC Logic........................................................................................................................................................... 280 DTC DETECTION LOGIC............................................................................................................................................. 280 Diagnosis Procedure................................................................................................................................................. 280 U1263 USB............................................................................................................................................................... 281 DTC Logic........................................................................................................................................................... 281 DTC DETECTION LOGIC............................................................................................................................................. 281 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 281 Diagnosis Procedure................................................................................................................................................. 281 U1265 AUDIO AMP......................................................................................................................................................... 282 DTC Logic........................................................................................................................................................... 282 Diagnosis Procedure................................................................................................................................................. 282 U12AA CONFIGURATION ERROR............................................................................................................................................... 283 DTC Logic........................................................................................................................................................... 283 DTC DETECTION LOGIC............................................................................................................................................. 283 Diagnosis Procedure................................................................................................................................................. 283 U12AB ANTENNA........................................................................................................................................................... 284 DTC Logic........................................................................................................................................................... 284 DTC DETECTION LOGIC............................................................................................................................................. 284 Diagnosis Procedure................................................................................................................................................. 284 U12AC AV CONTROL UNIT................................................................................................................................................... 285 DTC Logic........................................................................................................................................................... 285 DTC DETECTION LOGIC............................................................................................................................................. 285 U12AD AV CONTROL UNIT................................................................................................................................................... 286 DTC Logic........................................................................................................................................................... 286 DTC DETECTION LOGIC............................................................................................................................................. 286 U12AE AV CONTROL UNIT................................................................................................................................................... 287 DTC Logic........................................................................................................................................................... 287 DTC DETECTION LOGIC............................................................................................................................................. 287 U12AF AV CONTROL UNIT................................................................................................................................................... 288 DTC Logic........................................................................................................................................................... 288 DTC DETECTION LOGIC............................................................................................................................................. 288 U12B0 POWER SUPPLY VOLTAGE.............................................................................................................................................. 289 DTC Logic........................................................................................................................................................... 289 DTC DETECTION LOGIC............................................................................................................................................. 289 Diagnosis Procedure................................................................................................................................................. 289 U12B1 POWER SUPPLY VOLTAGE.............................................................................................................................................. 290 DTC Logic........................................................................................................................................................... 290 DTC DETECTION LOGIC............................................................................................................................................. 290 Diagnosis Procedure................................................................................................................................................. 290 U1310 AV CONTROL UNIT................................................................................................................................................... 291 DTC Logic........................................................................................................................................................... 291 DTC DETECTION LOGIC............................................................................................................................................. 291 POWER SUPPLY AND GROUND CIRCUIT......................................................................................................................................... 292 AV CONTROL UNIT..................................................................................................................................................... 292 AV CONTROL UNIT : Diagnosis Procedure........................................................................................................................... 292 AUDIO AMP........................................................................................................................................................... 292 AUDIO AMP. : Diagnosis Procedure................................................................................................................................ 292 FRONT DOOR SPEAKER...................................................................................................................................................... 294 Diagnosis Procedure................................................................................................................................................. 294 FRONT TWEETER........................................................................................................................................................... 297 Diagnosis Procedure................................................................................................................................................. 297 REAR DOOR SPEAKER....................................................................................................................................................... 300 Diagnosis Procedure................................................................................................................................................. 300 REAR TWEETER............................................................................................................................................................ 303 Diagnosis Procedure................................................................................................................................................. 303 SUBWOOFER............................................................................................................................................................... 306 Diagnosis Procedure................................................................................................................................................. 306 AMP. ON SIGNAL CIRCUIT.................................................................................................................................................. 309 Diagnosis Procedure................................................................................................................................................. 309 REAR VIEW CAMERA IMAGE SIGNAL CIRCUIT................................................................................................................................... 310 Diagnosis Procedure................................................................................................................................................. 310 STEERING SWITCH......................................................................................................................................................... 312 Diagnosis Procedure................................................................................................................................................. 312 MICROPHONE SIGNAL CIRCUIT............................................................................................................................................... 314 Diagnosis Procedure................................................................................................................................................. 314 USB CONNECTOR........................................................................................................................................................... 316 Diagnosis Procedure................................................................................................................................................. 316 AUXILIARY INPUT JACK.................................................................................................................................................... 317 Diagnosis Procedure................................................................................................................................................. 317 SYMPTOM DIAGNOSIS........................................................................................................................................................... 318 MULTI AV SYSTEM......................................................................................................................................................... 318 Symptom Table....................................................................................................................................................... 318 RELATED TO AUDIO................................................................................................................................................ 318 RELATED TO HANDS-FREE PHONE..................................................................................................................................... 321 Check Compatibility......................................................................................................................................... 321 RELATED TO NAVIGATION........................................................................................................................................... 322 RELATED TO REAR VIEW CAMERA..................................................................................................................................... 322 NORMAL OPERATING CONDITION.............................................................................................................................................. 323 Description......................................................................................................................................................... 323 RELATED TO NOISE................................................................................................................................................ 323 Type of Noise and Possible Cause............................................................................................................................ 323 RELATED TO HANDS-FREE PHONE..................................................................................................................................... 323 RELATED TO NAVIGATION........................................................................................................................................... 324 Basic Operation............................................................................................................................................. 324 Vehicle Mark................................................................................................................................................ 324 Destination, Passing Points and Menu Items Cannot be Selected/Set........................................................................................... 325 Voice Guide................................................................................................................................................. 325 Route Search................................................................................................................................................ 326 Examples of Current-Location Mark Displacement.............................................................................................................. 326 Location Correction by Map-Matching is Slow................................................................................................................. 330 Name of Road is Not Displayed............................................................................................................................... 330 Contents of Display Differ for Birdview™ and the (Flat) Map Screen.......................................................................................... 330 Vehicle Mark Shows a Position Which is Completely Wrong..................................................................................................... 330 Vehicle Mark Jumps.......................................................................................................................................... 331 Vehicle Mark is in a River or Sea........................................................................................................................... 331 Vehicle Mark Automatically Rotates.......................................................................................................................... 331 When Driving on Same Road, Sometimes Vehicle Mark is in Right Place and Sometimes it is in Wrong Place...................................................... 331 PRECAUTION.................................................................................................................................................................. 332 PRECAUTIONS............................................................................................................................................................. 332 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................................................... 332 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................ 332 Precaution for Trouble Diagnosis.................................................................................................................................... 332 AV COMMUNICATION SYSTEM......................................................................................................................................... 332 Precaution for Harness Repair....................................................................................................................................... 332 AV COMMUNICATION SYSTEM......................................................................................................................................... 332 Precaution for Work................................................................................................................................................. 333 PREPARATION................................................................................................................................................................. 334 PREPARATION............................................................................................................................................................. 334 Special Service Tools............................................................................................................................................... 334 Commercial Service Tools............................................................................................................................................ 334 REMOVAL AND INSTALLATION.................................................................................................................................................... 335 AV CONTROL UNIT......................................................................................................................................................... 335 Removal and Installation............................................................................................................................................ 335 REMOVAL......................................................................................................................................................... 335 INSTALLATION.................................................................................................................................................... 335 AUDIO AMP............................................................................................................................................................... 336 Removal and Installation............................................................................................................................................ 336 REMOVAL......................................................................................................................................................... 336 INSTALLATION.................................................................................................................................................... 336 FRONT TWEETER........................................................................................................................................................... 337 Removal and Installation............................................................................................................................................ 337 REMOVAL......................................................................................................................................................... 337 INSTALLATION.................................................................................................................................................... 337 FRONT DOOR SPEAKER...................................................................................................................................................... 338 Removal and Installation............................................................................................................................................ 338 REMOVAL......................................................................................................................................................... 338 INSTALLATION.................................................................................................................................................... 338 REAR DOOR SPEAKER....................................................................................................................................................... 339 Removal and Installation ........................................................................................................................................... 339 REMOVAL......................................................................................................................................................... 339 INSTALLATION.................................................................................................................................................... 339 REAR TWEETER............................................................................................................................................................ 340 Removal and Installation............................................................................................................................................ 340 REMOVAL......................................................................................................................................................... 340 INSTALLATION.................................................................................................................................................... 340 SUBWOOFER............................................................................................................................................................... 341 Removal and Installation............................................................................................................................................ 341 REMOVAL......................................................................................................................................................... 341 INSTALLATION.................................................................................................................................................... 341 STEERING SWITCH......................................................................................................................................................... 342 Removal and Installation............................................................................................................................................ 342 REMOVAL......................................................................................................................................................... 342 INSTALLATION.................................................................................................................................................... 342 MICROPHONE.............................................................................................................................................................. 343 Removal and Installation............................................................................................................................................ 343 REMOVAL......................................................................................................................................................... 343 INSTALLATION.................................................................................................................................................... 343 AUDIO ANTENNA........................................................................................................................................................... 344 Location of Antenna................................................................................................................................................. 344 Removal and Installation............................................................................................................................................ 344 REMOVAL......................................................................................................................................................... 344 INSTALLATION.................................................................................................................................................... 345 AUXILIARY INPUT JACK.................................................................................................................................................... 346 Removal and Installation............................................................................................................................................ 346 Removal......................................................................................................................................................... 346 Installation.................................................................................................................................................... 346 SATELLITE RADIO ANTENNA................................................................................................................................................. 347 Removal and Installation............................................................................................................................................ 347 REMOVAL......................................................................................................................................................... 347 INSTALLATION.................................................................................................................................................... 347 GPS ANTENNA............................................................................................................................................................. 348 Removal and Installation............................................................................................................................................ 348 REMOVAL......................................................................................................................................................... 348 INSTALLATION.................................................................................................................................................... 348 USB CONNECTOR........................................................................................................................................................... 349 Removal and Installation............................................................................................................................................ 349 REMOVAL......................................................................................................................................................... 349 INSTALLATION.................................................................................................................................................... 349 REAR VIEW CAMERA........................................................................................................................................................ 350 Removal and Installation............................................................................................................................................ 350 REMOVAL......................................................................................................................................................... 350 INSTALLATION.................................................................................................................................................... 350 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 BCS..................................................................................................................................................................................... 351 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 351 BASIC INSPECTION................................................................................................................................................................ 353 INSPECTION AND ADJUSTMENT................................................................................................................................................... 353 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT.......................................................................................................................... 353 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description........................................................................................................ 353 BEFORE REPLACEMENT.............................................................................................................................................. 353 AFTER REPLACEMENT............................................................................................................................................... 353 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Work Procedure..................................................................................................... 353 CONFIGURATION........................................................................................................................................................... 353 CONFIGURATION : Description......................................................................................................................................... 354 CONFIGURATION : Work Procedure...................................................................................................................................... 354 CONFIGURATION : Configuration List.................................................................................................................................. 355 SYSTEM DESCRIPTION.............................................................................................................................................................. 356 BODY CONTROL SYSTEM......................................................................................................................................................... 356 System Description...................................................................................................................................................... 356 OUTLINE............................................................................................................................................................. 356 BCM control function list........................................................................................................................................... 356 Component Parts Location................................................................................................................................................ 357 COMBINATION SWITCH READING SYSTEM........................................................................................................................................... 358 System Diagram.......................................................................................................................................................... 358 System Description...................................................................................................................................................... 358 OUTLINE............................................................................................................................................................. 358 COMBINATION SWITCH MATRIX........................................................................................................................................... 358 COMBINATION SWITCH READING FUNCTION................................................................................................................................. 359 Description..................................................................................................................................................... 359 Operation Example............................................................................................................................................... 359 WIPER INTERMITTENT DIAL POSITION SETTING (FRONT WIPER INTERMITTENT OPERATION)....................................................................................... 360 Component Parts Location................................................................................................................................................ 361 SIGNAL BUFFER SYSTEM........................................................................................................................................................ 362 System Diagram.......................................................................................................................................................... 362 System Description...................................................................................................................................................... 362 OUTLINE............................................................................................................................................................. 362 Signal transmission function list................................................................................................................................... 362 POWER CONSUMPTION CONTROL SYSTEM............................................................................................................................................ 363 System Diagram.......................................................................................................................................................... 363 System Description...................................................................................................................................................... 363 OUTLINE............................................................................................................................................................. 363 LOW POWER CONSUMPTION CONTROL WITH BCM.............................................................................................................................. 363 Sleep mode activation............................................................................................................................................... 363 Wake-up operation................................................................................................................................................... 364 Component Parts Location................................................................................................................................................ 364 DIAGNOSIS SYSTEM (BCM)...................................................................................................................................................... 365 COMMON ITEM............................................................................................................................................................. 365 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM).................................................................................................................. 365 APPLICATION ITEM................................................................................................................................................ 365 SYSTEM APPLICATION.............................................................................................................................................. 365 DOOR LOCK............................................................................................................................................................... 365 DOOR LOCK : CONSULT Function (BCM - DOOR LOCK)...................................................................................................................... 366 DATA MONITOR.................................................................................................................................................... 366 ACTIVE TEST..................................................................................................................................................... 366 WORK SUPPORT.................................................................................................................................................... 366 REAR DEFOGGER........................................................................................................................................................... 366 REAR DEFOGGER : CONSULT Function (BCM - REAR DEFOGGER).............................................................................................................. 366 DATA MONITOR.................................................................................................................................................... 366 ACTIVE TEST..................................................................................................................................................... 367 BUZZER.................................................................................................................................................................. 367 BUZZER : CONSULT Function (BCM - BUZZER)............................................................................................................................ 367 DATA MONITOR.................................................................................................................................................... 367 ACTIVE TEST..................................................................................................................................................... 367 INT LAMP................................................................................................................................................................ 367 INT LAMP : CONSULT Function (BCM - INT LAMP)........................................................................................................................ 367 DATA MONITOR.................................................................................................................................................... 367 ACTIVE TEST..................................................................................................................................................... 367 WORK SUPPORT.................................................................................................................................................... 368 MULTI REMOTE ENT........................................................................................................................................................ 368 MULTI REMOTE ENT : CONSULT Function (BCM - MULTI REMOTE ENT)........................................................................................................ 368 DATA MONITOR.................................................................................................................................................... 368 ACTIVE TEST..................................................................................................................................................... 369 WORK SUPPORT.................................................................................................................................................... 369 HEADLAMP................................................................................................................................................................ 369 HEADLAMP : CONSULT Function (BCM - HEAD LAMP)....................................................................................................................... 369 DATA MONITOR.................................................................................................................................................... 369 ACTIVE TEST..................................................................................................................................................... 370 WORK SUPPORT.................................................................................................................................................... 370 WIPER................................................................................................................................................................... 370 WIPER : CONSULT Function (BCM - WIPER).............................................................................................................................. 370 DATA MONITOR.................................................................................................................................................... 370 ACTIVE TEST..................................................................................................................................................... 371 WORK SUPPORT.................................................................................................................................................... 371 FLASHER................................................................................................................................................................. 371 FLASHER : CONSULT Function (BCM - FLASHER).......................................................................................................................... 371 DATA MONITOR.................................................................................................................................................... 371 ACTIVE TEST..................................................................................................................................................... 371 AIR CONDITIONER......................................................................................................................................................... 371 AIR CONDITIONER : CONSULT Function (BCM - AIR CONDITIONER).......................................................................................................... 371 DATA MONITOR.................................................................................................................................................... 371 COMB SW................................................................................................................................................................. 372 COMB SW : CONSULT Function (BCM - COMB SW).......................................................................................................................... 372 DATA MONITOR.................................................................................................................................................... 372 BCM..................................................................................................................................................................... 372 BCM : CONSULT Function (BCM - BCM).................................................................................................................................. 372 ECU IDENTIFICATION.............................................................................................................................................. 372 SELF DIAGNOSTIC RESULT.......................................................................................................................................... 372 WORK SUPPORT.................................................................................................................................................... 372 CONFIGURATION................................................................................................................................................... 372 CAN DIAG SUPPORT MNTR........................................................................................................................................... 372 IMMU.................................................................................................................................................................... 372 IMMU : CONSULT Function (BCM - IMMU)................................................................................................................................ 373 SELF DIAGNOSTIC RESULT.......................................................................................................................................... 373 DATA MONITOR.................................................................................................................................................... 373 ACTIVE TEST..................................................................................................................................................... 373 BATTERY SAVER........................................................................................................................................................... 373 BATTERY SAVER : CONSULT Function (BCM - BATTERY SAVER).............................................................................................................. 373 DATA MONITOR.................................................................................................................................................... 373 ACTIVE TEST..................................................................................................................................................... 373 WORK SUPPORT.................................................................................................................................................... 373 TRUNK................................................................................................................................................................... 373 TRUNK : CONSULT Function (BCM - TRUNK).............................................................................................................................. 373 DATA MONITOR.................................................................................................................................................... 373 THEFT ALM............................................................................................................................................................... 374 THEFT ALM : CONSULT Function (BCM - THEFT ALM)...................................................................................................................... 374 DATA MONITOR.................................................................................................................................................... 374 ACTIVE TEST..................................................................................................................................................... 374 WORK SUPPORT.................................................................................................................................................... 374 RETAINED PWR............................................................................................................................................................ 374 RETAINED PWR : CONSULT Function (BCM - RETAINED PWR)................................................................................................................ 374 DATA MONITOR.................................................................................................................................................... 374 ACTIVE TEST..................................................................................................................................................... 375 WORK SUPPORT.................................................................................................................................................... 375 SIGNAL BUFFER........................................................................................................................................................... 375 SIGNAL BUFFER : CONSULT Function (BCM - SIGNAL BUFFER).............................................................................................................. 375 DATA MONITOR.................................................................................................................................................... 375 ACTIVE TEST..................................................................................................................................................... 375 AIR PRESSURE MONITOR.................................................................................................................................................... 375 AIR PRESSURE MONITOR : CONSULT Function (BCM - AIR PRESSURE MONITOR)................................................................................................ 375 SELF DIAGNOSTIC RESULT.......................................................................................................................................... 375 DATA MONITOR.................................................................................................................................................... 375 ACTIVE TEST..................................................................................................................................................... 376 WORK SUPPORT.................................................................................................................................................... 376 PANIC ALARM............................................................................................................................................................. 376 PANIC ALARM : CONSULT Function (BCM - PANIC ALARM).................................................................................................................. 376 ACTIVE TEST..................................................................................................................................................... 376 DTC/CIRCUIT DIAGNOSIS........................................................................................................................................................... 377 U1000 CAN COMM CIRCUIT...................................................................................................................................................... 377 Description............................................................................................................................................................. 377 DTC Logic............................................................................................................................................................... 377 DTC DETECTION LOGIC................................................................................................................................................. 377 Diagnosis Procedure..................................................................................................................................................... 377 POWER SUPPLY AND GROUND CIRCUIT............................................................................................................................................. 378 Diagnosis Procedure..................................................................................................................................................... 378 COMBINATION SWITCH INPUT CIRCUIT............................................................................................................................................ 380 Diagnosis Procedure..................................................................................................................................................... 380 Special Repair Requirement.............................................................................................................................................. 380 COMBINATION SWITCH OUTPUT CIRCUIT........................................................................................................................................... 381 Diagnosis Procedure..................................................................................................................................................... 381 Special Repair Requirement.............................................................................................................................................. 382 ECU DIAGNOSIS INFORMATION....................................................................................................................................................... 383 BCM (BODY CONTROL MODULE)................................................................................................................................................... 383 Reference Value......................................................................................................................................................... 383 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................ 383 Terminal Layout......................................................................................................................................................... 386 Physical Values......................................................................................................................................................... 386 Fail Safe............................................................................................................................................................... 391 Fail-safe index..................................................................................................................................................... 391 DTC Inspection Priority Chart........................................................................................................................................... 391 DTC Index............................................................................................................................................................... 392 WIRING DIAGRAM.................................................................................................................................................................. 394 BCM (BODY CONTROL MODULE)................................................................................................................................................... 394 Wiring Diagram.......................................................................................................................................................... 394 SYMPTOM DIAGNOSIS............................................................................................................................................................... 398 COMBINATION SWITCH SYSTEM SYMPTOMS.......................................................................................................................................... 398 Symptom Table........................................................................................................................................................... 398 PRECAUTION...................................................................................................................................................................... 399 PRECAUTIONS................................................................................................................................................................. 399 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 399 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 399 REMOVAL AND INSTALLATION........................................................................................................................................................ 400 BCM (BODY CONTROL MODULE)................................................................................................................................................... 400 Removal and Installation................................................................................................................................................ 400 REMOVAL............................................................................................................................................................. 400 INSTALLATION........................................................................................................................................................ 400 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 BR...................................................................................................................................................................................... 401 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 401 PRECAUTION...................................................................................................................................................................... 403 PRECAUTIONS................................................................................................................................................................. 403 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 403 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 403 Precaution for Brake System............................................................................................................................................. 403 PREPARATION..................................................................................................................................................................... 404 PREPARATION................................................................................................................................................................. 404 Special Service Tool.................................................................................................................................................... 404 Commercial Service Tool................................................................................................................................................. 404 SYSTEM DESCRIPTION.............................................................................................................................................................. 405 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING........................................................................................................................ 405 NVH Troubleshooting Chart............................................................................................................................................... 405 BASIC INSPECTION................................................................................................................................................................ 406 FRONT DISC BRAKE............................................................................................................................................................ 406 BRAKE PAD............................................................................................................................................................... 406 BRAKE PAD : Inspection.............................................................................................................................................. 406 PAD WEAR........................................................................................................................................................ 406 DISC ROTOR.............................................................................................................................................................. 406 DISC ROTOR : Inspection............................................................................................................................................. 406 VISUAL.......................................................................................................................................................... 406 RUNOUT.......................................................................................................................................................... 406 THICKNESS....................................................................................................................................................... 406 REAR DISC BRAKE............................................................................................................................................................. 408 BRAKE PAD............................................................................................................................................................... 408 BRAKE PAD : Inspection.............................................................................................................................................. 408 PAD WEAR........................................................................................................................................................ 408 DISC ROTOR.............................................................................................................................................................. 408 DISC ROTOR : Inspection............................................................................................................................................. 408 VISUAL.......................................................................................................................................................... 408 RUNOUT.......................................................................................................................................................... 408 THICKNESS....................................................................................................................................................... 408 BRAKE BOOSTER............................................................................................................................................................... 409 Inspection.............................................................................................................................................................. 409 OPERATION........................................................................................................................................................... 409 AIR TIGHT........................................................................................................................................................... 409 VACUUM LINES................................................................................................................................................................ 410 Inspection.............................................................................................................................................................. 410 VISUAL INSPECTION................................................................................................................................................... 410 CHECK VALVE INSPECTION.............................................................................................................................................. 410 Airtightness Inspection......................................................................................................................................... 410 BRAKE MASTER CYLINDER....................................................................................................................................................... 411 On Board Inspection..................................................................................................................................................... 411 LEAK INSPECTION..................................................................................................................................................... 411 BRAKE TUBE AND HOSE......................................................................................................................................................... 412 Hydraulic Circuit....................................................................................................................................................... 412 FRONT BRAKE............................................................................................................................................................. 413 FRONT BRAKE : Inspection............................................................................................................................................ 413 INSPECTION AFTER REMOVAL........................................................................................................................................ 413 REAR BRAKE.............................................................................................................................................................. 414 REAR BRAKE : Inspection............................................................................................................................................. 414 INSPECTION AFTER REMOVAL........................................................................................................................................ 414 PERIODIC MAINTENANCE............................................................................................................................................................ 415 BRAKE PEDAL................................................................................................................................................................. 415 Inspection and Adjustment............................................................................................................................................... 415 INSPECTION.......................................................................................................................................................... 415 ADJUSTMENT.......................................................................................................................................................... 415 BRAKE FLUID................................................................................................................................................................. 417 On Board Inspection..................................................................................................................................................... 417 LEVEL CHECK......................................................................................................................................................... 417 Drain and Refill........................................................................................................................................................ 417 Bleeding Brake System................................................................................................................................................... 417 REMOVAL AND INSTALLATION........................................................................................................................................................ 419 BRAKE PEDAL................................................................................................................................................................. 419 Exploded View........................................................................................................................................................... 419 Removal and Installation................................................................................................................................................ 419 REMOVAL............................................................................................................................................................. 419 INSPECTION AFTER REMOVAL............................................................................................................................................ 420 INSTALLATION........................................................................................................................................................ 420 BRAKE TUBE AND HOSE......................................................................................................................................................... 421 Hydraulic Circuit....................................................................................................................................................... 421 Removal and Installation of Front Brake Piping and Brake Hose........................................................................................................... 422 REMOVAL............................................................................................................................................................. 422 INSTALLATION........................................................................................................................................................ 423 Removal and Installation of Rear Brake Piping and Brake Hose............................................................................................................ 423 REMOVAL............................................................................................................................................................. 423 INSTALLATION........................................................................................................................................................ 424 Inspection After Installation........................................................................................................................................... 424 BRAKE MASTER CYLINDER....................................................................................................................................................... 426 Removal and Installation................................................................................................................................................ 426 REMOVAL............................................................................................................................................................. 426 INSTALLATION........................................................................................................................................................ 427 BRAKE BOOSTER............................................................................................................................................................... 428 Removal and Installation................................................................................................................................................ 428 REMOVAL ............................................................................................................................................................ 429 INSTALLATION........................................................................................................................................................ 429 VACUUM LINES................................................................................................................................................................ 431 Removal and Installation................................................................................................................................................ 431 REMOVAL............................................................................................................................................................. 431 INSTALLATION........................................................................................................................................................ 431 FRONT DISC BRAKE............................................................................................................................................................ 432 Exploded View of Brake Pads............................................................................................................................................. 432 Removal and Installation of Brake Pad................................................................................................................................... 432 REMOVAL............................................................................................................................................................. 432 INSTALLATION........................................................................................................................................................ 433 Brake Burnishing........................................................................................................................................................ 433 Exploded View of Brake Caliper.......................................................................................................................................... 434 Removal and Installation of Brake Caliper and Disc Rotor................................................................................................................ 434 REMOVAL............................................................................................................................................................. 434 INSTALLATION........................................................................................................................................................ 435 REAR DISC BRAKE............................................................................................................................................................. 437 Exploded View of Brake Pad.............................................................................................................................................. 437 Removal and Installation of Brake Pad................................................................................................................................... 437 REMOVAL............................................................................................................................................................. 437 INSTALLATION........................................................................................................................................................ 438 Brake Burnishing........................................................................................................................................................ 438 Exploded View of Brake Caliper.......................................................................................................................................... 439 Removal and Installation of Brake Caliper and Disc Rotor................................................................................................................ 439 REMOVAL............................................................................................................................................................. 439 INSTALLATION........................................................................................................................................................ 440 UNIT DISASSEMBLY AND ASSEMBLY................................................................................................................................................... 443 BRAKE MASTER CYLINDER....................................................................................................................................................... 443 Disassembly and Assembly................................................................................................................................................ 443 DISASSEMBLY......................................................................................................................................................... 443 ASSEMBLY............................................................................................................................................................ 444 FRONT DISC BRAKE............................................................................................................................................................ 445 Exploded View of Brake Caliper.......................................................................................................................................... 445 Disassembly and Assembly................................................................................................................................................ 445 DISASSEMBLY......................................................................................................................................................... 445 CALIPER INSPECTION.................................................................................................................................................. 446 Cylinder Body................................................................................................................................................... 446 Torque Member................................................................................................................................................... 446 Piston.......................................................................................................................................................... 446 Sliding Pins, and Sliding Pin Boots............................................................................................................................. 446 ASSEMBLY............................................................................................................................................................ 446 REAR DISC BRAKE............................................................................................................................................................. 448 Exploded View of Brake Caliper.......................................................................................................................................... 448 Disassembly and Assembly................................................................................................................................................ 448 DISASSEMBLY......................................................................................................................................................... 448 CALIPER INSPECTION.................................................................................................................................................. 449 Cylinder Body................................................................................................................................................... 449 Torque Member................................................................................................................................................... 449 Piston.......................................................................................................................................................... 449 Sliding Pins and Sliding Pin Boots.............................................................................................................................. 449 ASSEMBLY............................................................................................................................................................ 449 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................................................................... 451 SERVICE DATA AND SPECIFICATIONS (SDS)....................................................................................................................................... 451 General Specification................................................................................................................................................... 451 Brake Pedal............................................................................................................................................................. 451 Brake Booster........................................................................................................................................................... 452 Check Valve............................................................................................................................................................. 452 Front Disc Brake........................................................................................................................................................ 452 Rear Disc Brake......................................................................................................................................................... 452 BRC..................................................................................................................................................................................... 453 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 453 TYPE 1.......................................................................................................................................................................... 459 BASIC INSPECTION............................................................................................................................................................ 459 APPLICATION NOTICE...................................................................................................................................................... 459 Application Notice.................................................................................................................................................. 459 DIAGNOSIS AND REPAIR WORKFLOW........................................................................................................................................... 460 Work Flow........................................................................................................................................................... 460 PRECAUTIONS FOR DIAGNOSIS....................................................................................................................................... 460 OVERALL SEQUENCE................................................................................................................................................ 461 DETAILED FLOW................................................................................................................................................... 461 Diagnostic Work Sheet............................................................................................................................................... 463 INSPECTION AND ADJUSTMENT............................................................................................................................................... 464 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT...................................................................................................................... 464 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description.................................................................................................... 464 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Requirement..................................................................................... 464 ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION................................................................................................................ 464 ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Description.............................................................................................. 464 ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement............................................................................... 464 ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION........................................................................................................ 464 CALIBRATION OF DECEL G SENSOR....................................................................................................................................... 465 CALIBRATION OF DECEL G SENSOR : Description..................................................................................................................... 465 CALIBRATION OF DECEL G SENSOR : Special Repair Requirement...................................................................................................... 465 CALIBRATION OF DECEL G SENSOR............................................................................................................................... 465 SYSTEM DESCRIPTION.......................................................................................................................................................... 467 APPLICATION NOTICE...................................................................................................................................................... 467 Application Notice.................................................................................................................................................. 467 VDC..................................................................................................................................................................... 468 System Diagram...................................................................................................................................................... 468 Hydraulic Circuit Diagram........................................................................................................................................... 468 System Description.................................................................................................................................................. 469 Component Parts Location............................................................................................................................................ 470 Component Description............................................................................................................................................... 471 TCS..................................................................................................................................................................... 472 System Diagram...................................................................................................................................................... 472 System Description.................................................................................................................................................. 472 Component Parts Location............................................................................................................................................ 473 Component Description............................................................................................................................................... 474 ABS..................................................................................................................................................................... 475 System Diagram...................................................................................................................................................... 475 System Description.................................................................................................................................................. 475 Component Parts Location............................................................................................................................................ 476 Component Description............................................................................................................................................... 477 EBD..................................................................................................................................................................... 478 System Diagram...................................................................................................................................................... 478 System Description.................................................................................................................................................. 478 Component Parts Location............................................................................................................................................ 479 Component Description............................................................................................................................................... 480 DIAGNOSIS SYSTEM [ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)]........................................................................................................ 481 CONSULT Function (ABS).............................................................................................................................................. 481 FUNCTION........................................................................................................................................................ 481 SELF DIAGNOSTIC RESULT.......................................................................................................................................... 481 Operation Procedure......................................................................................................................................... 481 How to Erase Self-diagnosis Results......................................................................................................................... 481 Display Item List........................................................................................................................................... 481 DATA MONITOR.................................................................................................................................................... 481 WORK SUPPORT.................................................................................................................................................... 483 ACTIVE TEST..................................................................................................................................................... 483 Test Item................................................................................................................................................... 484 DTC/CIRCUIT DIAGNOSIS....................................................................................................................................................... 485 APPLICATION NOTICE...................................................................................................................................................... 485 Application Notice.................................................................................................................................................. 485 C1101, C1102, C1103, C1104 WHEEL SENSOR-1............................................................................................................................... 486 Description......................................................................................................................................................... 486 DTC Logic........................................................................................................................................................... 486 DTC DETECTION LOGIC............................................................................................................................................. 486 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 486 Diagnosis Procedure................................................................................................................................................. 486 Component Inspection................................................................................................................................................ 488 Special Repair Requirement.......................................................................................................................................... 488 C1105, C1106, C1107, C1108 WHEEL SENSOR-2............................................................................................................................... 489 Description......................................................................................................................................................... 489 DTC Logic........................................................................................................................................................... 489 DTC DETECTION LOGIC............................................................................................................................................. 489 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 489 Diagnosis Procedure................................................................................................................................................. 489 Component Inspection................................................................................................................................................ 491 Special Repair Requirement.......................................................................................................................................... 491 C1109 POWER AND GROUND SYSTEM........................................................................................................................................... 492 Description......................................................................................................................................................... 492 DTC Logic........................................................................................................................................................... 492 DTC DETECTION LOGIC............................................................................................................................................. 492 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 492 Diagnosis Procedure................................................................................................................................................. 492 Special Repair Requirement.......................................................................................................................................... 493 C1110, C1170 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT).............................................................................................................. 494 DTC Logic........................................................................................................................................................... 494 DTC DETECTION LOGIC............................................................................................................................................. 494 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 494 Diagnosis Procedure................................................................................................................................................. 494 Special Repair Requirement.......................................................................................................................................... 494 C1111 ABS MOTOR, MOTOR RELAY SYSTEM..................................................................................................................................... 495 Description......................................................................................................................................................... 495 PUMP............................................................................................................................................................ 495 MOTOR........................................................................................................................................................... 495 DTC Logic........................................................................................................................................................... 495 DTC DETECTION LOGIC............................................................................................................................................. 495 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 495 Diagnosis Procedure................................................................................................................................................. 495 Component Inspection................................................................................................................................................ 496 Special Repair Requirement.......................................................................................................................................... 496 C1113, C1145, C1146 YAW RATE/SIDE/DECEL G SENSOR........................................................................................................................ 497 Description......................................................................................................................................................... 497 DTC Logic........................................................................................................................................................... 497 DTC DETECTION LOGIC............................................................................................................................................. 497 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 497 Diagnosis Procedure................................................................................................................................................. 497 Component Inspection................................................................................................................................................ 498 Special Repair Requirement.......................................................................................................................................... 498 C1115 WHEEL SENSOR...................................................................................................................................................... 499 Description......................................................................................................................................................... 499 DTC Logic........................................................................................................................................................... 499 DTC DETECTION LOGIC............................................................................................................................................. 499 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 499 Diagnosis Procedure................................................................................................................................................. 499 Component Inspection................................................................................................................................................ 500 Special Repair Requirement.......................................................................................................................................... 501 C1116 STOP LAMP SWITCH.................................................................................................................................................. 502 Description......................................................................................................................................................... 502 DTC Logic........................................................................................................................................................... 502 DTC DETECTION LOGIC............................................................................................................................................. 502 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 502 Diagnosis Procedure................................................................................................................................................. 502 Special Repair Requirement.......................................................................................................................................... 503 C1120, C1122, C1124, C1126 IN ABS SOL................................................................................................................................... 504 Description......................................................................................................................................................... 504 DTC Logic........................................................................................................................................................... 504 DTC DETECTION LOGIC............................................................................................................................................. 504 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 504 Diagnosis Procedure................................................................................................................................................. 504 Component Inspection................................................................................................................................................ 505 Special Repair Requirement.......................................................................................................................................... 505 C1121, C1123, C1125, C1127 OUT ABS SOL.................................................................................................................................. 507 Description......................................................................................................................................................... 507 DTC Logic........................................................................................................................................................... 507 DTC DETECTION LOGIC............................................................................................................................................. 507 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 507 Diagnosis Procedure................................................................................................................................................. 507 Component Inspection................................................................................................................................................ 508 Special Repair Requirement.......................................................................................................................................... 508 C1130, C1131, C1132, C1133, C1136 ENGINE SIGNAL......................................................................................................................... 510 Description......................................................................................................................................................... 510 DTC Logic........................................................................................................................................................... 510 DTC DETECTION LOGIC............................................................................................................................................. 510 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 510 Diagnosis Procedure................................................................................................................................................. 510 C1140 ACTUATOR RLY...................................................................................................................................................... 511 Description......................................................................................................................................................... 511 DTC Logic........................................................................................................................................................... 511 DTC DETECTION LOGIC............................................................................................................................................. 511 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 511 Diagnosis Procedure................................................................................................................................................. 511 Component Inspection................................................................................................................................................ 512 Special Repair Requirement.......................................................................................................................................... 512 C1143, C1144 STEERING ANGLE SENSOR...................................................................................................................................... 513 Description......................................................................................................................................................... 513 DTC Logic........................................................................................................................................................... 513 DTC DETECTION LOGIC............................................................................................................................................. 513 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 513 Diagnosis Procedure................................................................................................................................................. 513 Component Inspection................................................................................................................................................ 514 Special Repair Requirement.......................................................................................................................................... 514 C1155 BRAKE FLUID LEVEL SWITCH.......................................................................................................................................... 516 Description......................................................................................................................................................... 516 DTC Logic........................................................................................................................................................... 516 DTC DETECTION LOGIC............................................................................................................................................. 516 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 516 Diagnosis Procedure................................................................................................................................................. 516 Component Inspection................................................................................................................................................ 517 Special Repair Requirement.......................................................................................................................................... 517 C1156 ST ANG SEN COM CIR................................................................................................................................................ 519 Description......................................................................................................................................................... 519 DTC Logic........................................................................................................................................................... 519 DTC DETECTION LOGIC............................................................................................................................................. 519 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 519 Diagnosis Procedure................................................................................................................................................. 519 C1160 DECEL G SEN SET................................................................................................................................................... 520 Description......................................................................................................................................................... 520 DTC Logic........................................................................................................................................................... 520 DTC DETECTION LOGIC............................................................................................................................................. 520 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 520 Diagnosis Procedure................................................................................................................................................. 520 C1163 ST ANGLE SEN SAFE................................................................................................................................................. 521 Description......................................................................................................................................................... 521 DTC Logic........................................................................................................................................................... 521 DTC DETECTION LOGIC............................................................................................................................................. 521 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 521 Diagnosis Procedure................................................................................................................................................. 521 C1164, C1165, C1166, C1167 CV/SV SYSTEM................................................................................................................................. 522 Description......................................................................................................................................................... 522 CV1, CV2 (CUT VALVE)............................................................................................................................................ 522 SV1, SV2 (SUCTION VALVE)........................................................................................................................................ 522 DTC Logic........................................................................................................................................................... 522 DTC DETECTION LOGIC............................................................................................................................................. 522 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 522 Diagnosis Procedure................................................................................................................................................. 522 Component Inspection................................................................................................................................................ 523 Special Repair Requirement.......................................................................................................................................... 524 U1000 CAN COMM CIRCUIT.................................................................................................................................................. 525 Description......................................................................................................................................................... 525 DTC Logic........................................................................................................................................................... 525 DTC DETECTION LOGIC............................................................................................................................................. 525 Diagnosis Procedure................................................................................................................................................. 525 VDC OFF SWITCH.......................................................................................................................................................... 526 Description......................................................................................................................................................... 526 Component Function Check............................................................................................................................................ 526 Diagnosis Procedure................................................................................................................................................. 526 Component Inspection................................................................................................................................................ 527 Special Repair Requirement.......................................................................................................................................... 527 ABS WARNING LAMP........................................................................................................................................................ 528 Description......................................................................................................................................................... 528 Component Function Check............................................................................................................................................ 528 Diagnosis Procedure................................................................................................................................................. 528 Special Repair Requirement.......................................................................................................................................... 528 BRAKE WARNING LAMP...................................................................................................................................................... 529 Description......................................................................................................................................................... 529 Component Function Check............................................................................................................................................ 529 Diagnosis Procedure................................................................................................................................................. 529 Special Repair Requirement.......................................................................................................................................... 529 VDC OFF INDICATOR LAMP.................................................................................................................................................. 530 Description......................................................................................................................................................... 530 Component Function Check............................................................................................................................................ 530 Diagnosis Procedure................................................................................................................................................. 530 Special Repair Requirement.......................................................................................................................................... 531 SLIP INDICATOR LAMP..................................................................................................................................................... 532 Description......................................................................................................................................................... 532 Component Function Check............................................................................................................................................ 532 Diagnosis Procedure................................................................................................................................................. 532 Special Repair Requirement.......................................................................................................................................... 532 ECU DIAGNOSIS INFORMATION................................................................................................................................................... 533 APPLICATION NOTICE...................................................................................................................................................... 533 Application Notice.................................................................................................................................................. 533 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)........................................................................................................................... 534 Reference Value..................................................................................................................................................... 534 VALUES ON THE DIAGNOSIS TOOL.................................................................................................................................... 534 TERMINAL LAYOUT................................................................................................................................................. 537 Fail-Safe........................................................................................................................................................... 537 ABS/EBD SYSTEM.................................................................................................................................................. 537 VDC/TCS SYSTEM.................................................................................................................................................. 537 DTC No. Index....................................................................................................................................................... 538 WIRING DIAGRAM.............................................................................................................................................................. 540 BRAKE CONTROL SYSTEM - VDC.............................................................................................................................................. 540 Wiring Diagram - WITHOUT HILL DESCENT CONTROL/HILL START ASSIST..................................................................................................... 540 SYMPTOM DIAGNOSIS........................................................................................................................................................... 548 APPLICATION NOTICE...................................................................................................................................................... 548 Application Notice.................................................................................................................................................. 548 VDC/TCS/ABS............................................................................................................................................................. 549 Symptom Table....................................................................................................................................................... 549 EXCESSIVE ABS FUNCTION OPERATION FREQUENCY.............................................................................................................................. 550 Diagnosis Procedure................................................................................................................................................. 550 UNEXPECTED PEDAL REACTION............................................................................................................................................... 551 Diagnosis Procedure................................................................................................................................................. 551 THE BRAKING DISTANCE IS LONG............................................................................................................................................ 552 Diagnosis Procedure................................................................................................................................................. 552 ABS FUNCTION DOES NOT OPERATE........................................................................................................................................... 553 Diagnosis Procedure................................................................................................................................................. 553 PEDAL VIBRATION OR ABS OPERATION SOUND OCCURS........................................................................................................................... 554 Diagnosis Procedure................................................................................................................................................. 554 VEHICLE JERKS DURING VDC/TCS/ABS CONTROL................................................................................................................................ 555 Diagnosis Procedure................................................................................................................................................. 555 NORMAL OPERATING CONDITION.............................................................................................................................................. 556 Description......................................................................................................................................................... 556 PRECAUTION.................................................................................................................................................................. 557 PRECAUTIONS............................................................................................................................................................. 557 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................................................... 557 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................ 557 Precaution for Brake System......................................................................................................................................... 557 Precaution for Brake Control........................................................................................................................................ 558 Precaution for CAN System........................................................................................................................................... 558 PREPARATION................................................................................................................................................................. 560 PREPARATION............................................................................................................................................................. 560 Special Service Tool................................................................................................................................................ 560 Commercial Service Tool............................................................................................................................................. 560 UNIT REMOVAL AND INSTALLATION............................................................................................................................................... 561 WHEEL SENSORS........................................................................................................................................................... 561 Removal and Installation............................................................................................................................................ 561 REMOVAL......................................................................................................................................................... 561 INSTALLATION.................................................................................................................................................... 561 SENSOR ROTOR............................................................................................................................................................ 562 Removal and Installation............................................................................................................................................ 562 FRONT........................................................................................................................................................... 562 REAR (C200)..................................................................................................................................................... 562 Removal and Installation.................................................................................................................................... 562 REAR (M226)..................................................................................................................................................... 562 Removal..................................................................................................................................................... 562 Installation................................................................................................................................................ 562 ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)................................................................................................................................... 563 Removal and Installation............................................................................................................................................ 563 REMOVAL......................................................................................................................................................... 563 INSTALLATION.................................................................................................................................................... 563 STEERING ANGLE SENSOR................................................................................................................................................... 565 Removal and Installation............................................................................................................................................ 565 REMOVAL......................................................................................................................................................... 565 INSTALLATION.................................................................................................................................................... 565 YAW RATE/SIDE/DECEL G SENSOR............................................................................................................................................ 566 Removal and Installation............................................................................................................................................ 566 REMOVAL......................................................................................................................................................... 566 INSTALLATION.................................................................................................................................................... 566 TYPE 2.......................................................................................................................................................................... 567 BASIC INSPECTION............................................................................................................................................................ 567 APPLICATION NOTICE...................................................................................................................................................... 567 Application Notice.................................................................................................................................................. 567 DIAGNOSIS AND REPAIR WORKFLOW........................................................................................................................................... 568 Work Flow........................................................................................................................................................... 568 PRECAUTIONS FOR DIAGNOSIS....................................................................................................................................... 568 OVERALL SEQUENCE................................................................................................................................................ 569 DETAILED FLOW................................................................................................................................................... 569 Diagnostic Work Sheet............................................................................................................................................... 571 INSPECTION AND ADJUSTMENT............................................................................................................................................... 572 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT...................................................................................................................... 572 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description.................................................................................................... 572 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Requirement..................................................................................... 572 ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION................................................................................................................ 572 ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Description.............................................................................................. 572 ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement............................................................................... 572 ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION........................................................................................................ 572 CALIBRATION OF DECEL G SENSOR....................................................................................................................................... 573 CALIBRATION OF DECEL G SENSOR : Description..................................................................................................................... 573 CALIBRATION OF DECEL G SENSOR : Special Repair Requirement...................................................................................................... 573 CALIBRATION OF DECEL G SENSOR............................................................................................................................... 573 SYSTEM DESCRIPTION.......................................................................................................................................................... 575 APPLICATION NOTICE...................................................................................................................................................... 575 Application Notice.................................................................................................................................................. 575 Hill descent control.................................................................................................................................................... 576 System Diagram...................................................................................................................................................... 576 Hydraulic Circuit Diagram........................................................................................................................................... 576 System Description.................................................................................................................................................. 577 Component Parts Location............................................................................................................................................ 578 Component Description............................................................................................................................................... 579 Hill start assist....................................................................................................................................................... 580 System Diagram...................................................................................................................................................... 580 System Description.................................................................................................................................................. 580 Component Parts Location............................................................................................................................................ 581 Component Description............................................................................................................................................... 582 VDC..................................................................................................................................................................... 583 System Diagram...................................................................................................................................................... 583 System Description.................................................................................................................................................. 583 Component Parts Location............................................................................................................................................ 584 Component Description............................................................................................................................................... 585 TCS..................................................................................................................................................................... 586 System Diagram...................................................................................................................................................... 586 System Description.................................................................................................................................................. 586 Component Parts Location............................................................................................................................................ 587 Component Description............................................................................................................................................... 588 ABS..................................................................................................................................................................... 589 System Diagram...................................................................................................................................................... 589 System Description.................................................................................................................................................. 589 Component Parts Location............................................................................................................................................ 590 Component Description............................................................................................................................................... 591 EBD..................................................................................................................................................................... 592 System Diagram...................................................................................................................................................... 592 System Description.................................................................................................................................................. 592 Component Parts Location............................................................................................................................................ 593 Component Description............................................................................................................................................... 594 DIAGNOSIS SYSTEM [ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)]........................................................................................................ 595 CONSULT Function (ABS).............................................................................................................................................. 595 FUNCTION........................................................................................................................................................ 595 SELF DIAGNOSTIC RESULT.......................................................................................................................................... 595 Operation Procedure......................................................................................................................................... 595 How to Erase Self-diagnosis Results......................................................................................................................... 595 Display Item List........................................................................................................................................... 595 DATA MONITOR.................................................................................................................................................... 595 WORK SUPPORT.................................................................................................................................................... 597 ACTIVE TEST..................................................................................................................................................... 598 Test Item................................................................................................................................................... 598 DTC/CIRCUIT DIAGNOSIS....................................................................................................................................................... 600 APPLICATION NOTICE...................................................................................................................................................... 600 Application Notice.................................................................................................................................................. 600 C1101, C1102, C1103, C1104 WHEEL SENSOR-1............................................................................................................................... 601 Description......................................................................................................................................................... 601 DTC Logic........................................................................................................................................................... 601 DTC DETECTION LOGIC............................................................................................................................................. 601 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 601 Diagnosis Procedure................................................................................................................................................. 601 Component Inspection................................................................................................................................................ 603 Special Repair Requirement.......................................................................................................................................... 603 C1105, C1106, C1107, C1108 WHEEL SENSOR-2............................................................................................................................... 604 Description......................................................................................................................................................... 604 DTC Logic........................................................................................................................................................... 604 DTC DETECTION LOGIC............................................................................................................................................. 604 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 604 Diagnosis Procedure................................................................................................................................................. 604 Component Inspection................................................................................................................................................ 606 Special Repair Requirement.......................................................................................................................................... 606 C1109 POWER AND GROUND SYSTEM........................................................................................................................................... 607 Description......................................................................................................................................................... 607 DTC Logic........................................................................................................................................................... 607 DTC DETECTION LOGIC............................................................................................................................................. 607 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 607 Diagnosis Procedure................................................................................................................................................. 607 Special Repair Requirement.......................................................................................................................................... 608 C1110, C1170 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT).............................................................................................................. 609 DTC Logic........................................................................................................................................................... 609 DTC DETECTION LOGIC............................................................................................................................................. 609 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 609 Diagnosis Procedure................................................................................................................................................. 609 Special Repair Requirement.......................................................................................................................................... 609 C1111 ABS MOTOR, MOTOR RELAY SYSTEM..................................................................................................................................... 610 Description......................................................................................................................................................... 610 PUMP............................................................................................................................................................ 610 MOTOR........................................................................................................................................................... 610 DTC Logic........................................................................................................................................................... 610 DTC DETECTION LOGIC............................................................................................................................................. 610 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 610 Diagnosis Procedure................................................................................................................................................. 610 Component Inspection................................................................................................................................................ 611 Special Repair Requirement.......................................................................................................................................... 611 C1113, C1145, C1146 YAW RATE/SIDE/DECEL G SENSOR........................................................................................................................ 612 Description......................................................................................................................................................... 612 DTC Logic........................................................................................................................................................... 612 DTC DETECTION LOGIC............................................................................................................................................. 612 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 612 Diagnosis Procedure................................................................................................................................................. 612 Component Inspection................................................................................................................................................ 613 Special Repair Requirement.......................................................................................................................................... 613 C1115 WHEEL SENSOR...................................................................................................................................................... 614 Description......................................................................................................................................................... 614 DTC Logic........................................................................................................................................................... 614 DTC DETECTION LOGIC............................................................................................................................................. 614 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 614 Diagnosis Procedure................................................................................................................................................. 614 Component Inspection................................................................................................................................................ 615 Special Repair Requirement.......................................................................................................................................... 616 C1116 STOP LAMP SWITCH.................................................................................................................................................. 617 Description......................................................................................................................................................... 617 DTC Logic........................................................................................................................................................... 617 DTC DETECTION LOGIC............................................................................................................................................. 617 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 617 Diagnosis Procedure................................................................................................................................................. 617 Special Repair Requirement.......................................................................................................................................... 618 C1120, C1122, C1124, C1126 IN ABS SOL................................................................................................................................... 619 Description......................................................................................................................................................... 619 DTC Logic........................................................................................................................................................... 619 DTC DETECTION LOGIC............................................................................................................................................. 619 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 619 Diagnosis Procedure................................................................................................................................................. 619 Component Inspection................................................................................................................................................ 620 Special Repair Requirement.......................................................................................................................................... 620 C1121, C1123, C1125, C1127 OUT ABS SOL.................................................................................................................................. 622 Description......................................................................................................................................................... 622 DTC Logic........................................................................................................................................................... 622 DTC DETECTION LOGIC............................................................................................................................................. 622 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 622 Diagnosis Procedure................................................................................................................................................. 622 Component Inspection................................................................................................................................................ 623 Special Repair Requirement.......................................................................................................................................... 623 C1130, C1131, C1132, C1133, C1136 ENGINE SIGNAL......................................................................................................................... 625 Description......................................................................................................................................................... 625 DTC Logic........................................................................................................................................................... 625 DTC DETECTION LOGIC............................................................................................................................................. 625 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 625 Diagnosis Procedure................................................................................................................................................. 625 C1140 ACTUATOR RLY...................................................................................................................................................... 626 Description......................................................................................................................................................... 626 DTC Logic........................................................................................................................................................... 626 DTC DETECTION LOGIC............................................................................................................................................. 626 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 626 Diagnosis Procedure................................................................................................................................................. 626 Component Inspection................................................................................................................................................ 627 Special Repair Requirement.......................................................................................................................................... 627 C1143, C1144 STEERING ANGLE SENSOR...................................................................................................................................... 628 Description......................................................................................................................................................... 628 DTC Logic........................................................................................................................................................... 628 DTC DETECTION LOGIC............................................................................................................................................. 628 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 628 Diagnosis Procedure................................................................................................................................................. 628 Component Inspection................................................................................................................................................ 629 Special Repair Requirement.......................................................................................................................................... 629 C1155 BRAKE FLUID LEVEL SWITCH.......................................................................................................................................... 631 Description......................................................................................................................................................... 631 DTC Logic........................................................................................................................................................... 631 DTC DETECTION LOGIC............................................................................................................................................. 631 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 631 Diagnosis Procedure................................................................................................................................................. 631 Component Inspection................................................................................................................................................ 632 Special Repair Requirement.......................................................................................................................................... 632 C1156 ST ANG SEN COM CIR................................................................................................................................................ 634 Description......................................................................................................................................................... 634 DTC Logic........................................................................................................................................................... 634 DTC DETECTION LOGIC............................................................................................................................................. 634 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 634 Diagnosis Procedure................................................................................................................................................. 634 C1160 DECEL G SEN SET................................................................................................................................................... 635 Description......................................................................................................................................................... 635 DTC Logic........................................................................................................................................................... 635 DTC DETECTION LOGIC............................................................................................................................................. 635 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 635 Diagnosis Procedure................................................................................................................................................. 635 C1163 ST ANGLE SEN SAFE................................................................................................................................................. 636 Description......................................................................................................................................................... 636 DTC Logic........................................................................................................................................................... 636 DTC DETECTION LOGIC............................................................................................................................................. 636 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 636 Diagnosis Procedure................................................................................................................................................. 636 C1164, C1165, C1166, C1167 CV/SV SYSTEM................................................................................................................................. 637 Description......................................................................................................................................................... 637 CV1, CV2 (CUT VALVE)............................................................................................................................................ 637 SV1, SV2 (SUCTION VALVE)........................................................................................................................................ 637 DTC Logic........................................................................................................................................................... 637 DTC DETECTION LOGIC............................................................................................................................................. 637 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 637 Diagnosis Procedure................................................................................................................................................. 637 Component Inspection................................................................................................................................................ 638 Special Repair Requirement.......................................................................................................................................... 639 C1187 DIFFERENTIAL LOCK CONTROL UNIT.................................................................................................................................... 640 Description......................................................................................................................................................... 640 DTC Logic........................................................................................................................................................... 640 DTC DETECTION LOGIC............................................................................................................................................. 640 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 640 Diagnosis Procedure................................................................................................................................................. 640 U1000 CAN COMM CIRCUIT.................................................................................................................................................. 641 Description......................................................................................................................................................... 641 DTC Logic........................................................................................................................................................... 641 DTC DETECTION LOGIC............................................................................................................................................. 641 Diagnosis Procedure................................................................................................................................................. 641 Hill descent control SWITCH............................................................................................................................................. 642 Description......................................................................................................................................................... 642 Component Function Check............................................................................................................................................ 642 Diagnosis Procedure................................................................................................................................................. 642 Component Inspection................................................................................................................................................ 643 Special Repair Requirement.......................................................................................................................................... 643 VDC OFF SWITCH.......................................................................................................................................................... 644 Description......................................................................................................................................................... 644 Component Function Check............................................................................................................................................ 644 Diagnosis Procedure................................................................................................................................................. 644 Component Inspection................................................................................................................................................ 645 Special Repair Requirement.......................................................................................................................................... 645 ABS WARNING LAMP........................................................................................................................................................ 646 Description......................................................................................................................................................... 646 Component Function Check............................................................................................................................................ 646 Diagnosis Procedure................................................................................................................................................. 646 Special Repair Requirement.......................................................................................................................................... 646 BRAKE WARNING LAMP...................................................................................................................................................... 647 Description......................................................................................................................................................... 647 Component Function Check............................................................................................................................................ 647 Diagnosis Procedure................................................................................................................................................. 647 Special Repair Requirement.......................................................................................................................................... 647 Hill descent control INDICATOR LAMP..................................................................................................................................... 648 Description......................................................................................................................................................... 648 Component Function Check............................................................................................................................................ 648 Diagnosis Procedure................................................................................................................................................. 648 Special Repair Requirement.......................................................................................................................................... 648 VDC OFF INDICATOR LAMP.................................................................................................................................................. 649 Description......................................................................................................................................................... 649 Component Function Check............................................................................................................................................ 649 Diagnosis Procedure................................................................................................................................................. 649 Special Repair Requirement.......................................................................................................................................... 650 SLIP INDICATOR LAMP..................................................................................................................................................... 651 Description......................................................................................................................................................... 651 Component Function Check............................................................................................................................................ 651 Diagnosis Procedure................................................................................................................................................. 651 Special Repair Requirement.......................................................................................................................................... 651 ECU DIAGNOSIS INFORMATION................................................................................................................................................... 652 APPLICATION NOTICE...................................................................................................................................................... 652 Application Notice.................................................................................................................................................. 652 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)........................................................................................................................... 653 Reference Value..................................................................................................................................................... 653 VALUES ON THE DIAGNOSIS TOOL.................................................................................................................................... 653 TERMINAL LAYOUT................................................................................................................................................. 657 Fail-Safe........................................................................................................................................................... 657 ABS/EBD SYSTEM.................................................................................................................................................. 657 VDC/TCS SYSTEM.................................................................................................................................................. 657 DTC No. Index....................................................................................................................................................... 657 WIRING DIAGRAM.............................................................................................................................................................. 659 BRAKE CONTROL SYSTEM - VDC.............................................................................................................................................. 659 Wiring Diagram - WITH HILL DESCENT CONTROL/HILL START ASSIST........................................................................................................ 659 SYMPTOM DIAGNOSIS........................................................................................................................................................... 667 APPLICATION NOTICE...................................................................................................................................................... 667 Application Notice.................................................................................................................................................. 667 VDC/TCS/ABS............................................................................................................................................................. 668 Symptom Table....................................................................................................................................................... 668 EXCESSIVE ABS FUNCTION OPERATION FREQUENCY.............................................................................................................................. 669 Diagnosis Procedure................................................................................................................................................. 669 UNEXPECTED PEDAL REACTION............................................................................................................................................... 670 Diagnosis Procedure................................................................................................................................................. 670 THE BRAKING DISTANCE IS LONG............................................................................................................................................ 671 Diagnosis Procedure................................................................................................................................................. 671 ABS FUNCTION DOES NOT OPERATE........................................................................................................................................... 672 Diagnosis Procedure................................................................................................................................................. 672 PEDAL VIBRATION OR ABS OPERATION SOUND OCCURS........................................................................................................................... 673 Diagnosis Procedure................................................................................................................................................. 673 VEHICLE JERKS DURING VDC/TCS/ABS CONTROL................................................................................................................................ 674 Diagnosis Procedure................................................................................................................................................. 674 NORMAL OPERATING CONDITION.............................................................................................................................................. 675 Description......................................................................................................................................................... 675 PRECAUTION.................................................................................................................................................................. 676 PRECAUTIONS............................................................................................................................................................. 676 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................................................... 676 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................ 676 Precaution for Brake System......................................................................................................................................... 676 Precaution for Brake Control........................................................................................................................................ 677 Precaution for CAN System........................................................................................................................................... 677 PREPARATION................................................................................................................................................................. 679 PREPARATION............................................................................................................................................................. 679 Special Service Tool................................................................................................................................................ 679 Commercial Service Tool............................................................................................................................................. 679 UNIT REMOVAL AND INSTALLATION............................................................................................................................................... 680 WHEEL SENSORS........................................................................................................................................................... 680 Removal and Installation............................................................................................................................................ 680 REMOVAL......................................................................................................................................................... 680 INSTALLATION.................................................................................................................................................... 680 SENSOR ROTOR............................................................................................................................................................ 681 Removal and Installation............................................................................................................................................ 681 FRONT........................................................................................................................................................... 681 REAR............................................................................................................................................................ 681 Removal..................................................................................................................................................... 681 Installation................................................................................................................................................ 681 ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)................................................................................................................................... 682 Removal and Installation............................................................................................................................................ 682 REMOVAL......................................................................................................................................................... 682 INSTALLATION.................................................................................................................................................... 682 STEERING ANGLE SENSOR................................................................................................................................................... 684 Removal and Installation............................................................................................................................................ 684 REMOVAL......................................................................................................................................................... 684 INSTALLATION.................................................................................................................................................... 684 YAW RATE/SIDE/DECEL G SENSOR............................................................................................................................................ 685 Removal and Installation............................................................................................................................................ 685 REMOVAL......................................................................................................................................................... 685 INSTALLATION.................................................................................................................................................... 685 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 BRM..................................................................................................................................................................................... 686 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 686 FEATURES OF NEW MODEL........................................................................................................................................................... 687 BODY EXTERIOR PAINT COLOR................................................................................................................................................... 687 Body Exterior Paint Color............................................................................................................................................... 687 PRECAUTION...................................................................................................................................................................... 688 PRECAUTIONS................................................................................................................................................................. 688 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 688 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 688 HANDLING PRECAUTIONS........................................................................................................................................................ 689 Handling Precaution for Plastics........................................................................................................................................ 689 HANDLING PRECAUTIONS FOR PLASTICS................................................................................................................................... 689 LOCATION OF PLASTIC PARTS .......................................................................................................................................... 690 REMOVAL AND INSTALLATION........................................................................................................................................................ 692 BODY COMPONENT PARTS........................................................................................................................................................ 692 Body Component Parts.................................................................................................................................................... 692 UNDERBODY COMPONENT PARTS .......................................................................................................................................... 692 BODY COMPONENT PARTS................................................................................................................................................ 694 FRAME COMPONENT PARTS............................................................................................................................................... 696 CORROSION PROTECTION........................................................................................................................................................ 698 Corrosion Protection.................................................................................................................................................... 698 DESCRIPTION......................................................................................................................................................... 698 ANTI-CORROSIVE PRECOATED STEEL (GALVANNEALED STEEL)............................................................................................................ 698 PHOSPHATE COATING TREATMENT AND CATIONIC ELECTRODEPOSITION PRIMER.............................................................................................. 698 ANTI-CORROSIVE WAX.................................................................................................................................................. 698 UNDERCOATING........................................................................................................................................................ 699 Precautions in undercoating..................................................................................................................................... 699 Body Sealing............................................................................................................................................................ 700 DESCRIPTION......................................................................................................................................................... 700 BODY CONSTRUCTION........................................................................................................................................................... 704 Body Construction....................................................................................................................................................... 704 BODY CONSTRUCTION................................................................................................................................................... 704 BODY ALIGNMENT.............................................................................................................................................................. 705 Body Alignment.......................................................................................................................................................... 705 BODY CENTER MARKS................................................................................................................................................... 705 PANEL PARTS MATCHING MARKS.......................................................................................................................................... 705 DESCRIPTION......................................................................................................................................................... 706 Engine Compartment.................................................................................................................................................. 707 MEASUREMENT..................................................................................................................................................... 708 MEASUREMENT POINTS.............................................................................................................................................. 709 Underbody........................................................................................................................................................... 709 MEASUREMENT..................................................................................................................................................... 710 MEASUREMENT POINTS.............................................................................................................................................. 711 Passenger Compartment............................................................................................................................................... 712 MEASUREMENT..................................................................................................................................................... 713 MEASUREMENT POINTS.............................................................................................................................................. 714 Rear Body........................................................................................................................................................... 716 MEASUREMENT..................................................................................................................................................... 717 MEASUREMENT POINTS.............................................................................................................................................. 718 Body Mounting........................................................................................................................................................... 718 REPAIRING HIGH STRENGTH STEEL............................................................................................................................................... 720 Precaution in Repairing High Strength Steel............................................................................................................................. 720 High strength steel (hss) used in NISSAN vehicles................................................................................................................... 720 REPLACEMENT OPERATIONS...................................................................................................................................................... 723 Replacement Operation................................................................................................................................................... 723 DESCRIPTION......................................................................................................................................................... 723 HOODLEDGE........................................................................................................................................................... 725 LH.............................................................................................................................................................. 725 RH.............................................................................................................................................................. 726 FRONT PILLAR........................................................................................................................................................ 727 CENTER PILLAR....................................................................................................................................................... 729 OUTER SILL ......................................................................................................................................................... 731 REAR FENDER......................................................................................................................................................... 732 REAR FENDER EXTENSION............................................................................................................................................... 733 MAIN BACK PILLAR.................................................................................................................................................... 734 REAR FLOOR REAR..................................................................................................................................................... 735 REAR CROSSMEMBER.................................................................................................................................................... 735 Rear Floor Upper Extensions..................................................................................................................................... 736 Crossmember..................................................................................................................................................... 737 CRUSH HORN.......................................................................................................................................................... 737 Foam Repair............................................................................................................................................................. 738 URETHANE FOAM APPLICATIONS.......................................................................................................................................... 738 FILL PROCEDURES..................................................................................................................................................... 739 CCS..................................................................................................................................................................................... 740 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 740 PRECAUTION...................................................................................................................................................................... 741 PRECAUTIONS................................................................................................................................................................. 741 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 741 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 741 SYSTEM DESCRIPTION.............................................................................................................................................................. 742 AUTOMATIC SPEED CONTROL DEVICE (ASCD)....................................................................................................................................... 742 Information............................................................................................................................................................. 742 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 CHG..................................................................................................................................................................................... 743 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 743 BASIC INSPECTION................................................................................................................................................................ 744 DIAGNOSIS AND REPAIR WORKFLOW............................................................................................................................................... 744 Work Flow (With EXP-800 NI or GR8-1200 NI).............................................................................................................................. 744 CHARGING SYSTEM DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI............................................................................................................ 744 OVERALL SEQUENCE.................................................................................................................................................... 745 DETAILED FLOW....................................................................................................................................................... 745 Work Flow (Without EXP-800 NI or GR8-1200 NI)........................................................................................................................... 747 OVERALL SEQUENCE.................................................................................................................................................... 747 DETAILED FLOW....................................................................................................................................................... 748 SYSTEM DESCRIPTION.............................................................................................................................................................. 750 CHARGING SYSTEM............................................................................................................................................................. 750 System Diagram.......................................................................................................................................................... 750 System Description...................................................................................................................................................... 750 Component Description................................................................................................................................................... 750 POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM............................................................................................................................ 751 System Diagram.......................................................................................................................................................... 751 System Description...................................................................................................................................................... 751 Component Description................................................................................................................................................... 751 DTC/CIRCUIT DIAGNOSIS........................................................................................................................................................... 752 CHARGING SYSTEM PRELIMINARY INSPECTION...................................................................................................................................... 752 Diagnosis Procedure..................................................................................................................................................... 752 POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM OPERATION INSPECTION....................................................................................................... 753 Diagnosis Procedure..................................................................................................................................................... 753 B TERMINAL CIRCUIT.......................................................................................................................................................... 755 Description............................................................................................................................................................. 755 Diagnosis Procedure..................................................................................................................................................... 755 L TERMINAL CIRCUIT (OPEN)................................................................................................................................................... 756 Description............................................................................................................................................................. 756 Diagnosis Procedure..................................................................................................................................................... 756 L TERMINAL CIRCUIT (SHORT).................................................................................................................................................. 758 Description............................................................................................................................................................. 758 Diagnosis Procedure..................................................................................................................................................... 758 S TERMINAL CIRCUIT.......................................................................................................................................................... 759 Description............................................................................................................................................................. 759 Diagnosis Procedure..................................................................................................................................................... 759 WIRING DIAGRAM.................................................................................................................................................................. 760 CHARGING SYSTEM............................................................................................................................................................. 760 Wiring Diagram.......................................................................................................................................................... 760 SYMPTOM DIAGNOSIS............................................................................................................................................................... 766 CHARGING SYSTEM............................................................................................................................................................. 766 Symptom Table........................................................................................................................................................... 766 PRECAUTION...................................................................................................................................................................... 767 PRECAUTIONS................................................................................................................................................................. 767 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 767 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 767 Precaution for Power Generation Variable Voltage Control System......................................................................................................... 767 PREPARATION..................................................................................................................................................................... 768 PREPARATION................................................................................................................................................................. 768 Special Service Tool.................................................................................................................................................... 768 Commercial Service Tool................................................................................................................................................. 768 REMOVAL AND INSTALLATION........................................................................................................................................................ 769 GENERATOR................................................................................................................................................................... 769 Exploded View........................................................................................................................................................... 769 Removal and Installation................................................................................................................................................ 769 REMOVAL............................................................................................................................................................. 769 INSTALLATION........................................................................................................................................................ 769 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................................................................... 771 SERVICE DATA AND SPECIFICATIONS (SDS)....................................................................................................................................... 771 Generator............................................................................................................................................................... 771 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 CL...................................................................................................................................................................................... 772 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 772 SYMPTOM DIAGNOSIS............................................................................................................................................................... 773 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING........................................................................................................................ 773 NVH Troubleshooting Chart............................................................................................................................................... 773 CLUTCH.............................................................................................................................................................. 773 PRECAUTION...................................................................................................................................................................... 774 PRECAUTIONS................................................................................................................................................................. 774 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 774 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 774 Service Notice or Precautions........................................................................................................................................... 774 PREPARATION..................................................................................................................................................................... 775 PREPARATION................................................................................................................................................................. 775 Special Service Tool.................................................................................................................................................... 775 Commercial Service Tool................................................................................................................................................. 775 PERIODIC MAINTENANCE............................................................................................................................................................ 777 CLUTCH PEDAL................................................................................................................................................................ 777 On-Vehicle Inspection and Adjustment.................................................................................................................................... 777 CLUTCH FLUID................................................................................................................................................................ 778 Bleeding................................................................................................................................................................ 778 REMOVAL AND INSTALLATION........................................................................................................................................................ 779 CLUTCH PEDAL................................................................................................................................................................ 779 Exploded View........................................................................................................................................................... 779 Removal and Installation................................................................................................................................................ 779 REMOVAL............................................................................................................................................................. 779 INSTALLATION........................................................................................................................................................ 779 Inspection.............................................................................................................................................................. 779 INSPECTION AFTER REMOVAL............................................................................................................................................ 779 CLUTCH MASTER CYLINDER...................................................................................................................................................... 780 Exploded View........................................................................................................................................................... 780 Removal and Installation................................................................................................................................................ 780 REMOVAL............................................................................................................................................................. 780 INSTALLATION........................................................................................................................................................ 780 OPERATING CYLINDER.......................................................................................................................................................... 781 Exploded View........................................................................................................................................................... 781 Removal and Installation................................................................................................................................................ 781 REMOVAL............................................................................................................................................................. 781 INSTALLATION........................................................................................................................................................ 781 CLUTCH PIPING............................................................................................................................................................... 782 Exploded View........................................................................................................................................................... 782 Removal and Installation................................................................................................................................................ 782 UNIT REMOVAL AND INSTALLATION................................................................................................................................................... 783 CLUTCH RELEASE MECHANISM.................................................................................................................................................... 783 Exploded View........................................................................................................................................................... 783 Removal and Installation................................................................................................................................................ 783 REMOVAL............................................................................................................................................................. 783 INSTALLATION........................................................................................................................................................ 783 Inspection.............................................................................................................................................................. 784 INSPECTION AFTER REMOVAL............................................................................................................................................ 784 CLUTCH DISC, CLUTCH COVER................................................................................................................................................... 786 Exploded View........................................................................................................................................................... 786 Removal and Installation................................................................................................................................................ 786 REMOVAL............................................................................................................................................................. 786 INSTALLATION........................................................................................................................................................ 786 Inspection and Adjustment............................................................................................................................................... 787 INSPECTION AND ADJUSTMENT AFTER REMOVAL............................................................................................................................. 787 Clutch Disc..................................................................................................................................................... 787 Clutch Cover.................................................................................................................................................... 787 Flywheel........................................................................................................................................................ 788 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................................................................... 789 SERVICE DATA AND SPECIFICATIONS (SDS)....................................................................................................................................... 789 Clutch Control System................................................................................................................................................... 789 Clutch Master Cylinder.................................................................................................................................................. 789 Clutch Operating Cylinder............................................................................................................................................... 789 Clutch Disc............................................................................................................................................................. 789 Clutch Cover............................................................................................................................................................ 789 Clutch Pedal............................................................................................................................................................ 790 CO...................................................................................................................................................................................... 791 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 791 VQ40DE.......................................................................................................................................................................... 792 PRECAUTION.................................................................................................................................................................. 792 PRECAUTIONS............................................................................................................................................................. 792 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................................................... 792 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................ 792 Precaution for Liquid Gasket........................................................................................................................................ 792 REMOVAL OF LIQUID GASKET ....................................................................................................................................... 792 LIQUID GASKET APPLICATION PROCEDURE............................................................................................................................. 792 PREPARATION................................................................................................................................................................. 794 PREPARATION............................................................................................................................................................. 794 Special Service Tool................................................................................................................................................ 794 Commercial Service Tool............................................................................................................................................. 794 SYSTEM DESCRIPTION.......................................................................................................................................................... 796 COOLING SYSTEM.......................................................................................................................................................... 796 Cooling Circuit..................................................................................................................................................... 796 Schematic........................................................................................................................................................... 797 OVERHEATING CAUSE ANALYSIS.............................................................................................................................................. 798 Troubleshooting Chart............................................................................................................................................... 798 PERIODIC MAINTENANCE........................................................................................................................................................ 800 ENGINE COOLANT.......................................................................................................................................................... 800 System Inspection................................................................................................................................................... 800 CHECKING COOLING SYSTEM HOSES................................................................................................................................... 800 CHECKING RESERVOIR LEVEL........................................................................................................................................ 800 CHECKING COOLING SYSTEM FOR LEAKS............................................................................................................................... 800 CHECKING RESERVOIR CAP.......................................................................................................................................... 800 CHECKING RADIATOR CAP........................................................................................................................................... 801 CHECKING RADIATOR............................................................................................................................................... 801 Changing Engine Coolant............................................................................................................................................. 801 DRAINING ENGINE COOLANT......................................................................................................................................... 801 REFILLING ENGINE COOLANT........................................................................................................................................ 802 FLUSHING COOLING SYSTEM......................................................................................................................................... 804 REMOVAL AND INSTALLATION.................................................................................................................................................... 805 RADIATOR................................................................................................................................................................ 805 Exploded View....................................................................................................................................................... 805 Removal and Installation............................................................................................................................................ 805 REMOVAL......................................................................................................................................................... 805 INSTALLATION.................................................................................................................................................... 807 INSPECTION AFTER INSTALLATION................................................................................................................................... 807 ENGINE COOLING FAN...................................................................................................................................................... 808 Exploded View....................................................................................................................................................... 808 Removal and Installation (Crankshaft driven type)................................................................................................................... 808 REMOVAL......................................................................................................................................................... 808 INSPECTION AFTER REMOVAL........................................................................................................................................ 808 Fan Coupling................................................................................................................................................ 808 Fan Bracket................................................................................................................................................. 808 INSTALLATION.................................................................................................................................................... 809 INSPECTION AFTER INSTALLATION................................................................................................................................... 809 Removal and Installation (Motor driven type)........................................................................................................................ 809 REMOVAL......................................................................................................................................................... 809 INSTALLATION.................................................................................................................................................... 810 INSPECTION AFTER INSTALLATION................................................................................................................................... 810 WATER PUMP.............................................................................................................................................................. 811 Exploded View....................................................................................................................................................... 811 Removal and Installation............................................................................................................................................ 811 REMOVAL......................................................................................................................................................... 811 INSPECTION AFTER REMOVAL........................................................................................................................................ 813 INSTALLATION.................................................................................................................................................... 813 INSPECTION AFTER INSTALLATION................................................................................................................................... 815 WATER INLET AND THERMOSTAT ASSEMBLY..................................................................................................................................... 816 Exploded View....................................................................................................................................................... 816 Removal and Installation............................................................................................................................................ 816 REMOVAL......................................................................................................................................................... 816 INSPECTION AFTER REMOVAL........................................................................................................................................ 816 INSTALLATION.................................................................................................................................................... 817 INSPECTION AFTER INSTALLATION................................................................................................................................... 817 WATER OUTLET AND WATER PIPING........................................................................................................................................... 818 Exploded View....................................................................................................................................................... 818 Removal and Installation............................................................................................................................................ 818 REMOVAL......................................................................................................................................................... 818 INSTALLATION.................................................................................................................................................... 819 INSPECTION AFTER INSTALLATION................................................................................................................................... 819 SERVICE DATA AND SPECIFICATIONS (SDS)....................................................................................................................................... 820 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................................................................................... 820 Standard and Limit.................................................................................................................................................. 820 ENGINE COOLANT CAPACITY (APPROXIMATE)........................................................................................................................... 820 RADIATOR........................................................................................................................................................ 820 THERMOSTAT...................................................................................................................................................... 820 DEF..................................................................................................................................................................................... 821 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 821 BASIC INSPECTION................................................................................................................................................................ 823 DIAGNOSIS AND REPAIR WORKFLOW............................................................................................................................................... 823 Repair Work Flow........................................................................................................................................................ 823 DETAILED FLOW....................................................................................................................................................... 823 SYSTEM DESCRIPTION.............................................................................................................................................................. 824 MANUAL A/C IDENTIFICATION TABLE............................................................................................................................................. 824 Application Table....................................................................................................................................................... 824 REAR WINDOW DEFOGGER SYSTEM................................................................................................................................................. 825 System Diagram.......................................................................................................................................................... 825 System Description...................................................................................................................................................... 825 Operation Description............................................................................................................................................... 825 Timer Function...................................................................................................................................................... 825 INPUT/OUTPUT SIGNAL CHART........................................................................................................................................... 825 Component Parts Location................................................................................................................................................ 826 Component Description................................................................................................................................................... 826 DIAGNOSIS SYSTEM (BCM)...................................................................................................................................................... 827 COMMON ITEM............................................................................................................................................................. 827 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM).................................................................................................................. 827 APPLICATION ITEM................................................................................................................................................ 827 SYSTEM APPLICATION.............................................................................................................................................. 827 REAR DEFOGGER........................................................................................................................................................... 827 REAR DEFOGGER : CONSULT Function (BCM - REAR DEFOGGER).............................................................................................................. 828 DATA MONITOR.................................................................................................................................................... 828 ACTIVE TEST..................................................................................................................................................... 828 DTC/CIRCUIT DIAGNOSIS........................................................................................................................................................... 829 MANUAL A/C IDENTIFICATION TABLE............................................................................................................................................. 829 Application Table....................................................................................................................................................... 829 REAR WINDOW DEFOGGER SWITCH................................................................................................................................................. 830 Description............................................................................................................................................................. 830 Component Function Check................................................................................................................................................ 830 Diagnosis Procedure Front Air Control (Type 1).......................................................................................................................... 830 Diagnosis Procedure Front Air Control (Type 2).......................................................................................................................... 830 REAR WINDOW DEFOGGER RELAY.................................................................................................................................................. 832 Description............................................................................................................................................................. 832 Component Function Check................................................................................................................................................ 832 Diagnosis Procedure..................................................................................................................................................... 832 REAR WINDOW DEFOGGER POWER SUPPLY AND GROUND CIRCUIT........................................................................................................................ 833 Description............................................................................................................................................................. 833 Component Function Check................................................................................................................................................ 833 Diagnosis Procedure..................................................................................................................................................... 833 Component Inspection.................................................................................................................................................... 834 DOOR MIRROR DEFOGGER LH..................................................................................................................................................... 835 Description............................................................................................................................................................. 835 Component Function Check................................................................................................................................................ 835 Diagnosis Procedure..................................................................................................................................................... 835 Component Inspection.................................................................................................................................................... 837 DOOR MIRROR DEFOGGER RH..................................................................................................................................................... 838 Description............................................................................................................................................................. 838 Component Function Check................................................................................................................................................ 838 Diagnosis Procedure..................................................................................................................................................... 838 Component Inspection.................................................................................................................................................... 840 ECU DIAGNOSIS INFORMATION....................................................................................................................................................... 841 BCM (BODY CONTROL MODULE)................................................................................................................................................... 841 Reference Value......................................................................................................................................................... 841 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................ 841 Terminal Layout......................................................................................................................................................... 844 Physical Values......................................................................................................................................................... 844 WIRING DIAGRAM.................................................................................................................................................................. 850 REAR WINDOW DEFOGGER........................................................................................................................................................ 850 Wiring Diagram.......................................................................................................................................................... 850 SYMPTOM DIAGNOSIS............................................................................................................................................................... 858 REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER DO NOT OPERATE................................................................................................................ 858 Diagnosis Procedure..................................................................................................................................................... 858 REAR WINDOW DEFOGGER DOES NOT OPERATE BUT BOTH OF DOOR MIRROR DEFOGGER OPERATE.............................................................................................. 859 Diagnosis Procedure..................................................................................................................................................... 859 BOTH DOORS MIRROR DEFOGGER DON’T OPERATE BUT REAR WINDOW DEFOGGER OPERATES.................................................................................................. 860 Diagnosis Procedure..................................................................................................................................................... 860 DRIVER SIDE DOOR MIRROR DEFOGGER DOES NOT OPERATE........................................................................................................................... 861 Diagnosis Procedure..................................................................................................................................................... 861 PASSENGER SIDE DOOR MIRROR DEFOGGER DOES NOT OPERATE........................................................................................................................ 862 Diagnosis Procedure..................................................................................................................................................... 862 REAR WINDOW DEFOGGER SWITCH DOES NOT LIGHT, BUT REAR WINDOW DEFOGGER OPERATES............................................................................................... 863 Diagnosis Procedure..................................................................................................................................................... 863 PRECAUTION...................................................................................................................................................................... 864 PRECAUTIONS................................................................................................................................................................. 864 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 864 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 864 Handling for Adhesive and Primer........................................................................................................................................ 864 REMOVAL AND INSTALLATION........................................................................................................................................................ 865 REAR WINDOW DEFOGGER........................................................................................................................................................ 865 Filament Check.......................................................................................................................................................... 865 Filament Repair......................................................................................................................................................... 865 REPAIR EQUIPMENT.................................................................................................................................................... 865 REPAIRING PROCEDURE................................................................................................................................................. 866 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 DLK..................................................................................................................................................................................... 867 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 867 BASIC INSPECTION................................................................................................................................................................ 870 DIAGNOSIS AND REPAIR WORKFLOW............................................................................................................................................... 870 Work Flow............................................................................................................................................................... 870 OVERALL SEQUENCE.................................................................................................................................................... 870 DETAILED FLOW....................................................................................................................................................... 870 INSPECTION AND ADJUSTMENT................................................................................................................................................... 873 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT.......................................................................................................................... 873 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description........................................................................................................ 873 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Requirement......................................................................................... 873 SYSTEM DESCRIPTION.............................................................................................................................................................. 874 AUTOMATIC DOOR LOCKS........................................................................................................................................................ 874 System Diagram.......................................................................................................................................................... 874 System Description...................................................................................................................................................... 874 DOOR LOCK FUNCTION.................................................................................................................................................. 874 Functions Available by Operating the Door Lock and Unlock Switches on Driver Door and Passenger Door............................................................ 874 Functions Available by Operating the Key Cylinder Switch on Driver Door or Back Door............................................................................ 874 Selective Unlock Operation...................................................................................................................................... 874 AUTOMATIC DOOR LOCKS (LOCK OPERATION)............................................................................................................................... 874 Vehicle Speed Sensing Auto Door Lock*1.......................................................................................................................... 874 Setting change of Automatic Door Locks (LOCK) Function.......................................................................................................... 875 AUTOMATIC DOOR LOCKS (UNLOCK OPERATION)............................................................................................................................. 875 IGN OFF Interlock Door Unlock*1................................................................................................................................. 875 Setting change of Automatic Door Locks (UNLOCK) Function........................................................................................................ 875 Component Parts Location................................................................................................................................................ 876 Component Description................................................................................................................................................... 876 DOOR LOCK FUNCTION.......................................................................................................................................................... 878 DOOR LOCK AND UNLOCK SWITCH............................................................................................................................................. 878 DOOR LOCK AND UNLOCK SWITCH : System Diagram........................................................................................................................ 878 DOOR LOCK AND UNLOCK SWITCH : System Description.................................................................................................................... 878 DOOR LOCK FUNCTION.............................................................................................................................................. 878 Functions Available by Operating the Door Lock and Unlock Switches on Driver Door and Passenger Door........................................................ 878 Functions Available by Operating the Key Cylinder Switch on Driver Door or Back Door........................................................................ 878 Selective Unlock Operation.................................................................................................................................. 878 Key Reminder System......................................................................................................................................... 878 DOOR LOCK AND UNLOCK SWITCH : Component Parts Location.............................................................................................................. 879 DOOR LOCK AND UNLOCK SWITCH : Component Description................................................................................................................. 879 REMOTE KEYLESS ENTRY.................................................................................................................................................... 880 REMOTE KEYLESS ENTRY : System Diagram............................................................................................................................... 880 REMOTE KEYLESS ENTRY : System Description........................................................................................................................... 880 OPERATED PROCEDURE.............................................................................................................................................. 880 REMOTE CONTROL ENTRY FUNCTIONS.................................................................................................................................. 880 REMOTE CONTROL ENTRY OPERATION CONDITIONS....................................................................................................................... 880 AUTO LOCK FUNCTION.............................................................................................................................................. 880 Operation Description....................................................................................................................................... 880 ACTIVE CHECK FUNCTION........................................................................................................................................... 881 Operation Description....................................................................................................................................... 881 HAZARD AND HORN REMINDER........................................................................................................................................ 881 INTERIOR LAMP OPERATION......................................................................................................................................... 881 PANIC ALARM OPERATION........................................................................................................................................... 881 KEYLESS POWER WINDOW DOWN (OPEN) OPERATION...................................................................................................................... 881 REMOTE KEYLESS ENTRY : Component Parts Location..................................................................................................................... 882 REMOTE KEYLESS ENTRY : Component Description........................................................................................................................ 882 DIAGNOSIS SYSTEM (BCM)...................................................................................................................................................... 883 COMMON ITEM............................................................................................................................................................. 883 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM).................................................................................................................. 883 APPLICATION ITEM................................................................................................................................................ 883 SYSTEM APPLICATION.............................................................................................................................................. 883 DOOR LOCK............................................................................................................................................................... 883 DOOR LOCK : CONSULT Function (BCM - DOOR LOCK)...................................................................................................................... 884 DATA MONITOR.................................................................................................................................................... 884 ACTIVE TEST..................................................................................................................................................... 884 WORK SUPPORT.................................................................................................................................................... 884 MULTI REMOTE ENT........................................................................................................................................................ 884 MULTI REMOTE ENT : CONSULT Function (BCM - MULTI REMOTE ENT)........................................................................................................ 884 DATA MONITOR.................................................................................................................................................... 884 ACTIVE TEST..................................................................................................................................................... 885 WORK SUPPORT.................................................................................................................................................... 885 DTC/CIRCUIT DIAGNOSIS........................................................................................................................................................... 886 U1000 CAN COMM CIRCUIT...................................................................................................................................................... 886 Description............................................................................................................................................................. 886 DTC Logic............................................................................................................................................................... 886 DTC DETECTION LOGIC................................................................................................................................................. 886 Diagnosis Procedure..................................................................................................................................................... 886 U1010 CONTROL UNIT (CAN).................................................................................................................................................... 887 DTC Logic............................................................................................................................................................... 887 DTC DETECTION LOGIC................................................................................................................................................. 887 Diagnosis Procedure..................................................................................................................................................... 887 Special Repair Requirement.............................................................................................................................................. 887 POWER SUPPLY AND GROUND CIRCUIT............................................................................................................................................. 888 BCM (BODY CONTROL MODULE)............................................................................................................................................... 888 BCM (BODY CONTROL MODULE) : Diagnosis Procedure..................................................................................................................... 888 DOOR SWITCH................................................................................................................................................................. 890 Description............................................................................................................................................................. 890 Component Function Check................................................................................................................................................ 890 Diagnosis Procedure..................................................................................................................................................... 890 DOOR LOCK AND UNLOCK SWITCH................................................................................................................................................. 893 Description............................................................................................................................................................. 893 Component Function Check................................................................................................................................................ 893 Diagnosis Procedure..................................................................................................................................................... 893 KEY CYLINDER SWITCH......................................................................................................................................................... 897 DRIVER SIDE............................................................................................................................................................. 897 DRIVER SIDE : Description........................................................................................................................................... 897 DRIVER SIDE : Component Function Check.............................................................................................................................. 897 DRIVER SIDE : Diagnosis Procedure................................................................................................................................... 897 BACK DOOR............................................................................................................................................................... 899 BACK DOOR : Description............................................................................................................................................. 899 BACK DOOR : Component Function Check................................................................................................................................ 899 BACK DOOR : Diagnosis Procedure..................................................................................................................................... 899 DOOR LOCK ACTUATOR.......................................................................................................................................................... 902 DRIVER SIDE............................................................................................................................................................. 902 DRIVER SIDE : Description........................................................................................................................................... 902 DRIVER SIDE : Component Function Check.............................................................................................................................. 902 DRIVER SIDE : Diagnosis Procedure................................................................................................................................... 902 PASSENGER SIDE.......................................................................................................................................................... 903 PASSENGER SIDE : Description........................................................................................................................................ 903 PASSENGER SIDE : Component Function Check........................................................................................................................... 903 PASSENGER SIDE : Diagnosis Procedure................................................................................................................................ 903 REAR LH................................................................................................................................................................. 904 REAR LH : Description............................................................................................................................................... 904 REAR LH : Component Function Check.................................................................................................................................. 904 REAR LH : Diagnosis Procedure....................................................................................................................................... 904 REAR RH................................................................................................................................................................. 905 REAR RH : Description............................................................................................................................................... 905 REAR RH : Component Function Check.................................................................................................................................. 906 REAR RH : Diagnosis Procedure....................................................................................................................................... 906 BACK DOOR............................................................................................................................................................... 907 BACK DOOR : Description............................................................................................................................................. 907 BACK DOOR : Component Function Check................................................................................................................................ 907 BACK DOOR : Diagnosis Procedure..................................................................................................................................... 907 REMOTE KEYLESS ENTRY RECEIVER............................................................................................................................................... 909 Description............................................................................................................................................................. 909 Component Function Check................................................................................................................................................ 909 Diagnosis Procedure..................................................................................................................................................... 909 KEYFOB BATTERY AND FUNCTION................................................................................................................................................. 911 Description............................................................................................................................................................. 911 Component Function Check................................................................................................................................................ 911 Diagnosis Procedure..................................................................................................................................................... 911 HORN FUNCTION............................................................................................................................................................... 913 Description............................................................................................................................................................. 913 Component Function Check................................................................................................................................................ 913 Diagnosis Procedure..................................................................................................................................................... 913 WARNING CHIME FUNCTION...................................................................................................................................................... 915 Description............................................................................................................................................................. 915 Component Function Check................................................................................................................................................ 915 Diagnosis Procedure..................................................................................................................................................... 915 HAZARD FUNCTION............................................................................................................................................................. 916 Description............................................................................................................................................................. 916 Component Function Check................................................................................................................................................ 916 Diagnosis Procedure..................................................................................................................................................... 916 KEY SWITCH (BCM INPUT)...................................................................................................................................................... 917 Diagnosis Procedure..................................................................................................................................................... 917 HEADLAMP FUNCTION........................................................................................................................................................... 918 Diagnosis Procedure..................................................................................................................................................... 918 MAP LAMP AND IGNITION KEYHOLE ILLUMINATION FUNCTION......................................................................................................................... 919 Diagnosis Procedure..................................................................................................................................................... 919 KEYFOB ID SET UP WITH CONSULT............................................................................................................................................... 920 ID Code Entry Procedure................................................................................................................................................. 920 KEYFOB ID SET UP WITH CONSULT....................................................................................................................................... 920 KEYFOB ID SET UP WITHOUT CONSULT............................................................................................................................................ 921 ID Code Entry Procedure................................................................................................................................................. 921 KEYFOB ID SET UP WITHOUT CONSULT.................................................................................................................................... 921 ECU DIAGNOSIS INFORMATION....................................................................................................................................................... 923 BCM (BODY CONTROL MODULE)................................................................................................................................................... 923 Reference Value......................................................................................................................................................... 923 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................ 923 Terminal Layout......................................................................................................................................................... 926 Physical Values......................................................................................................................................................... 926 Fail Safe............................................................................................................................................................... 931 Fail-safe index..................................................................................................................................................... 931 DTC Inspection Priority Chart........................................................................................................................................... 931 DTC Index............................................................................................................................................................... 932 WIRING DIAGRAM.................................................................................................................................................................. 934 POWER DOOR LOCK SYSTEM...................................................................................................................................................... 934 Wiring Diagram.......................................................................................................................................................... 934 REMOTE KEYLESS ENTRY SYSTEM................................................................................................................................................. 945 Wiring Diagram.......................................................................................................................................................... 945 SYMPTOM DIAGNOSIS............................................................................................................................................................... 955 DOOR LOCK................................................................................................................................................................... 955 Symptom Table........................................................................................................................................................... 955 DOOR LOCK SYSTEM.................................................................................................................................................... 955 REMOTE KEYLESS ENTRY SYSTEM................................................................................................................................................. 956 Symptom Table........................................................................................................................................................... 956 REMOTE KEYLESS ENTRY SYSTEM......................................................................................................................................... 956 SQUEAK AND RATTLE TROUBLE DIAGNOSES......................................................................................................................................... 958 Work Flow............................................................................................................................................................... 958 CUSTOMER INTERVIEW.................................................................................................................................................. 958 DUPLICATE THE NOISE AND TEST DRIVE.................................................................................................................................. 958 CHECK RELATED SERVICE BULLETINS..................................................................................................................................... 959 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE........................................................................................................................ 959 REPAIR THE CAUSE ................................................................................................................................................... 959 CONFIRM THE REPAIR.................................................................................................................................................. 960 Generic Squeak and Rattle Troubleshooting............................................................................................................................... 960 INSTRUMENT PANEL.................................................................................................................................................... 960 CENTER CONSOLE...................................................................................................................................................... 960 DOORS............................................................................................................................................................... 960 TRUNK............................................................................................................................................................... 960 SUNROOF/HEADLINING.................................................................................................................................................. 961 OVERHEAD CONSOLE (FRONT AND REAR)................................................................................................................................... 961 SEATS............................................................................................................................................................... 961 UNDERHOOD........................................................................................................................................................... 961 Diagnostic Worksheet.................................................................................................................................................... 962 PRECAUTION...................................................................................................................................................................... 964 PRECAUTIONS................................................................................................................................................................. 964 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".............................................................................. 964 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS.................................................................................................... 964 Precaution for Servicing Doors and locks................................................................................................................................ 964 PREPARATION..................................................................................................................................................................... 965 PREPARATION................................................................................................................................................................. 965 Special Service Tool.................................................................................................................................................... 965 Commercial Service Tool................................................................................................................................................. 965 REMOVAL AND INSTALLATION........................................................................................................................................................ 966 HOOD........................................................................................................................................................................ 966 Fitting Adjustment...................................................................................................................................................... 966 CLEARANCE AND SURFACE HEIGHT ADJUSTMENT............................................................................................................................. 966 HOOD LOCK ADJUSTMENT................................................................................................................................................ 967 Removal and Installation of Hood Assembly............................................................................................................................... 967 REMOVAL............................................................................................................................................................. 967 INSTALLATION........................................................................................................................................................ 968 Removal and Installation of Hood Lock Control........................................................................................................................... 968 REMOVAL............................................................................................................................................................. 968 INSTALLATION........................................................................................................................................................ 968 Hood Lock Control Inspection............................................................................................................................................ 969 DOOR........................................................................................................................................................................ 970 Fitting Adjustment...................................................................................................................................................... 970 FRONT DOOR.......................................................................................................................................................... 970 Longitudinal clearance and surface height adjustment at front end............................................................................................... 970 REAR DOOR........................................................................................................................................................... 970 Longitudinal clearance and surface height adjustment at front end............................................................................................... 970 BACK DOOR........................................................................................................................................................... 970 Longitudinal clearance and surface height adjustment ........................................................................................................... 970 STRIKER ADJUSTMENT.................................................................................................................................................. 971 Body Side Doors................................................................................................................................................. 971 Back Door....................................................................................................................................................... 972 Removal and Installation................................................................................................................................................ 972 FRONT DOOR.......................................................................................................................................................... 972 Removal......................................................................................................................................................... 972 Installation.................................................................................................................................................... 973 REAR DOOR........................................................................................................................................................... 973 Removal......................................................................................................................................................... 973 Installation.................................................................................................................................................... 973 BACK DOOR........................................................................................................................................................... 974 Removal......................................................................................................................................................... 974 Installation.................................................................................................................................................... 974 Back Door Stay Disposal................................................................................................................................................. 974 FRONT DOOR LOCK............................................................................................................................................................. 975 Component Structure..................................................................................................................................................... 975 Removal and Installation................................................................................................................................................ 975 REMOVAL............................................................................................................................................................. 975 INSTALLATION........................................................................................................................................................ 977 Disassembly and Assembly................................................................................................................................................ 977 DOOR KEY CYLINDER ASSEMBLY.......................................................................................................................................... 977 REAR DOOR LOCK.............................................................................................................................................................. 978 Component Structure..................................................................................................................................................... 978 Removal and Installation................................................................................................................................................ 978 REMOVAL............................................................................................................................................................. 978 INSTALLATION........................................................................................................................................................ 978 BACK DOOR LOCK.............................................................................................................................................................. 979 Component Structure..................................................................................................................................................... 979 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 DLN..................................................................................................................................................................................... 980 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents................................................................................................................................................................... 980 TRANSFER: TX15B................................................................................................................................................................. 986 BASIC INSPECTION............................................................................................................................................................ 986 DIAGNOSIS AND REPAIR WORKFLOW........................................................................................................................................... 986 Work Flow........................................................................................................................................................... 986 WORK FLOW....................................................................................................................................................... 986 DETAILED FLOW................................................................................................................................................... 986 SYSTEM DESCRIPTION.......................................................................................................................................................... 988 4WD SYSTEM.............................................................................................................................................................. 988 System Diagram...................................................................................................................................................... 988 COMPONENT DESCRIPTION........................................................................................................................................... 988 System Description.................................................................................................................................................. 989 TRANSFER CONTROL DEVICE......................................................................................................................................... 989 Actuator Motor.............................................................................................................................................. 989 Actuator Position Switch.................................................................................................................................... 989 WAIT DETECTION SWITCH........................................................................................................................................... 989 4LO SWITCH...................................................................................................................................................... 989 ATP SWITCH (A/T MODELS)......................................................................................................................................... 989 PNP SWITCH (M/T models)......................................................................................................................................... 989 TRANSFER CONTROL UNIT........................................................................................................................................... 989 TRANSFER SHIFT HIGH AND LOW RELAYS.............................................................................................................................. 989 TRANSFER SHUT OFF RELAYS........................................................................................................................................ 989 4WD SHIFT SWITCH AND INDICATOR LAMP............................................................................................................................. 989 4WD Shift Switch............................................................................................................................................ 990 4WD Shift Indicator Lamp.................................................................................................................................... 990 4LO Indicator Lamp.......................................................................................................................................... 990 4WD WARNING LAMP................................................................................................................................................ 990 4WD Warning Lamp Indication................................................................................................................................. 990 ATP WARNING LAMP (A/T MODELS)................................................................................................................................... 990 Component Parts Location............................................................................................................................................ 991 CAN Communication................................................................................................................................................... 992 Cross-Sectional View................................................................................................................................................ 992 Power Transfer...................................................................................................................................................... 993 POWER TRANSFER DIAGRAM.......................................................................................................................................... 993 POWER TRANSFER FLOW............................................................................................................................................. 993 DIAGNOSIS SYSTEM (TRANSFER CONTROL UNIT)................................................................................................................................ 995 CONSULT Function (ALL MODE AWD/4WD)................................................................................................................................. 995 FUNCTION........................................................................................................................................................ 995 SELF DIAGNOSTIC RESULT.......................................................................................................................................... 995 Operation Procedure......................................................................................................................................... 995 How to Erase Self-diagnostic Results........................................................................................................................ 995 <GRAPHIC> SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT)........................................................................................................... 995 Description................................................................................................................................................. 995 Diagnostic Procedure (A/T models)........................................................................................................................... 995 Diagnostic Procedure (M/T models)........................................................................................................................... 996 Self-diagnosis example...................................................................................................................................... 996 DATA MONITOR.................................................................................................................................................... 996 Operation Procedure......................................................................................................................................... 996 Display Item List........................................................................................................................................... 996 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.................................................................................................................... 998 NVH Troubleshooting Chart........................................................................................................................................... 998 DTC/CIRCUIT DIAGNOSIS....................................................................................................................................................... 999 P1801, P1811 POWER SUPPLY CIRCUIT FOR TRANSFER CONTROL UNIT............................................................................................................. 999 Description......................................................................................................................................................... 999 DTC Logic........................................................................................................................................................... 999 DTC DETECTION LOGIC............................................................................................................................................. 999 DTC CONFIRMATION PROCEDURE...................................................................................................................................... 999 Diagnosis Procedure................................................................................................................................................. 999 Component Inspection................................................................................................................................................1001 P1802 - P1804, P1809 TRANSFER CONTROL UNIT..............................................................................................................................1002 Description.........................................................................................................................................................1002 DTC Logic...........................................................................................................................................................1002 DTC DETECTION LOGIC.............................................................................................................................................1002 DTC CONFIRMATION PROCEDURE......................................................................................................................................1002 Diagnosis Procedure.................................................................................................................................................1002 P1807 VEHICLE SPEED SENSOR (A/T)........................................................................................................................................1004 Description.........................................................................................................................................................1004 DTC Logic...........................................................................................................................................................1004 DTC DETECTION LOGIC.............................................................................................................................................1004 DTC CONFIRMATION PROCEDURE......................................................................................................................................1004 Diagnosis Procedure.................................................................................................................................................1004 P1808 VEHICLE SPEED SENSOR (ABS)........................................................................................................................................1005 Description.........................................................................................................................................................1005 DTC Logic...........................................................................................................................................................1005 DTC DETECTION LOGIC.............................................................................................................................................1005 DTC CONFIRMATION PROCEDURE......................................................................................................................................1005 Diagnosis Procedure.................................................................................................................................................1005 P1810 4 LO SWITCH.......................................................................................................................................................1006 Description.........................................................................................................................................................1006 DTC Logic...........................................................................................................................................................1006 DTC DETECTION LOGIC.............................................................................................................................................1006 DTC CONFIRMATION PROCEDURE......................................................................................................................................1006 Diagnosis Procedure.................................................................................................................................................1006 Component Inspection................................................................................................................................................1008 P1813 4WD SHIFT SWITCH..................................................................................................................................................1009 Description.........................................................................................................................................................1009 DTC Logic...........................................................................................................................................................1009 DTC DETECTION LOGIC.............................................................................................................................................1009 DTC CONFIRMATION PROCEDURE......................................................................................................................................1009 Diagnosis Procedure.................................................................................................................................................1009 Component Inspection................................................................................................................................................1011 P1814 WAIT DETECTION SWITCH.............................................................................................................................................1012 Description.........................................................................................................................................................1012 DTC Logic...........................................................................................................................................................1012 DTC DETECTION LOGIC.............................................................................................................................................1012 DTC CONFIRMATION PROCEDURE......................................................................................................................................1012 Diagnosis Procedure.................................................................................................................................................1012 Component Inspection................................................................................................................................................1014 P1816 PNP SWITCH (A/T)..................................................................................................................................................1015 Description.........................................................................................................................................................1015 DTC Logic...........................................................................................................................................................1015 DTC DETECTION LOGIC.............................................................................................................................................1015 DTC CONFIRMATION PROCEDURE......................................................................................................................................1015 Diagnosis Procedure.................................................................................................................................................1015 P1816 PNP SWITCH (M/T)..................................................................................................................................................1016 Description.........................................................................................................................................................1016 DTC Logic...........................................................................................................................................................1016 DTC DETECTION LOGIC.............................................................................................................................................1016 DTC CONFIRMATION PROCEDURE......................................................................................................................................1016 Diagnosis Procedure.................................................................................................................................................1016 Component Inspection................................................................................................................................................1017 P1817 ACTUATOR MOTOR....................................................................................................................................................1019 Description.........................................................................................................................................................1019 DTC Logic...........................................................................................................................................................1019 DTC DETECTION LOGIC.............................................................................................................................................1019 DTC CONFIRMATION PROCEDURE......................................................................................................................................1019 Diagnosis Procedure.................................................................................................................................................1019 Component Inspection................................................................................................................................................1024 ACTUATOR MOTOR..................................................................................................................................................1024 TRANSFER RELAY..................................................................................................................................................1024 P1818 ACTUATOR POSITION SWITCH..........................................................................................................................................1026 Description.........................................................................................................................................................1026 DTC Logic...........................................................................................................................................................1026 DTC DETECTION LOGIC.............................................................................................................................................1026 DTC CONFIRMATION PROCEDURE......................................................................................................................................1026 Diagnosis Procedure.................................................................................................................................................1026 P1819 TRANSFER CONTROL DEVICE...........................................................................................................................................1029 Description.........................................................................................................................................................1029 DTC Logic...........................................................................................................................................................1029 DTC DETECTION LOGIC.............................................................................................................................................1029 DTC CONFIRMATION PROCEDURE......................................................................................................................................1029 Diagnosis Procedure.................................................................................................................................................1029 P1820 ENGINE SPEED SIGNAL...............................................................................................................................................1032 Description.........................................................................................................................................................1032 DTC Logic...........................................................................................................................................................1032 DTC DETECTION LOGIC.............................................................................................................................................1032 DTC CONFIRMATION PROCEDURE......................................................................................................................................1032 Diagnosis Procedure.................................................................................................................................................1032 U1000 CAN COMM CIRCUIT..................................................................................................................................................1033 Description.........................................................................................................................................................1033 DTC Logic...........................................................................................................................................................1033 DTC DETECTION LOGIC.............................................................................................................................................1033 DTC CONFIRMATION PROCEDURE......................................................................................................................................1033 Diagnosis Procedure.................................................................................................................................................1033 U1010 CONTROL UNIT (CAN)................................................................................................................................................1034 Description.........................................................................................................................................................1034 DTC Logic...........................................................................................................................................................1034 DTC DETECTION LOGIC.............................................................................................................................................1034 DTC CONFIRMATION PROCEDURE......................................................................................................................................1034 Diagnosis Procedure.................................................................................................................................................1034 ECU DIAGNOSIS INFORMATION...................................................................................................................................................1035 TRANSFER CONTROL UNIT...................................................................................................................................................1035 Reference Value.....................................................................................................................................................1035 VALUE ON THE DIAGNOSIS TOOL.....................................................................................................................................1035 CONSULT data monitor item...................................................................................................................................1035 PHYSICAL VALUES.................................................................................................................................................1036 Terminal Layout.............................................................................................................................................1037 DTC Index...........................................................................................................................................................1038 DTC CHART.......................................................................................................................................................1038 FLASH CODE CHART................................................................................................................................................1040 WIRING DIAGRAM..............................................................................................................................................................1042 PART TIME 4WD SYSTEM....................................................................................................................................................1042 Wiring Diagram......................................................................................................................................................1042 SYMPTOM DIAGNOSIS...........................................................................................................................................................1051 4WD SYSTEM SYMPTOMS.....................................................................................................................................................1051 Symptom Table.......................................................................................................................................................1051 4WD WARNING LAMP DOES NOT TURN ON.......................................................................................................................................1052 Description.........................................................................................................................................................1052 Diagnosis Procedure.................................................................................................................................................1052 4WD SHIFT INDICATOR LAMP AND 4LO INDICATOR LAMP DO NOT TURN ON..........................................................................................................1053 Description.........................................................................................................................................................1053 Diagnosis Procedure.................................................................................................................................................1053 4WD SHIFT INDICATOR LAMP OR 4LO INDICATOR LAMP DO NOT CHANGE............................................................................................................1054 Description.........................................................................................................................................................1054 Diagnosis Procedure.................................................................................................................................................1054 ATP WARNING LAMP DOES NOT TURN ON.......................................................................................................................................1056 Description.........................................................................................................................................................1056 Diagnosis Procedure.................................................................................................................................................1056 4WD SHIFT INDICATOR LAMP KEEPS FLASHING.................................................................................................................................1057 Description.........................................................................................................................................................1057 Diagnosis Procedure.................................................................................................................................................1057 4WD WARNING LAMP FLASHES SLOWLY.........................................................................................................................................1058 Description.........................................................................................................................................................1058 Diagnosis Procedure.................................................................................................................................................1058 ATP SWITCH..............................................................................................................................................................1059 Description.........................................................................................................................................................1059 Diagnosis Procedure.................................................................................................................................................1059 Component Inspection................................................................................................................................................1061 PRECAUTION..................................................................................................................................................................1062 PRECAUTIONS.............................................................................................................................................................1062 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1062 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1062 Precaution for Transfer Assembly and Transfer Control Unit Replacement..............................................................................................1062 CHECK 4WD SHIFT INDICATOR PATTERN...............................................................................................................................1062 METHOD FOR ADJUSTMENT WITH 4WD SHIFT SWITCH AT “2WD”............................................................................................................1063 Select Adjustment Pattern...................................................................................................................................1063 Pattern A...................................................................................................................................................1064 Pattern B...................................................................................................................................................1064 METHOD FOR ADJUSTMENT WITH 4WD SHIFT SWITCH AT “4H” OR “4LO”....................................................................................................1064 Precaution..........................................................................................................................................................1064 Service Notice......................................................................................................................................................1065 PREPARATION.................................................................................................................................................................1066 PREPARATION.............................................................................................................................................................1066 Special Service Tool................................................................................................................................................1066 Commercial Service Tool.............................................................................................................................................1068 PERIODIC MAINTENANCE........................................................................................................................................................1069 TRANSFER FLUID..........................................................................................................................................................1069 Replacement.........................................................................................................................................................1069 DRAINING........................................................................................................................................................1069 FILLING.........................................................................................................................................................1069 Inspection..........................................................................................................................................................1069 FLUID LEAKAGE AND FLUID LEVEL...................................................................................................................................1069 REMOVAL AND INSTALLATION....................................................................................................................................................1070 TRANSFER CONTROL UNIT...................................................................................................................................................1070 Removal and Installation............................................................................................................................................1070 REMOVAL.........................................................................................................................................................1070 INSTALLATION....................................................................................................................................................1070 FRONT OIL SEAL..........................................................................................................................................................1071 Removal and Installation............................................................................................................................................1071 REMOVAL.........................................................................................................................................................1071 INSTALLATION....................................................................................................................................................1071 REAR OIL SEAL...........................................................................................................................................................1073 Removal and Installation............................................................................................................................................1073 REMOVAL.........................................................................................................................................................1073 INSTALLATION....................................................................................................................................................1073 TRANSFER CONTROL DEVICE.................................................................................................................................................1075 Removal and Installation............................................................................................................................................1075 REMOVAL.........................................................................................................................................................1075 INSTALLATION....................................................................................................................................................1075 AIR BREATHER HOSE.......................................................................................................................................................1077 Removal and Installation............................................................................................................................................1077 COMPONENTS......................................................................................................................................................1077 REMOVAL.........................................................................................................................................................1077 INSTALLATION....................................................................................................................................................1077 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1079 TRANSFER ASSEMBLY.......................................................................................................................................................1079 Removal and Installation............................................................................................................................................1079 REMOVAL.........................................................................................................................................................1079 INSTALLATION....................................................................................................................................................1079 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1080 TRANSFER ASSEMBLY.......................................................................................................................................................1080 Exploded View.......................................................................................................................................................1080 COMPONENTS......................................................................................................................................................1080 Disassembly and Assembly............................................................................................................................................1081 DISASSEMBLY.....................................................................................................................................................1081 INSPECTION AFTER DISASSEMBLY ...................................................................................................................................1087 Case........................................................................................................................................................1087 Sleeve......................................................................................................................................................1087 Gear, Shaft and Drive Chain.................................................................................................................................1087 Bearing.....................................................................................................................................................1088 ASSEMBLY........................................................................................................................................................1088 PLANETARY CARRIER.......................................................................................................................................................1097 Disassembly and Assembly............................................................................................................................................1097 DISASSEMBLY.....................................................................................................................................................1097 INSPECTION AFTER DISASSEMBLY....................................................................................................................................1098 Bearing.....................................................................................................................................................1098 Planetary Carrier...........................................................................................................................................1098 Sun Gear....................................................................................................................................................1098 Internal Gear...............................................................................................................................................1098 ASSEMBLY........................................................................................................................................................1099 FRONT DRIVE SHAFT.......................................................................................................................................................1101 Disassembly and Assembly............................................................................................................................................1101 DISASSEMBLY.....................................................................................................................................................1101 INSPECTION AFTER DISASSEMBLY....................................................................................................................................1101 Front Drive Shaft...........................................................................................................................................1101 Bearing.....................................................................................................................................................1101 ASSEMBLY........................................................................................................................................................1101 SHIFT CONTROL...........................................................................................................................................................1103 Disassembly and Assembly............................................................................................................................................1103 DISASSEMBLY (A/T MODELS)........................................................................................................................................1103 DISASSEMBLY (M/T MODELS)........................................................................................................................................1103 INSPECTION AFTER DISASSEMBLY....................................................................................................................................1103 Shift Fork..................................................................................................................................................1103 Shift Rod and Fork Components...............................................................................................................................1104 ASSEMBLY (A/T MODELS)...........................................................................................................................................1104 ASSEMBLY (M/T MODELS)...........................................................................................................................................1105 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1106 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1106 General Specification...............................................................................................................................................1106 Inspection and Adjustment...........................................................................................................................................1106 PINION GEAR END PLAY............................................................................................................................................1106 CLEARANCE BETWEEN SHIFT FORK AND SLEEVE.........................................................................................................................1106 PROPELLER SHAFT: 2F1310.........................................................................................................................................................1107 PRECAUTION..................................................................................................................................................................1107 PRECAUTIONS.............................................................................................................................................................1107 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1107 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1107 PREPARATION.................................................................................................................................................................1108 PREPARATION.............................................................................................................................................................1108 Commercial Service Tool.............................................................................................................................................1108 SYSTEM DESCRIPTION..........................................................................................................................................................1109 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................................................................1109 NVH Troubleshooting Chart...........................................................................................................................................1109 BASIC INSPECTION............................................................................................................................................................1110 PROPELLER SHAFT ASSEMBLY................................................................................................................................................1110 Inspection..........................................................................................................................................................1110 APPEARANCE AND NOISE INSPECTION.................................................................................................................................1110 PROPELLER SHAFT VIBRATION.......................................................................................................................................1110 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1111 PROPELLER SHAFT.........................................................................................................................................................1111 Removal and Installation............................................................................................................................................1111 COMPONENTS......................................................................................................................................................1111 REMOVAL.........................................................................................................................................................1111 INSPECTION .....................................................................................................................................................1111 INSTALLATION....................................................................................................................................................1112 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1113 PROPELLER SHAFT.........................................................................................................................................................1113 Disassembly and Assembly............................................................................................................................................1113 DISASSEMBLY.....................................................................................................................................................1113 Journal.....................................................................................................................................................1113 ASSEMBLY........................................................................................................................................................1113 Journal.....................................................................................................................................................1114 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1115 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1115 General Specification...............................................................................................................................................1115 PROPELLER SHAFT RUNOUT..........................................................................................................................................1115 PROPELLER SHAFT JOINT FLEX EFFORT...............................................................................................................................1115 JOURNAL AXIAL PLAY..............................................................................................................................................1115 Snap Ring...........................................................................................................................................................1115 PROPELLER SHAFT: 2S1330.........................................................................................................................................................1116 PRECAUTION..................................................................................................................................................................1116 PRECAUTIONS.............................................................................................................................................................1116 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1116 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1116 PREPARATION.................................................................................................................................................................1117 PREPARATION.............................................................................................................................................................1117 Commercial Service Tool.............................................................................................................................................1117 SYSTEM DESCRIPTION..........................................................................................................................................................1118 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................................................................1118 NVH Troubleshooting Chart...........................................................................................................................................1118 BASIC INSPECTION............................................................................................................................................................1119 PROPELLER SHAFT ASSEMBLY................................................................................................................................................1119 Inspection..........................................................................................................................................................1119 APPEARANCE AND NOISE INSPECTION.................................................................................................................................1119 PROPELLER SHAFT VIBRATION.......................................................................................................................................1119 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1120 PROPELLER SHAFT.........................................................................................................................................................1120 Removal and Installation............................................................................................................................................1120 COMPONENTS......................................................................................................................................................1120 REMOVAL.........................................................................................................................................................1120 INSPECTION .....................................................................................................................................................1120 INSTALLATION....................................................................................................................................................1121 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1122 PROPELLER SHAFT.........................................................................................................................................................1122 Disassembly and Assembly............................................................................................................................................1122 DISASSEMBLY.....................................................................................................................................................1122 Journal.....................................................................................................................................................1122 ASSEMBLY........................................................................................................................................................1122 Journal.....................................................................................................................................................1123 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1124 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1124 General Specification...............................................................................................................................................1124 PROPELLER SHAFT RUNOUT..........................................................................................................................................1124 PROPELLER SHAFT JOINT FLEX EFFORT...............................................................................................................................1124 JOURNAL AXIAL PLAY..............................................................................................................................................1124 Snap Ring...........................................................................................................................................................1124 2S1330-BJ100 ...................................................................................................................................................................1125 PRECAUTION..................................................................................................................................................................1125 PRECAUTIONS.............................................................................................................................................................1125 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1125 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1125 PREPARATION.................................................................................................................................................................1126 PREPARATION.............................................................................................................................................................1126 Commercial Service Tool.............................................................................................................................................1126 SYSTEM DESCRIPTION..........................................................................................................................................................1127 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................................................................1127 NVH Troubleshooting Chart...........................................................................................................................................1127 BASIC INSPECTION............................................................................................................................................................1128 PROPELLER SHAFT ASSEMBLY................................................................................................................................................1128 Inspection..........................................................................................................................................................1128 APPEARANCE AND NOISE INSPECTION.................................................................................................................................1128 PROPELLER SHAFT VIBRATION.......................................................................................................................................1128 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1129 PROPELLER SHAFT.........................................................................................................................................................1129 Removal and Installation............................................................................................................................................1129 COMPONENTS......................................................................................................................................................1129 REMOVAL.........................................................................................................................................................1129 INSPECTION .....................................................................................................................................................1129 INSTALLATION....................................................................................................................................................1130 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1131 PROPELLER SHAFT.........................................................................................................................................................1131 Disassembly and Assembly............................................................................................................................................1131 DISASSEMBLY.....................................................................................................................................................1131 Journal.....................................................................................................................................................1131 ASSEMBLY........................................................................................................................................................1131 Journal.....................................................................................................................................................1132 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1133 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1133 General Specification...............................................................................................................................................1133 PROPELLER SHAFT RUNOUT..........................................................................................................................................1133 PROPELLER SHAFT JOINT FLEX EFFORT...............................................................................................................................1133 JOURNAL AXIAL PLAY..............................................................................................................................................1133 Snap Ring...........................................................................................................................................................1133 FRONT FINAL DRIVE: R180A........................................................................................................................................................1134 PRECAUTION..................................................................................................................................................................1134 PRECAUTIONS.............................................................................................................................................................1134 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1134 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1134 Precaution for Servicing Front Final Drive..........................................................................................................................1134 PREPARATION.................................................................................................................................................................1135 PREPARATION.............................................................................................................................................................1135 Special Service Tool................................................................................................................................................1135 Commercial Service Tool.............................................................................................................................................1137 SYSTEM DESCRIPTION..........................................................................................................................................................1138 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING....................................................................................................................1138 NVH Troubleshooting Chart...........................................................................................................................................1138 DESCRIPTION.............................................................................................................................................................1139 Cross-Sectional View................................................................................................................................................1139 PERIODIC MAINTENANCE........................................................................................................................................................1140 DIFFERENTIAL GEAR OIL...................................................................................................................................................1140 Changing Differential Gear Oil......................................................................................................................................1140 DRAINING........................................................................................................................................................1140 FILLING.........................................................................................................................................................1140 Checking Differential Gear Oil......................................................................................................................................1140 DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL.........................................................................................................................1140 REMOVAL AND INSTALLATION....................................................................................................................................................1141 FRONT OIL SEAL..........................................................................................................................................................1141 Removal and Installation............................................................................................................................................1141 REMOVAL.........................................................................................................................................................1141 INSTALLATION....................................................................................................................................................1141 SIDE OIL SEAL...........................................................................................................................................................1143 Removal and Installation............................................................................................................................................1143 REMOVAL.........................................................................................................................................................1143 INSTALLATION....................................................................................................................................................1143 CARRIER COVER...........................................................................................................................................................1144 Removal and Installation............................................................................................................................................1144 REMOVAL.........................................................................................................................................................1144 INSTALLATION....................................................................................................................................................1144 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1145 FRONT FINAL DRIVE ASSEMBLY..............................................................................................................................................1145 Removal and Installation............................................................................................................................................1145 REMOVAL.........................................................................................................................................................1145 INSTALLATION....................................................................................................................................................1146 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1147 FRONT FINAL DRIVE.......................................................................................................................................................1147 Disassembly and Assembly............................................................................................................................................1147 COMPONENTS......................................................................................................................................................1147 ASSEMBLY INSPECTION AND ADJUSTMENT..............................................................................................................................1148 Total Preload Torque........................................................................................................................................1148 Drive Gear Runout...........................................................................................................................................1148 Tooth Contact...............................................................................................................................................1149 Backlash....................................................................................................................................................1150 Companion Flange Runout.....................................................................................................................................1150 DISASSEMBLY.....................................................................................................................................................1150 Differential side shaft.....................................................................................................................................1150 Differential Assembly.......................................................................................................................................1152 Drive Pinion Assembly.......................................................................................................................................1154 INSPECTION AFTER DISASSEMBLY....................................................................................................................................1155 Drive Pinion and Drive Gear.................................................................................................................................1155 Bearing.....................................................................................................................................................1155 Side Gear and Pinion Mate Gear..............................................................................................................................1155 Side Gear Thrust Washer and Pinion Mate Thrust Washer.......................................................................................................1155 Gear Carrier................................................................................................................................................1155 Companion Flange............................................................................................................................................1155 ADJUSTING AND SELECTING WASHERS.................................................................................................................................1155 Side Gear Back Clearance....................................................................................................................................1155 Drive Pinion Height.........................................................................................................................................1156 ASSEMBLY........................................................................................................................................................1159 Drive Pinion Assembly.......................................................................................................................................1159 Differential Assembly.......................................................................................................................................1161 Differential side shaft.....................................................................................................................................1164 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1166 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1166 General Specification...............................................................................................................................................1166 Inspection and Adjustment...........................................................................................................................................1166 DRIVE GEAR RUNOUT...............................................................................................................................................1166 SIDE GEAR CLEARANCE.............................................................................................................................................1166 PRELOAD TORQUE..................................................................................................................................................1166 BACKLASH........................................................................................................................................................1166 COMPANION FLANGE RUNOUT.........................................................................................................................................1166 SELECTIVE PARTS.................................................................................................................................................1166 Drive Pinion Height Adjusting Washer........................................................................................................................1166 Side Gear Thrust Washer.....................................................................................................................................1167 Side Bearing Adjusting Washer...............................................................................................................................1167 C200............................................................................................................................................................................1168 PRECAUTION..................................................................................................................................................................1168 PRECAUTIONS.............................................................................................................................................................1168 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1168 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1168 Precaution for Servicing Rear Final Drive...........................................................................................................................1168 PREPARATION.................................................................................................................................................................1169 PREPARATION.............................................................................................................................................................1169 Special Service Tool................................................................................................................................................1169 Commercial Service Tool.............................................................................................................................................1171 SYSTEM DESCRIPTION..........................................................................................................................................................1172 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING....................................................................................................................1172 NVH Troubleshooting Chart...........................................................................................................................................1172 DESCRIPTION.............................................................................................................................................................1173 Cross-Sectional View................................................................................................................................................1173 PERIODIC MAINTENANCE........................................................................................................................................................1174 DIFFERENTIAL GEAR OIL...................................................................................................................................................1174 Changing Differential Gear Oil......................................................................................................................................1174 DRAINING........................................................................................................................................................1174 FILLING.........................................................................................................................................................1174 Checking Differential Gear Oil......................................................................................................................................1174 DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL.........................................................................................................................1174 REMOVAL AND INSTALLATION....................................................................................................................................................1175 FRONT OIL SEAL..........................................................................................................................................................1175 Removal and Installation............................................................................................................................................1175 REMOVAL.........................................................................................................................................................1175 INSTALLATION....................................................................................................................................................1175 CARRIER COVER...........................................................................................................................................................1177 Removal and Installation............................................................................................................................................1177 REMOVAL.........................................................................................................................................................1177 INSTALLATION....................................................................................................................................................1177 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1178 REAR FINAL DRIVE........................................................................................................................................................1178 Removal and Installation............................................................................................................................................1178 REMOVAL.........................................................................................................................................................1178 INSTALLATION....................................................................................................................................................1178 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1179 REAR FINAL DRIVE........................................................................................................................................................1179 Disassembly and Assembly............................................................................................................................................1179 COMPONENTS......................................................................................................................................................1179 ASSEMBLY INSPECTION AND ADJUSTMENT..............................................................................................................................1180 Total Preload Torque........................................................................................................................................1180 Drive Gear Runout...........................................................................................................................................1180 Tooth Contact...............................................................................................................................................1181 Backlash....................................................................................................................................................1182 Companion Flange Runout.....................................................................................................................................1182 DISASSEMBLY.....................................................................................................................................................1183 Differential Assembly.......................................................................................................................................1183 Drive Pinion Assembly.......................................................................................................................................1185 INSPECTION AFTER DISASSEMBLY....................................................................................................................................1186 Drive Pinion and Drive Gear.................................................................................................................................1186 Bearing.....................................................................................................................................................1187 Side Gear and Pinion Mate Gear..............................................................................................................................1187 Side Gear Thrust Washer and Pinion Mate Thrust Washer.......................................................................................................1187 Gear Carrier................................................................................................................................................1187 Companion Flange............................................................................................................................................1187 ADJUSTING AND SELECTING WASHERS.................................................................................................................................1187 Side Gear Back Clearance....................................................................................................................................1187 Side Bearing Preload Torque.................................................................................................................................1188 Drive Pinion Height.........................................................................................................................................1189 ASSEMBLY........................................................................................................................................................1192 Drive Pinion Assembly.......................................................................................................................................1192 Differential Assembly.......................................................................................................................................1194 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1198 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1198 General Specification...............................................................................................................................................1198 C200............................................................................................................................................................1198 Inspection and Adjustment...........................................................................................................................................1198 DRIVE GEAR RUNOUT...............................................................................................................................................1198 SIDE GEAR CLEARANCE.............................................................................................................................................1198 PRELOAD TORQUE..................................................................................................................................................1198 BACKLASH........................................................................................................................................................1198 COMPANION FLANGE RUNOUT.........................................................................................................................................1198 SELECTIVE PARTS.................................................................................................................................................1199 Side Gear Thrust Washer.....................................................................................................................................1199 Drive Pinion Height Adjusting Washer........................................................................................................................1199 Side Bearing Adjusting Washer...............................................................................................................................1199 REAR FINAL DRIVE: M226 .........................................................................................................................................................1200 PRECAUTION..................................................................................................................................................................1200 PRECAUTIONS.............................................................................................................................................................1200 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1200 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1200 Precaution for Servicing Rear Final Drive...........................................................................................................................1200 PREPARATION.................................................................................................................................................................1201 PREPARATION.............................................................................................................................................................1201 Special Service Tool................................................................................................................................................1201 Commercial Service Tool.............................................................................................................................................1202 SYSTEM DESCRIPTION..........................................................................................................................................................1203 DESCRIPTION.............................................................................................................................................................1203 Cross-Sectional View................................................................................................................................................1203 SYMPTOM DIAGNOSIS...........................................................................................................................................................1204 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING....................................................................................................................1204 NVH Troubleshooting Chart...........................................................................................................................................1204 PERIODIC MAINTENANCE........................................................................................................................................................1205 DIFFERENTIAL GEAR OIL...................................................................................................................................................1205 Changing Differential Gear Oil......................................................................................................................................1205 DRAINING........................................................................................................................................................1205 FILLING.........................................................................................................................................................1205 Checking Differential Gear Oil......................................................................................................................................1205 DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL.........................................................................................................................1205 REMOVAL AND INSTALLATION....................................................................................................................................................1206 FRONT OIL SEAL..........................................................................................................................................................1206 Removal and Installation............................................................................................................................................1206 REMOVAL.........................................................................................................................................................1206 INSTALLATION....................................................................................................................................................1206 CARRIER COVER...........................................................................................................................................................1208 Removal and Installation............................................................................................................................................1208 REMOVAL.........................................................................................................................................................1208 INSTALLATION....................................................................................................................................................1208 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1209 REAR FINAL DRIVE ASSEMBLY...............................................................................................................................................1209 Removal and Installation............................................................................................................................................1209 REMOVAL.........................................................................................................................................................1209 INSTALLATION....................................................................................................................................................1209 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1210 REAR FINAL DRIVE ASSEMBLY...............................................................................................................................................1210 Disassembly and Assembly............................................................................................................................................1210 COMPONENTS......................................................................................................................................................1210 ASSEMBLY INSPECTION AND ADJUSTMENT..............................................................................................................................1210 Total Preload Torque........................................................................................................................................1211 Tooth Contact...............................................................................................................................................1211 Backlash....................................................................................................................................................1212 Companion Flange Runout.....................................................................................................................................1213 DISASSEMBLY.....................................................................................................................................................1213 Differential Assembly.......................................................................................................................................1213 Drive Pinion Assembly.......................................................................................................................................1214 INSPECTION AFTER DISASSEMBLY....................................................................................................................................1215 Drive Pinion and Drive Gear.................................................................................................................................1216 Bearings....................................................................................................................................................1216 Differential Case Assembly..................................................................................................................................1216 Companion Flange............................................................................................................................................1216 ASSEMBLY........................................................................................................................................................1216 Drive Pinion Assembly.......................................................................................................................................1216 Differential Assembly.......................................................................................................................................1217 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1219 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1219 General Specification...............................................................................................................................................1219 Inspection and Adjustment...........................................................................................................................................1219 DIFFERENTIAL SIDE GEAR CLEARANCE................................................................................................................................1219 PRELOAD TORQUE..................................................................................................................................................1219 BACKLASH........................................................................................................................................................1219 COMPANION FLANGE RUNOUT.........................................................................................................................................1219 REAR FINAL DRIVE: M226 (ELD) ...................................................................................................................................................1220 BASIC INSPECTION............................................................................................................................................................1220 DIAGNOSIS AND REPAIR WORKFLOW...........................................................................................................................................1220 Work Flow...........................................................................................................................................................1220 OVERALL SEQUENCE................................................................................................................................................1220 DETAILED FLOW...................................................................................................................................................1220 SYSTEM DESCRIPTION..........................................................................................................................................................1222 DIFFERENTIAL LOCK SYSTEM................................................................................................................................................1222 Cross-Sectional View................................................................................................................................................1222 System Diagram......................................................................................................................................................1223 System Description..................................................................................................................................................1223 DIFFERENTIAL LOCK SYSTEM OPERATION..............................................................................................................................1223 DIFFERENTIAL LOCK OPERATION.....................................................................................................................................1223 DIFFERENTIAL LOCK INDICATOR LAMP OPERATION......................................................................................................................1224 Component Parts Location............................................................................................................................................1224 Component Description...............................................................................................................................................1225 DIAGNOSIS SYSTEM (DIFFERENTIAL LOCK CONTROL UNIT).......................................................................................................................1226 DIFFERENTIAL LOCK CONTROL UNIT......................................................................................................................................1226 DIFFERENTIAL LOCK CONTROL UNIT : CONSULT Function (DIFF LOCK)...................................................................................................1226 APPLICATION ITEM............................................................................................................................................1226 SELF DIAGNOSTIC RESULT......................................................................................................................................1226 DATA MONITOR................................................................................................................................................1226 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING....................................................................................................................1227 NVH Troubleshooting Chart...........................................................................................................................................1227 DTC/CIRCUIT DIAGNOSIS.......................................................................................................................................................1228 U1000 CAN COMM CIRCUIT..................................................................................................................................................1228 Description.........................................................................................................................................................1228 DTC Logic...........................................................................................................................................................1228 DTC DETECTION LOGIC.............................................................................................................................................1228 Diagnosis Procedure.................................................................................................................................................1228 P1833 INITIAL START.....................................................................................................................................................1229 Description.........................................................................................................................................................1229 DTC Logic...........................................................................................................................................................1229 Diagnosis Procedure.................................................................................................................................................1229 P1834 CONTROL UNIT 1....................................................................................................................................................1230 Description.........................................................................................................................................................1230 DTC Logic...........................................................................................................................................................1230 P1835 CONTROL UNIT 2....................................................................................................................................................1231 Description.........................................................................................................................................................1231 DTC Logic...........................................................................................................................................................1231 P1836 CONTROL UNIT 3....................................................................................................................................................1232 Description.........................................................................................................................................................1232 DTC Logic...........................................................................................................................................................1232 P1837 CONTROL UNIT 4....................................................................................................................................................1233 Description.........................................................................................................................................................1233 DTC Logic...........................................................................................................................................................1233 P1838 ON SWITCH.........................................................................................................................................................1234 Description.........................................................................................................................................................1234 DTC Logic...........................................................................................................................................................1234 Diagnosis Procedure.................................................................................................................................................1234 P1839 POSITION SWITCH ON................................................................................................................................................1236 Description.........................................................................................................................................................1236 DTC Logic...........................................................................................................................................................1236 Diagnosis Procedure.................................................................................................................................................1236 P1844 RELAY.............................................................................................................................................................1238 Description.........................................................................................................................................................1238 DTC Logic...........................................................................................................................................................1238 Diagnosis Procedure.................................................................................................................................................1238 P1847 SOLENOID CIRCUIT..................................................................................................................................................1239 Description.........................................................................................................................................................1239 DTC Logic...........................................................................................................................................................1239 P1848 SOLENOID DISCONNECT...............................................................................................................................................1240 Description.........................................................................................................................................................1240 DTC Logic...........................................................................................................................................................1240 Diagnosis Procedure.................................................................................................................................................1240 P1849 SOLENOID SHORT....................................................................................................................................................1242 Description.........................................................................................................................................................1242 DTC Logic...........................................................................................................................................................1242 Diagnosis Procedure.................................................................................................................................................1242 P1850 SOLENOID CURRENT..................................................................................................................................................1244 Description.........................................................................................................................................................1244 DTC Logic...........................................................................................................................................................1244 Diagnosis Procedure.................................................................................................................................................1244 C1203 ABS SYSTEM........................................................................................................................................................1246 Description.........................................................................................................................................................1246 DTC Logic...........................................................................................................................................................1246 LOCK INDICATOR LAMP.....................................................................................................................................................1247 Description.........................................................................................................................................................1247 Component Function Check............................................................................................................................................1247 Diagnosis Procedure.................................................................................................................................................1247 ECU DIAGNOSIS INFORMATION...................................................................................................................................................1249 DIFFERENTIAL LOCK CONTROL UNIT..........................................................................................................................................1249 Reference Value.....................................................................................................................................................1249 DTC Index...........................................................................................................................................................1250 WIRING DIAGRAM..............................................................................................................................................................1251 REAR FINAL DRIVE........................................................................................................................................................1251 Wiring Diagram......................................................................................................................................................1251 SYMPTOM DIAGNOSIS...........................................................................................................................................................1255 DIFF LOCK INDICATOR LAMP INOPERATIVE....................................................................................................................................1255 Inspection Procedure................................................................................................................................................1255 DIAGNOSTIC PROCEDURE............................................................................................................................................1255 DIFF LOCK INDICATOR LAMP DOES NOT TURN ON WITH DIFFERENTIAL LOCK SWITCHED ON............................................................................................1256 Inspection Procedure................................................................................................................................................1256 DIAGNOSTIC PROCEDURE............................................................................................................................................1256 DIFF LOCK INDICATOR LAMP FLASHES WHILE DRIVING..........................................................................................................................1257 Description.........................................................................................................................................................1257 Inspection Procedure................................................................................................................................................1257 DIAGNOSTIC PROCEDURE............................................................................................................................................1257 PRECAUTION..................................................................................................................................................................1258 PRECAUTIONS.............................................................................................................................................................1258 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1258 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1258 Precaution..........................................................................................................................................................1258 Precaution for Servicing Rear Final Drive...........................................................................................................................1259 PREPARATION.................................................................................................................................................................1260 PREPARATION.............................................................................................................................................................1260 Special Service Tool................................................................................................................................................1260 Commercial Service Tool.............................................................................................................................................1261 PERIODIC MAINTENANCE........................................................................................................................................................1262 DIFFERENTIAL GEAR OIL...................................................................................................................................................1262 Changing Differential Gear Oil......................................................................................................................................1262 DRAINING........................................................................................................................................................1262 FILLING.........................................................................................................................................................1262 Checking Differential Gear Oil......................................................................................................................................1262 DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL.........................................................................................................................1262 REMOVAL AND INSTALLATION....................................................................................................................................................1263 DIFFERENTIAL LOCK CONTROL UNIT..........................................................................................................................................1263 Removal and Installation............................................................................................................................................1263 REMOVAL.........................................................................................................................................................1263 INSTALLATION....................................................................................................................................................1263 DIFFERENTIAL LOCK POSITION SWITCH.......................................................................................................................................1264 Removal and Installation............................................................................................................................................1264 REMOVAL.........................................................................................................................................................1264 Differential Lock Position Switch...........................................................................................................................1264 INSTALLATION....................................................................................................................................................1265 FRONT OIL SEAL..........................................................................................................................................................1268 Removal and Installation............................................................................................................................................1268 REMOVAL.........................................................................................................................................................1268 INSTALLATION....................................................................................................................................................1268 CARRIER COVER...........................................................................................................................................................1270 Removal and Installation............................................................................................................................................1270 REMOVAL.........................................................................................................................................................1270 INSTALLATION....................................................................................................................................................1270 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1271 REAR FINAL DRIVE ASSEMBLY...............................................................................................................................................1271 Removal and Installation............................................................................................................................................1271 REMOVAL.........................................................................................................................................................1271 INSTALLATION....................................................................................................................................................1271 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1272 REAR FINAL DRIVE........................................................................................................................................................1272 Disassembly and Assembly............................................................................................................................................1272 COMPONENTS......................................................................................................................................................1272 INSPECTION AND ADJUSTMENT.......................................................................................................................................1273 Total Preload Torque........................................................................................................................................1273 Tooth Contact...............................................................................................................................................1273 Backlash....................................................................................................................................................1274 Companion Flange Runout.....................................................................................................................................1275 DISASSEMBLY.....................................................................................................................................................1275 Differential Assembly.......................................................................................................................................1275 Drive Pinion Assembly.......................................................................................................................................1277 INSPECTION AFTER DISASSEMBLY....................................................................................................................................1278 Drive Pinion and Drive Gear.................................................................................................................................1278 Bearings....................................................................................................................................................1278 Differential Case Assembly..................................................................................................................................1278 Differential Lock Solenoid..................................................................................................................................1278 Companion Flange............................................................................................................................................1278 ASSEMBLY........................................................................................................................................................1278 Drive Pinion Assembly.......................................................................................................................................1278 Differential Assembly.......................................................................................................................................1280 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1282 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1282 General Specification...............................................................................................................................................1282 Inspection and Adjustment...........................................................................................................................................1282 PRELOAD TORQUE..................................................................................................................................................1282 BACKLASH........................................................................................................................................................1282 COMPANION FLANGE RUNOUT.........................................................................................................................................1282 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 EC......................................................................................................................................................................................1283 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................1283 VQ40DE..........................................................................................................................................................................1290 PRECAUTION..................................................................................................................................................................1290 PRECAUTIONS.............................................................................................................................................................1290 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1290 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1290 Precaution for Procedure without Cowl Top Cover.....................................................................................................................1290 On Board Diagnosis (OBD) System of Engine and A/T...................................................................................................................1290 Precaution..........................................................................................................................................................1291 PREPARATION.................................................................................................................................................................1294 PREPARATION.............................................................................................................................................................1294 Special Service Tool................................................................................................................................................1294 Commercial Service Tool.............................................................................................................................................1295 SYSTEM DESCRIPTION..........................................................................................................................................................1296 ENGINE CONTROL SYSTEM...................................................................................................................................................1296 System Diagram......................................................................................................................................................1296 Engine Control Component Parts Location.............................................................................................................................1297 MULTIPORT FUEL INJECTION SYSTEM.........................................................................................................................................1305 System Description..................................................................................................................................................1305 INPUT/OUTPUT SIGNAL CHART.......................................................................................................................................1305 SYSTEM DESCRIPTION..............................................................................................................................................1305 VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION...........................................................................................................1305 MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)............................................................................................................1306 Open Loop Control...........................................................................................................................................1306 MIXTURE RATIO SELF-LEARNING CONTROL.............................................................................................................................1306 FUEL INJECTION TIMING...........................................................................................................................................1307 Sequential Multiport Fuel Injection System..................................................................................................................1307 Simultaneous Multiport Fuel Injection System................................................................................................................1307 FUEL SHUT-OFF...................................................................................................................................................1307 ELECTRIC IGNITION SYSTEM................................................................................................................................................1308 System Description..................................................................................................................................................1308 INPUT/OUTPUT SIGNAL CHART.......................................................................................................................................1308 SYSTEM DESCRIPTION..............................................................................................................................................1308 AIR CONDITIONING CUT CONTROL............................................................................................................................................1309 Input/Output Signal Chart...........................................................................................................................................1309 System Description..................................................................................................................................................1309 AUTOMATIC SPEED CONTROL DEVICE (ASCD)...................................................................................................................................1310 System Description..................................................................................................................................................1310 INPUT/OUTPUT SIGNAL CHART.......................................................................................................................................1310 BASIC ASCD SYSTEM...............................................................................................................................................1310 SET OPERATION...................................................................................................................................................1310 ACCELERATE OPERATION............................................................................................................................................1310 CANCEL OPERATION................................................................................................................................................1310 COAST OPERATION.................................................................................................................................................1311 RESUME OPERATION................................................................................................................................................1311 Component Description...............................................................................................................................................1311 ASCD STEERING SWITCH............................................................................................................................................1311 BRAKE PEDAL POSITION SWITCH.....................................................................................................................................1311 CLUTCH PEDAL POSITION SWITCH....................................................................................................................................1311 STOP LAMP SWITCH................................................................................................................................................1311 ELECTRIC THROTTLE CONTROL ACTUATOR .............................................................................................................................1311 ASCD INDICATOR..................................................................................................................................................1311 CAN COMMUNICATION.......................................................................................................................................................1312 System Description..................................................................................................................................................1312 COOLING FAN CONTROL.....................................................................................................................................................1313 Description.........................................................................................................................................................1313 SYSTEM DESCRIPTION..............................................................................................................................................1313 Cooling Fan Control.........................................................................................................................................1313 Cooling Fan Operation.......................................................................................................................................1313 Cooling Fan Relay Operation.................................................................................................................................1313 EVAPORATIVE EMISSION SYSTEM.............................................................................................................................................1314 Description.........................................................................................................................................................1314 SYSTEM DESCRIPTION..............................................................................................................................................1314 EVAPORATIVE EMISSION LINE DRAWING...............................................................................................................................1315 INTAKE VALVE TIMING CONTROL.............................................................................................................................................1317 Description.........................................................................................................................................................1317 SYSTEM DESCRIPTION..............................................................................................................................................1317 FUEL FILLER CAP WARNING SYSTEM..........................................................................................................................................1318 System Diagram......................................................................................................................................................1318 System Description..................................................................................................................................................1318 INPUT/OUTPUT SIGNAL CHART.......................................................................................................................................1318 SYSTEM DESCRIPTION..............................................................................................................................................1318 Reset Operation.............................................................................................................................................1318 INTAKE MANIFOLD RUNNER CONTROL..........................................................................................................................................1320 System Description..................................................................................................................................................1320 SYSTEM DIAGRAM..................................................................................................................................................1320 SYSTEM DESCRIPTION..............................................................................................................................................1320 VARIABLE INDUCTION AIR SYSTEM...........................................................................................................................................1321 Description.........................................................................................................................................................1321 SYSTEM DESCRIPTION..............................................................................................................................................1321 COMPONENT DESCRIPTION...........................................................................................................................................1321 Power Valve.................................................................................................................................................1321 VIAS Control Solenoid Valve.................................................................................................................................1322 Vacuum Hose Drawing.................................................................................................................................................1323 ON BOARD DIAGNOSTIC (OBD) SYSTEM........................................................................................................................................1324 Diagnosis Description...............................................................................................................................................1324 GST (Generic Scan Tool).............................................................................................................................................1324 DIAGNOSIS SYSTEM (ECM)..................................................................................................................................................1325 DIAGNOSIS DESCRIPTION...............................................................................................................................................1325 DIAGNOSIS DESCRIPTION : 1st Trip Detection Logic and Two Trip Detection Logic...................................................................................1325 DIAGNOSIS DESCRIPTION : DTC and Freeze Frame Data...............................................................................................................1325 DTC AND 1ST TRIP DTC........................................................................................................................................1325 FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA............................................................................................................1325 DIAGNOSIS DESCRIPTION : Counter System..........................................................................................................................1326 RELATIONSHIP BETWEEN MIL, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS...........................................................................................1326 COUNTER SYSTEM CHART........................................................................................................................................1326 Relationship Between MIL, DTC, 1st Trip DTC and Driving Patterns for “Misfire <Exhaust Quality Deterioration>”, “Fuel Injection System”.....................1326 Explanation for Driving Patterns for “Misfire <Exhaust Quality Deterioration>”, “Fuel Injection System”.....................................................1327 Driving Pattern B.......................................................................................................................................1327 Driving Pattern C.......................................................................................................................................1328 Relationship Between MIL, DTC, 1st Trip DTC and Driving Patterns Except For “Misfire <Exhaust Quality Deterioration>”, “Fuel Injection System”..............1328 Explanation for Driving Patterns Except for “Misfire <Exhaust Quality Deterioration>”, “Fuel Injection System”..............................................1329 Driving Pattern A.......................................................................................................................................1329 Driving Pattern B.......................................................................................................................................1329 DIAGNOSIS DESCRIPTION : Driving Pattern.........................................................................................................................1329 DRIVING PATTERN A...........................................................................................................................................1329 DRIVING PATTERN B...........................................................................................................................................1329 DRIVING PATTERN C...........................................................................................................................................1329 DRIVING PATTERN D...........................................................................................................................................1330 DIAGNOSIS DESCRIPTION : System Readiness Test (SRT) Code........................................................................................................1330 SRT SET TIMING..............................................................................................................................................1330 DIAGNOSIS DESCRIPTION : Permanent Diagnostic Trouble Code (Permanent DTC).......................................................................................1331 PERMANENT DTC SET TIMING....................................................................................................................................1332 DIAGNOSIS DESCRIPTION : Malfunction Indicator Lamp (MIL)........................................................................................................1332 On Board Diagnosis Function.........................................................................................................................................1332 ON BOARD DIAGNOSIS ITEM.........................................................................................................................................1332 BULB CHECK MODE.................................................................................................................................................1332 Description.................................................................................................................................................1332 Operation Procedure.........................................................................................................................................1332 SRT STATUS MODE.................................................................................................................................................1332 Description.................................................................................................................................................1332 Operation Procedure.........................................................................................................................................1332 MALFUNCTION WARNING MODE........................................................................................................................................1333 Description.................................................................................................................................................1333 Operation Procedure.........................................................................................................................................1333 SELF-DIAGNOSTIC RESULTS MODE....................................................................................................................................1333 Description.................................................................................................................................................1333 How to Set Self-diagnostic Results Mode.....................................................................................................................1333 How to Read Self-diagnostic Results.........................................................................................................................1334 How to Erase Self-diagnostic Results........................................................................................................................1335 CONSULT Function....................................................................................................................................................1335 FUNCTION........................................................................................................................................................1335 SELF-DIAGNOSTIC RESULT MODE.....................................................................................................................................1335 Self Diagnostic Item........................................................................................................................................1335 How to Read DTC and 1st Trip DTC............................................................................................................................1335 How to Erase DTC and 1st Trip DTC...........................................................................................................................1336 Freeze Frame Data and 1st Trip Freeze Frame Data............................................................................................................1336 DATA MONITOR MODE...............................................................................................................................................1336 Monitored Item..............................................................................................................................................1336 WORK SUPPORT MODE...............................................................................................................................................1341 Work Item...................................................................................................................................................1341 ACTIVE TEST MODE................................................................................................................................................1341 Test Item...................................................................................................................................................1341 DTC WORK SUPPORT................................................................................................................................................1342 SRT STATUS Mode.............................................................................................................................................1343 PERMANENT DTC STATUS Mode...................................................................................................................................1343 SRT WORK SUPPORT Mode.......................................................................................................................................1343 PERMANENT DTC WORK SUPPORT Mode.............................................................................................................................1343 DTC WORK SUPPORT Mode.......................................................................................................................................1343 ECU DIAGNOSIS INFORMATION...................................................................................................................................................1345 ECM.....................................................................................................................................................................1345 CONSULT Reference Value in Data Monitor Mode........................................................................................................................1345 ECM Harness Connector Terminal Layout...............................................................................................................................1349 ECM Terminal and Reference Value....................................................................................................................................1349 PREPARATION.....................................................................................................................................................1349 ECM INSPECTION TABLE............................................................................................................................................1349 Fail-Safe Chart.....................................................................................................................................................1358 DTC Inspection Priority Chart.......................................................................................................................................1359 DTC Index...........................................................................................................................................................1360 EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS...................................................................................................................1360 Test Value and Test Limit...........................................................................................................................................1365 WIRING DIAGRAM..............................................................................................................................................................1373 ENGINE CONTROL SYSTEM...................................................................................................................................................1373 Wiring Diagram......................................................................................................................................................1373 BASIC INSPECTION............................................................................................................................................................1394 DIAGNOSIS AND REPAIR WORKFLOW...........................................................................................................................................1394 Trouble Diagnosis Introduction......................................................................................................................................1394 INTRODUCTION....................................................................................................................................................1394 WORK FLOW.......................................................................................................................................................1394 Overall Sequence............................................................................................................................................1394 Detailed Flow...............................................................................................................................................1395 DIAGNOSTIC WORKSHEET............................................................................................................................................1398 Description.................................................................................................................................................1398 Worksheet Sample............................................................................................................................................1399 INSPECTION AND ADJUSTMENT...............................................................................................................................................1400 Basic Inspection....................................................................................................................................................1400 Idle Speed and Ignition Timing Check................................................................................................................................1404 IDLE SPEED......................................................................................................................................................1404 <GRAPHIC> With CONSULT......................................................................................................................................1404 <GRAPHIC> With GST..........................................................................................................................................1404 IGNITION TIMING.................................................................................................................................................1404 Additional Service When Replacing ECM...............................................................................................................................1404 DESCRIPTION.....................................................................................................................................................1404 PROGRAMMING OPERATION...........................................................................................................................................1404 WORK PROCEDURE..................................................................................................................................................1404 VIN Registration....................................................................................................................................................1406 DESCRIPTION.....................................................................................................................................................1406 OPERATION PROCEDURE.............................................................................................................................................1406 <GRAPHIC> With CONSULT......................................................................................................................................1406 Accelerator Pedal Released Position Learning........................................................................................................................1406 DESCRIPTION.....................................................................................................................................................1406 OPERATION PROCEDURE.............................................................................................................................................1406 Throttle Valve Closed Position Learning.............................................................................................................................1406 DESCRIPTION.....................................................................................................................................................1406 OPERATION PROCEDURE.............................................................................................................................................1406 Idle Air Volume Learning............................................................................................................................................1407 DESCRIPTION.....................................................................................................................................................1407 PREPARATION.....................................................................................................................................................1407 OPERATION PROCEDURE.............................................................................................................................................1407 <GRAPHIC> With CONSULT......................................................................................................................................1407 <GRAPHIC> Without CONSULT...................................................................................................................................1407 DIAGNOSTIC PROCEDURE............................................................................................................................................1408 HOW TO SET SRT CODE.....................................................................................................................................................1409 Description.........................................................................................................................................................1409 OUTLINE.........................................................................................................................................................1409 SRT ITEM........................................................................................................................................................1409 SRT SERVICE PROCEDURE...........................................................................................................................................1409 SRT Set Driving Pattern.............................................................................................................................................1410 Work Procedure......................................................................................................................................................1412 HOW TO ERASE PERMANENT DTC..............................................................................................................................................1415 Description.........................................................................................................................................................1415 OUTLINE.........................................................................................................................................................1415 When a DTC is stored in ECM.................................................................................................................................1415 When a DTC is not stored in ECM.............................................................................................................................1415 PERMANENT DTC ITEM..............................................................................................................................................1415 PERMANENT DTC SERVICE PROCEDURE.................................................................................................................................1416 Work Procedure (Group A)............................................................................................................................................1416 Work Procedure (Group B)............................................................................................................................................1418 DTC/CIRCUIT DIAGNOSIS.......................................................................................................................................................1421 TROUBLE DIAGNOSIS - SPECIFICATION VALUE.................................................................................................................................1421 Description.........................................................................................................................................................1421 Testing Condition...................................................................................................................................................1421 Inspection Procedure................................................................................................................................................1421 Diagnosis Procedure.................................................................................................................................................1421 OVERALL SEQUENCE................................................................................................................................................1421 DETAILED PROCEDURE..............................................................................................................................................1423 POWER SUPPLY AND GROUND CIRCUIT.........................................................................................................................................1429 Diagnosis Procedure.................................................................................................................................................1429 Ground Inspection...................................................................................................................................................1432 U0101 CAN COMM CIRCUIT..................................................................................................................................................1433 Description.........................................................................................................................................................1433 On Board Diagnosis Logic............................................................................................................................................1433 DTC Confirmation Procedure..........................................................................................................................................1433 Diagnosis Procedure.................................................................................................................................................1433 U1001 CAN COMM CIRCUIT..................................................................................................................................................1434 Description.........................................................................................................................................................1434 On Board Diagnosis Logic............................................................................................................................................1434 DTC Confirmation Procedure..........................................................................................................................................1434 Diagnosis Procedure.................................................................................................................................................1434 P0011, P0021 IVT CONTROL................................................................................................................................................1435 On Board Diagnosis Logic............................................................................................................................................1435 FAIL-SAFE MODE..................................................................................................................................................1435 DTC Confirmation Procedure..........................................................................................................................................1435 <GRAPHIC> WITH CONSULT..........................................................................................................................................1435 <GRAPHIC> WITH GST..............................................................................................................................................1436 Diagnosis Procedure.................................................................................................................................................1436 Component Inspection................................................................................................................................................1437 INTAKE VALVE TIMING CONTROL SOLENOID VALVE......................................................................................................................1437 P0031, P0032, P0051, P0052 A/F SENSOR 1 HEATER..........................................................................................................................1438 Description.........................................................................................................................................................1438 SYSTEM DESCRIPTION..............................................................................................................................................1438 On Board Diagnosis Logic............................................................................................................................................1438 DTC Confirmation Procedure..........................................................................................................................................1438 Diagnosis Procedure.................................................................................................................................................1438 Component Inspection................................................................................................................................................1440 AIR FUEL RATIO (A/F) SENSOR 1 HEATER............................................................................................................................1440 P0037, P0038, P0057, P0058 HO2S2 HEATER.................................................................................................................................1441 Description.........................................................................................................................................................1441 SYSTEM DESCRIPTION..............................................................................................................................................1441 OPERATION.......................................................................................................................................................1441 On Board Diagnosis Logic............................................................................................................................................1441 DTC Confirmation Procedure..........................................................................................................................................1441 <GRAPHIC> WITH CONSULT..........................................................................................................................................1441 <GRAPHIC> WITH GST..............................................................................................................................................1442 Diagnosis Procedure.................................................................................................................................................1442 Component Inspection................................................................................................................................................1443 HEATED OXYGEN SENSOR 2 HEATER...................................................................................................................................1443 P0075, P0081 IVT CONTROL SOLENOID VALVE.................................................................................................................................1445 Component Description...............................................................................................................................................1445 On Board Diagnosis Logic............................................................................................................................................1445 DTC Confirmation Procedure..........................................................................................................................................1445 Diagnosis Procedure.................................................................................................................................................1445 Component Inspection................................................................................................................................................1446 INTAKE VALVE TIMING CONTROL SOLENOID VALVE......................................................................................................................1446 P0101 MAF SENSOR........................................................................................................................................................1448 Component Description...............................................................................................................................................1448 On Board Diagnosis Logic............................................................................................................................................1448 DTC Confirmation Procedure..........................................................................................................................................1448 Diagnosis Procedure.................................................................................................................................................1449 Component Inspection................................................................................................................................................1450 MASS AIR FLOW SENSOR............................................................................................................................................1450 <GRAPHIC> With CONSULT......................................................................................................................................1450 <GRAPHIC> Without CONSULT...................................................................................................................................1451 P0102, P0103 MAF SENSOR.................................................................................................................................................1452 Component Description...............................................................................................................................................1452 On Board Diagnosis Logic............................................................................................................................................1452 FAIL-SAFE MODE..................................................................................................................................................1452 DTC Confirmation Procedure..........................................................................................................................................1452 PROCEDURE FOR DTC P0102.........................................................................................................................................1452 PROCEDURE FOR DTC P0103.........................................................................................................................................1452 Diagnosis Procedure.................................................................................................................................................1453 Component Inspection................................................................................................................................................1454 MASS AIR FLOW SENSOR............................................................................................................................................1454 <GRAPHIC> With CONSULT......................................................................................................................................1454 <GRAPHIC> Without CONSULT...................................................................................................................................1455 P0111 IAT SENSOR........................................................................................................................................................1456 Component Description...............................................................................................................................................1456 On Board Diagnosis Logic............................................................................................................................................1456 DTC Confirmation Procedure..........................................................................................................................................1456 Component Function Check............................................................................................................................................1457 Diagnosis Procedure.................................................................................................................................................1457 Component Inspection................................................................................................................................................1458 P0112, P0113 IAT SENSOR.................................................................................................................................................1459 Component Description...............................................................................................................................................1459 On Board Diagnosis Logic............................................................................................................................................1459 DTC Confirmation Procedure..........................................................................................................................................1459 Diagnosis Procedure.................................................................................................................................................1459 Component Inspection................................................................................................................................................1460 INTAKE AIR TEMPERATURE SENSOR...................................................................................................................................1460 P0116 ECT SENSOR........................................................................................................................................................1462 Component Description...............................................................................................................................................1462 On Board Diagnosis Logic............................................................................................................................................1462 DTC Confirmation Procedure..........................................................................................................................................1462 Component Function Check............................................................................................................................................1463 Diagnosis Procedure.................................................................................................................................................1464 Component Inspection................................................................................................................................................1464 ENGINE COOLANT TEMPERATURE SENSOR...............................................................................................................................1464 P0117, P0118 ECT SENSOR.................................................................................................................................................1465 Component Description...............................................................................................................................................1465 On Board Diagnosis Logic............................................................................................................................................1465 FAIL-SAFE MODE..................................................................................................................................................1465 DTC Confirmation Procedure..........................................................................................................................................1466 Diagnosis Procedure.................................................................................................................................................1466 Component Inspection................................................................................................................................................1467 ENGINE COOLANT TEMPERATURE SENSOR...............................................................................................................................1467 P0122, P0123 TP SENSOR..................................................................................................................................................1468 Component Description...............................................................................................................................................1468 On Board Diagnosis Logic............................................................................................................................................1468 FAIL-SAFE MODE..................................................................................................................................................1468 DTC Confirmation Procedure..........................................................................................................................................1468 Diagnosis Procedure.................................................................................................................................................1468 Component Inspection................................................................................................................................................1470 THROTTLE POSITION SENSOR........................................................................................................................................1470 P0125 ECT SENSOR........................................................................................................................................................1472 Component Description...............................................................................................................................................1472 On Board Diagnosis Logic............................................................................................................................................1472 DTC Confirmation Procedure..........................................................................................................................................1472 <GRAPHIC> WITH CONSULT..........................................................................................................................................1472 <GRAPHIC> WITH GST..............................................................................................................................................1473 Diagnosis Procedure.................................................................................................................................................1473 Component Inspection................................................................................................................................................1473 ENGINE COOLANT TEMPERATURE SENSOR...............................................................................................................................1473 P0127 IAT SENSOR........................................................................................................................................................1475 Component Description...............................................................................................................................................1475 On Board Diagnosis Logic............................................................................................................................................1475 DTC Confirmation Procedure..........................................................................................................................................1475 <GRAPHIC> WITH CONSULT..........................................................................................................................................1475 <GRAPHIC> WITH GST..............................................................................................................................................1476 Diagnosis Procedure.................................................................................................................................................1476 Component Inspection................................................................................................................................................1476 INTAKE AIR TEMPERATURE SENSOR...................................................................................................................................1476 P0128 THERMOSTAT FUNCTION...............................................................................................................................................1478 On Board Diagnosis Logic............................................................................................................................................1478 DTC Confirmation Procedure..........................................................................................................................................1478 <GRAPHIC> WITH CONSULT..........................................................................................................................................1478 <GRAPHIC> WITH GST..............................................................................................................................................1478 Diagnosis Procedure.................................................................................................................................................1478 Component Inspection................................................................................................................................................1479 ENGINE COOLANT TEMPERATURE SENSOR...............................................................................................................................1479 P0130, P0150 A/F SENSOR 1...............................................................................................................................................1480 Component Description...............................................................................................................................................1480 On Board Diagnosis Logic............................................................................................................................................1480 DTC Confirmation Procedure..........................................................................................................................................1480 PROCEDURE FOR MALFUNCTION A.....................................................................................................................................1480 PROCEDURE FOR MALFUNCTION B.....................................................................................................................................1481 <GRAPHIC> With CONSULT......................................................................................................................................1481 Overall Function Check..............................................................................................................................................1481 PROCEDURE FOR MALFUNCTION B.....................................................................................................................................1481 <GRAPHIC> With GST..........................................................................................................................................1481 Diagnosis Procedure.................................................................................................................................................1481 P0131, P0151 A/F SENSOR 1...............................................................................................................................................1484 Component Description...............................................................................................................................................1484 On Board Diagnosis Logic............................................................................................................................................1484 DTC Confirmation Procedure..........................................................................................................................................1484 <GRAPHIC> WITH CONSULT..........................................................................................................................................1484 <GRAPHIC> WITH GST..............................................................................................................................................1485 Diagnosis Procedure.................................................................................................................................................1485 P0132, P0152 A/F SENSOR 1...............................................................................................................................................1487 Component Description...............................................................................................................................................1487 On Board Diagnosis Logic............................................................................................................................................1487 DTC Confirmation Procedure..........................................................................................................................................1487 <GRAPHIC> WITH CONSULT..........................................................................................................................................1487 <GRAPHIC> WITH GST..............................................................................................................................................1488 Diagnosis Procedure.................................................................................................................................................1488 P0133, P0153 A/F SENSOR 1...............................................................................................................................................1490 Component Description...............................................................................................................................................1490 On Board Diagnosis Logic............................................................................................................................................1490 DTC Confirmation Procedure..........................................................................................................................................1490 <GRAPHIC> WITH CONSULT..........................................................................................................................................1490 <GRAPHIC> WITH GST..............................................................................................................................................1491 Diagnosis Procedure.................................................................................................................................................1491 P0137, P0157 HO2S2......................................................................................................................................................1495 Component Description...............................................................................................................................................1495 On Board Diagnosis Logic............................................................................................................................................1495 DTC Confirmation Procedure..........................................................................................................................................1495 <GRAPHIC> WITH CONSULT..........................................................................................................................................1495 Overall Function Check..............................................................................................................................................1496 <GRAPHIC> WITH GST..............................................................................................................................................1496 Diagnosis Procedure.................................................................................................................................................1496 Component Inspection................................................................................................................................................1498 HEATED OXYGEN SENSOR 2..........................................................................................................................................1498 <GRAPHIC> With CONSULT......................................................................................................................................1498 <GRAPHIC> Without CONSULT...................................................................................................................................1499 P0138, P0158 HO2S2......................................................................................................................................................1500 Component Description...............................................................................................................................................1500 On Board Diagnosis Logic............................................................................................................................................1500 MALFUNCTION A...................................................................................................................................................1500 MALFUNCTION B...................................................................................................................................................1500 DTC Confirmation Procedure..........................................................................................................................................1501 PROCEDURE FOR MALFUNCTION A.....................................................................................................................................1501 <GRAPHIC> With CONSULT......................................................................................................................................1501 <GRAPHIC> With GST..........................................................................................................................................1501 PROCEDURE FOR MALFUNCTION B.....................................................................................................................................1501 <GRAPHIC> With CONSULT......................................................................................................................................1501 Overall Function Check..............................................................................................................................................1501 PROCEDURE FOR MALFUNCTION B.....................................................................................................................................1501 <GRAPHIC> With GST..........................................................................................................................................1502 Diagnosis Procedure.................................................................................................................................................1502 PROCEDURE FOR MALFUNCTION A.....................................................................................................................................1502 PROCEDURE FOR MALFUNCTION B.....................................................................................................................................1504 Component Inspection................................................................................................................................................1506 HEATED OXYGEN SENSOR 2..........................................................................................................................................1506 <GRAPHIC> With CONSULT......................................................................................................................................1506 <GRAPHIC> Without CONSULT...................................................................................................................................1507 P0139, P0159 HO2S2......................................................................................................................................................1508 Component Description...............................................................................................................................................1508 On Board Diagnosis Logic............................................................................................................................................1508 DTC Confirmation Procedure..........................................................................................................................................1508 Overall Function Check..............................................................................................................................................1510 <GRAPHIC> WITH GST..............................................................................................................................................1510 Diagnosis Procedure.................................................................................................................................................1510 Component Inspection................................................................................................................................................1512 HEATED OXYGEN SENSOR 2..........................................................................................................................................1512 <GRAPHIC> With CONSULT......................................................................................................................................1512 <GRAPHIC> Without CONSULT...................................................................................................................................1513 P0171, P0174 FUEL INJECTION SYSTEM FUNCTION.............................................................................................................................1514 On Board Diagnosis Logic............................................................................................................................................1514 DTC Confirmation Procedure..........................................................................................................................................1514 <GRAPHIC> WITH CONSULT..........................................................................................................................................1514 <GRAPHIC> WITH GST..............................................................................................................................................1515 Diagnosis Procedure.................................................................................................................................................1515 P0172, P0175 FUEL INJECTION SYSTEM FUNCTION.............................................................................................................................1520 On Board Diagnosis Logic............................................................................................................................................1520 DTC Confirmation Procedure..........................................................................................................................................1520 <GRAPHIC> WITH CONSULT..........................................................................................................................................1520 <GRAPHIC> WITH GST..............................................................................................................................................1521 Diagnosis Procedure.................................................................................................................................................1521 P0181 FTT SENSOR........................................................................................................................................................1526 Component Description...............................................................................................................................................1526 On Board Diagnosis Logic............................................................................................................................................1526 DTC Confirmation Procedure..........................................................................................................................................1526 Component Function Check............................................................................................................................................1528 Diagnosis Procedure.................................................................................................................................................1528 Component Inspection................................................................................................................................................1529 FUEL TANK TEMPERATURE SENSOR....................................................................................................................................1529 P0182, P0183 FTT SENSOR.................................................................................................................................................1531 Component Description...............................................................................................................................................1531 On Board Diagnosis Logic............................................................................................................................................1531 DTC Confirmation Procedure..........................................................................................................................................1531 Diagnosis Procedure.................................................................................................................................................1531 Component Inspection................................................................................................................................................1533 FUEL TANK TEMPERATURE SENSOR....................................................................................................................................1533 P0196 EOT SENSOR........................................................................................................................................................1534 DTC Logic...........................................................................................................................................................1534 DTC DETECTION LOGIC.............................................................................................................................................1534 DTC CONFIRMATION PROCEDURE......................................................................................................................................1534 Component Function Check............................................................................................................................................1536 Diagnosis Procedure.................................................................................................................................................1536 Component Inspection................................................................................................................................................1536 P0197, P0198 EOT SENSOR.................................................................................................................................................1538 DTC Logic...........................................................................................................................................................1538 DTC DETECTION LOGIC.............................................................................................................................................1538 DTC CONFIRMATION PROCEDURE......................................................................................................................................1538 Diagnosis Procedure.................................................................................................................................................1538 Component Inspection................................................................................................................................................1539 P0222, P0223 TP SENSOR..................................................................................................................................................1540 Component Description...............................................................................................................................................1540 On Board Diagnosis Logic............................................................................................................................................1540 FAIL-SAFE MODE..................................................................................................................................................1540 DTC Confirmation Procedure..........................................................................................................................................1540 Diagnosis Procedure.................................................................................................................................................1540 Component Inspection................................................................................................................................................1543 THROTTLE POSITION SENSOR........................................................................................................................................1543 P0300, P0301, P0302, P0303, P0304, P0305, P0306 MISFIRE.................................................................................................................1544 On Board Diagnosis Logic............................................................................................................................................1544 DTC Confirmation Procedure..........................................................................................................................................1544 <GRAPHIC> WITH CONSULT..........................................................................................................................................1544 <GRAPHIC> WITH GST..............................................................................................................................................1545 Diagnosis Procedure.................................................................................................................................................1545 P0327, P0328, P0332, P0333 KS...........................................................................................................................................1551 Component Description...............................................................................................................................................1551 On Board Diagnosis Logic............................................................................................................................................1551 DTC Confirmation Procedure..........................................................................................................................................1551 Diagnosis Procedure.................................................................................................................................................1551 Component Inspection................................................................................................................................................1553 KNOCK SENSOR....................................................................................................................................................1553 P0335 CKP SENSOR (POS)..................................................................................................................................................1554 Component Description...............................................................................................................................................1554 On Board Diagnosis Logic............................................................................................................................................1554 DTC Confirmation Procedure..........................................................................................................................................1554 Diagnosis Procedure.................................................................................................................................................1554 Component Inspection................................................................................................................................................1556 CRANKSHAFT POSITION SENSOR (POS)................................................................................................................................1556 P0340, P0345 CMP SENSOR (PHASE).........................................................................................................................................1557 Component Description...............................................................................................................................................1557 On Board Diagnosis Logic............................................................................................................................................1557 DTC Confirmation Procedure..........................................................................................................................................1557 Diagnosis Procedure.................................................................................................................................................1558 Component Inspection................................................................................................................................................1559 CAMSHAFT POSITION SENSOR (PHASE)................................................................................................................................1559 P0420, P0430 THREE WAY CATALYST FUNCTION................................................................................................................................1561 On Board Diagnosis Logic............................................................................................................................................1561 DTC Confirmation Procedure..........................................................................................................................................1561 <GRAPHIC> WITH CONSULT..........................................................................................................................................1561 Overall Function Check..............................................................................................................................................1562 <GRAPHIC> WITH GST..............................................................................................................................................1562 Diagnosis Procedure.................................................................................................................................................1562 P0441 EVAP CONTROL SYSTEM...............................................................................................................................................1565 System Description..................................................................................................................................................1565 On Board Diagnosis Logic............................................................................................................................................1565 DTC Confirmation Procedure..........................................................................................................................................1565 <GRAPHIC> WITH CONSULT..........................................................................................................................................1566 Overall Function Check..............................................................................................................................................1566 <GRAPHIC> WITH GST..............................................................................................................................................1566 Diagnosis Procedure.................................................................................................................................................1566 Component Inspection................................................................................................................................................1569 DRAIN FILTER....................................................................................................................................................1569 P0442 EVAP CONTROL SYSTEM...............................................................................................................................................1570 On Board Diagnosis Logic............................................................................................................................................1570 DTC Confirmation Procedure..........................................................................................................................................1571 <GRAPHIC> WITH CONSULT..........................................................................................................................................1571 <GRAPHIC> WITH GST..............................................................................................................................................1571 Diagnosis Procedure.................................................................................................................................................1571 Component Inspection................................................................................................................................................1576 FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)......................................................................................................1576 DRAIN FILTER....................................................................................................................................................1576 P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE.................................................................................................................1577 Description.........................................................................................................................................................1577 SYSTEM DESCRIPTION..............................................................................................................................................1577 COMPONENT DESCRIPTION...........................................................................................................................................1577 On Board Diagnosis Logic............................................................................................................................................1577 DTC Confirmation Procedure..........................................................................................................................................1578 PROCEDURE FOR MALFUNCTION A.....................................................................................................................................1578 <GRAPHIC> With CONSULT......................................................................................................................................1578 <GRAPHIC> With GST..........................................................................................................................................1578 PROCEDURE FOR MALFUNCTION B.....................................................................................................................................1578 <GRAPHIC> With CONSULT......................................................................................................................................1578 <GRAPHIC> With GST..........................................................................................................................................1578 Diagnosis Procedure.................................................................................................................................................1579 Component Inspection................................................................................................................................................1581 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ..............................................................................................................1581 <GRAPHIC> With CONSULT......................................................................................................................................1581 <GRAPHIC> Without CONSULT...................................................................................................................................1581 DRAIN FILTER....................................................................................................................................................1581 P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE..........................................................................................................1583 Description.........................................................................................................................................................1583 SYSTEM DESCRIPTION .............................................................................................................................................1583 COMPONENT DESCRIPTION...........................................................................................................................................1583 On Board Diagnosis Logic............................................................................................................................................1583 DTC Confirmation Procedure..........................................................................................................................................1584 Diagnosis Procedure.................................................................................................................................................1584 Component Inspection................................................................................................................................................1585 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...............................................................................................................1585 <GRAPHIC> With CONSULT......................................................................................................................................1585 <GRAPHIC> Without CONSULT...................................................................................................................................1585 P0447 EVAP CANISTER VENT CONTROL VALVE..................................................................................................................................1586 Component Description...............................................................................................................................................1586 On Board Diagnosis Logic............................................................................................................................................1586 DTC Confirmation Procedure..........................................................................................................................................1586 Diagnosis Procedure.................................................................................................................................................1586 Component Inspection................................................................................................................................................1588 EVAP CANISTER VENT CONTROL VALVE................................................................................................................................1588 <GRAPHIC> With CONSULT......................................................................................................................................1588 <GRAPHIC> Without CONSULT...................................................................................................................................1588 DRAIN FILTER....................................................................................................................................................1589 P0448 EVAP CANISTER VENT CONTROL VALVE..................................................................................................................................1590 Component Description...............................................................................................................................................1590 On Board Diagnosis Logic............................................................................................................................................1590 DTC Confirmation Procedure..........................................................................................................................................1590 <GRAPHIC> WITH CONSULT..........................................................................................................................................1590 <GRAPHIC> WITH GST..............................................................................................................................................1591 Diagnosis Procedure.................................................................................................................................................1591 Component Inspection................................................................................................................................................1592 EVAP CANISTER VENT CONTROL VALVE................................................................................................................................1592 <GRAPHIC> With CONSULT......................................................................................................................................1592 <GRAPHIC> Without CONSULT...................................................................................................................................1593 DRAIN FILTER....................................................................................................................................................1594 P0451 EVAP CONTROL SYSTEM PRESSURE SENSOR...............................................................................................................................1595 Component Description...............................................................................................................................................1595 On Board Diagnosis Logic............................................................................................................................................1595 DTC Confirmation Procedure..........................................................................................................................................1595 DTC CONFIRMATION PROCEDURE......................................................................................................................................1595 Diagnosis Procedure.................................................................................................................................................1596 Component Inspection................................................................................................................................................1597 EVAP CONTROL SYSTEM PRESSURE SENSOR.............................................................................................................................1597 P0452 EVAP CONTROL SYSTEM PRESSURE SENSOR...............................................................................................................................1599 Component Description...............................................................................................................................................1599 On Board Diagnosis Logic............................................................................................................................................1599 DTC Confirmation Procedure..........................................................................................................................................1599 <GRAPHIC> WITH CONSULT..........................................................................................................................................1599 <GRAPHIC> WITH GST..............................................................................................................................................1600 Diagnosis Procedure.................................................................................................................................................1600 Component Inspection................................................................................................................................................1602 EVAP CONTROL SYSTEM PRESSURE SENSOR.............................................................................................................................1602 P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR...............................................................................................................................1603 Component Description...............................................................................................................................................1603 On Board Diagnosis Logic............................................................................................................................................1603 DTC Confirmation Procedure..........................................................................................................................................1603 <GRAPHIC> With CONSULT..........................................................................................................................................1603 <GRAPHIC> With GST..............................................................................................................................................1604 Diagnosis Procedure.................................................................................................................................................1604 Component Inspection................................................................................................................................................1607 EVAP CONTROL SYSTEM PRESSURE SENSOR.............................................................................................................................1607 DRAIN FILTER....................................................................................................................................................1607 P0455 EVAP CONTROL SYSTEM...............................................................................................................................................1608 On Board Diagnosis Logic............................................................................................................................................1608 DTC Confirmation Procedure..........................................................................................................................................1608 <GRAPHIC> WITH CONSULT..........................................................................................................................................1609 <GRAPHIC> WITH GST..............................................................................................................................................1609 Diagnosis Procedure.................................................................................................................................................1609 Component Inspection................................................................................................................................................1613 FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)......................................................................................................1613 P0456 EVAP CONTROL SYSTEM...............................................................................................................................................1615 On Board Diagnosis Logic............................................................................................................................................1615 DTC Confirmation Procedure..........................................................................................................................................1616 <GRAPHIC> WITH CONSULT..........................................................................................................................................1616 Overall Function Check..............................................................................................................................................1616 <GRAPHIC> WITH GST..............................................................................................................................................1616 Diagnosis Procedure.................................................................................................................................................1617 Component Inspection................................................................................................................................................1622 FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)......................................................................................................1622 P0460 FUEL LEVEL SENSOR.................................................................................................................................................1623 Component Description...............................................................................................................................................1623 On Board Diagnosis Logic............................................................................................................................................1623 DTC Confirmation Procedure..........................................................................................................................................1623 Diagnosis Procedure.................................................................................................................................................1623 P0461 FUEL LEVEL SENSOR.................................................................................................................................................1625 Component Description...............................................................................................................................................1625 On Board Diagnosis Logic............................................................................................................................................1625 Overall Function Check..............................................................................................................................................1625 <GRAPHIC> WITH CONSULT..........................................................................................................................................1625 <GRAPHIC> WITH GST..............................................................................................................................................1626 Diagnosis Procedure.................................................................................................................................................1626 P0462, P0463 FUEL LEVEL SENSOR..........................................................................................................................................1627 Component Description...............................................................................................................................................1627 On Board Diagnosis Logic............................................................................................................................................1627 DTC Confirmation Procedure..........................................................................................................................................1627 Diagnosis Procedure.................................................................................................................................................1627 P0500 VSS...............................................................................................................................................................1629 Description.........................................................................................................................................................1629 On Board Diagnosis Logic............................................................................................................................................1629 FAIL-SAFE MODE..................................................................................................................................................1629 DTC Confirmation Procedure..........................................................................................................................................1629 <GRAPHIC> WITH CONSULT..........................................................................................................................................1629 Overall Function Check..............................................................................................................................................1630 <GRAPHIC> WITH GST..............................................................................................................................................1630 Diagnosis Procedure.................................................................................................................................................1630 P0506 ISC SYSTEM........................................................................................................................................................1631 Description.........................................................................................................................................................1631 On Board Diagnosis Logic............................................................................................................................................1631 DTC Confirmation Procedure..........................................................................................................................................1631 Diagnosis Procedure.................................................................................................................................................1631 P0507 ISC SYSTEM........................................................................................................................................................1633 Description.........................................................................................................................................................1633 On Board Diagnosis Logic............................................................................................................................................1633 DTC Confirmation Procedure..........................................................................................................................................1633 Diagnosis Procedure.................................................................................................................................................1633 P050A, P050E COLD START CONTROL.........................................................................................................................................1635 Description.........................................................................................................................................................1635 On Board Diagnosis Logic............................................................................................................................................1635 DTC Confirmation Procedure..........................................................................................................................................1635 DTC CONFIRMATION PROCEDURE......................................................................................................................................1635 Diagnosis Procedure.................................................................................................................................................1636 P0550 PSP SENSOR........................................................................................................................................................1637 Component Description...............................................................................................................................................1637 On Board Diagnosis Logic............................................................................................................................................1637 DTC Confirmation Procedure..........................................................................................................................................1637 Diagnosis Procedure.................................................................................................................................................1637 Component Inspection................................................................................................................................................1638 POWER STEERING PRESSURE SENSOR..................................................................................................................................1638 P0603 ECM POWER SUPPLY..................................................................................................................................................1640 Component Description...............................................................................................................................................1640 On Board Diagnosis Logic............................................................................................................................................1640 DTC Confirmation Procedure..........................................................................................................................................1640 Diagnosis Procedure.................................................................................................................................................1640 P0605 ECM...............................................................................................................................................................1642 Component Description...............................................................................................................................................1642 On Board Diagnosis Logic............................................................................................................................................1642 FAIL-SAFE MODE..................................................................................................................................................1642 DTC Confirmation Procedure..........................................................................................................................................1642 PROCEDURE FOR MALFUNCTION A.....................................................................................................................................1642 PROCEDURE FOR MALFUNCTION B.....................................................................................................................................1642 <GRAPHIC> With CONSULT......................................................................................................................................1642 PROCEDURE FOR MALFUNCTION C.....................................................................................................................................1642 <GRAPHIC> With CONSULT......................................................................................................................................1642 Diagnosis Procedure.................................................................................................................................................1643 P0607 ECM...............................................................................................................................................................1644 Description.........................................................................................................................................................1644 On Board Diagnosis Logic............................................................................................................................................1644 DTC Confirmation Procedure..........................................................................................................................................1644 Diagnosis Procedure.................................................................................................................................................1644 P0643 SENSOR POWER SUPPLY...............................................................................................................................................1645 On Board Diagnosis Logic............................................................................................................................................1645 FAIL-SAFE MODE..................................................................................................................................................1645 DTC Confirmation Procedure..........................................................................................................................................1645 Diagnosis Procedure.................................................................................................................................................1645 P0850 PNP SWITCH........................................................................................................................................................1648 Component Description...............................................................................................................................................1648 On Board Diagnosis Logic............................................................................................................................................1648 DTC Confirmation Procedure..........................................................................................................................................1648 <GRAPHIC> WITH CONSULT..........................................................................................................................................1648 Overall Function Check..............................................................................................................................................1649 <GRAPHIC> WITH GST..............................................................................................................................................1649 Diagnosis Procedure.................................................................................................................................................1649 A/T MODELS......................................................................................................................................................1649 M/T MODELS......................................................................................................................................................1650 P1148, P1168 CLOSED LOOP CONTROL........................................................................................................................................1652 On Board Diagnosis Logic............................................................................................................................................1652 P1212 TCS COMMUNICATION LINE............................................................................................................................................1653 Description.........................................................................................................................................................1653 On Board Diagnosis Logic............................................................................................................................................1653 DTC Confirmation Procedure..........................................................................................................................................1653 Diagnosis Procedure.................................................................................................................................................1653 P1217 ENGINE OVER TEMPERATURE...........................................................................................................................................1654 On Board Diagnosis Logic............................................................................................................................................1654 Overall Function Check..............................................................................................................................................1654 <GRAPHIC> WITH CONSULT..........................................................................................................................................1654 <GRAPHIC> WITH GST..............................................................................................................................................1655 Diagnosis Procedure.................................................................................................................................................1655 Main 12 Causes of Overheating.......................................................................................................................................1656 P1225 TP SENSOR.........................................................................................................................................................1658 Component Description...............................................................................................................................................1658 On Board Diagnosis Logic............................................................................................................................................1658 DTC Confirmation Procedure..........................................................................................................................................1658 Diagnosis Procedure.................................................................................................................................................1658 P1226 TP SENSOR.........................................................................................................................................................1660 Component Description...............................................................................................................................................1660 On Board Diagnosis Logic............................................................................................................................................1660 DTC Confirmation Procedure..........................................................................................................................................1660 Diagnosis Procedure.................................................................................................................................................1660 P1550 BATTERY CURRENT SENSOR............................................................................................................................................1662 Component Description...............................................................................................................................................1662 On Board Diagnosis Logic............................................................................................................................................1662 DTC Confirmation Procedure..........................................................................................................................................1662 Diagnosis Procedure.................................................................................................................................................1662 Component Inspection................................................................................................................................................1664 BATTERY CURRENT SENSOR..........................................................................................................................................1664 P1551, P1552 BATTERY CURRENT SENSOR.....................................................................................................................................1665 Component Description...............................................................................................................................................1665 On Board Diagnosis Logic............................................................................................................................................1665 DTC Confirmation Procedure..........................................................................................................................................1665 Diagnosis Procedure.................................................................................................................................................1665 Component Inspection................................................................................................................................................1667 BATTERY CURRENT SENSOR..........................................................................................................................................1667 P1553 BATTERY CURRENT SENSOR............................................................................................................................................1668 Component Description...............................................................................................................................................1668 On Board Diagnosis Logic............................................................................................................................................1668 DTC Confirmation Procedure..........................................................................................................................................1668 Diagnosis Procedure.................................................................................................................................................1668 Component Inspection................................................................................................................................................1670 BATTERY CURRENT SENSOR..........................................................................................................................................1670 P1554 BATTERY CURRENT SENSOR............................................................................................................................................1671 Component Description...............................................................................................................................................1671 On Board Diagnosis Logic............................................................................................................................................1671 Overall Function Check..............................................................................................................................................1671 <GRAPHIC> WITH CONSULT..........................................................................................................................................1671 <GRAPHIC> WITH GST..............................................................................................................................................1671 Diagnosis Procedure.................................................................................................................................................1671 Component Inspection................................................................................................................................................1673 BATTERY CURRENT SENSOR..........................................................................................................................................1673 P1564 ASCD STEERING SWITCH..............................................................................................................................................1674 Component Description...............................................................................................................................................1674 On Board Diagnosis Logic............................................................................................................................................1674 DTC Confirmation Procedure..........................................................................................................................................1674 <GRAPHIC> WITH CONSULT..........................................................................................................................................1674 Diagnosis Procedure.................................................................................................................................................1674 Component Inspection................................................................................................................................................1676 ASCD STEERING SWITCH............................................................................................................................................1676 P1572 ASCD BRAKE SWITCH.................................................................................................................................................1677 Component Description...............................................................................................................................................1677 On Board Diagnosis Logic............................................................................................................................................1677 DTC Confirmation Procedure..........................................................................................................................................1677 <GRAPHIC> WITH CONSULT..........................................................................................................................................1677 <GRAPHIC> WITH GST..............................................................................................................................................1678 Diagnosis Procedure.................................................................................................................................................1678 A/T MODELS......................................................................................................................................................1678 M/T MODELS......................................................................................................................................................1680 Component Inspection................................................................................................................................................1683 BRAKE PEDAL POSITION SWITCH.....................................................................................................................................1683 CLUTCH PEDAL POSITION SWITCH....................................................................................................................................1683 STOP LAMP SWITCH................................................................................................................................................1683 P1574 ASCD VEHICLE SPEED SENSOR.........................................................................................................................................1685 Component Description...............................................................................................................................................1685 On Board Diagnosis Logic............................................................................................................................................1685 DTC Confirmation Procedure..........................................................................................................................................1685 Diagnosis Procedure.................................................................................................................................................1685 P1715 INPUT SPEED SENSOR................................................................................................................................................1687 Description.........................................................................................................................................................1687 On Board Diagnosis Logic............................................................................................................................................1687 Diagnosis Procedure.................................................................................................................................................1687 P1800 VIAS CONTROL SOLENOID VALVE 1.....................................................................................................................................1688 Component Description...............................................................................................................................................1688 On Board Diagnosis Logic............................................................................................................................................1688 DTC Confirmation Procedure..........................................................................................................................................1688 Diagnosis Procedure.................................................................................................................................................1688 Component Inspection................................................................................................................................................1689 VIAS CONTROL SOLENOID VALVE.....................................................................................................................................1689 <GRAPHIC> With CONSULT......................................................................................................................................1689 <GRAPHIC> With GST..........................................................................................................................................1689 P1805 BRAKE SWITCH......................................................................................................................................................1691 Description.........................................................................................................................................................1691 On Board Diagnosis Logic............................................................................................................................................1691 FAIL-SAFE MODE..................................................................................................................................................1691 DTC Confirmation Procedure..........................................................................................................................................1691 Diagnosis Procedure.................................................................................................................................................1691 Component Inspection................................................................................................................................................1692 STOP LAMP SWITCH................................................................................................................................................1692 P2004 INTAKE MANIFOLD RUNNER CONTROL VALVE..............................................................................................................................1693 DTC Logic...........................................................................................................................................................1693 DTC DETECTION LOGIC.............................................................................................................................................1693 DTC CONFIRMATION PROCEDURE......................................................................................................................................1693 Diagnosis Procedure.................................................................................................................................................1693 Component Inspection................................................................................................................................................1694 P2014, P2016, P2017, P2018 INTAKE MANIFOLD RUNNER CONTROL VALVE POSITION SENSOR.........................................................................................1696 DTC Logic...........................................................................................................................................................1696 DTC DETECTION LOGIC.............................................................................................................................................1696 DTC CONFIRMATION PROCEDURE......................................................................................................................................1696 Diagnosis Procedure.................................................................................................................................................1696 P2096, P2097, P2098, P2099 A/F SENSOR 1.................................................................................................................................1699 Component Description...............................................................................................................................................1699 On Board Diagnosis Logic............................................................................................................................................1699 DTC Confirmation Procedure..........................................................................................................................................1699 <GRAPHIC> WITH CONSULT..........................................................................................................................................1700 <GRAPHIC> WITH GST..............................................................................................................................................1700 Diagnosis Procedure.................................................................................................................................................1700 P2100, P2103 THROTTLE CONTROL MOTOR RELAY...............................................................................................................................1705 Component Description...............................................................................................................................................1705 On Board Diagnosis Logic............................................................................................................................................1705 FAIL-SAFE MODE..................................................................................................................................................1705 DTC Confirmation Procedure..........................................................................................................................................1705 PROCEDURE FOR DTC P2100.........................................................................................................................................1705 PROCEDURE FOR DTC P2103.........................................................................................................................................1705 Diagnosis Procedure.................................................................................................................................................1705 P2101 ELECTRIC THROTTLE CONTROL FUNCTION................................................................................................................................1708 Description.........................................................................................................................................................1708 On Board Diagnosis Logic............................................................................................................................................1708 FAIL-SAFE MODE..................................................................................................................................................1708 DTC Confirmation Procedure..........................................................................................................................................1708 Diagnosis Procedure.................................................................................................................................................1708 Component Inspection................................................................................................................................................1711 THROTTLE CONTROL MOTOR..........................................................................................................................................1711 P2118 THROTTLE CONTROL MOTOR............................................................................................................................................1712 Component Description...............................................................................................................................................1712 On Board Diagnosis Logic............................................................................................................................................1712 FAIL-SAFE MODE..................................................................................................................................................1712 DTC Confirmation Procedure..........................................................................................................................................1712 Diagnosis Procedure.................................................................................................................................................1712 Component Inspection................................................................................................................................................1713 THROTTLE CONTROL MOTOR..........................................................................................................................................1713 P2119 ELECTRIC THROTTLE CONTROL ACTUATOR................................................................................................................................1714 Component Description...............................................................................................................................................1714 On Board Diagnosis Logic............................................................................................................................................1714 FAIL-SAFE MODE..................................................................................................................................................1714 DTC Confirmation Procedure..........................................................................................................................................1714 PROCEDURE FOR MALFUNCTION A AND B...............................................................................................................................1714 PROCEDURE FOR MALFUNCTION C.....................................................................................................................................1715 <GRAPHIC> With CONSULT......................................................................................................................................1715 Diagnosis Procedure.................................................................................................................................................1715 P2122, P2123 APP SENSOR.................................................................................................................................................1716 Component Description...............................................................................................................................................1716 On Board Diagnosis Logic............................................................................................................................................1716 FAIL-SAFE MODE..................................................................................................................................................1716 DTC Confirmation Procedure..........................................................................................................................................1716 Diagnosis Procedure.................................................................................................................................................1717 Component Inspection................................................................................................................................................1718 ACCELERATOR PEDAL POSITION SENSOR...............................................................................................................................1718 P2127, P2128 APP SENSOR.................................................................................................................................................1719 Component Description...............................................................................................................................................1719 On Board Diagnosis Logic............................................................................................................................................1719 FAIL-SAFE MODE..................................................................................................................................................1719 DTC Confirmation Procedure..........................................................................................................................................1719 Diagnosis Procedure.................................................................................................................................................1719 Component Inspection................................................................................................................................................1721 ACCELERATOR PEDAL POSITION SENSOR...............................................................................................................................1721 P2135 TP SENSOR.........................................................................................................................................................1723 Component Description...............................................................................................................................................1723 On Board Diagnosis Logic............................................................................................................................................1723 FAIL-SAFE MODE..................................................................................................................................................1723 DTC Confirmation Procedure..........................................................................................................................................1723 Diagnosis Procedure.................................................................................................................................................1723 Component Inspection................................................................................................................................................1725 THROTTLE POSITION SENSOR........................................................................................................................................1725 P2138 APP SENSOR........................................................................................................................................................1727 Component Description...............................................................................................................................................1727 On Board Diagnosis Logic............................................................................................................................................1727 FAIL-SAFE MODE..................................................................................................................................................1727 DTC Confirmation Procedure..........................................................................................................................................1727 Diagnosis Procedure.................................................................................................................................................1728 Component Inspection................................................................................................................................................1730 ACCELERATOR PEDAL POSITION SENSOR...............................................................................................................................1730 ASCD BRAKE SWITCH.......................................................................................................................................................1731 Component Description...............................................................................................................................................1731 Diagnosis Procedure.................................................................................................................................................1731 A/T MODELS......................................................................................................................................................1731 M/T MODELS......................................................................................................................................................1733 Component Inspection................................................................................................................................................1736 BRAKE PEDAL POSITION SWITCH.....................................................................................................................................1736 CLUTCH PEDAL POSITION SWITCH....................................................................................................................................1736 STOP LAMP SWITCH ...............................................................................................................................................1736 ASCD INDICATOR..........................................................................................................................................................1737 Component Description...............................................................................................................................................1737 Diagnosis Procedure.................................................................................................................................................1737 COOLING FAN.............................................................................................................................................................1738 Description.........................................................................................................................................................1738 COMPONENT DESCRIPTION...........................................................................................................................................1738 Cooling Fan Motor...........................................................................................................................................1738 Diagnosis Procedure.................................................................................................................................................1738 Component Inspection................................................................................................................................................1739 COOLING FAN MOTOR...............................................................................................................................................1739 ELECTRICAL LOAD SIGNAL..................................................................................................................................................1740 Description.........................................................................................................................................................1740 Diagnosis Procedure.................................................................................................................................................1740 FUEL INJECTOR...........................................................................................................................................................1742 Component Description...............................................................................................................................................1742 Diagnosis Procedure.................................................................................................................................................1742 Component Inspection................................................................................................................................................1744 FUEL INJECTOR...................................................................................................................................................1744 FUEL PUMP...............................................................................................................................................................1746 Description.........................................................................................................................................................1746 SYSTEM DESCRIPTION..............................................................................................................................................1746 COMPONENT DESCRIPTION...........................................................................................................................................1746 Diagnosis Procedure.................................................................................................................................................1746 Component Inspection................................................................................................................................................1748 FUEL PUMP.......................................................................................................................................................1748 IGNITION SIGNAL.........................................................................................................................................................1749 Component Description...............................................................................................................................................1749 IGNITION COIL & POWER TRANSISTOR................................................................................................................................1749 Diagnosis Procedure.................................................................................................................................................1749 Component Inspection................................................................................................................................................1752 IGNITION COIL WITH POWER TRANSISTOR.............................................................................................................................1752 CONDENSER-1.....................................................................................................................................................1753 ON BOARD REFUELING VAPOR RECOVERY (ORVR)................................................................................................................................1754 System Description..................................................................................................................................................1754 Diagnosis Procedure.................................................................................................................................................1754 SYMPTOM: FUEL ODOR FROM EVAP CANISTER IS STRONG.................................................................................................................1754 SYMPTOM: CANNOT REFUEL/FUEL ODOR FROM THE FUEL FILLER OPENING IS STRONG WHILE REFUELING.........................................................................1755 Component Inspection................................................................................................................................................1757 REFUELING EVAP VAPOR CUT VALVE..................................................................................................................................1757 <GRAPHIC> With CONSULT......................................................................................................................................1757 <GRAPHIC> Without CONSULT...................................................................................................................................1757 DRAIN FILTER....................................................................................................................................................1758 POSITIVE CRANKCASE VENTILATION..........................................................................................................................................1759 Description.........................................................................................................................................................1759 SYSTEM DESCRIPTION..............................................................................................................................................1759 Component Inspection................................................................................................................................................1759 PCV (POSITIVE CRANKCASE VENTILATION) VALVE......................................................................................................................1759 PCV VALVE VENTILATION HOSE......................................................................................................................................1760 REFRIGERANT PRESSURE SENSOR.............................................................................................................................................1761 Component Description...............................................................................................................................................1761 Diagnosis Procedure.................................................................................................................................................1761 VIAS....................................................................................................................................................................1764 Diagnosis Procedure.................................................................................................................................................1764 Component Inspection................................................................................................................................................1766 VIAS CONTROL SOLENOID VALVE.....................................................................................................................................1766 <GRAPHIC> With CONSULT......................................................................................................................................1766 <GRAPHIC> Without CONSULT...................................................................................................................................1766 VACUUM TANK.....................................................................................................................................................1766 SYMPTOM DIAGNOSIS...........................................................................................................................................................1768 ENGINE CONTROL SYSTEM SYMPTOMS..........................................................................................................................................1768 Symptom Matrix Chart................................................................................................................................................1768 SYSTEM - BASIC ENGINE CONTROL SYSTEM............................................................................................................................1768 SYSTEM - ENGINE MECHANICAL & OTHER..............................................................................................................................1769 NORMAL OPERATING CONDITION..............................................................................................................................................1772 Fuel Cut Control (at No Load and High Engine Speed).................................................................................................................1772 INPUT/OUTPUT SIGNAL CHART.......................................................................................................................................1772 SYSTEM DESCRIPTION..............................................................................................................................................1772 PERIODIC MAINTENANCE........................................................................................................................................................1773 FUEL PRESSURE...........................................................................................................................................................1773 Fuel Pressure Check.................................................................................................................................................1773 FUEL PRESSURE RELEASE...........................................................................................................................................1773 <GRAPHIC> With CONSULT......................................................................................................................................1773 <GRAPHIC> Without CONSULT...................................................................................................................................1773 FUEL PRESSURE CHECK.............................................................................................................................................1773 EVAP LEAK CHECK.........................................................................................................................................................1775 How to Detect Fuel Vapor Leakage....................................................................................................................................1775 <GRAPHIC> WITH CONSULT..........................................................................................................................................1775 <GRAPHIC> WITHOUT CONSULT.......................................................................................................................................1775 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1776 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1776 Fuel Pressure.......................................................................................................................................................1776 Idle Speed and Ignition Timing......................................................................................................................................1776 Calculated Load Value...............................................................................................................................................1776 Mass Air Flow Sensor................................................................................................................................................1776 Intake Air Temperature Sensor.......................................................................................................................................1776 Engine Coolant Temperature Sensor...................................................................................................................................1776 Air Fuel Ratio (A/F) Sensor 1 Heater................................................................................................................................1776 Heated Oxygen sensor 2 Heater.......................................................................................................................................1777 Crankshaft Position Sensor (POS)....................................................................................................................................1777 Camshaft Position Sensor (PHASE)....................................................................................................................................1777 Throttle Control Motor..............................................................................................................................................1777 Fuel Injector.......................................................................................................................................................1777 Fuel Pump...........................................................................................................................................................1777 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 EM......................................................................................................................................................................................1778 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................1778 VQ40DE..........................................................................................................................................................................1780 PRECAUTION..................................................................................................................................................................1780 PRECAUTIONS.............................................................................................................................................................1780 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................1780 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................1780 Precaution for Drain Engine Coolant.................................................................................................................................1780 Precaution for Disconnecting Fuel Piping............................................................................................................................1780 Precaution for Removal and Disassembly..............................................................................................................................1780 Precaution for Inspection, Repair and Replacement...................................................................................................................1780 Precaution for Assembly and Installation............................................................................................................................1781 Parts Requiring Angle Tightening....................................................................................................................................1781 Precaution for Liquid Gasket........................................................................................................................................1781 REMOVAL OF LIQUID GASKET .......................................................................................................................................1781 LIQUID GASKET APPLICATION PROCEDURE.............................................................................................................................1781 PREPARATION.................................................................................................................................................................1783 PREPARATION.............................................................................................................................................................1783 Special Service Tool................................................................................................................................................1783 Commercial Service Tool.............................................................................................................................................1785 SYSTEM DESCRIPTION..........................................................................................................................................................1788 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING....................................................................................................................1788 NVH Troubleshooting - Engine Noise..................................................................................................................................1788 Use the Chart Below to Help You Find the Cause of the Symptom.......................................................................................................1788 PERIODIC MAINTENANCE........................................................................................................................................................1790 DRIVE BELTS.............................................................................................................................................................1790 Exploded View.......................................................................................................................................................1790 Checking Drive Belts................................................................................................................................................1790 Adjustment..........................................................................................................................................................1790 Removal and Installation............................................................................................................................................1790 REMOVAL.........................................................................................................................................................1790 INSTALLATION....................................................................................................................................................1791 Drive Belt Auto-Tensioner and Idler Pulley..........................................................................................................................1791 REMOVAL.........................................................................................................................................................1791 INSTALLATION....................................................................................................................................................1791 AIR CLEANER FILTER......................................................................................................................................................1792 Exploded View.......................................................................................................................................................1792 Removal and Installation............................................................................................................................................1792 REMOVAL.........................................................................................................................................................1792 INSTALLATION....................................................................................................................................................1792 SPARK PLUG..............................................................................................................................................................1793 Exploded View.......................................................................................................................................................1793 Removal and Installation............................................................................................................................................1793 REMOVAL.........................................................................................................................................................1793 INSPECTION AFTER REMOVAL........................................................................................................................................1793 INSTALLATION....................................................................................................................................................1794 CAMSHAFT VALVE CLEARANCE................................................................................................................................................1795 Valve Clearance.....................................................................................................................................................1795 INSPECTION......................................................................................................................................................1795 ADJUSTMENT......................................................................................................................................................1797 COMPRESSION PRESSURE....................................................................................................................................................1799 Compression Pressure................................................................................................................................................1799 CHECKING COMPRESSION PRESSURE...................................................................................................................................1799 REMOVAL AND INSTALLATION....................................................................................................................................................1801 AIR CLEANER AND AIR DUCT................................................................................................................................................1801 Exploded View.......................................................................................................................................................1801 Removal and Installation............................................................................................................................................1801 REMOVAL.........................................................................................................................................................1801 INSPECTION AFTER REMOVAL........................................................................................................................................1801 INSTALLATION....................................................................................................................................................1801 INTAKE MANIFOLD COLLECTOR...............................................................................................................................................1802 Exploded View.......................................................................................................................................................1802 Removal and Installation............................................................................................................................................1802 REMOVAL.........................................................................................................................................................1802 INSTALLATION....................................................................................................................................................1803 Intake Manifold Collector...................................................................................................................................1803 Intake Manifold Collector Support...........................................................................................................................1804 Electric Throttle Control Actuator..........................................................................................................................1804 INTAKE MANIFOLD.........................................................................................................................................................1805 Exploded View.......................................................................................................................................................1805 Removal and Installation............................................................................................................................................1805 REMOVAL.........................................................................................................................................................1805 INSPECTION AFTER REMOVAL........................................................................................................................................1805 Surface Distortion..........................................................................................................................................1805 INSTALLATION....................................................................................................................................................1806 Intake Manifold.............................................................................................................................................1806 EXHAUST MANIFOLD AND THREE WAY CATALYST.................................................................................................................................1807 Exploded View.......................................................................................................................................................1807 Removal and Installation (Three Way Catalyst).......................................................................................................................1807 REMOVAL ........................................................................................................................................................1807 INSTALLATION....................................................................................................................................................1808 Removal and Installation (Exhaust Manifold).........................................................................................................................1808 REMOVAL (LH)....................................................................................................................................................1808 INSPECTION AFTER REMOVAL (LH)...................................................................................................................................1808 Surface Distortion..........................................................................................................................................1808 INSTALLATION (LH)...............................................................................................................................................1809 Exhaust Manifold Gasket.....................................................................................................................................1809 Exhaust Manifold............................................................................................................................................1809 REMOVAL (RH)....................................................................................................................................................1809 INSPECTION AFTER REMOVAL (RH)...................................................................................................................................1810 Surface Distortion..........................................................................................................................................1810 INSTALLATION (RH)...............................................................................................................................................1810 Exhaust Manifold Gasket.....................................................................................................................................1810 Exhaust Manifold............................................................................................................................................1810 OIL PAN AND OIL STRAINER................................................................................................................................................1811 Exploded View.......................................................................................................................................................1811 Removal and Installation............................................................................................................................................1811 REMOVAL (LOWER).................................................................................................................................................1811 INSPECTION AFTER REMOVAL........................................................................................................................................1812 INSTALLATION (LOWER)............................................................................................................................................1812 INSPECTION AFTER INSTALLATION...................................................................................................................................1813 REMOVAL (UPPER).................................................................................................................................................1813 INSPECTION AFTER REMOVAL........................................................................................................................................1814 INSTALLATION (UPPER)............................................................................................................................................1814 INSPECTION AFTER INSTALLATION...................................................................................................................................1815 IGNITION COIL...........................................................................................................................................................1817 Exploded View.......................................................................................................................................................1817 Removal and Installation............................................................................................................................................1817 REMOVAL (LH)....................................................................................................................................................1817 INSTALLATION (LH)...............................................................................................................................................1817 REMOVAL (RH)....................................................................................................................................................1817 INSTALLATION (RH)...............................................................................................................................................1817 ROCKER COVER............................................................................................................................................................1818 Exploded View.......................................................................................................................................................1818 Removal and Installation............................................................................................................................................1818 REMOVAL (LH)....................................................................................................................................................1818 INSTALLATION (LH)...............................................................................................................................................1819 REMOVAL (RH)....................................................................................................................................................1819 INSTALLATION (RH)...............................................................................................................................................1820 FUEL INJECTOR AND FUEL TUBE.............................................................................................................................................1822 Exploded View.......................................................................................................................................................1822 Removal and Installation............................................................................................................................................1822 REMOVAL.........................................................................................................................................................1822 INSTALLATION....................................................................................................................................................1824 INSPECTION AFTER INSTALLATION...................................................................................................................................1826 Check on Fuel Leakage.......................................................................................................................................1826 INTAKE VALVE TIMING CONTROL.............................................................................................................................................1827 Intake Valve Timing Control Solenoid Valve (LH).....................................................................................................................1827 REMOVAL.........................................................................................................................................................1827 INSTALLATION....................................................................................................................................................1827 Intake Valve Timing Control Solenoid Valve (RH).....................................................................................................................1827 REMOVAL.........................................................................................................................................................1827 INSTALLATION....................................................................................................................................................1827 FRONT TIMING CHAIN CASE.................................................................................................................................................1828 Exploded View.......................................................................................................................................................1828 Removal and Installation............................................................................................................................................1828 REMOVAL.........................................................................................................................................................1828 INSTALLATION....................................................................................................................................................1831 INSPECTION AFTER INSTALLATION...................................................................................................................................1835 TIMING CHAIN............................................................................................................................................................1836 Exploded View.......................................................................................................................................................1836 Removal and Installation............................................................................................................................................1836 REMOVAL.........................................................................................................................................................1836 INSPECTION AFTER REMOVAL........................................................................................................................................1838 INSTALLATION....................................................................................................................................................1838 INSPECTION AFTER INSTALLATION...................................................................................................................................1842 TIMING CHAIN TENSIONER..................................................................................................................................................1844 Exploded View.......................................................................................................................................................1844 Removal and Installation (Primary Timing Chain Tensioner)...........................................................................................................1844 REMOVAL.........................................................................................................................................................1844 INSTALLATION....................................................................................................................................................1845 Removal and Installation (Secondary Timing Chain Tensioner).........................................................................................................1845 REMOVAL.........................................................................................................................................................1845 INSTALLATION....................................................................................................................................................1845 Removal and Installation (Secondary Timing Chain Tensioner Shoe)....................................................................................................1845 REMOVAL.........................................................................................................................................................1845 INSTALLATION....................................................................................................................................................1846 REAR TIMING CHAIN CASE..................................................................................................................................................1847 Exploded View.......................................................................................................................................................1847 Removal and Installation............................................................................................................................................1847 REMOVAL.........................................................................................................................................................1847 INSTALLATION....................................................................................................................................................1849 INSPECTION AFTER INSTALLATION...................................................................................................................................1851 CAMSHAFT................................................................................................................................................................1852 Exploded View.......................................................................................................................................................1852 Removal and Installation............................................................................................................................................1853 REMOVAL.........................................................................................................................................................1853 INSPECTION AFTER REMOVAL........................................................................................................................................1854 Camshaft Runout.............................................................................................................................................1854 Camshaft Cam Height.........................................................................................................................................1854 Camshaft Journal Oil Clearance..............................................................................................................................1855 Camshaft End Play...........................................................................................................................................1855 Camshaft Sprocket Runout....................................................................................................................................1856 Valve Lifter ...............................................................................................................................................1856 Valve Lifter Clearance......................................................................................................................................1856 INSTALLATION....................................................................................................................................................1857 INSPECTION AFTER INSTALLATION...................................................................................................................................1860 Inspection of Camshaft Sprocket (INT) Oil Groove............................................................................................................1860 INSPECTION AFTER INSTALLATION...................................................................................................................................1861 OIL SEAL................................................................................................................................................................1862 Removal and Installation of Valve Oil Seal..........................................................................................................................1862 REMOVAL.........................................................................................................................................................1862 INSTALLATION....................................................................................................................................................1862 Removal and Installation of Front Oil Seal..........................................................................................................................1862 REMOVAL.........................................................................................................................................................1862 INSTALLATION....................................................................................................................................................1863 Removal and Installation of Rear Oil Seal...........................................................................................................................1863 REMOVAL.........................................................................................................................................................1863 INSTALLATION....................................................................................................................................................1864 CYLINDER HEAD...........................................................................................................................................................1865 Exploded View.......................................................................................................................................................1865 Removal and Installation............................................................................................................................................1865 REMOVAL.........................................................................................................................................................1865 INSPECTION AFTER REMOVAL........................................................................................................................................1866 Cylinder Head Bolts Outer Diameter..........................................................................................................................1866 Cylinder Head Distortion....................................................................................................................................1866 INSTALLATION....................................................................................................................................................1866 INSPECTION AFTER INSTALLATION...................................................................................................................................1868 Exploded View.......................................................................................................................................................1869 Disassembly and Assembly............................................................................................................................................1869 DISASSEMBLY.....................................................................................................................................................1869 ASSEMBLY........................................................................................................................................................1870 Inspection After Disassembly........................................................................................................................................1871 VALVE DIMENSIONS................................................................................................................................................1871 VALVE GUIDE CLEARANCE...........................................................................................................................................1871 Valve Stem Diameter.........................................................................................................................................1871 Valve Guide Inner Diameter..................................................................................................................................1871 Valve Guide Clearance.......................................................................................................................................1872 VALVE GUIDE REPLACEMENT.........................................................................................................................................1872 VALVE SEAT CONTACT..............................................................................................................................................1873 VALVE SEAT REPLACEMENT..........................................................................................................................................1873 VALVE SPRING SQUARENESS.........................................................................................................................................1874 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD..........................................................................................................1874 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................1876 ENGINE ASSEMBLY.........................................................................................................................................................1876 Exploded View.......................................................................................................................................................1876 Removal and Installation............................................................................................................................................1876 REMOVAL.........................................................................................................................................................1877 Preparation.................................................................................................................................................1877 INSTALLATION....................................................................................................................................................1878 INSPECTION AFTER INSTALLATION...................................................................................................................................1878 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................1879 ENGINE UNIT.............................................................................................................................................................1879 Exploded View.......................................................................................................................................................1879 Disassembly and Assembly............................................................................................................................................1880 DISASSEMBLY.....................................................................................................................................................1880 ASSEMBLY........................................................................................................................................................1883 Inspection After Disassembly........................................................................................................................................1889 CRANKSHAFT END PLAY.............................................................................................................................................1889 CONNECTING ROD SIDE CLEARANCE...................................................................................................................................1889 PISTON TO PISTON PIN CLEARANCE..................................................................................................................................1890 Piston Pin Hole Diameter....................................................................................................................................1890 Piston Pin Outer Diameter...................................................................................................................................1890 Piston to Piston Pin Oil Clearance..........................................................................................................................1890 PISTON RING SIDE CLEARANCE......................................................................................................................................1890 PISTON RING END GAP.............................................................................................................................................1891 CONNECTING ROD BEND AND TORSION.................................................................................................................................1891 CONNECTING ROD DIAMETER (BIG END)...............................................................................................................................1891 CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)................................................................................................................1892 Connecting Rod Bushing Inside Diameter (Small End)..........................................................................................................1892 Piston Pin Diameter.........................................................................................................................................1892 Connecting Rod Bushing Oil Clearance (Small End)............................................................................................................1892 CYLINDER BLOCK DISTORTION.......................................................................................................................................1893 MAIN BEARING HOUSING INNER DIAMETER.............................................................................................................................1893 PISTON TO CYLINDER BORE CLEARANCE...............................................................................................................................1893 Cylinder Bore Inner Diameter................................................................................................................................1893 Piston Skirt Diameter.......................................................................................................................................1894 Piston to Cylinder Bore Clearance...........................................................................................................................1894 Re-boring Cylinder Bore.....................................................................................................................................1894 CRANKSHAFT MAIN JOURNAL DIAMETER................................................................................................................................1894 CRANKSHAFT PIN JOURNAL DIAMETER.................................................................................................................................1895 OUT-OF-ROUND AND TAPER OF CRANKSHAFT............................................................................................................................1895 CRANKSHAFT RUNOUT...............................................................................................................................................1895 CONNECTING ROD BEARING OIL CLEARANCE............................................................................................................................1895 Method by Calculation.......................................................................................................................................1895 Method of Using Plastigage..................................................................................................................................1896 MAIN BEARING OIL CLEARANCE......................................................................................................................................1896 Method by Calculation.......................................................................................................................................1896 Method of Using Plastigage..................................................................................................................................1896 CRUSH HEIGHT OF MAIN BEARING....................................................................................................................................1897 CRUSH HEIGHT OF CONNECTING ROD BEARING..........................................................................................................................1897 LOWER CYLINDER BLOCK BOLT OUTER DIAMETER........................................................................................................................1897 CONNECTING ROD BOLT OUTER DIAMETER..............................................................................................................................1897 FLYWHEEL RUNOUT (M/T MODELS)....................................................................................................................................1898 Flywheel Deflection.........................................................................................................................................1898 MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)........................................................................................................................1898 Movement Amount of Thrust (Fore-and-Aft) Direction..........................................................................................................1898 Movement Amount in Radial (Rotation) Direction..............................................................................................................1898 DRIVE PLATE (A/T MODELS)........................................................................................................................................1898 OIL JET.........................................................................................................................................................1899 OIL JET RELIEF VALVE............................................................................................................................................1899 Dowel Pin Alignment.................................................................................................................................................1899 REMOVAL.........................................................................................................................................................1899 INSTALLATION (A/T MODELS).......................................................................................................................................1899 INSTALLATION (M/T MODELS).......................................................................................................................................1900 HOW TO SELECT PISTON AND BEARING........................................................................................................................................1901 How to Select Piston and Bearing....................................................................................................................................1901 DESCRIPTION.....................................................................................................................................................1901 HOW TO SELECT PISTON............................................................................................................................................1901 When New Cylinder Block is Used.............................................................................................................................1901 When Cylinder Block is Reused...............................................................................................................................1901 Piston Selection Table......................................................................................................................................1902 HOW TO SELECT CONNECTING ROD BEARING............................................................................................................................1902 When New Connecting Rod and Crankshaft are Used.............................................................................................................1902 When Crankshaft and Connecting Rod are Reused...............................................................................................................1902 Connecting Rod Bearing Selection Table......................................................................................................................1902 Undersize Bearings Usage Guide..............................................................................................................................1902 HOW TO SELECT MAIN BEARING......................................................................................................................................1903 When New Cylinder Block and Crankshaft are Used.............................................................................................................1903 When Cylinder Block and Crankshaft are Reused...............................................................................................................1903 Main Bearing Selection Table................................................................................................................................1904 Main Bearing Grade Table (All Journals).....................................................................................................................1904 Undersize Bearing Usage Guide...............................................................................................................................1905 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................1906 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................1906 Standard and Limit..................................................................................................................................................1906 GENERAL SPECIFICATIONS..........................................................................................................................................1906 DRIVE BELT......................................................................................................................................................1906 INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD.................................................................................................1906 SPARK PLUG......................................................................................................................................................1907 CAMSHAFT AND CAMSHAFT BEARING...................................................................................................................................1907 Valve Seal..................................................................................................................................................1907 Valve Lifter................................................................................................................................................1907 Valve Clearance.............................................................................................................................................1908 Available Valve Lifter......................................................................................................................................1908 CYLINDER HEAD...................................................................................................................................................1909 Valve Dimensions............................................................................................................................................1909 Valve Guide.................................................................................................................................................1910 Valve Seat..................................................................................................................................................1910 Valve Spring................................................................................................................................................1911 Spark Plug Tube.............................................................................................................................................1911 CYLINDER BLOCK..................................................................................................................................................1911 PISTON, PISTON RING AND PISTON PIN..............................................................................................................................1912 Available Piston............................................................................................................................................1912 Piston Ring.................................................................................................................................................1912 Piston Pin..................................................................................................................................................1913 CONNECTING ROD..................................................................................................................................................1913 CRANKSHAFT......................................................................................................................................................1913 MAIN BEARING....................................................................................................................................................1914 Undersize...................................................................................................................................................1915 Main Bearing Oil Clearance..................................................................................................................................1915 CONNECTING ROD BEARING..........................................................................................................................................1915 Undersize...................................................................................................................................................1915 Connecting Rod Bearing Oil Clearance........................................................................................................................1915 EX......................................................................................................................................................................................1917 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................1917 PRECAUTION......................................................................................................................................................................1918 PRECAUTIONS.................................................................................................................................................................1918 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................1918 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................1918 PREPARATION.....................................................................................................................................................................1919 PREPARATION.................................................................................................................................................................1919 Special Service Tool....................................................................................................................................................1919 Commercial Service Tool.................................................................................................................................................1919 PERIODIC MAINTENANCE............................................................................................................................................................1920 EXHAUST SYSTEM..............................................................................................................................................................1920 Checking Exhaust System.................................................................................................................................................1920 REMOVAL AND INSTALLATION........................................................................................................................................................1921 EXHAUST SYSTEM..............................................................................................................................................................1921 Exploded View...........................................................................................................................................................1921 Removal and Installation................................................................................................................................................1921 REMOVAL.............................................................................................................................................................1921 INSTALLATION........................................................................................................................................................1921 INSPECTION AFTER INSTALLATION.......................................................................................................................................1922 EXL.....................................................................................................................................................................................1923 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................1923 BASIC INSPECTION................................................................................................................................................................1926 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................1926 Work Flow...............................................................................................................................................................1926 OVERALL SEQUENCE....................................................................................................................................................1926 DETAILED FLOW.......................................................................................................................................................1927 SYSTEM DESCRIPTION..............................................................................................................................................................1929 HEADLAMP....................................................................................................................................................................1929 System Diagram..........................................................................................................................................................1929 System Description......................................................................................................................................................1929 HIGH BEAM OPERATION/FLASH-TO-PASS OPERATION.........................................................................................................................1929 Component Parts Location................................................................................................................................................1929 Component Description...................................................................................................................................................1930 DAYTIME RUNNING LIGHT SYSTEM................................................................................................................................................1931 System Diagram..........................................................................................................................................................1931 System Description......................................................................................................................................................1931 OPERATION...........................................................................................................................................................1931 Component Parts Location................................................................................................................................................1932 Component Description...................................................................................................................................................1932 AUTO LIGHT SYSTEM...........................................................................................................................................................1934 System Diagram..........................................................................................................................................................1934 System Description......................................................................................................................................................1934 AUTO LIGHT OPERATION................................................................................................................................................1934 Component Parts Location................................................................................................................................................1935 Component Description...................................................................................................................................................1935 OFF-ROAD LAMPS..............................................................................................................................................................1936 System Diagram..........................................................................................................................................................1936 System Description......................................................................................................................................................1936 OFF ROAD LAMP OPERATION.............................................................................................................................................1936 Component Parts Location................................................................................................................................................1936 Component Description...................................................................................................................................................1937 FRONT FOG LAMP..............................................................................................................................................................1938 System Diagram..........................................................................................................................................................1938 System Description......................................................................................................................................................1938 FRONT FOG LAMP OPERATION............................................................................................................................................1938 Component Parts Location................................................................................................................................................1938 Component Description...................................................................................................................................................1938 TURN SIGNAL AND HAZARD WARNING LAMPS........................................................................................................................................1940 System Diagram..........................................................................................................................................................1940 System Description......................................................................................................................................................1940 TURN SIGNAL OPERATION...............................................................................................................................................1940 HAZARD LAMP OPERATION...............................................................................................................................................1940 REMOTE KEYLESS ENTRY OPERATION......................................................................................................................................1940 Component Parts Location................................................................................................................................................1940 Component Description...................................................................................................................................................1941 PARKING, LICENSE PLATE AND TAIL LAMPS.......................................................................................................................................1942 System Diagram..........................................................................................................................................................1942 System Description......................................................................................................................................................1942 PARKING, LICENCE PLATE AND TAIL LAMPS OPERATION.....................................................................................................................1942 EXTERIOR LAMP BATTERY SAVER CONTROL.................................................................................................................................1942 Component Parts Location................................................................................................................................................1942 Component Description...................................................................................................................................................1943 TRAILER TOW.................................................................................................................................................................1944 System Diagram..........................................................................................................................................................1944 System Description......................................................................................................................................................1944 TRAILER TAIL LAMP OPERATION.........................................................................................................................................1944 TRAILER TURN SIGNAL LAMP OPERATION..................................................................................................................................1944 TRAILER HAZARD LAMP OPERATION.......................................................................................................................................1944 TRAILER BRAKE LAMP OPERATION........................................................................................................................................1944 Component Parts Location................................................................................................................................................1945 Component Description...................................................................................................................................................1945 COMBINATION SWITCH READING SYSTEM...........................................................................................................................................1946 System Diagram..........................................................................................................................................................1946 System Description......................................................................................................................................................1946 OUTLINE.............................................................................................................................................................1946 COMBINATION SWITCH MATRIX...........................................................................................................................................1946 COMBINATION SWITCH READING FUNCTION.................................................................................................................................1947 Description.....................................................................................................................................................1947 Operation Example...............................................................................................................................................1947 WIPER INTERMITTENT DIAL POSITION SETTING (FRONT WIPER INTERMITTENT OPERATION).......................................................................................1948 Component Parts Location................................................................................................................................................1949 DIAGNOSIS SYSTEM (BCM)......................................................................................................................................................1950 COMMON ITEM.............................................................................................................................................................1950 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM)..................................................................................................................1950 APPLICATION ITEM................................................................................................................................................1950 SYSTEM APPLICATION..............................................................................................................................................1950 HEADLAMP................................................................................................................................................................1950 HEADLAMP : CONSULT Function (BCM - HEAD LAMP).......................................................................................................................1951 DATA MONITOR....................................................................................................................................................1951 ACTIVE TEST.....................................................................................................................................................1951 WORK SUPPORT....................................................................................................................................................1951 FLASHER.................................................................................................................................................................1952 FLASHER : CONSULT Function (BCM - FLASHER)..........................................................................................................................1952 DATA MONITOR....................................................................................................................................................1952 ACTIVE TEST.....................................................................................................................................................1952 COMB SW.................................................................................................................................................................1952 COMB SW : CONSULT Function (BCM - COMB SW)..........................................................................................................................1952 DATA MONITOR....................................................................................................................................................1952 DIAGNOSIS SYSTEM (IPDM E/R).................................................................................................................................................1954 Diagnosis Description...................................................................................................................................................1954 AUTO ACTIVE TEST....................................................................................................................................................1954 Description.....................................................................................................................................................1954 Operation Procedure.............................................................................................................................................1954 Inspection in Auto Active Test Mode.............................................................................................................................1954 Concept of auto active test.....................................................................................................................................1955 Diagnosis chart in auto active test mode........................................................................................................................1955 CONSULT Function (IPDM E/R).............................................................................................................................................1956 APPLICATION ITEM....................................................................................................................................................1956 SELF DIAGNOSTIC RESULT..............................................................................................................................................1956 DATA MONITOR........................................................................................................................................................1956 ACTIVE TEST.........................................................................................................................................................1957 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................1958 POWER SUPPLY AND GROUND CIRCUIT.............................................................................................................................................1958 BCM (BODY CONTROL MODULE)...............................................................................................................................................1958 BCM (BODY CONTROL MODULE) : Diagnosis Procedure.....................................................................................................................1958 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)............................................................................................................1959 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) : Diagnosis Procedure..................................................................................1959 HEADLAMP (HI) CIRCUIT.......................................................................................................................................................1961 Description.............................................................................................................................................................1961 Component Function Check................................................................................................................................................1961 Diagnosis Procedure.....................................................................................................................................................1961 HEADLAMP (LO) CIRCUIT.......................................................................................................................................................1964 Description.............................................................................................................................................................1964 Component Function Check................................................................................................................................................1964 Diagnosis Procedure.....................................................................................................................................................1964 Component Inspection....................................................................................................................................................1967 DAYTIME LIGHT RELAY CIRCUIT.................................................................................................................................................1968 Description.............................................................................................................................................................1968 Diagnosis Procedure.....................................................................................................................................................1968 Component Inspection....................................................................................................................................................1969 OFF-ROAD LAMPS SWITCH CIRCUIT...............................................................................................................................................1970 Description.............................................................................................................................................................1970 Component Function Check................................................................................................................................................1970 Diagnosis Procedure.....................................................................................................................................................1970 OFF-ROAD LAMP COVER SENSOR CIRCUIT..........................................................................................................................................1972 Description.............................................................................................................................................................1972 Component Function Check................................................................................................................................................1972 Diagnosis Procedure.....................................................................................................................................................1972 OFF-ROAD LAMPS CIRCUIT......................................................................................................................................................1975 Description.............................................................................................................................................................1975 Component Function Check................................................................................................................................................1975 Diagnosis Procedure.....................................................................................................................................................1975 Component Inspection....................................................................................................................................................1977 FRONT FOG LAMP CIRCUIT......................................................................................................................................................1978 Description.............................................................................................................................................................1978 Component Function Check................................................................................................................................................1978 Diagnosis Procedure.....................................................................................................................................................1978 PARKING LAMP CIRCUIT........................................................................................................................................................1980 Description.............................................................................................................................................................1980 Component Function Check................................................................................................................................................1980 Diagnosis Procedure.....................................................................................................................................................1980 TURN SIGNAL LAMP CIRCUIT....................................................................................................................................................1983 Description.............................................................................................................................................................1983 Component Function Check................................................................................................................................................1983 Diagnosis Procedure.....................................................................................................................................................1983 OPTICAL SENSOR..............................................................................................................................................................1986 Description.............................................................................................................................................................1986 Diagnosis Procedure.....................................................................................................................................................1986 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................1987 BCM (BODY CONTROL MODULE)...................................................................................................................................................1987 Reference Value.........................................................................................................................................................1987 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................1987 Terminal Layout.........................................................................................................................................................1990 Physical Values.........................................................................................................................................................1990 Fail Safe...............................................................................................................................................................1995 Fail-safe index.....................................................................................................................................................1995 DTC Inspection Priority Chart...........................................................................................................................................1995 DTC Index...............................................................................................................................................................1996 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)................................................................................................................1998 Reference Value.........................................................................................................................................................1998 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................1998 Terminal Layout.........................................................................................................................................................1999 Physical Values.........................................................................................................................................................1999 PHYSICAL VALUES.....................................................................................................................................................1999 Fail Safe...............................................................................................................................................................2003 CAN COMMUNICATION CONTROL...........................................................................................................................................2003 If No CAN Communication Is Available With ECM...................................................................................................................2003 If No CAN Communication Is Available With BCM...................................................................................................................2003 IGNITION RELAY MALFUNCTION DETECTION FUNCTION.......................................................................................................................2003 FRONT WIPER CONTROL.................................................................................................................................................2003 STARTER MOTOR PROTECTION FUNCTION...................................................................................................................................2003 DTC Index...............................................................................................................................................................2004 WIRING DIAGRAM..................................................................................................................................................................2005 HEADLAMP....................................................................................................................................................................2005 Wiring Diagram .........................................................................................................................................................2005 DAYTIME LIGHT SYSTEM........................................................................................................................................................2009 Wiring Diagram..........................................................................................................................................................2009 AUTO LIGHT SYSTEM...........................................................................................................................................................2017 Wiring Diagram..........................................................................................................................................................2017 FRONT FOG LAMP SYSTEM.......................................................................................................................................................2022 Wiring Diagram..........................................................................................................................................................2022 OFF-ROAD LAMPS..............................................................................................................................................................2026 Wiring Diagram..........................................................................................................................................................2026 TURN SIGNAL AND HAZARD WARNING LAMP SYSTEM..................................................................................................................................2031 Wiring Diagram..........................................................................................................................................................2031 PARKING, LICENSE PLATE AND TAIL LAMPS SYSTEM................................................................................................................................2037 Wiring Diagram..........................................................................................................................................................2037 STOP LAMP...................................................................................................................................................................2043 Wiring Diagram..........................................................................................................................................................2043 BACK-UP LAMP................................................................................................................................................................2047 Wiring Diagram..........................................................................................................................................................2047 TRAILER TOW.................................................................................................................................................................2051 Wiring Diagram..........................................................................................................................................................2051 SYMPTOM DIAGNOSIS...............................................................................................................................................................2059 EXTERIOR LIGHTING SYSTEM SYMPTOMS...........................................................................................................................................2059 Symptom Table...........................................................................................................................................................2059 NORMAL OPERATING CONDITION..................................................................................................................................................2062 Description.............................................................................................................................................................2062 AUTO LIGHT SYSTEM...................................................................................................................................................2062 BOTH SIDE HEADLAMPS DO NOT SWITCH TO HIGH BEAM..............................................................................................................................2063 Description.............................................................................................................................................................2063 Diagnosis Procedure.....................................................................................................................................................2063 DAYTIME LIGHT SYSTEM INOPERATIVE............................................................................................................................................2064 Description.............................................................................................................................................................2064 Diagnosis Procedure.....................................................................................................................................................2064 BOTH SIDE HEADLAMPS (LO) ARE NOT TURNED ON..................................................................................................................................2065 Description.............................................................................................................................................................2065 Diagnosis Procedure.....................................................................................................................................................2065 PARKING, LICENSE PLATE AND TAIL LAMPS ARE NOT TURNED ON.....................................................................................................................2066 Description.............................................................................................................................................................2066 Diagnosis Procedure.....................................................................................................................................................2066 BOTH SIDE FRONT FOG LAMPS ARE NOT TURNED ON.................................................................................................................................2067 Description.............................................................................................................................................................2067 Diagnosis Procedure.....................................................................................................................................................2067 PRECAUTION......................................................................................................................................................................2068 PRECAUTIONS.................................................................................................................................................................2068 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2068 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2068 Precaution for Work.....................................................................................................................................................2068 PREPARATION.....................................................................................................................................................................2069 PREPARATION.................................................................................................................................................................2069 Special Service Tool....................................................................................................................................................2069 PERIODIC MAINTENANCE............................................................................................................................................................2070 ADJUSTMENT AND INSPECTION...................................................................................................................................................2070 HEADLAMP................................................................................................................................................................2070 HEADLAMP : Aiming Adjustment........................................................................................................................................2070 LOW BEAM AND HIGH BEAM..........................................................................................................................................2070 FRONT FOG LAMP..........................................................................................................................................................2071 FRONT FOG LAMP : Aiming Adjustment..................................................................................................................................2071 REMOVAL AND INSTALLATION........................................................................................................................................................2073 HEADLAMP....................................................................................................................................................................2073 Bulb Replacement........................................................................................................................................................2073 HEADLAMP............................................................................................................................................................2073 Removal.........................................................................................................................................................2073 Installation....................................................................................................................................................2073 FRONT TURN SIGNAL/PARKING LAMP......................................................................................................................................2073 Removal.........................................................................................................................................................2073 Installation....................................................................................................................................................2073 FRONT SIDE MARKER LAMP..............................................................................................................................................2073 Removal.........................................................................................................................................................2073 Installation....................................................................................................................................................2073 Removal and Installation................................................................................................................................................2073 FRONT COMBINATION LAMP..............................................................................................................................................2073 Removal.........................................................................................................................................................2073 Installation....................................................................................................................................................2074 Disassembly and Assembly................................................................................................................................................2074 FRONT COMBINATION LAMP..............................................................................................................................................2074 DISASSEMBLY.........................................................................................................................................................2074 ASSEMBLY............................................................................................................................................................2075 FRONT FOG LAMP..............................................................................................................................................................2076 Bulb Replacement........................................................................................................................................................2076 Removal and Installation................................................................................................................................................2076 FRONT FOG LAMP......................................................................................................................................................2076 Removal.........................................................................................................................................................2076 Installation....................................................................................................................................................2076 LIGHTING & TURN SIGNAL SWITCH...............................................................................................................................................2077 Removal and Installation................................................................................................................................................2077 REMOVAL.............................................................................................................................................................2077 INSTALLATION........................................................................................................................................................2077 HAZARD SWITCH...............................................................................................................................................................2078 Removal and Installation................................................................................................................................................2078 REMOVAL.............................................................................................................................................................2078 INSTALLATION........................................................................................................................................................2078 OPTICAL SENSOR..............................................................................................................................................................2079 Removal and Installation................................................................................................................................................2079 REMOVAL.............................................................................................................................................................2079 INSTALLATION........................................................................................................................................................2079 HIGH-MOUNTED STOP LAMP......................................................................................................................................................2080 High-Mounted Stop Lamp..................................................................................................................................................2080 BULB REPLACEMENT....................................................................................................................................................2080 REMOVAL AND INSTALLATION............................................................................................................................................2080 Removal.........................................................................................................................................................2080 Installation....................................................................................................................................................2080 LICENSE PLATE LAMP..........................................................................................................................................................2081 Bulb Replacement........................................................................................................................................................2081 REMOVAL.............................................................................................................................................................2081 IINSTALLATION.......................................................................................................................................................2081 Removal and Installation................................................................................................................................................2081 REMOVAL.............................................................................................................................................................2081 INSTALLATION........................................................................................................................................................2081 REAR COMBINATION LAMP.......................................................................................................................................................2082 Bulb Replacement........................................................................................................................................................2082 REMOVAL.............................................................................................................................................................2082 INSTALLATION........................................................................................................................................................2082 Removal and Installation................................................................................................................................................2082 REMOVAL.............................................................................................................................................................2082 INSTALLATION........................................................................................................................................................2083 OFF-ROAD LAMPS..............................................................................................................................................................2084 Removal and Installation................................................................................................................................................2084 OFF ROAD LAMPS......................................................................................................................................................2084 Removal.........................................................................................................................................................2084 Installation....................................................................................................................................................2084 Disassembly and Assembly................................................................................................................................................2085 Disassembly.........................................................................................................................................................2085 Assembly ...........................................................................................................................................................2085 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2086 BULB SPECIFICATIONS.........................................................................................................................................................2086 Bulb Specifications.....................................................................................................................................................2086 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 EXT.....................................................................................................................................................................................2087 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2087 PRECAUTION......................................................................................................................................................................2088 PRECAUTIONS.................................................................................................................................................................2088 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2088 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2088 Service Notice..........................................................................................................................................................2088 Precaution for Procedure without Cowl Top Cover.........................................................................................................................2088 Precaution for Work.....................................................................................................................................................2088 PREPARATION.....................................................................................................................................................................2090 PREPARATION.................................................................................................................................................................2090 Special Service Tool....................................................................................................................................................2090 Commercial Service Tool.................................................................................................................................................2090 CLIP LIST...................................................................................................................................................................2091 Descriptions for Clips..................................................................................................................................................2091 SYMPTOM DIAGNOSIS...............................................................................................................................................................2095 SQUEAK AND RATTLE TROUBLE DIAGNOSES.........................................................................................................................................2095 Work Flow...............................................................................................................................................................2095 CUSTOMER INTERVIEW..................................................................................................................................................2095 DUPLICATE THE NOISE AND TEST DRIVE..................................................................................................................................2095 CHECK RELATED SERVICE BULLETINS.....................................................................................................................................2096 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE........................................................................................................................2096 REPAIR THE CAUSE ...................................................................................................................................................2096 CONFIRM THE REPAIR..................................................................................................................................................2097 Generic Squeak and Rattle Troubleshooting...............................................................................................................................2097 INSTRUMENT PANEL....................................................................................................................................................2097 CENTER CONSOLE......................................................................................................................................................2097 DOORS...............................................................................................................................................................2097 TRUNK...............................................................................................................................................................2097 SUNROOF/HEADLINING..................................................................................................................................................2098 OVERHEAD CONSOLE (FRONT AND REAR)...................................................................................................................................2098 SEATS...............................................................................................................................................................2098 UNDERHOOD...........................................................................................................................................................2098 Diagnostic Worksheet....................................................................................................................................................2099 REMOVAL AND INSTALLATION........................................................................................................................................................2101 FRONT BUMPER................................................................................................................................................................2101 Removal and Installation................................................................................................................................................2101 REMOVAL.............................................................................................................................................................2102 INSTALLATION........................................................................................................................................................2102 REAR BUMPER.................................................................................................................................................................2103 Removal and Installation................................................................................................................................................2103 REMOVAL.............................................................................................................................................................2103 INSTALLATION........................................................................................................................................................2103 FRONT GRILLE................................................................................................................................................................2105 Removal and Installation................................................................................................................................................2105 REMOVAL.............................................................................................................................................................2105 INSTALLATION........................................................................................................................................................2105 COWL TOP....................................................................................................................................................................2106 Removal and Installation................................................................................................................................................2106 REMOVAL.............................................................................................................................................................2106 INSTALLATION........................................................................................................................................................2106 FRONT FENDER................................................................................................................................................................2107 Removal and Installation................................................................................................................................................2107 REMOVAL.............................................................................................................................................................2107 INSTALLATION........................................................................................................................................................2107 FENDER PROTECTOR............................................................................................................................................................2108 Removal and Installation................................................................................................................................................2108 FRONT FENDER PROTECTOR..............................................................................................................................................2108 Removal.........................................................................................................................................................2108 Installation....................................................................................................................................................2108 REAR FENDER PROTECTOR...............................................................................................................................................2108 Removal.........................................................................................................................................................2108 Installation....................................................................................................................................................2109 MUDGUARD....................................................................................................................................................................2110 Removal and Installation................................................................................................................................................2110 REMOVAL.............................................................................................................................................................2110 INSTALLATION........................................................................................................................................................2110 RUNNING BOARDS..............................................................................................................................................................2111 Removal and Installation................................................................................................................................................2111 REMOVAL.............................................................................................................................................................2111 INSTALLATION........................................................................................................................................................2111 ROOF RACK...................................................................................................................................................................2112 Removal and Installation................................................................................................................................................2112 REMOVAL.............................................................................................................................................................2112 INSTALLATION........................................................................................................................................................2112 DOOR OUTSIDE MOLDING........................................................................................................................................................2113 Removal and Installation................................................................................................................................................2113 REMOVAL.............................................................................................................................................................2113 INSTALLATION........................................................................................................................................................2113 SIDE GUARD MOLDING..........................................................................................................................................................2114 Removal and Installation................................................................................................................................................2114 Removal.............................................................................................................................................................2114 Installation........................................................................................................................................................2114 FAX.....................................................................................................................................................................................2115 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2115 PRECAUTION......................................................................................................................................................................2116 PRECAUTIONS.................................................................................................................................................................2116 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2116 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2116 Precautions for Driveshaft..............................................................................................................................................2116 PREPARATION.....................................................................................................................................................................2117 PREPARATION.................................................................................................................................................................2117 Special Service Tool....................................................................................................................................................2117 Commercial Service Tool.................................................................................................................................................2117 SYMPTOM DIAGNOSIS...............................................................................................................................................................2118 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING........................................................................................................................2118 NVH Troubleshooting Chart...............................................................................................................................................2118 PERIODIC MAINTENANCE............................................................................................................................................................2119 WHEEL HUB...................................................................................................................................................................2119 On-Vehicle Inspection and Service.......................................................................................................................................2119 WHEEL BEARING INSPECTION............................................................................................................................................2119 UNIT REMOVAL AND INSTALLATION...................................................................................................................................................2120 DRIVE SHAFT.................................................................................................................................................................2120 Removal and Installation................................................................................................................................................2120 REMOVAL ............................................................................................................................................................2120 INSPECTION AFTER REMOVAL............................................................................................................................................2120 INSTALLATION........................................................................................................................................................2120 WHEEL HUB...................................................................................................................................................................2122 Removal and Installation................................................................................................................................................2122 REMOVAL.............................................................................................................................................................2122 INSPECTION AFTER REMOVAL............................................................................................................................................2123 INSTALLATION........................................................................................................................................................2123 UNIT DISASSEMBLY AND ASSEMBLY...................................................................................................................................................2124 DRIVE SHAFT.................................................................................................................................................................2124 Disassembly and Assembly................................................................................................................................................2124 DISASSEMBLY.........................................................................................................................................................2124 Final Drive Side................................................................................................................................................2124 Wheel Side......................................................................................................................................................2125 INSPECTION AFTER DISASSEMBLY........................................................................................................................................2125 Shaft...........................................................................................................................................................2125 Joint Sub-assembly..............................................................................................................................................2125 Housing.........................................................................................................................................................2125 Ball Cage.......................................................................................................................................................2125 Steel Ball......................................................................................................................................................2125 Inner Race......................................................................................................................................................2125 ASSEMBLY............................................................................................................................................................2125 Final Drive Side................................................................................................................................................2126 Wheel Side......................................................................................................................................................2127 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2129 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2129 Wheel Bearing...........................................................................................................................................................2129 Drive Shaft.............................................................................................................................................................2129 Boot Bands..............................................................................................................................................................2129 FL......................................................................................................................................................................................2130 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2130 PRECAUTION......................................................................................................................................................................2131 PRECAUTIONS.................................................................................................................................................................2131 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2131 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2131 General Precaution......................................................................................................................................................2131 PREPARATION.....................................................................................................................................................................2133 PREPARATION.................................................................................................................................................................2133 Special Service Tool....................................................................................................................................................2133 Commercial Service Tool.................................................................................................................................................2133 PERIODIC MAINTENANCE............................................................................................................................................................2134 FUEL SYSTEM.................................................................................................................................................................2134 Checking Fuel Line......................................................................................................................................................2134 REMOVAL AND INSTALLATION........................................................................................................................................................2135 FUEL TANK...................................................................................................................................................................2135 Removal and Installation................................................................................................................................................2135 REMOVAL.............................................................................................................................................................2136 INSTALLATION........................................................................................................................................................2139 INSPECTION AFTER INSTALLATION.......................................................................................................................................2139 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY..................................................................................................................2140 Removal and Installation................................................................................................................................................2140 REMOVAL.............................................................................................................................................................2141 INSTALLATION........................................................................................................................................................2143 INSPECTION AFTER INSTALLATION.......................................................................................................................................2144 EVAP CANISTER...............................................................................................................................................................2145 Component Inspection....................................................................................................................................................2145 EVAP CANISTER.......................................................................................................................................................2145 Removal and Installation................................................................................................................................................2145 EVAP CANISTER.......................................................................................................................................................2145 Removal.........................................................................................................................................................2145 Installation....................................................................................................................................................2146 EVAP CANISTER CONTROL PRESSURE SENSOR...............................................................................................................................2146 Removal.........................................................................................................................................................2146 Installation....................................................................................................................................................2146 EVAP CANISTER VENT CONTROL VALVE....................................................................................................................................2146 Removal.........................................................................................................................................................2146 Installation....................................................................................................................................................2146 UNIT DISASSEMBLY AND ASSEMBLY...................................................................................................................................................2147 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY..................................................................................................................2147 Disassembly and Assembly................................................................................................................................................2147 Disassembly.........................................................................................................................................................2147 Assembly............................................................................................................................................................2147 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2148 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2148 Standard and Limit......................................................................................................................................................2148 FSU.....................................................................................................................................................................................2149 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2149 PRECAUTION......................................................................................................................................................................2150 PRECAUTIONS.................................................................................................................................................................2150 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2150 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2150 Precaution for Front Suspension.........................................................................................................................................2150 PREPARATION.....................................................................................................................................................................2151 PREPARATION.................................................................................................................................................................2151 Special Service Tool....................................................................................................................................................2151 Commercial Service Tool.................................................................................................................................................2151 SYMPTOM DIAGNOSIS...............................................................................................................................................................2153 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING........................................................................................................................2153 NVH Troubleshooting Chart...............................................................................................................................................2153 PERIODIC MAINTENANCE............................................................................................................................................................2154 ON-VEHICLE SERVICE..........................................................................................................................................................2154 Front Suspension Parts..................................................................................................................................................2154 Front Wheel Alignment...................................................................................................................................................2154 PRELIMINARY INSPECTION..............................................................................................................................................2154 GENERAL INFORMATION AND RECOMMENDATIONS.............................................................................................................................2154 THE ALIGNMENT PROCESS...............................................................................................................................................2155 CAMBER AND CASTER...................................................................................................................................................2155 TOE-IN..............................................................................................................................................................2156 FRONT WHEEL TURNING ANGLE...........................................................................................................................................2156 UPPER BALL JOINT AND LOWER BALL JOINT.......................................................................................................................................2158 Inspection..............................................................................................................................................................2158 Swinging Force .....................................................................................................................................................2158 Turning Force.......................................................................................................................................................2158 Vertical End Play...................................................................................................................................................2158 KNUCKLE.....................................................................................................................................................................2160 On-Vehicle Inspection and Service.......................................................................................................................................2160 REMOVAL AND INSTALLATION........................................................................................................................................................2161 FRONT SUSPENSION ASSEMBLY...................................................................................................................................................2161 Component...............................................................................................................................................................2161 UNIT REMOVAL AND INSTALLATION...................................................................................................................................................2162 COIL SPRING AND SHOCK ABSORBER..............................................................................................................................................2162 Removal and Installation................................................................................................................................................2162 REMOVAL.............................................................................................................................................................2162 INSTALLATION........................................................................................................................................................2162 Disposal................................................................................................................................................................2162 STABILIZER BAR..............................................................................................................................................................2163 Removal and Installation................................................................................................................................................2163 REMOVAL.............................................................................................................................................................2163 INSPECTION AFTER REMOVAL............................................................................................................................................2163 INSTALLATION........................................................................................................................................................2163 UPPER LINK..................................................................................................................................................................2164 Removal and Installation................................................................................................................................................2164 REMOVAL.............................................................................................................................................................2164 INSPECTION AFTER REMOVAL............................................................................................................................................2164 Upper Link......................................................................................................................................................2164 Upper Link Ball Joint...........................................................................................................................................2164 INSTALLATION........................................................................................................................................................2164 LOWER LINK..................................................................................................................................................................2165 Removal and Installation................................................................................................................................................2165 REMOVAL.............................................................................................................................................................2165 INSPECTION AFTER REMOVAL............................................................................................................................................2165 Lower Link......................................................................................................................................................2165 Lower Link Bushing..............................................................................................................................................2165 INSTALLATION........................................................................................................................................................2165 UPPER BALL JOINT AND LOWER BALL JOINT.......................................................................................................................................2166 Removal and Installation................................................................................................................................................2166 KNUCKLE.....................................................................................................................................................................2167 Removal and Installation................................................................................................................................................2167 REMOVAL.............................................................................................................................................................2167 INSPECTION AFTER REMOVAL............................................................................................................................................2168 INSTALLATION........................................................................................................................................................2168 UNIT DISASSEMBLY AND ASSEMBLY...................................................................................................................................................2170 COIL SPRING AND SHOCK ABSORBER..............................................................................................................................................2170 Disassembly and Assembly................................................................................................................................................2170 DISASSEMBLY.........................................................................................................................................................2170 INSPECTION AFTER DISASSEMBLY........................................................................................................................................2170 Shock Absorber Assembly.........................................................................................................................................2170 Mounting Insulator and Rubber Parts.............................................................................................................................2170 Coil Spring.....................................................................................................................................................2170 ASSEMBLY............................................................................................................................................................2170 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2172 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2172 General Specification (Front)...........................................................................................................................................2172 Spring Free Height......................................................................................................................................................2172 Wheel Alignment (Unladen*1)*6...........................................................................................................................................2172 Ball Joint..............................................................................................................................................................2173 Wheelarch Height (Unladen*1)............................................................................................................................................2173 GW......................................................................................................................................................................................2174 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2174 PRECAUTION......................................................................................................................................................................2175 PRECAUTIONS.................................................................................................................................................................2175 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2175 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2175 Handling for Adhesive and Primer........................................................................................................................................2175 Precaution for Procedure without Cowl Top Cover.........................................................................................................................2175 PREPARATION.....................................................................................................................................................................2176 PREPARATION.................................................................................................................................................................2176 Special Service Tool....................................................................................................................................................2176 Commercial Service Tool.................................................................................................................................................2176 SYMPTOM DIAGNOSIS...............................................................................................................................................................2177 SQUEAK AND RATTLE TROUBLE DIAGNOSES.........................................................................................................................................2177 Work Flow...............................................................................................................................................................2177 CUSTOMER INTERVIEW..................................................................................................................................................2177 DUPLICATE THE NOISE AND TEST DRIVE..................................................................................................................................2177 CHECK RELATED SERVICE BULLETINS.....................................................................................................................................2178 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE........................................................................................................................2178 REPAIR THE CAUSE ...................................................................................................................................................2178 CONFIRM THE REPAIR..................................................................................................................................................2179 Generic Squeak and Rattle Troubleshooting...............................................................................................................................2179 INSTRUMENT PANEL....................................................................................................................................................2179 CENTER CONSOLE......................................................................................................................................................2179 DOORS...............................................................................................................................................................2179 TRUNK...............................................................................................................................................................2179 SUNROOF/HEADLINING..................................................................................................................................................2180 OVERHEAD CONSOLE (FRONT AND REAR)...................................................................................................................................2180 SEATS...............................................................................................................................................................2180 UNDERHOOD...........................................................................................................................................................2180 Diagnostic Worksheet....................................................................................................................................................2181 UNIT REMOVAL AND INSTALLATION...................................................................................................................................................2183 WINDSHIELD GLASS............................................................................................................................................................2183 Removal and Installation................................................................................................................................................2183 REMOVAL.............................................................................................................................................................2183 INSTALLATION........................................................................................................................................................2183 Repairing Water Leaks for Windshield............................................................................................................................2186 FRONT DOOR GLASS AND REGULATOR..............................................................................................................................................2187 Front Door Glass........................................................................................................................................................2187 REMOVAL.............................................................................................................................................................2187 INSTALLATION........................................................................................................................................................2187 FITTING INSPECTION..................................................................................................................................................2187 Front Door Glass Regulator..............................................................................................................................................2187 REMOVAL.............................................................................................................................................................2187 DISASSEMBLY AND ASSEMBLY............................................................................................................................................2188 INSPECTION AFTER REMOVAL............................................................................................................................................2188 INSTALLATION........................................................................................................................................................2189 REAR DOOR GLASS AND REGULATOR...............................................................................................................................................2191 Rear Door Glass.........................................................................................................................................................2191 REMOVAL.............................................................................................................................................................2191 INSTALLATION........................................................................................................................................................2191 FITTING INSPECTION..................................................................................................................................................2191 Rear Door Glass Regulator...............................................................................................................................................2191 REMOVAL.............................................................................................................................................................2191 INSPECTION AFTER REMOVAL............................................................................................................................................2192 INSTALLATION........................................................................................................................................................2192 SIDE WINDOW GLASS...........................................................................................................................................................2194 Removal and Installation................................................................................................................................................2194 REMOVAL.............................................................................................................................................................2195 INSTALLATION........................................................................................................................................................2195 Repairing Water Leaks for Side Window Glass.....................................................................................................................2195 BACK DOOR WINDOW GLASS......................................................................................................................................................2196 Removal and Installation................................................................................................................................................2196 REMOVAL.............................................................................................................................................................2196 INSTALLATION .......................................................................................................................................................2197 HA......................................................................................................................................................................................2198 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2198 PRECAUTION......................................................................................................................................................................2199 PRECAUTIONS.................................................................................................................................................................2199 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2199 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2199 Precaution for Working with HFC-134a (R-134a)...........................................................................................................................2199 Contaminated Refrigerant................................................................................................................................................2200 General Refrigerant Precaution..........................................................................................................................................2200 Precaution for Leak Detection Dye.......................................................................................................................................2200 A/C Identification Label................................................................................................................................................2201 Precaution for Refrigerant Connection...................................................................................................................................2201 FEATURES OF NEW TYPE REFRIGERANT CONNECTION.........................................................................................................................2201 O-RING AND REFRIGERANT CONNECTION...................................................................................................................................2201 O-Ring Specifications *.........................................................................................................................................2203 Precaution for Service of Compressor....................................................................................................................................2204 Precaution for Service Equipment........................................................................................................................................2204 RECOVERY/RECYCLING EQUIPMENT........................................................................................................................................2204 ELECTRONIC LEAK DETECTOR............................................................................................................................................2204 VACUUM PUMP.........................................................................................................................................................2204 MANIFOLD GAUGE SET..................................................................................................................................................2205 SERVICE HOSES.......................................................................................................................................................2205 SERVICE COUPLERS....................................................................................................................................................2205 REFRIGERANT WEIGHT SCALE............................................................................................................................................2206 CHARGING CYLINDER...................................................................................................................................................2206 PREPARATION.....................................................................................................................................................................2207 PREPARATION.................................................................................................................................................................2207 Special Service Tool....................................................................................................................................................2207 HFC-134a (R-134a) Service Tool and Equipment............................................................................................................................2207 Commercial Service Tool.................................................................................................................................................2209 SYSTEM DESCRIPTION..............................................................................................................................................................2211 REFRIGERATION SYSTEM........................................................................................................................................................2211 Refrigerant Cycle.......................................................................................................................................................2211 REFRIGERANT FLOW....................................................................................................................................................2211 FREEZE PROTECTION...................................................................................................................................................2211 Refrigerant System Protection...........................................................................................................................................2211 REFRIGERANT PRESSURE SENSOR.........................................................................................................................................2211 PRESSURE RELIEF VALVE...............................................................................................................................................2211 PERIODIC MAINTENANCE............................................................................................................................................................2213 REFRIGERATION SYSTEM........................................................................................................................................................2213 HFC-134a (R-134a) Service Procedure.....................................................................................................................................2213 SETTING OF SERVICE TOOLS AND EQUIPMENT..............................................................................................................................2213 Discharging Refrigerant.........................................................................................................................................2213 Evacuating System and Charging Refrigerant......................................................................................................................2213 OIL.........................................................................................................................................................................2215 Maintenance of Oil Quantity in Compressor...............................................................................................................................2215 OIL.................................................................................................................................................................2215 CHECKING AND ADJUSTING..............................................................................................................................................2215 Oil Adjusting Procedure for Components Replacement Except Compressor............................................................................................2215 Oil Adjustment Procedure for Compressor Replacement.............................................................................................................2215 FLUORESCENT LEAK DETECTOR...................................................................................................................................................2217 Checking of Refrigerant Leaks...........................................................................................................................................2217 PRELIMINARY CHECK...................................................................................................................................................2217 Checking System for Leaks Using the Fluorescent Dye Leak Detector.......................................................................................................2217 Dye Injection...........................................................................................................................................................2217 ELECTRICAL LEAK DETECTOR....................................................................................................................................................2219 Checking of Refrigerant Leaks...........................................................................................................................................2219 PRELIMINARY CHECK...................................................................................................................................................2219 Electronic Refrigerant Leak Detector....................................................................................................................................2219 PRECAUTIONS FOR HANDLING LEAK DETECTOR..............................................................................................................................2219 CHECKING PROCEDURE..................................................................................................................................................2220 REMOVAL AND INSTALLATION........................................................................................................................................................2222 REFRIGERATION SYSTEM........................................................................................................................................................2222 Component...............................................................................................................................................................2222 HFC-134a (R-134a) Service Procedure.....................................................................................................................................2224 SETTING OF SERVICE TOOLS AND EQUIPMENT..............................................................................................................................2224 Discharging Refrigerant.........................................................................................................................................2224 Evacuating System and Charging Refrigerant......................................................................................................................2224 COMPRESSOR..................................................................................................................................................................2225 Removal and Installation of Compressor..................................................................................................................................2225 REMOVAL.............................................................................................................................................................2225 INSTALLATION........................................................................................................................................................2225 Removal and Installation of Compressor Clutch...........................................................................................................................2226 REMOVAL.............................................................................................................................................................2226 INSPECTION..........................................................................................................................................................2227 Clutch Disc.....................................................................................................................................................2227 Pulley..........................................................................................................................................................2227 Coil............................................................................................................................................................2227 INSTALLATION........................................................................................................................................................2227 BREAK-IN OPERATION..................................................................................................................................................2228 HIGH-PRESSURE FLEXIBLE HOSE.................................................................................................................................................2229 Removal and Installation................................................................................................................................................2229 REMOVAL.............................................................................................................................................................2229 INSTALLATION........................................................................................................................................................2229 HIGH-PRESSURE PIPE..........................................................................................................................................................2230 Removal and Installation................................................................................................................................................2230 REMOVAL.............................................................................................................................................................2230 INSTALLATION........................................................................................................................................................2230 LOW-PRESSURE FLEXIBLE HOSE..................................................................................................................................................2231 Removal and Installation................................................................................................................................................2231 REMOVAL.............................................................................................................................................................2231 INSTALLATION........................................................................................................................................................2231 LOW-PRESSURE PIPE...........................................................................................................................................................2232 Removal and Installation................................................................................................................................................2232 REMOVAL.............................................................................................................................................................2232 INSTALLATION........................................................................................................................................................2232 CONDENSER...................................................................................................................................................................2233 Removal and Installation of Condenser...................................................................................................................................2233 REMOVAL.............................................................................................................................................................2233 INSTALLATION........................................................................................................................................................2233 Removal and Installation of Liquid Tank.................................................................................................................................2233 REFRIGERANT PRESSURE SENSOR.................................................................................................................................................2234 Removal and Installation................................................................................................................................................2234 REMOVAL.............................................................................................................................................................2234 INSTALLATION........................................................................................................................................................2234 EXPANSION VALVE.............................................................................................................................................................2235 Removal and Installation................................................................................................................................................2235 REMOVAL.............................................................................................................................................................2235 INSTALLATION........................................................................................................................................................2235 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2236 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2236 Service Data and Specification (SDS)....................................................................................................................................2236 COMPRESSOR..........................................................................................................................................................2236 OIL.................................................................................................................................................................2236 REFRIGERANT.........................................................................................................................................................2236 HAC.....................................................................................................................................................................................2237 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2237 MANUAL A/C (TYPE 1).............................................................................................................................................................2240 BASIC INSPECTION............................................................................................................................................................2240 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2240 Application Table...................................................................................................................................................2240 DIAGNOSIS AND REPAIR WORKFLOW...........................................................................................................................................2241 How to Perform Trouble Diagnosis For Quick And Accurate Repair......................................................................................................2241 WORK FLOW.......................................................................................................................................................2241 INSPECTION AND ADJUSTMENT...............................................................................................................................................2242 Operational Check...................................................................................................................................................2242 CHECKING BLOWER.................................................................................................................................................2242 CHECK A/C SWITCH................................................................................................................................................2242 CHECKING DISCHARGE AIR..........................................................................................................................................2242 CHECKING RECIRCULATION..........................................................................................................................................2242 CHECKING TEMPERATURE DECREASE...................................................................................................................................2242 CHECKING TEMPERATURE INCREASE...................................................................................................................................2242 SYSTEM DESCRIPTION..........................................................................................................................................................2243 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2243 Application Table...................................................................................................................................................2243 FUNCTION INFORMATION....................................................................................................................................................2244 Component Part Location.............................................................................................................................................2244 ENGINE COMPARTMENT..............................................................................................................................................2244 PASSENGER COMPARTMENT...........................................................................................................................................2245 REFRIGERATION SYSTEM....................................................................................................................................................2246 Refrigerant Cycle...................................................................................................................................................2246 REFRIGERANT FLOW................................................................................................................................................2246 FREEZE PROTECTION...............................................................................................................................................2246 Refrigerant System Protection.......................................................................................................................................2246 REFRIGERANT PRESSURE SENSOR.....................................................................................................................................2246 PRESSURE RELIEF VALVE...........................................................................................................................................2246 MANUAL AIR CONDITIONER SYSTEM...........................................................................................................................................2247 Control System Diagram..............................................................................................................................................2247 CONTROL SYSTEM..................................................................................................................................................2247 Control System Description..........................................................................................................................................2247 CONTROL OPERATION...............................................................................................................................................2247 TEMPERATURE CONTROL DIAL (TEMPERATURE CONTROL)..................................................................................................................2248 RECIRCULATION () SWITCH.........................................................................................................................................2248 DEFROSTER () SWITCH.............................................................................................................................................2248 REAR WINDOW DEFOGGER SWITCH.....................................................................................................................................2248 OFF SWITCH (BLOWER SPEED DIAL)..................................................................................................................................2248 A/C SWITCH .....................................................................................................................................................2248 MODE SWITCHES...................................................................................................................................................2248 FRONT BLOWER CONTROL DIAL.......................................................................................................................................2248 MAGNET CLUTCH CONTROL...........................................................................................................................................2248 Defrost latching logic......................................................................................................................................2249 Discharge Air Flow..................................................................................................................................................2249 Switches And Their Control Function.................................................................................................................................2250 SWITCHES AND THEIR CONTROL FUNCTION.............................................................................................................................2250 DIAGNOSIS SYSTEM (BCM)..................................................................................................................................................2251 COMMON ITEM.........................................................................................................................................................2251 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM)..............................................................................................................2251 APPLICATION ITEM............................................................................................................................................2251 SYSTEM APPLICATION..........................................................................................................................................2251 AIR CONDITIONER.....................................................................................................................................................2251 AIR CONDITIONER : CONSULT Function (BCM - AIR CONDITIONER)......................................................................................................2252 DATA MONITOR................................................................................................................................................2252 SELF-DIAGNOSIS FUNCTION.................................................................................................................................................2253 Front Air Control Self-Diagnosis....................................................................................................................................2253 A/C SYSTEM SELF-DIAGNOSIS FUNCTION .............................................................................................................................2253 DESCRIPTION.....................................................................................................................................................2253 SELF-DIAGNOSTIC MODE............................................................................................................................................2253 Front Air Control Self-Diagnosis Chart..............................................................................................................................2253 SELF-DIAGNOSTIC CHART...........................................................................................................................................2253 DTC/CIRCUIT DIAGNOSIS.......................................................................................................................................................2254 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2254 Application Table...................................................................................................................................................2254 MODE DOOR MOTOR.........................................................................................................................................................2255 System Description..................................................................................................................................................2255 SYSTEM DESCRIPTION..............................................................................................................................................2255 Component Parts.............................................................................................................................................2255 System Operation............................................................................................................................................2255 COMPONENT DESCRIPTION...........................................................................................................................................2255 Mode Door Motor.............................................................................................................................................2255 Mode Door Motor Component Function Check............................................................................................................................2255 INSPECTION FLOW.................................................................................................................................................2256 Mode Door Motor Diagnosis Procedure.................................................................................................................................2256 SYMPTOM:........................................................................................................................................................2256 AIR MIX DOOR MOTOR......................................................................................................................................................2259 System Description..................................................................................................................................................2259 SYSTEM DESCRIPTION..............................................................................................................................................2259 Component Parts.............................................................................................................................................2259 System Operation............................................................................................................................................2259 Air Mix Door Control Specification..........................................................................................................................2259 COMPONENT DESCRIPTION...........................................................................................................................................2259 Air Mix Door Motor..........................................................................................................................................2259 Air Mix Door Motor Component Function Check.........................................................................................................................2260 INSPECTION FLOW.................................................................................................................................................2260 Air Mix Door Motor Diagnosis Procedure..............................................................................................................................2260 SYMPTOM:........................................................................................................................................................2260 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR.....................................................................................................................2260 INTAKE DOOR MOTOR.......................................................................................................................................................2263 System Description..................................................................................................................................................2263 SYSTEM DESCRIPTION..............................................................................................................................................2263 Component Parts.............................................................................................................................................2263 System Operation............................................................................................................................................2263 COMPONENT DESCRIPTION...........................................................................................................................................2263 Intake door motor...........................................................................................................................................2263 Intake Door Motor Component Function Check..........................................................................................................................2263 INSPECTION FLOW.................................................................................................................................................2263 Intake Door Motor Diagnosis Procedure...............................................................................................................................2264 SYMPTOM:........................................................................................................................................................2264 DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR......................................................................................................................2264 BLOWER MOTOR............................................................................................................................................................2265 System Description..................................................................................................................................................2265 COMPONENT DESCRIPTION...........................................................................................................................................2265 Component Parts.............................................................................................................................................2265 System Operation............................................................................................................................................2265 COMPONENT DESCRIPTION...........................................................................................................................................2265 Variable Blower Control.....................................................................................................................................2265 Front Blower Motor Component Function Check.........................................................................................................................2265 INSPECTION FLOW.................................................................................................................................................2265 Front Blower Motor Diagnosis Procedure..............................................................................................................................2266 DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR...........................................................................................................................2266 Front Blower Motor Component Inspection.............................................................................................................................2269 COMPONENT INSPECTION ...........................................................................................................................................2269 Front Blower Motor Relay....................................................................................................................................2269 Front Blower Motor..........................................................................................................................................2270 MAGNET CLUTCH...........................................................................................................................................................2271 System Description..................................................................................................................................................2271 SYSTEM DESCRIPTION..............................................................................................................................................2271 Low Temperature Protection Control..........................................................................................................................2271 Magnet Clutch Component Function Check..............................................................................................................................2271 INSPECTION FLOW.................................................................................................................................................2271 Magnet Clutch Diagnosis Procedure...................................................................................................................................2271 DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH..........................................................................................................................2271 INTAKE SENSOR...........................................................................................................................................................2276 System Description..................................................................................................................................................2276 COMPONENT DESCRIPTION...........................................................................................................................................2276 Intake Sensor...............................................................................................................................................2276 Intake Sensor Diagnosis Procedure...................................................................................................................................2276 DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR..........................................................................................................................2276 Intake Sensor Component Inspection..................................................................................................................................2277 COMPONENT INSPECTION............................................................................................................................................2277 Intake Sensor...............................................................................................................................................2277 POWER SUPPLY AND GROUND CIRCUIT FOR CONTROLLER..........................................................................................................................2279 Component Description...............................................................................................................................................2279 COMPONENT DESCRIPTION...........................................................................................................................................2279 Front Air Control...........................................................................................................................................2279 Potentio Temperature Control (PTC)..........................................................................................................................2279 Front Air Control Component Function Check..........................................................................................................................2279 INSPECTION FLOW.................................................................................................................................................2279 Front Air Control Power and Ground Diagnosis Procedure..............................................................................................................2279 DIAGNOSTIC PROCEDURE FOR A/C SYSTEM.............................................................................................................................2279 ECU DIAGNOSIS INFORMATION...................................................................................................................................................2281 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2281 Application Table...................................................................................................................................................2281 AIR CONDITIONER CONTROL.................................................................................................................................................2282 Front Air Control Terminals Reference Values........................................................................................................................2282 FRONT AIR CONTROL HARNESS CONNECTOR TERMINAL LAYOUT.............................................................................................................2282 TERMINALS AND REFERENCE VALUES FOR FRONT AIR CONTROL ...........................................................................................................2282 WIRING DIAGRAM..............................................................................................................................................................2284 AIR CONDITIONER CONTROL.................................................................................................................................................2284 Wiring Diagram - With VBC...........................................................................................................................................2284 SYMPTOM DIAGNOSIS...........................................................................................................................................................2291 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2291 Application Table...................................................................................................................................................2291 AIR CONDITIONER CONTROL.................................................................................................................................................2292 Symptom Matrix Chart................................................................................................................................................2292 SYMPTOM TABLE...................................................................................................................................................2292 INSUFFICIENT COOLING....................................................................................................................................................2293 Component Function Check............................................................................................................................................2293 INSPECTION FLOW.................................................................................................................................................2293 Diagnostic Work Flow................................................................................................................................................2294 Performance Chart...................................................................................................................................................2296 TEST CONDITION..................................................................................................................................................2296 Testing must be performed as follows:.......................................................................................................................2296 TEST READING....................................................................................................................................................2297 Recirculating-to-discharge Air Temperature Table............................................................................................................2297 Trouble Diagnoses for Abnormal Pressure.............................................................................................................................2297 Both High- and Low-pressure Sides are Too High..................................................................................................................2298 High-pressure Side is Too High and Low-pressure Side is Too Low.................................................................................................2298 High-pressure Side is Too Low and Low-pressure Side is Too High.................................................................................................2298 Both High- and Low-pressure Sides are Too Low...................................................................................................................2299 Low-pressure Side Sometimes Becomes Negative....................................................................................................................2299 Low-pressure Side Becomes Negative..............................................................................................................................2299 INSUFFICIENT HEATING....................................................................................................................................................2301 Component Function Check............................................................................................................................................2301 INSPECTION FLOW.................................................................................................................................................2301 NOISE...................................................................................................................................................................2303 Component Function Check............................................................................................................................................2303 INSPECTION FLOW.................................................................................................................................................2303 PRECAUTION..................................................................................................................................................................2305 PRECAUTIONS.............................................................................................................................................................2305 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................2305 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................2305 Working with HFC-134a (R-134a)......................................................................................................................................2305 CONTAMINATED REFRIGERANT........................................................................................................................................2305 Precaution for Service Equipment....................................................................................................................................2306 MANIFOLD GAUGE SET..............................................................................................................................................2306 SERVICE HOSES...................................................................................................................................................2306 SERVICE COUPLERS................................................................................................................................................2306 MANUAL A/C (TYPE 2).............................................................................................................................................................2307 BASIC INSPECTION............................................................................................................................................................2307 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2307 Application Table...................................................................................................................................................2307 DIAGNOSIS AND REPAIR WORKFLOW...........................................................................................................................................2308 How to Perform Trouble Diagnosis For Quick And Accurate Repair......................................................................................................2308 WORK FLOW.......................................................................................................................................................2308 INSPECTION AND ADJUSTMENT...............................................................................................................................................2309 Operational Check...................................................................................................................................................2309 CHECKING BLOWER.................................................................................................................................................2309 CHECK A/C SWITCH................................................................................................................................................2309 CHECKING DISCHARGE AIR..........................................................................................................................................2309 CHECKING RECIRCULATION..........................................................................................................................................2309 CHECKING TEMPERATURE DECREASE...................................................................................................................................2309 CHECKING TEMPERATURE INCREASE...................................................................................................................................2309 SYSTEM DESCRIPTION..........................................................................................................................................................2311 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2311 Application Table...................................................................................................................................................2311 FUNCTION INFORMATION....................................................................................................................................................2312 Component Part Location.............................................................................................................................................2312 ENGINE COMPARTMENT..............................................................................................................................................2312 PASSENGER COMPARTMENT...........................................................................................................................................2313 REFRIGERATION SYSTEM....................................................................................................................................................2314 Refrigerant Cycle...................................................................................................................................................2314 REFRIGERANT FLOW................................................................................................................................................2314 FREEZE PROTECTION...............................................................................................................................................2314 Refrigerant System Protection.......................................................................................................................................2314 REFRIGERANT PRESSURE SENSOR.....................................................................................................................................2314 PRESSURE RELIEF VALVE...........................................................................................................................................2314 MANUAL AIR CONDITIONER SYSTEM...........................................................................................................................................2315 Control System Diagram..............................................................................................................................................2315 CONTROL SYSTEM..................................................................................................................................................2315 Control System Description..........................................................................................................................................2315 CONTROL OPERATION...............................................................................................................................................2315 TEMPERATURE CONTROL DIAL (TEMPERATURE CONTROL)..................................................................................................................2316 RECIRCULATION () SWITCH.........................................................................................................................................2316 REAR WINDOW DEFOGGER SWITCH ....................................................................................................................................2316 OFF SWITCH (BLOWER SPEED SET TO 0)..............................................................................................................................2316 A/C SWITCH .....................................................................................................................................................2316 MODE DIAL.......................................................................................................................................................2316 FRONT BLOWER CONTROL DIAL.......................................................................................................................................2316 MAGNET CLUTCH CONTROL...........................................................................................................................................2316 Defrost latching logic......................................................................................................................................2317 Discharge Air Flow..................................................................................................................................................2317 Switches And Their Control Function.................................................................................................................................2318 SWITCHES AND THEIR CONTROL FUNCTION.............................................................................................................................2318 DIAGNOSIS SYSTEM (BCM)..................................................................................................................................................2319 COMMON ITEM.........................................................................................................................................................2319 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM)..............................................................................................................2319 APPLICATION ITEM............................................................................................................................................2319 SYSTEM APPLICATION..........................................................................................................................................2319 AIR CONDITIONER.....................................................................................................................................................2319 AIR CONDITIONER : CONSULT Function (BCM - AIR CONDITIONER)......................................................................................................2320 DATA MONITOR................................................................................................................................................2320 DTC/CIRCUIT DIAGNOSIS.......................................................................................................................................................2321 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2321 Application Table...................................................................................................................................................2321 MODE DOOR MOTOR.........................................................................................................................................................2322 System Description..................................................................................................................................................2322 SYSTEM DESCRIPTION..............................................................................................................................................2322 Component Parts.............................................................................................................................................2322 System Operation............................................................................................................................................2322 COMPONENT DESCRIPTION...........................................................................................................................................2322 Mode Door Motor.............................................................................................................................................2322 Mode Door Motor Component Function Check............................................................................................................................2322 INSPECTION FLOW.................................................................................................................................................2323 Mode Door Motor Diagnosis Procedure.................................................................................................................................2323 AIR MIX DOOR MOTOR......................................................................................................................................................2326 System Description..................................................................................................................................................2326 SYSTEM DESCRIPTION..............................................................................................................................................2326 Component Parts.............................................................................................................................................2326 System Operation............................................................................................................................................2326 Air Mix Door Control Specification..........................................................................................................................2326 COMPONENT DESCRIPTION...........................................................................................................................................2326 Air Mix Door Motor..........................................................................................................................................2326 Air Mix Door Motor Component Function Check.........................................................................................................................2327 INSPECTION FLOW.................................................................................................................................................2327 Air Mix Door Motor Diagnosis Procedure..............................................................................................................................2327 INTAKE DOOR MOTOR.......................................................................................................................................................2330 System Description..................................................................................................................................................2330 SYSTEM DESCRIPTION..............................................................................................................................................2330 Component Parts.............................................................................................................................................2330 System Operation............................................................................................................................................2330 COMPONENT DESCRIPTION...........................................................................................................................................2330 Intake door motor...........................................................................................................................................2330 Intake Door Motor Component Function Check..........................................................................................................................2330 INSPECTION FLOW.................................................................................................................................................2330 Intake Door Motor Diagnosis Procedure...............................................................................................................................2331 DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR......................................................................................................................2331 BLOWER MOTOR............................................................................................................................................................2332 System Description..................................................................................................................................................2332 COMPONENT DESCRIPTION...........................................................................................................................................2332 Component Parts.............................................................................................................................................2332 System Operation............................................................................................................................................2332 COMPONENT DESCRIPTION...........................................................................................................................................2332 Blower Motor Resistor.......................................................................................................................................2332 Front Blower Motor Component Function Check.........................................................................................................................2332 INSPECTION FLOW.................................................................................................................................................2332 Front Blower Motor Diagnosis Procedure..............................................................................................................................2333 Front Blower Motor Component Inspection.............................................................................................................................2338 COMPONENT INSPECTION............................................................................................................................................2338 Front Blower Motor Relay....................................................................................................................................2338 Front Blower Motor..........................................................................................................................................2339 Front Blower Switch.........................................................................................................................................2339 Front Blower Motor Resistor.................................................................................................................................2339 MAGNET CLUTCH...........................................................................................................................................................2341 System Description..................................................................................................................................................2341 SYSTEM DESCRIPTION..............................................................................................................................................2341 Low Temperature Protection Control..........................................................................................................................2341 Magnet Clutch Component Function Check..............................................................................................................................2341 INSPECTION FLOW.................................................................................................................................................2341 Magnet Clutch Diagnosis Procedure...................................................................................................................................2341 DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH..........................................................................................................................2341 INTAKE SENSOR...........................................................................................................................................................2346 System Description..................................................................................................................................................2346 COMPONENT DESCRIPTION...........................................................................................................................................2346 Intake Sensor...............................................................................................................................................2346 Intake Sensor Diagnosis Procedure...................................................................................................................................2346 DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR..........................................................................................................................2346 Intake Sensor Component Inspection..................................................................................................................................2347 COMPONENT INSPECTION............................................................................................................................................2347 Intake Sensor...............................................................................................................................................2347 POWER SUPPLY AND GROUND CIRCUIT FOR CONTROLLER..........................................................................................................................2348 Component Description...............................................................................................................................................2348 COMPONENT DESCRIPTION...........................................................................................................................................2348 Front Air Control...........................................................................................................................................2348 Potentio Temperature Control (PTC)..........................................................................................................................2348 Front Air Control Component Function Check..........................................................................................................................2348 INSPECTION FLOW.................................................................................................................................................2348 Front Air Control Power and Ground Diagnosis Procedure..............................................................................................................2348 DIAGNOSTIC PROCEDURE FOR A/C SYSTEM.............................................................................................................................2348 ECU DIAGNOSIS INFORMATION...................................................................................................................................................2350 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2350 Application Table...................................................................................................................................................2350 AIR CONDITIONER CONTROL.................................................................................................................................................2351 Front Air Control Terminals Reference Values........................................................................................................................2351 FRONT AIR CONTROL HARNESS CONNECTOR TERMINAL LAYOUT.............................................................................................................2351 TERMINALS AND REFERENCE VALUES FOR FRONT AIR CONTROL ...........................................................................................................2351 WIRING DIAGRAM..............................................................................................................................................................2353 AIR CONDITIONER CONTROL.................................................................................................................................................2353 Wiring Diagram - Without VBC........................................................................................................................................2353 SYMPTOM DIAGNOSIS...........................................................................................................................................................2360 MANUAL A/C IDENTIFICATION TABLE.........................................................................................................................................2360 Application Table...................................................................................................................................................2360 AIR CONDITIONER CONTROL.................................................................................................................................................2361 Symptom Matrix Chart................................................................................................................................................2361 SYMPTOM TABLE...................................................................................................................................................2361 INSUFFICIENT COOLING....................................................................................................................................................2362 Component Function Check............................................................................................................................................2362 INSPECTION FLOW.................................................................................................................................................2362 Diagnostic Work Flow................................................................................................................................................2363 Performance Chart...................................................................................................................................................2365 TEST CONDITION..................................................................................................................................................2365 Testing must be performed as follows:.......................................................................................................................2365 TEST READING....................................................................................................................................................2366 Recirculating-to-discharge Air Temperature Table............................................................................................................2366 Trouble Diagnoses for Abnormal Pressure.............................................................................................................................2366 Both High- and Low-pressure Sides are Too High..................................................................................................................2367 High-pressure Side is Too High and Low-pressure Side is Too Low.................................................................................................2367 High-pressure Side is Too Low and Low-pressure Side is Too High.................................................................................................2367 Both High- and Low-pressure Sides are Too Low...................................................................................................................2368 Low-pressure Side Sometimes Becomes Negative....................................................................................................................2368 Low-pressure Side Becomes Negative..............................................................................................................................2368 INSUFFICIENT HEATING....................................................................................................................................................2370 Component Function Check............................................................................................................................................2370 INSPECTION FLOW.................................................................................................................................................2370 NOISE...................................................................................................................................................................2372 Component Function Check............................................................................................................................................2372 INSPECTION FLOW.................................................................................................................................................2372 PRECAUTION..................................................................................................................................................................2374 PRECAUTIONS.............................................................................................................................................................2374 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................2374 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................2374 Working with HFC-134a (R-134a)......................................................................................................................................2374 CONTAMINATED REFRIGERANT........................................................................................................................................2374 Precaution for Service Equipment....................................................................................................................................2375 MANIFOLD GAUGE SET..............................................................................................................................................2375 SERVICE HOSES...................................................................................................................................................2375 SERVICE COUPLERS................................................................................................................................................2375 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 HRN.....................................................................................................................................................................................2376 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2376 PRECAUTION......................................................................................................................................................................2377 PRECAUTIONS.................................................................................................................................................................2377 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2377 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2377 WIRING DIAGRAM..................................................................................................................................................................2378 HORN........................................................................................................................................................................2378 Wiring Diagram..........................................................................................................................................................2378 REMOVAL AND INSTALLATION........................................................................................................................................................2380 HORN........................................................................................................................................................................2380 Removal and Installation................................................................................................................................................2380 REMOVAL.............................................................................................................................................................2380 INSTALLATION........................................................................................................................................................2380 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 INL.....................................................................................................................................................................................2381 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2381 BASIC INSPECTION................................................................................................................................................................2383 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................2383 Work Flow...............................................................................................................................................................2383 OVERALL SEQUENCE....................................................................................................................................................2383 DETAILED FLOW.......................................................................................................................................................2384 SYSTEM DESCRIPTION..............................................................................................................................................................2386 INTERIOR ROOM LAMP CONTROL SYSTEM...........................................................................................................................................2386 System Diagram..........................................................................................................................................................2386 System Description......................................................................................................................................................2386 OUTLINE.............................................................................................................................................................2386 ROOM LAMP TIMER OPERATION...........................................................................................................................................2386 INTERIOR LAMP BATTERY SAVER CONTROL.................................................................................................................................2386 Component Parts Location................................................................................................................................................2387 Component Description...................................................................................................................................................2388 ILLUMINATION CONTROL SYSTEM.................................................................................................................................................2389 System Diagram..........................................................................................................................................................2389 System Description......................................................................................................................................................2389 BATTERY SAVER CONTROL...............................................................................................................................................2389 Component Parts Location................................................................................................................................................2390 Component Description...................................................................................................................................................2390 DIAGNOSIS SYSTEM (BCM)......................................................................................................................................................2391 COMMON ITEM.............................................................................................................................................................2391 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM)..................................................................................................................2391 APPLICATION ITEM................................................................................................................................................2391 SYSTEM APPLICATION..............................................................................................................................................2391 INT LAMP................................................................................................................................................................2391 INT LAMP : CONSULT Function (BCM - INT LAMP)........................................................................................................................2392 DATA MONITOR....................................................................................................................................................2392 ACTIVE TEST.....................................................................................................................................................2392 WORK SUPPORT....................................................................................................................................................2392 BATTERY SAVER...........................................................................................................................................................2392 BATTERY SAVER : CONSULT Function (BCM - BATTERY SAVER)..............................................................................................................2393 DATA MONITOR....................................................................................................................................................2393 ACTIVE TEST.....................................................................................................................................................2393 WORK SUPPORT....................................................................................................................................................2393 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................2394 POWER SUPPLY AND GROUND CIRCUIT.............................................................................................................................................2394 BCM.....................................................................................................................................................................2394 BCM : Diagnosis Procedure...........................................................................................................................................2394 BATTERY SAVER OUTPUT/POWER SUPPLY CIRCUIT...................................................................................................................................2396 Description.............................................................................................................................................................2396 Component Function Check................................................................................................................................................2396 Diagnosis Procedure.....................................................................................................................................................2396 INTERIOR ROOM LAMP CONTROL CIRCUIT..........................................................................................................................................2398 Description.............................................................................................................................................................2398 Component Function Check................................................................................................................................................2398 Diagnosis Procedure.....................................................................................................................................................2398 CARGO LAMP CONTROL CIRCUIT..................................................................................................................................................2400 Description.............................................................................................................................................................2400 Component Function Check................................................................................................................................................2400 Diagnosis Procedure.....................................................................................................................................................2400 IGNITION KEYHOLE ILLUMINATION CONTROL CIRCUIT...............................................................................................................................2402 Description.............................................................................................................................................................2402 Component Function Check................................................................................................................................................2402 Diagnosis Procedure.....................................................................................................................................................2402 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................2404 BCM (BODY CONTROL MODULE)...................................................................................................................................................2404 Reference Value.........................................................................................................................................................2404 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................2404 Terminal Layout.........................................................................................................................................................2407 Physical Values.........................................................................................................................................................2407 Fail Safe...............................................................................................................................................................2412 Fail-safe index.....................................................................................................................................................2412 DTC Inspection Priority Chart...........................................................................................................................................2412 DTC Index...............................................................................................................................................................2413 WIRING DIAGRAM..................................................................................................................................................................2415 INTERIOR ROOM LAMP..........................................................................................................................................................2415 Wiring Diagram..........................................................................................................................................................2415 ILLUMINATION................................................................................................................................................................2426 Wiring Diagram..........................................................................................................................................................2426 SYMPTOM DIAGNOSIS...............................................................................................................................................................2436 INTERIOR LIGHTING SYSTEM SYMPTOMS...........................................................................................................................................2436 Symptom Table...........................................................................................................................................................2436 PRECAUTION......................................................................................................................................................................2437 PRECAUTIONS.................................................................................................................................................................2437 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2437 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2437 Precaution for Work.....................................................................................................................................................2437 PREPARATION.....................................................................................................................................................................2438 PREPARATION.................................................................................................................................................................2438 Special Service Tool....................................................................................................................................................2438 REMOVAL AND INSTALLATION........................................................................................................................................................2439 INTERIOR ROOM LAMP..........................................................................................................................................................2439 Removal and Installation................................................................................................................................................2439 FRONT ROOM/MAP LAMP ASSEMBLY........................................................................................................................................2439 Removal.........................................................................................................................................................2439 Installation....................................................................................................................................................2439 Bulb Replacement................................................................................................................................................2439 ROOM LAMP 2ND ROW...................................................................................................................................................2439 Removal.........................................................................................................................................................2439 Installation....................................................................................................................................................2440 Bulb Replacement................................................................................................................................................2440 CARGO LAMP .........................................................................................................................................................2440 Removal.........................................................................................................................................................2440 Installation....................................................................................................................................................2441 Bulb Replacement................................................................................................................................................2441 VANITY LAMP.........................................................................................................................................................2441 Removal.........................................................................................................................................................2441 Installation....................................................................................................................................................2441 Bulb Replacement................................................................................................................................................2441 ILLUMINATION................................................................................................................................................................2442 Removal and Installation................................................................................................................................................2442 ILLUMINATION CONTROL SWITCH.........................................................................................................................................2442 Removal.........................................................................................................................................................2442 Installation....................................................................................................................................................2442 SHIFT SELECTOR FINISHER LAMP........................................................................................................................................2442 Removal.........................................................................................................................................................2442 Installation....................................................................................................................................................2442 Bulb Replacement................................................................................................................................................2442 IGNITION KEYHOLE ILLUMINATION LAMP..................................................................................................................................2442 Removal.........................................................................................................................................................2442 Installation....................................................................................................................................................2443 Bulb Replacement................................................................................................................................................2443 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2444 BULB SPECIFICATIONS.........................................................................................................................................................2444 Bulb Specifications.....................................................................................................................................................2444 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 INT.....................................................................................................................................................................................2445 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2445 PRECAUTION......................................................................................................................................................................2446 PRECAUTIONS.................................................................................................................................................................2446 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2446 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2446 Precaution for Work.....................................................................................................................................................2446 PREPARATION.....................................................................................................................................................................2447 PREPARATION.................................................................................................................................................................2447 Special Service Tool....................................................................................................................................................2447 Commercial Service Tool.................................................................................................................................................2447 CLIP LIST...................................................................................................................................................................2448 Descriptions for Clips..................................................................................................................................................2448 SYMPTOM DIAGNOSIS...............................................................................................................................................................2452 SQUEAK AND RATTLE TROUBLE DIAGNOSES.........................................................................................................................................2452 Work Flow...............................................................................................................................................................2452 CUSTOMER INTERVIEW..................................................................................................................................................2452 DUPLICATE THE NOISE AND TEST DRIVE..................................................................................................................................2452 CHECK RELATED SERVICE BULLETINS.....................................................................................................................................2453 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE........................................................................................................................2453 REPAIR THE CAUSE ...................................................................................................................................................2453 CONFIRM THE REPAIR..................................................................................................................................................2454 Generic Squeak and Rattle Troubleshooting...............................................................................................................................2454 INSTRUMENT PANEL....................................................................................................................................................2454 CENTER CONSOLE......................................................................................................................................................2454 DOORS...............................................................................................................................................................2454 TRUNK...............................................................................................................................................................2454 SUNROOF/HEADLINING..................................................................................................................................................2455 OVERHEAD CONSOLE (FRONT AND REAR)...................................................................................................................................2455 SEATS...............................................................................................................................................................2455 UNDERHOOD...........................................................................................................................................................2455 Diagnostic Worksheet....................................................................................................................................................2456 REMOVAL AND INSTALLATION........................................................................................................................................................2458 DOOR FINISHER...............................................................................................................................................................2458 Removal and Installation................................................................................................................................................2458 FRONT DOOR..........................................................................................................................................................2458 Removal.........................................................................................................................................................2458 Installation....................................................................................................................................................2459 REAR DOOR...........................................................................................................................................................2459 Removal.........................................................................................................................................................2459 Installation....................................................................................................................................................2460 BODY SIDE TRIM..............................................................................................................................................................2461 Component...............................................................................................................................................................2461 Removal and Installation................................................................................................................................................2462 LOWER DASH SIDE FINISHER............................................................................................................................................2462 Removal.........................................................................................................................................................2462 Installation....................................................................................................................................................2462 CENTER PILLAR LOWER FINISHER........................................................................................................................................2462 Removal.........................................................................................................................................................2462 Installation....................................................................................................................................................2462 CENTER PILLAR UPPER FINISHER........................................................................................................................................2462 Removal.........................................................................................................................................................2462 Installation....................................................................................................................................................2462 FRONT PILLAR LOWER FINISHER.........................................................................................................................................2462 Removal.........................................................................................................................................................2462 Installation....................................................................................................................................................2462 FRONT PILLAR UPPER FINISHER.........................................................................................................................................2462 Removal.........................................................................................................................................................2462 Installation....................................................................................................................................................2462 KICK PLATES.........................................................................................................................................................2462 Removal.........................................................................................................................................................2462 Installation....................................................................................................................................................2462 FLOOR TRIM..................................................................................................................................................................2463 Removal and Installation................................................................................................................................................2463 FRONT CARPET........................................................................................................................................................2463 Removal.........................................................................................................................................................2463 Installation....................................................................................................................................................2463 REAR CARPET.........................................................................................................................................................2463 Removal.........................................................................................................................................................2463 Installation....................................................................................................................................................2464 HEADLINING..................................................................................................................................................................2465 Removal and Installation................................................................................................................................................2465 REMOVAL.............................................................................................................................................................2465 INSTALLATION........................................................................................................................................................2466 LUGGAGE FLOOR TRIM..........................................................................................................................................................2467 Component...............................................................................................................................................................2467 Removal and Installation................................................................................................................................................2468 REMOVAL.............................................................................................................................................................2468 INSTALLATION........................................................................................................................................................2469 BACK DOOR TRIM..............................................................................................................................................................2470 Removal and Installation................................................................................................................................................2470 REMOVAL.............................................................................................................................................................2470 INSTALLATION........................................................................................................................................................2470 IP......................................................................................................................................................................................2471 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2471 PRECAUTION......................................................................................................................................................................2472 PRECAUTIONS.................................................................................................................................................................2472 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2472 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2472 Precaution for Work.....................................................................................................................................................2472 PREPARATION.....................................................................................................................................................................2473 PREPARATION.................................................................................................................................................................2473 Special Service Tool....................................................................................................................................................2473 Commercial Service Tools................................................................................................................................................2473 SYMPTOM DIAGNOSIS...............................................................................................................................................................2474 SQUEAK AND RATTLE TROUBLE DIAGNOSES.........................................................................................................................................2474 Work Flow...............................................................................................................................................................2474 CUSTOMER INTERVIEW..................................................................................................................................................2474 DUPLICATE THE NOISE AND TEST DRIVE..................................................................................................................................2474 CHECK RELATED SERVICE BULLETINS.....................................................................................................................................2475 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE........................................................................................................................2475 REPAIR THE CAUSE ...................................................................................................................................................2475 CONFIRM THE REPAIR..................................................................................................................................................2476 Generic Squeak and Rattle Troubleshooting...............................................................................................................................2476 INSTRUMENT PANEL....................................................................................................................................................2476 CENTER CONSOLE......................................................................................................................................................2476 DOORS...............................................................................................................................................................2476 TRUNK...............................................................................................................................................................2476 SUNROOF/HEADLINING..................................................................................................................................................2477 OVERHEAD CONSOLE (FRONT AND REAR)...................................................................................................................................2477 SEATS...............................................................................................................................................................2477 UNDERHOOD...........................................................................................................................................................2477 Diagnostic Worksheet....................................................................................................................................................2478 REMOVAL AND INSTALLATION........................................................................................................................................................2480 INSTRUMENT PANEL ASSEMBLY...................................................................................................................................................2480 Exploded View...........................................................................................................................................................2480 Removal and Installation................................................................................................................................................2481 REMOVAL.............................................................................................................................................................2481 INSTALLATION........................................................................................................................................................2481 STEERING COLUMN COVERS......................................................................................................................................................2482 Removal and Installation................................................................................................................................................2482 REMOVAL.............................................................................................................................................................2482 INSTALLATION........................................................................................................................................................2482 CLUSTER LID A...............................................................................................................................................................2483 Removal and Installation................................................................................................................................................2483 REMOVAL.............................................................................................................................................................2483 INSTALLATION........................................................................................................................................................2483 INSTRUMENT LOWER PANEL LH...................................................................................................................................................2484 Removal and Installation................................................................................................................................................2484 REMOVAL.............................................................................................................................................................2484 INSTALLATION........................................................................................................................................................2484 CLUSTER LID C...............................................................................................................................................................2485 Removal and Installation................................................................................................................................................2485 TYPE 1 .............................................................................................................................................................2485 Removal.........................................................................................................................................................2485 Installation....................................................................................................................................................2485 TYPE 2 .............................................................................................................................................................2486 Removal.........................................................................................................................................................2486 Installation....................................................................................................................................................2486 CLUSTER LID D...............................................................................................................................................................2487 Removal and Installation................................................................................................................................................2487 TYPE 1..............................................................................................................................................................2487 Removal.........................................................................................................................................................2487 Installation....................................................................................................................................................2487 TYPE 2..............................................................................................................................................................2487 Removal.........................................................................................................................................................2487 Installation....................................................................................................................................................2488 UPPER GLOVE BOX.............................................................................................................................................................2489 Removal and Installation................................................................................................................................................2489 REMOVAL.............................................................................................................................................................2489 INSTALLATION........................................................................................................................................................2489 INSTRUMENT LOWER PANEL RH AND GLOVE BOX.....................................................................................................................................2490 Removal and Installation................................................................................................................................................2490 REMOVAL.............................................................................................................................................................2490 INSTALLATION........................................................................................................................................................2490 A/T FINISHER................................................................................................................................................................2491 Removal and Installation................................................................................................................................................2491 REMOVAL.............................................................................................................................................................2491 INSTALLATION........................................................................................................................................................2491 CENTER CONSOLE..............................................................................................................................................................2492 Removal and Installation................................................................................................................................................2492 CENTER CONSOLE......................................................................................................................................................2492 Removal.........................................................................................................................................................2492 Installation....................................................................................................................................................2492 UNIT DISASSEMBLY AND ASSEMBLY...................................................................................................................................................2493 INSTRUMENT LOWER PANEL RH AND GLOVE BOX.....................................................................................................................................2493 Exploded View...........................................................................................................................................................2493 Disassembly and Assembly................................................................................................................................................2493 INSTRUMENT LOWER PANEL RH AND GLOVE BOX.............................................................................................................................2493 Disassembly.....................................................................................................................................................2493 Assembly........................................................................................................................................................2493 UPPER GLOVE BOX.....................................................................................................................................................2493 Disassembly.....................................................................................................................................................2493 Assembly........................................................................................................................................................2494 CENTER CONSOLE ASSEMBLY ....................................................................................................................................................2495 Exploded View...........................................................................................................................................................2495 Disassembly and Assembly................................................................................................................................................2495 DISASSEMBLY.........................................................................................................................................................2495 ASSEMBLY............................................................................................................................................................2496 LAN.....................................................................................................................................................................................2497 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2497 CAN FUNDAMENTAL.................................................................................................................................................................2499 PRECAUTION..................................................................................................................................................................2499 PRECAUTIONS.............................................................................................................................................................2499 Precaution for Trouble Diagnosis....................................................................................................................................2499 Precaution for Harness Repair.......................................................................................................................................2499 SYSTEM DESCRIPTION..........................................................................................................................................................2500 CAN COMMUNICATION SYSTEM................................................................................................................................................2500 System Description..................................................................................................................................................2500 System Diagram......................................................................................................................................................2500 CAN Communication Control Circuit...................................................................................................................................2501 DIAG ON CAN.............................................................................................................................................................2502 Description.........................................................................................................................................................2502 System Diagram......................................................................................................................................................2502 TROUBLE DIAGNOSIS.......................................................................................................................................................2503 Condition of Error Detection........................................................................................................................................2503 CAN COMMUNICATION SYSTEM ERROR..................................................................................................................................2503 WHEN DTC OF CAN COMMUNICATION IS INDICATED EVEN THOUGH CAN COMMUNICATION SYSTEM IS NORMAL.......................................................................2503 Symptom When Error Occurs in CAN Communication System...............................................................................................................2503 ERROR EXAMPLE...................................................................................................................................................2503 Example: TCM branch line open circuit.......................................................................................................................2503 Example: Data link connector branch line open circuit.......................................................................................................2504 Example: Main Line Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Open Circuit...............................................2505 Example: CAN-H, CAN-L Harness Short Circuit.................................................................................................................2505 Self-Diagnosis......................................................................................................................................................2506 CAN Diagnostic Support Monitor......................................................................................................................................2506 MONITOR ITEM (CONSULT)..........................................................................................................................................2506 Without PAST................................................................................................................................................2507 With PAST...................................................................................................................................................2507 MONITOR ITEM (ON-BOARD DIAGNOSIS)...............................................................................................................................2507 BASIC INSPECTION............................................................................................................................................................2509 DIAGNOSIS AND REPAIR WORKFLOW...........................................................................................................................................2509 Information Needed for Trouble Diagnosis............................................................................................................................2509 How to Use CAN Communication Signal Chart...........................................................................................................................2509 Trouble Diagnosis Flow Chart........................................................................................................................................2510 Trouble Diagnosis Procedure.........................................................................................................................................2510 INTERVIEW WITH CUSTOMER.........................................................................................................................................2510 INSPECTION OF VEHICLE CONDITION.................................................................................................................................2511 CHECK OF CAN SYSTEM TYPE (HOW TO USE CAN SYSTEM TYPE SPECIFICATION CHART).......................................................................................2511 CAN System Type Specification Chart (Style A)...............................................................................................................2511 CAN System Type Specification Chart (Style B)...............................................................................................................2512 CREATE INTERVIEW SHEET..........................................................................................................................................2513 Interview Sheet (Example)...................................................................................................................................2514 COLLECT DATA....................................................................................................................................................2514 Collect CONSULT Data........................................................................................................................................2514 Create On-board Diagnosis Copy Sheet........................................................................................................................2515 CREATE DIAGNOSIS SHEET..........................................................................................................................................2516 Print Diagnosis Sheet.......................................................................................................................................2516 Check Collected Data........................................................................................................................................2516 DETECT THE ROOT CAUSE...........................................................................................................................................2517 Present Error - Open Circuit -..............................................................................................................................2517 Present Error - Short Circuit -.............................................................................................................................2523 Past Error - Open Circuit -.................................................................................................................................2524 Past Error - Short Circuit -................................................................................................................................2530 CAN.............................................................................................................................................................................2532 HOW TO USE THIS MANUAL......................................................................................................................................................2532 HOW TO USE THIS SECTION.................................................................................................................................................2532 Caution.............................................................................................................................................................2532 Abbreviation List...................................................................................................................................................2532 PRECAUTION..................................................................................................................................................................2533 PRECAUTIONS.............................................................................................................................................................2533 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................2533 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................2533 Precautions for Trouble Diagnosis...................................................................................................................................2533 Precautions for Harness Repair......................................................................................................................................2533 BASIC INSPECTION............................................................................................................................................................2535 DIAGNOSIS AND REPAIR WORKFLOW...........................................................................................................................................2535 Interview Sheet.....................................................................................................................................................2535 Diagnosis Sheet (CAN Type 1)........................................................................................................................................2536 Diagnosis Sheet (CAN Type 2)........................................................................................................................................2537 Diagnosis Sheet (CAN Type 3)........................................................................................................................................2538 Diagnosis Sheet (CAN Type 4)........................................................................................................................................2539 Diagnosis Sheet (CAN Type 5)........................................................................................................................................2540 Diagnosis Sheet (CAN Type 6)........................................................................................................................................2541 Diagnosis Sheet (CAN Type 7)........................................................................................................................................2542 SYSTEM DESCRIPTION..........................................................................................................................................................2543 CAN COMMUNICATION SYSTEM................................................................................................................................................2543 CAN System Specification Chart......................................................................................................................................2543 VEHICLE EQUIPMENT IDENTIFICATION INFORMATION....................................................................................................................2543 CAN Communication Signal Chart......................................................................................................................................2543 TROUBLE DIAGNOSIS.......................................................................................................................................................2546 CAN Diagnostic Support Monitor......................................................................................................................................2546 MONITOR ITEM LIST (CONSULT).....................................................................................................................................2546 ECM.........................................................................................................................................................2546 TCM.........................................................................................................................................................2546 AV Control Unit.............................................................................................................................................2546 Transfer Control Unit.......................................................................................................................................2547 Air Bag Diagnosis Sensor Unit...............................................................................................................................2547 BCM.........................................................................................................................................................2547 Differential Lock Control Unit..............................................................................................................................2548 Combination Meter...........................................................................................................................................2548 ABS Actuator and Electric Unit (Control Unit)...............................................................................................................2548 IPDM E/R....................................................................................................................................................2549 DTC Index...........................................................................................................................................................2549 WIRING DIAGRAM..............................................................................................................................................................2551 CAN SYSTEM..............................................................................................................................................................2551 Wiring Diagram......................................................................................................................................................2551 DTC/CIRCUIT DIAGNOSIS.......................................................................................................................................................2557 CAN COMMUNICATION SYSTEM................................................................................................................................................2557 Component Parts Location............................................................................................................................................2557 MALFUNCTION AREA CHART..................................................................................................................................................2558 Main Line...........................................................................................................................................................2558 Branch Line.........................................................................................................................................................2558 Short Circuit.......................................................................................................................................................2558 MAIN LINE BETWEEN TCM AND DLC CIRCUIT...................................................................................................................................2559 Diagnosis Procedure.................................................................................................................................................2559 MAIN LINE BETWEEN TCM AND AV CIRCUIT....................................................................................................................................2561 Diagnosis Procedure.................................................................................................................................................2561 MAIN LINE BETWEEN AV AND DLC CIRCUIT....................................................................................................................................2563 Diagnosis Procedure.................................................................................................................................................2563 MAIN LINE BETWEEN DLC AND ABS CIRCUIT...................................................................................................................................2564 Diagnosis Procedure.................................................................................................................................................2564 ECM BRANCH LINE CIRCUIT.................................................................................................................................................2565 Diagnosis Procedure.................................................................................................................................................2565 TCM BRANCH LINE CIRCUIT.................................................................................................................................................2566 Diagnosis Procedure.................................................................................................................................................2566 AV BRANCH LINE CIRCUIT..................................................................................................................................................2567 Diagnosis Procedure.................................................................................................................................................2567 4WD BRANCH LINE CIRCUIT.................................................................................................................................................2568 Diagnosis Procedure.................................................................................................................................................2568 A-BAG BRANCH LINE CIRCUIT...............................................................................................................................................2569 Diagnosis Procedure.................................................................................................................................................2569 BCM BRANCH LINE CIRCUIT.................................................................................................................................................2570 Diagnosis Procedure.................................................................................................................................................2570 DIFF BRANCH LINE CIRCUIT................................................................................................................................................2571 Diagnosis Procedure.................................................................................................................................................2571 DLC BRANCH LINE CIRCUIT.................................................................................................................................................2572 Diagnosis Procedure.................................................................................................................................................2572 M&A BRANCH LINE CIRCUIT.................................................................................................................................................2573 Diagnosis Procedure.................................................................................................................................................2573 STRG BRANCH LINE CIRCUIT................................................................................................................................................2574 Diagnosis Procedure.................................................................................................................................................2574 ABS BRANCH LINE CIRCUIT.................................................................................................................................................2575 Diagnosis Procedure.................................................................................................................................................2575 IPDM-E BRANCH LINE CIRCUIT..............................................................................................................................................2576 Diagnosis Procedure.................................................................................................................................................2576 CAN COMMUNICATION CIRCUIT...............................................................................................................................................2577 Diagnosis Procedure.................................................................................................................................................2577 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 LU......................................................................................................................................................................................2579 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2579 VQ40DE..........................................................................................................................................................................2580 PRECAUTION..................................................................................................................................................................2580 PRECAUTIONS.............................................................................................................................................................2580 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................2580 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................2580 Precaution for Liquid Gasket........................................................................................................................................2580 REMOVAL OF LIQUID GASKET .......................................................................................................................................2580 LIQUID GASKET APPLICATION PROCEDURE.............................................................................................................................2580 PREPARATION.................................................................................................................................................................2582 PREPARATION.............................................................................................................................................................2582 Special Service Tool................................................................................................................................................2582 Commercial Service Tool.............................................................................................................................................2582 SYSTEM DESCRIPTION..........................................................................................................................................................2584 LUBRICATION SYSTEM......................................................................................................................................................2584 Lubrication Circuit.................................................................................................................................................2584 System Chart........................................................................................................................................................2584 PERIODIC MAINTENANCE........................................................................................................................................................2585 ENGINE OIL..............................................................................................................................................................2585 Inspection..........................................................................................................................................................2585 OIL LEVEL.......................................................................................................................................................2585 OIL APPEARANCE..................................................................................................................................................2585 OIL LEAKAGE.....................................................................................................................................................2585 OIL PRESSURE CHECK..............................................................................................................................................2585 Changing Engine Oil.................................................................................................................................................2586 OIL FILTER..............................................................................................................................................................2588 Removal and Installation............................................................................................................................................2588 REMOVAL.........................................................................................................................................................2588 INSTALLATION....................................................................................................................................................2588 INSPECTION AFTER INSTALLATION...................................................................................................................................2588 REMOVAL AND INSTALLATION....................................................................................................................................................2589 OIL COOLER..............................................................................................................................................................2589 Exploded View.......................................................................................................................................................2589 Removal and Installation............................................................................................................................................2589 REMOVAL.........................................................................................................................................................2589 INSPECTION AFTER REMOVAL........................................................................................................................................2590 Oil Cooler..................................................................................................................................................2590 Relief Valve................................................................................................................................................2590 INSTALLATION....................................................................................................................................................2590 INSPECTION AFTER INSTALLATION...................................................................................................................................2590 OIL PUMP................................................................................................................................................................2592 Exploded View.......................................................................................................................................................2592 Removal and Installation............................................................................................................................................2592 REMOVAL.........................................................................................................................................................2592 INSTALLATION....................................................................................................................................................2592 INSPECTION AFTER INSTALLATION...................................................................................................................................2592 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................2594 OIL PUMP................................................................................................................................................................2594 Disassembly and Assembly............................................................................................................................................2594 DISASSEMBLY.....................................................................................................................................................2594 INSPECTION AFTER DISASSEMBLY ...................................................................................................................................2594 Clearance of Oil Pump Parts.................................................................................................................................2594 Regulator Valve Clearance...................................................................................................................................2595 ASSEMBLY........................................................................................................................................................2595 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2596 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................2596 Standard and Limit..................................................................................................................................................2596 OIL PRESSURE....................................................................................................................................................2596 OIL PUMP........................................................................................................................................................2596 REGULATOR VALVE.................................................................................................................................................2596 ENGINE OIL CAPACITY (APPROXIMATE)...............................................................................................................................2596 MA......................................................................................................................................................................................2597 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2597 PRECAUTION......................................................................................................................................................................2599 PRECAUTIONS.................................................................................................................................................................2599 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2599 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2599 PREPARATION.....................................................................................................................................................................2600 PREPARATION.................................................................................................................................................................2600 Special Service Tool....................................................................................................................................................2600 Commercial Service Tool.................................................................................................................................................2600 PERIODIC MAINTENANCE............................................................................................................................................................2601 GENERAL MAINTENANCE.........................................................................................................................................................2601 General Maintenance.....................................................................................................................................................2601 PERIODIC MAINTENANCE........................................................................................................................................................2604 Introduction of Periodic Maintenance....................................................................................................................................2604 Schedule 1..............................................................................................................................................................2604 EMISSION CONTROL SYSTEM MAINTENANCE.................................................................................................................................2604 CHASSIS AND BODY MAINTENANCE........................................................................................................................................2605 Schedule 2..............................................................................................................................................................2606 EMISSION CONTROL SYSTEM MAINTENANCE.................................................................................................................................2606 CHASSIS AND BODY MAINTENANCE........................................................................................................................................2607 RECOMMENDED FLUIDS AND LUBRICANTS...........................................................................................................................................2609 Fluids and Lubricants...................................................................................................................................................2609 SAE Viscosity Number....................................................................................................................................................2610 Anti-Freeze Coolant Mixture Ratio.......................................................................................................................................2610 ENGINE MAINTENANCE..........................................................................................................................................................2611 DRIVE BELT..............................................................................................................................................................2611 DRIVE BELT : Exploded View..........................................................................................................................................2611 DRIVE BELT : Checking Drive Belts...................................................................................................................................2611 DRIVE BELT : Adjustment.............................................................................................................................................2611 ENGINE COOLANT..........................................................................................................................................................2611 ENGINE COOLANT : System Inspection..................................................................................................................................2611 CHECKING RESERVOIR LEVEL........................................................................................................................................2612 ENGINE COOLANT : Changing Engine Coolant............................................................................................................................2612 DRAINING ENGINE COOLANT.........................................................................................................................................2612 REFILLING ENGINE COOLANT........................................................................................................................................2613 FUEL LINES..............................................................................................................................................................2614 FUEL LINES : Checking Fuel Line.....................................................................................................................................2614 FUEL FILTER.............................................................................................................................................................2614 FUEL FILTER : Changing Fuel Filter..................................................................................................................................2614 AIR CLEANER FILTER......................................................................................................................................................2615 AIR CLEANER FILTER : Exploded View..................................................................................................................................2615 AIR CLEANER FILTER : Removal and Installation.......................................................................................................................2615 REMOVAL.........................................................................................................................................................2615 INSTALLATION....................................................................................................................................................2615 ENGINE OIL..............................................................................................................................................................2615 ENGINE OIL : Inspection.............................................................................................................................................2615 OIL LEVEL.......................................................................................................................................................2615 ENGINE OIL : Changing Engine Oil....................................................................................................................................2616 OIL FILTER..............................................................................................................................................................2616 OIL FILTER : Removal and Installation...............................................................................................................................2616 REMOVAL.........................................................................................................................................................2616 INSTALLATION....................................................................................................................................................2617 INSPECTION AFTER INSTALLATION...................................................................................................................................2617 SPARK PLUG..............................................................................................................................................................2617 SPARK PLUG : Exploded View..........................................................................................................................................2618 SPARK PLUG : Removal and Installation...............................................................................................................................2618 REMOVAL.........................................................................................................................................................2618 INSPECTION AFTER REMOVAL........................................................................................................................................2618 INSTALLATION....................................................................................................................................................2619 EVAP VAPOR LINES........................................................................................................................................................2619 EVAP VAPOR LINES : Checking EVAP Vapor Line.........................................................................................................................2619 CHASSIS AND BODY MAINTENANCE................................................................................................................................................2620 IN-CABIN MICROFILTER....................................................................................................................................................2620 IN-CABIN MICROFILTER : Removal and Installation.....................................................................................................................2620 REPLACEMENT PROCEDURE...........................................................................................................................................2620 EXHAUST SYSTEM..........................................................................................................................................................2620 EXHAUST SYSTEM : Checking the Exhaust System........................................................................................................................2621 A/T FLUID...............................................................................................................................................................2621 A/T FLUID : Checking the A/T Fluid (ATF)............................................................................................................................2621 A/T FLUID : Changing the A/T Fluid (ATF)............................................................................................................................2623 M/T OIL.................................................................................................................................................................2624 M/T OIL : Checking Manual Transmission Fluid (MT)...................................................................................................................2624 OIL LEAKAGE AND OIL LEVEL.......................................................................................................................................2624 M/T OIL : Changing Manual Transmission Fluid (MT)...................................................................................................................2624 DRAINING........................................................................................................................................................2624 FILLING.........................................................................................................................................................2624 TRANSFER FLUID..........................................................................................................................................................2624 TRANSFER FLUID : Checking Transfer Fluid (TX15B)....................................................................................................................2624 FLUID LEAKAGE AND FLUID LEVEL...................................................................................................................................2624 TRANSFER FLUID : Changing Transfer Fluid (TX15B)....................................................................................................................2625 DRAINING........................................................................................................................................................2625 FILLING.........................................................................................................................................................2625 PROPELLER SHAFT.........................................................................................................................................................2625 PROPELLER SHAFT : Checking Propeller Shaft..........................................................................................................................2625 DIFFERENTIAL GEAR OIL...................................................................................................................................................2625 DIFFERENTIAL GEAR OIL : Checking Front Final Drive Oil (R180A)......................................................................................................2626 DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL.........................................................................................................................2626 DIFFERENTIAL GEAR OIL : Changing Front Final Drive Oil (R180A)......................................................................................................2626 DRAINING........................................................................................................................................................2626 FILLING.........................................................................................................................................................2626 DIFFERENTIAL GEAR OIL : Checking Rear Final Drive Oil (C200)........................................................................................................2626 DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL.........................................................................................................................2626 DIFFERENTIAL GEAR OIL : Changing Rear Final Drive Oil (C200)........................................................................................................2627 DRAINING........................................................................................................................................................2627 FILLING.........................................................................................................................................................2627 DIFFERENTIAL GEAR OIL : Checking Rear Final Drive Oil (M226)........................................................................................................2627 DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL.........................................................................................................................2627 DIFFERENTIAL GEAR OIL : Changing Rear Final Drive Oil (M226)........................................................................................................2628 DRAINING........................................................................................................................................................2628 FILLING.........................................................................................................................................................2628 WHEELS..................................................................................................................................................................2628 WHEELS : Adjustment.................................................................................................................................................2628 BALANCING WHEELS (ADHESIVE WEIGHT TYPE).........................................................................................................................2628 Preparation Before Adjustment...............................................................................................................................2628 Wheel Balance Adjustment....................................................................................................................................2628 TIRE ROTATION...................................................................................................................................................2629 BRAKE FLUID LEVEL AND LEAKS.............................................................................................................................................2630 BRAKE FLUID LEVEL AND LEAKS : Checking Brake Fluid Level and Leaks..................................................................................................2630 BRAKE LINES AND CABLES..................................................................................................................................................2630 BRAKE LINES AND CABLES : Checking Brake Line and Cables.............................................................................................................2630 DISC BRAKE..............................................................................................................................................................2630 DISC BRAKE : Checking Disc Brake....................................................................................................................................2630 ROTOR...........................................................................................................................................................2630 CALIPER.........................................................................................................................................................2631 PAD.............................................................................................................................................................2631 STEERING GEAR AND LINKAGE...............................................................................................................................................2631 STEERING GEAR AND LINKAGE : Checking Steering Gear and Linkage......................................................................................................2631 STEERING GEAR...................................................................................................................................................2631 STEERING LINKAGE................................................................................................................................................2631 POWER STEERING FLUID AND LINES..........................................................................................................................................2631 POWER STEERING FLUID AND LINES : Checking Power Steering Fluid and Line.............................................................................................2632 CHECKING FLUID LEVEL............................................................................................................................................2632 CHECKING LINES..................................................................................................................................................2632 AXLE AND SUSPENSION PARTS...............................................................................................................................................2632 AXLE AND SUSPENSION PARTS : Checking Axle and Suspension Parts......................................................................................................2632 FRONT AND REAR AXLE AND SUSPENSION PARTS........................................................................................................................2632 FRONT DRIVE SHAFT...............................................................................................................................................2632 LOCKS, HINGES AND HOOD LATCH............................................................................................................................................2633 LOCKS, HINGES AND HOOD LATCH : Lubricating Locks, Hinges and Hood Latches...........................................................................................2634 SEAT BELT, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS...................................................................................................................2634 SEAT BELT, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS : Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters.............................................2634 MIR.....................................................................................................................................................................................2636 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2636 WIRING DIAGRAM..................................................................................................................................................................2637 DOOR MIRROR.................................................................................................................................................................2637 Wiring Diagram - With Heated Mirrors....................................................................................................................................2637 Wiring Diagram - Without Heated Mirrors.................................................................................................................................2640 INSIDE MIRROR...............................................................................................................................................................2643 Wiring Diagram..........................................................................................................................................................2643 PRECAUTION......................................................................................................................................................................2646 PRECAUTIONS.................................................................................................................................................................2646 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2646 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2646 Precaution for Work.....................................................................................................................................................2646 PREPARATION.....................................................................................................................................................................2647 PREPARATION.................................................................................................................................................................2647 Special Service Tool....................................................................................................................................................2647 Commercial Service Tool.................................................................................................................................................2647 UNIT REMOVAL AND INSTALLATION...................................................................................................................................................2648 INSIDE MIRROR...............................................................................................................................................................2648 Exploded view...........................................................................................................................................................2648 Removal and Installation................................................................................................................................................2648 REMOVAL.............................................................................................................................................................2648 INSTALLATION........................................................................................................................................................2648 DOOR MIRROR.................................................................................................................................................................2649 Door Mirror Assembly....................................................................................................................................................2649 EXPLODED VIEW.......................................................................................................................................................2649 MANUAL MIRROR.......................................................................................................................................................2649 Removal.........................................................................................................................................................2649 Installation....................................................................................................................................................2649 POWER MIRROR........................................................................................................................................................2649 Removal.........................................................................................................................................................2649 Installation....................................................................................................................................................2649 Door Mirror Glass.......................................................................................................................................................2650 REMOVAL ............................................................................................................................................................2650 INSTALLATION........................................................................................................................................................2650 UNIT DISASSEMBLY AND ASSEMBLY...................................................................................................................................................2651 DOOR MIRROR.................................................................................................................................................................2651 Mirror Actuator.........................................................................................................................................................2651 DISASSEMBLY AND ASSEMBLY............................................................................................................................................2651 Disassembly.....................................................................................................................................................2651 Assembly........................................................................................................................................................2651 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 MWI.....................................................................................................................................................................................2652 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2652 BASIC INSPECTION................................................................................................................................................................2655 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................2655 Work Flow...............................................................................................................................................................2655 DETAILED FLOW.......................................................................................................................................................2655 SYSTEM DESCRIPTION..............................................................................................................................................................2656 METER SYSTEM................................................................................................................................................................2656 METER SYSTEM............................................................................................................................................................2656 METER SYSTEM : System Diagram.......................................................................................................................................2656 METER SYSTEM : System Description...................................................................................................................................2656 COMBINATION METER...............................................................................................................................................2656 METER SYSTEM : Arrangement of Combination Meter.....................................................................................................................2657 METER SYSTEM : Component Parts Location.............................................................................................................................2658 METER SYSTEM : Component Description................................................................................................................................2658 SPEEDOMETER.............................................................................................................................................................2659 SPEEDOMETER : System Diagram........................................................................................................................................2659 SPEEDOMETER : System Description....................................................................................................................................2659 SPEEDOMETER : Component Parts Location..............................................................................................................................2659 SPEEDOMETER : Component Description.................................................................................................................................2660 TACHOMETER..............................................................................................................................................................2660 TACHOMETER : System Diagram.........................................................................................................................................2660 TACHOMETER : System Description.....................................................................................................................................2660 TACHOMETER : Component Parts Location...............................................................................................................................2661 TACHOMETER : Component Description..................................................................................................................................2661 ENGINE COOLANT TEMPERATURE GAUGE........................................................................................................................................2661 ENGINE COOLANT TEMPERATURE GAUGE : System Diagram...................................................................................................................2661 ENGINE COOLANT TEMPERATURE GAUGE : System Description...............................................................................................................2662 ENGINE COOLANT TEMPERATURE GAUGE : Component Parts Location.........................................................................................................2662 ENGINE COOLANT TEMPERATURE GAUGE : Component Description............................................................................................................2662 FUEL GAUGE..............................................................................................................................................................2662 FUEL GAUGE : System Diagram.........................................................................................................................................2663 FUEL GAUGE : System Description.....................................................................................................................................2663 FUEL GAUGE : Component Parts Location...............................................................................................................................2663 FUEL GAUGE : Component Description..................................................................................................................................2664 ENGINE OIL PRESSURE GAUGE...............................................................................................................................................2664 ENGINE OIL PRESSURE GAUGE : System Diagram..........................................................................................................................2664 ENGINE OIL PRESSURE GAUGE : System Description......................................................................................................................2664 ENGINE OIL PRESSURE GAUGE : Component Parts Location................................................................................................................2664 ENGINE OIL PRESSURE GAUGE : Component Description...................................................................................................................2665 VOLTAGE GAUGE...........................................................................................................................................................2665 VOLTAGE GAUGE : System Diagram......................................................................................................................................2665 VOLTAGE GAUGE : System Description..................................................................................................................................2665 VOLTAGE GAUGE : Component Parts Location............................................................................................................................2666 VOLTAGE GAUGE : Component Description...............................................................................................................................2666 ODO/TRIP METER..........................................................................................................................................................2666 ODO/TRIP METER : System Diagram.....................................................................................................................................2666 ODO/TRIP METER : System Description.................................................................................................................................2667 LOOSE FUEL CAP WARNING..........................................................................................................................................2667 CHECK TIRE PRESSURE WARNING.....................................................................................................................................2667 HOW TO CHANGE THE DISPLAY FOR ODO/TRIP METER....................................................................................................................2667 ODO/TRIP METER : Component Parts Location...........................................................................................................................2667 ODO/TRIP METER : Component Description..............................................................................................................................2668 SHIFT POSITION INDICATOR................................................................................................................................................2668 SHIFT POSITION INDICATOR : System Diagram...........................................................................................................................2668 SHIFT POSITION INDICATOR : System Description.......................................................................................................................2668 SHIFT POSITION INDICATOR : Component Parts Location.................................................................................................................2668 SHIFT POSITION INDICATOR : Component Description....................................................................................................................2669 WARNING LAMPS/INDICATOR LAMPS...........................................................................................................................................2669 WARNING LAMPS/INDICATOR LAMPS : System Diagram......................................................................................................................2669 WARNING LAMPS/INDICATOR LAMPS : System Description..................................................................................................................2669 OIL PRESSURE WARNING LAMP.......................................................................................................................................2669 WARNING LAMPS/INDICATOR LAMPS : Component Parts Location............................................................................................................2670 WARNING LAMPS/INDICATOR LAMPS : Component Description...............................................................................................................2670 TRIP COMPUTER...........................................................................................................................................................2670 TRIP COMPUTER : System Diagram......................................................................................................................................2671 TRIP COMPUTER : System Description..................................................................................................................................2671 FUNCTION........................................................................................................................................................2671 DTE (DISTANCE TO EMPTY) INDICATION..............................................................................................................................2671 TRIP DISTANCE...................................................................................................................................................2671 TRIP TIME.......................................................................................................................................................2671 AVERAGE FUEL CONSUMPTION........................................................................................................................................2671 AVERAGE VEHICLE SPEED...........................................................................................................................................2671 HOW TO CHANGE/RESET INDICATION..................................................................................................................................2671 TRIP COMPUTER : Component Parts Location............................................................................................................................2672 TRIP COMPUTER : Component Description...............................................................................................................................2672 COMPASS.....................................................................................................................................................................2673 Description.............................................................................................................................................................2673 DESCRIPTION.........................................................................................................................................................2673 ZONE VARIATION SETTING PROCEDURE....................................................................................................................................2673 CALIBRATION PROCEDURE...............................................................................................................................................2673 DIAGNOSIS SYSTEM (METER)....................................................................................................................................................2675 Diagnosis Description...................................................................................................................................................2675 SELF-DIAGNOSIS MODE.................................................................................................................................................2675 OPERATION PROCEDURE.................................................................................................................................................2675 COMBINATION METER SELF-DIAGNOSIS MODE FUNCTIONS.....................................................................................................................2675 CONSULT Function (METER/M&A)............................................................................................................................................2676 SELF-DIAG RESULTS...................................................................................................................................................2677 Display Item List...............................................................................................................................................2677 DATA MONITOR........................................................................................................................................................2677 Display Item List...............................................................................................................................................2677 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................2679 DTC U1000 CAN COMMUNICATION.................................................................................................................................................2679 DTC Logic...............................................................................................................................................................2679 DTC DETECTION LOGIC.................................................................................................................................................2679 Diagnosis Procedure.....................................................................................................................................................2679 DTC B2205 VEHICLE SPEED CIRCUIT.............................................................................................................................................2680 Description.............................................................................................................................................................2680 DTC Logic...............................................................................................................................................................2680 Diagnosis Procedure.....................................................................................................................................................2680 POWER SUPPLY AND GROUND CIRCUIT.............................................................................................................................................2681 COMBINATION METER.......................................................................................................................................................2681 COMBINATION METER : Diagnosis Procedure.............................................................................................................................2681 BCM (BODY CONTROL MODULE)...............................................................................................................................................2681 BCM (BODY CONTROL MODULE) : Diagnosis Procedure.....................................................................................................................2682 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)............................................................................................................2682 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) : Diagnosis Procedure..................................................................................2683 FUEL LEVEL SENSOR SIGNAL CIRCUIT............................................................................................................................................2684 Description.............................................................................................................................................................2684 Component Function Check................................................................................................................................................2684 Diagnosis Procedure.....................................................................................................................................................2684 Component Inspection....................................................................................................................................................2685 OIL PRESSURE SWITCH SIGNAL CIRCUIT..........................................................................................................................................2687 Description.............................................................................................................................................................2687 Component Function Check................................................................................................................................................2687 Diagnosis Procedure.....................................................................................................................................................2687 Component Inspection....................................................................................................................................................2687 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................2689 COMBINATION METER...........................................................................................................................................................2689 Reference Value.........................................................................................................................................................2689 TERMINAL LAYOUT.....................................................................................................................................................2689 PHYSICAL VALUES.....................................................................................................................................................2689 Fail Safe...............................................................................................................................................................2690 DTC Index...............................................................................................................................................................2691 BCM (BODY CONTROL MODULE)...................................................................................................................................................2692 Reference Value.........................................................................................................................................................2692 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................2692 Terminal Layout.........................................................................................................................................................2695 Physical Values.........................................................................................................................................................2695 Fail Safe...............................................................................................................................................................2700 Fail-safe index.....................................................................................................................................................2700 DTC Inspection Priority Chart...........................................................................................................................................2700 DTC Index...............................................................................................................................................................2701 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)................................................................................................................2703 Reference Value.........................................................................................................................................................2703 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................2703 Terminal Layout.........................................................................................................................................................2704 Physical Values.........................................................................................................................................................2704 PHYSICAL VALUES.....................................................................................................................................................2704 Fail Safe...............................................................................................................................................................2708 CAN COMMUNICATION CONTROL...........................................................................................................................................2708 If No CAN Communication Is Available With ECM...................................................................................................................2708 If No CAN Communication Is Available With BCM...................................................................................................................2708 IGNITION RELAY MALFUNCTION DETECTION FUNCTION.......................................................................................................................2708 FRONT WIPER CONTROL.................................................................................................................................................2708 STARTER MOTOR PROTECTION FUNCTION...................................................................................................................................2708 DTC Index...............................................................................................................................................................2709 WIRING DIAGRAM..................................................................................................................................................................2710 COMPASS.....................................................................................................................................................................2710 Wiring Diagram..........................................................................................................................................................2710 METER.......................................................................................................................................................................2712 Wiring Diagram..........................................................................................................................................................2712 SYMPTOM DIAGNOSIS...............................................................................................................................................................2728 THE FUEL GAUGE POINTER DOES NOT MOVE........................................................................................................................................2728 Description.............................................................................................................................................................2728 Diagnosis Procedure.....................................................................................................................................................2728 THE FUEL GAUGE POINTER DOES NOT MOVE TO "F" WHEN REFUELING..................................................................................................................2729 Description.............................................................................................................................................................2729 Diagnosis Procedure.....................................................................................................................................................2729 THE OIL PRESSURE WARNING LAMP DOES NOT TURN ON..............................................................................................................................2730 Description.............................................................................................................................................................2730 Diagnosis Procedure.....................................................................................................................................................2730 THE OIL PRESSURE WARNING LAMP DOES NOT TURN OFF.............................................................................................................................2731 Description.............................................................................................................................................................2731 Diagnosis Procedure.....................................................................................................................................................2731 NORMAL OPERATING CONDITION..................................................................................................................................................2732 COMPASS.................................................................................................................................................................2732 COMPASS : Description...............................................................................................................................................2732 COMPASS.........................................................................................................................................................2732 PRECAUTION......................................................................................................................................................................2733 PRECAUTIONS.................................................................................................................................................................2733 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2733 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2733 PREPARATION.....................................................................................................................................................................2734 PREPARATION.................................................................................................................................................................2734 Commercial Service Tools................................................................................................................................................2734 REMOVAL AND INSTALLATION........................................................................................................................................................2735 COMBINATION METER...........................................................................................................................................................2735 Removal and Installation................................................................................................................................................2735 REMOVAL.............................................................................................................................................................2735 INSTALLATION........................................................................................................................................................2735 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 PB......................................................................................................................................................................................2736 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2736 PRECAUTION......................................................................................................................................................................2737 PRECAUTIONS.................................................................................................................................................................2737 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2737 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2737 PREPARATION.....................................................................................................................................................................2738 PREPARATION.................................................................................................................................................................2738 Commercial Service Tool.................................................................................................................................................2738 REMOVAL AND INSTALLATION........................................................................................................................................................2739 PARKING BRAKE SYSTEM........................................................................................................................................................2739 On-Vehicle Service......................................................................................................................................................2739 LEVER STROKE........................................................................................................................................................2739 INSPECTION..........................................................................................................................................................2739 ADJUSTMENT..........................................................................................................................................................2739 UNIT REMOVAL AND INSTALLATION...................................................................................................................................................2740 PARKING BRAKE CONTROL.......................................................................................................................................................2740 Component...............................................................................................................................................................2740 Removal and Installation................................................................................................................................................2741 REMOVAL.............................................................................................................................................................2741 INSTALLATION........................................................................................................................................................2741 PARKING BRAKE SHOE..........................................................................................................................................................2742 Component...............................................................................................................................................................2742 Removal and Installation................................................................................................................................................2742 REMOVAL.............................................................................................................................................................2742 INSPECTION AFTER REMOVAL............................................................................................................................................2743 Lining Thickness Inspection.....................................................................................................................................2743 Drum Inner Diameter Inspection..................................................................................................................................2743 Other Inspections...............................................................................................................................................2743 INSTALLATION........................................................................................................................................................2743 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2745 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2745 Parking Drum Brake......................................................................................................................................................2745 Parking Brake Control...................................................................................................................................................2745 PCS.....................................................................................................................................................................................2746 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2746 IPDM E/R........................................................................................................................................................................2747 SYSTEM DESCRIPTION..........................................................................................................................................................2747 RELAY CONTROL SYSTEM....................................................................................................................................................2747 System Diagram......................................................................................................................................................2747 System Description..................................................................................................................................................2748 Component Parts Location............................................................................................................................................2749 POWER CONTROL SYSTEM....................................................................................................................................................2750 System Diagram......................................................................................................................................................2750 System Description..................................................................................................................................................2750 COOLING FAN CONTROL.............................................................................................................................................2750 SIGNAL BUFFER SYSTEM....................................................................................................................................................2751 System Diagram......................................................................................................................................................2751 System Description..................................................................................................................................................2751 POWER CONSUMPTION CONTROL SYSTEM........................................................................................................................................2752 System Diagram......................................................................................................................................................2752 System Description..................................................................................................................................................2752 OUTLINE.........................................................................................................................................................2752 SLEEP MODE ACTIVATION...........................................................................................................................................2752 WAKE-UP OPERATION...............................................................................................................................................2752 Component Parts Location............................................................................................................................................2753 DIAGNOSIS SYSTEM (IPDM E/R).............................................................................................................................................2754 Diagnosis Description...............................................................................................................................................2754 AUTO ACTIVE TEST................................................................................................................................................2754 Description.................................................................................................................................................2754 Operation Procedure.........................................................................................................................................2754 Inspection in Auto Active Test Mode.........................................................................................................................2754 Concept of auto active test.................................................................................................................................2755 Diagnosis chart in auto active test mode....................................................................................................................2755 CONSULT Function (IPDM E/R).........................................................................................................................................2756 APPLICATION ITEM................................................................................................................................................2756 SELF DIAGNOSTIC RESULT..........................................................................................................................................2756 DATA MONITOR....................................................................................................................................................2756 ACTIVE TEST.....................................................................................................................................................2757 DTC/CIRCUIT DIAGNOSIS.......................................................................................................................................................2758 U1000 CAN COMM CIRCUIT..................................................................................................................................................2758 Description.........................................................................................................................................................2758 DTC Logic...........................................................................................................................................................2758 DTC DETECTION LOGIC.............................................................................................................................................2758 DTC CONFIRMATION PROCEDURE......................................................................................................................................2758 Diagnosis Procedure.................................................................................................................................................2758 POWER SUPPLY AND GROUND CIRCUIT.........................................................................................................................................2759 Diagnosis Procedure.................................................................................................................................................2759 ECU DIAGNOSIS INFORMATION...................................................................................................................................................2760 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)............................................................................................................2760 Reference Value.....................................................................................................................................................2760 VALUES ON THE DIAGNOSIS TOOL....................................................................................................................................2760 Terminal Layout.....................................................................................................................................................2761 Physical Values.....................................................................................................................................................2762 PHYSICAL VALUES.................................................................................................................................................2762 Fail Safe...........................................................................................................................................................2765 CAN COMMUNICATION CONTROL.......................................................................................................................................2765 If No CAN Communication Is Available With ECM...............................................................................................................2765 If No CAN Communication Is Available With BCM...............................................................................................................2765 IGNITION RELAY MALFUNCTION DETECTION FUNCTION...................................................................................................................2765 FRONT WIPER CONTROL.............................................................................................................................................2765 STARTER MOTOR PROTECTION FUNCTION...............................................................................................................................2765 DTC Index...........................................................................................................................................................2766 WIRING DIAGRAM..............................................................................................................................................................2767 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)............................................................................................................2767 Wiring Diagram......................................................................................................................................................2767 PRECAUTION..................................................................................................................................................................2771 PRECAUTIONS.............................................................................................................................................................2771 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................2771 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................2771 REMOVAL AND INSTALLATION....................................................................................................................................................2772 BCM (BODY CONTROL MODULE)...............................................................................................................................................2772 Removal and Installation............................................................................................................................................2772 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................2773 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)............................................................................................................2773 Removal and Installation............................................................................................................................................2773 REMOVAL.........................................................................................................................................................2773 INSTALLATION....................................................................................................................................................2773 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 PG......................................................................................................................................................................................2774 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2774 PRECAUTION......................................................................................................................................................................2775 PRECAUTIONS.................................................................................................................................................................2775 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2775 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2775 Precaution for Power Generation Variable Voltage Control System.........................................................................................................2775 PREPARATION.....................................................................................................................................................................2776 PREPARATION.................................................................................................................................................................2776 Special Service Tool....................................................................................................................................................2776 Commercial Service Tool.................................................................................................................................................2776 BASIC INSPECTION................................................................................................................................................................2777 BATTERY.....................................................................................................................................................................2777 How to Handle Battery...................................................................................................................................................2777 METHODS OF PREVENTING OVER-DISCHARGE................................................................................................................................2777 Work Flow...............................................................................................................................................................2777 BATTERY DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI....................................................................................................................2777 BATTERY DIAGNOSIS WITHOUT EXP-800 NI OR GR8-1200 NI.................................................................................................................2777 Checking Electrolyte Level......................................................................................................................................2777 Specific Gravity Check..........................................................................................................................................2778 Charging The Battery............................................................................................................................................2779 INSPECTION AND ADJUSTMENT...................................................................................................................................................2780 ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL..............................................................................................................2780 ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Special Repair Requirement.............................................................................2780 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................2781 POWER SUPPLY ROUTING CIRCUIT................................................................................................................................................2781 Wiring Diagram-Battery Power Supply.....................................................................................................................................2781 Wiring Diagram-Accessory Power Supply...................................................................................................................................2790 Wiring Diagram-Ignition Power Supply....................................................................................................................................2793 Fuse....................................................................................................................................................................2799 Fusible Link............................................................................................................................................................2799 Circuit Breaker (Built Into BCM)........................................................................................................................................2799 GROUND CIRCUIT..............................................................................................................................................................2800 Ground Distribution.....................................................................................................................................................2800 Main Harness........................................................................................................................................................2800 Engine Room Harness.................................................................................................................................................2803 Engine Control Harness..............................................................................................................................................2806 Body Harness........................................................................................................................................................2807 Body No. 2 Harness..................................................................................................................................................2808 Back Door No. 2 and Back Door Harness...............................................................................................................................2809 HARNESS.....................................................................................................................................................................2810 Harness Layout..........................................................................................................................................................2810 HOW TO READ HARNESS LAYOUT .........................................................................................................................................2810 OUTLINE ............................................................................................................................................................2811 MAIN HARNESS........................................................................................................................................................2812 ENGINE ROOM HARNESS (RH VIEW).......................................................................................................................................2814 ENGINE ROOM HARNESS (PASSENGER COMPARTMENT).........................................................................................................................2816 ENGINE ROOM HARNESS (LH VIEW).......................................................................................................................................2818 ENGINE CONTROL HARNESS..............................................................................................................................................2819 CHASSIS HARNESS.....................................................................................................................................................2821 BODY HARNESS........................................................................................................................................................2822 BODY NO. 2 HARNESS..................................................................................................................................................2824 ROOM LAMP HARNESS...................................................................................................................................................2826 FRONT DOOR LH HARNESS...............................................................................................................................................2827 FRONT DOOR RH HARNESS...............................................................................................................................................2828 REAR DOOR LH HARNESS................................................................................................................................................2829 REAR DOOR RH HARNESS................................................................................................................................................2830 BACK DOOR HARNESS...................................................................................................................................................2831 ELECTRICAL UNITS LOCATION...................................................................................................................................................2833 Electrical Units Location...............................................................................................................................................2833 ENGINE COMPARTMENT..................................................................................................................................................2833 PASSENGER COMPARTMENT...............................................................................................................................................2834 HARNESS CONNECTOR...........................................................................................................................................................2836 Description.............................................................................................................................................................2836 HARNESS CONNECTOR (TAB-LOCKING TYPE)................................................................................................................................2836 HARNESS CONNECTOR (SLIDE-LOCKING TYPE)..............................................................................................................................2836 HARNESS CONNECTOR (LEVER LOCKING TYPE)..............................................................................................................................2837 HARNESS CONNECTOR (DIRECT-CONNECT SRS COMPONENT TYPE)...............................................................................................................2838 STANDARDIZED RELAY..........................................................................................................................................................2839 Description.............................................................................................................................................................2839 NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS....................................................................................................................2839 TYPE OF STANDARDIZED RELAYS.........................................................................................................................................2839 FUSE BLOCK-JUNCTION BOX (J/B)...............................................................................................................................................2841 Terminal Arrangement....................................................................................................................................................2841 FUSE AND FUSIBLE LINK BOX...................................................................................................................................................2842 Terminal Arrangement....................................................................................................................................................2842 FUSE AND RELAY BOX..........................................................................................................................................................2843 Terminal Arrangement....................................................................................................................................................2843 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)................................................................................................................2844 IPDM E/R Terminal Arrangement...........................................................................................................................................2844 REMOVAL AND INSTALLATION........................................................................................................................................................2845 BATTERY.....................................................................................................................................................................2845 Removal and Installation................................................................................................................................................2845 REMOVAL.............................................................................................................................................................2845 INSTALLATION........................................................................................................................................................2845 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2846 BATTERY.....................................................................................................................................................................2846 Battery.................................................................................................................................................................2846 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 PWC.....................................................................................................................................................................................2847 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2847 BASIC INSPECTION................................................................................................................................................................2849 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................2849 Work Flow...............................................................................................................................................................2849 DETAILED FLOW.......................................................................................................................................................2849 SYSTEM DESCRIPTION..............................................................................................................................................................2850 POWER WINDOW SYSTEM.........................................................................................................................................................2850 System Diagram..........................................................................................................................................................2850 FRONT WINDOW ANTI-PINCH SYSTEM......................................................................................................................................2850 System Description......................................................................................................................................................2850 MAIN POWER WINDOW AND DOOR LOCK/UNLOCK SWITCH.......................................................................................................................2850 POWER WINDOW AND DOOR LOCK/UNLOCK SWITCH RH.........................................................................................................................2850 POWER WINDOW OPERATION..............................................................................................................................................2851 POWER WINDOW AUTO DOWN OPERATION (FRONT LH).........................................................................................................................2851 RETAINED POWER OPERATION ...........................................................................................................................................2851 POWER WINDOW LOCK...................................................................................................................................................2851 Component Parts Location................................................................................................................................................2851 Component Description...................................................................................................................................................2852 FRONT WINDOW ANTI-PINCH SYSTEM......................................................................................................................................2852 DIAGNOSIS SYSTEM (BCM)......................................................................................................................................................2853 COMMON ITEM.............................................................................................................................................................2853 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM)..................................................................................................................2853 APPLICATION ITEM................................................................................................................................................2853 SYSTEM APPLICATION..............................................................................................................................................2853 RETAINED PWR............................................................................................................................................................2853 RETAINED PWR : CONSULT Function (BCM - RETAINED PWR)................................................................................................................2854 DATA MONITOR....................................................................................................................................................2854 ACTIVE TEST.....................................................................................................................................................2854 WORK SUPPORT....................................................................................................................................................2854 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................2855 POWER SUPPLY AND GROUND CIRCUIT.............................................................................................................................................2855 BCM.....................................................................................................................................................................2855 BCM : Diagnosis Procedure...........................................................................................................................................2855 POWER WINDOW MAIN SWITCH................................................................................................................................................2856 POWER WINDOW MAIN SWITCH : Description..............................................................................................................................2856 POWER WINDOW MAIN SWITCH : Component Function Check.................................................................................................................2856 Main Power Window And Door Lock/Unlock Switch ..................................................................................................................2856 POWER WINDOW MAIN SWITCH : Diagnosis Procedure......................................................................................................................2856 POWER WINDOW MAIN SWITCH : Component Inspection.....................................................................................................................2859 FRONT POWER WINDOW SWITCH...............................................................................................................................................2861 FRONT POWER WINDOW SWITCH : Description.............................................................................................................................2861 FRONT POWER WINDOW SWITCH : Component Function Check................................................................................................................2861 Power Window And Door Lock/Unlock Switch RH ....................................................................................................................2861 FRONT POWER WINDOW SWITCH : Diagnosis Procedure.....................................................................................................................2861 REAR POWER WINDOW SWITCH................................................................................................................................................2862 REAR POWER WINDOW SWITCH : Description..............................................................................................................................2862 REAR POWER WINDOW SWITCH : Component Function Check.................................................................................................................2862 Rear Power Window Switch .......................................................................................................................................2862 REAR POWER WINDOW SWITCH : Diagnosis Procedure......................................................................................................................2863 REAR POWER WINDOW SWITCH : Component Inspection.....................................................................................................................2864 COMPONENT INSPECTION............................................................................................................................................2864 POWER WINDOW MOTOR..........................................................................................................................................................2866 DRIVER SIDE.............................................................................................................................................................2866 DRIVER SIDE : Description...........................................................................................................................................2866 DRIVER SIDE : Component Function Check..............................................................................................................................2866 DRIVER SIDE : Diagnosis Procedure...................................................................................................................................2866 DRIVER SIDE : Component Inspection..................................................................................................................................2867 COMPONENT INSPECTION............................................................................................................................................2867 PASSENGER SIDE..........................................................................................................................................................2867 PASSENGER SIDE : Description........................................................................................................................................2867 PASSENGER SIDE : Component Function Check...........................................................................................................................2867 PASSENGER SIDE : Diagnosis Procedure................................................................................................................................2867 PASSENGER SIDE : Component Inspection...............................................................................................................................2868 COMPONENT INSPECTION............................................................................................................................................2868 REAR LH.................................................................................................................................................................2869 REAR LH : Description...............................................................................................................................................2869 REAR LH : Component Function Check..................................................................................................................................2869 REAR LH : Diagnosis Procedure.......................................................................................................................................2869 REAR LH : Component Inspection......................................................................................................................................2870 COMPONENT INSPECTION............................................................................................................................................2870 REAR RH.................................................................................................................................................................2870 REAR RH : Description...............................................................................................................................................2870 REAR RH : Component Function Check..................................................................................................................................2870 REAR RH : Diagnosis Procedure.......................................................................................................................................2871 REAR RH : Component Inspection......................................................................................................................................2872 COMPONENT INSPECTION............................................................................................................................................2872 DOOR SWITCH.................................................................................................................................................................2873 Description.............................................................................................................................................................2873 Component Function Check................................................................................................................................................2873 Diagnosis Procedure.....................................................................................................................................................2873 Component Inspection....................................................................................................................................................2874 POWER WINDOW LOCK SWITCH....................................................................................................................................................2875 Description.............................................................................................................................................................2875 Component Function Check................................................................................................................................................2875 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................2876 POWER WINDOW SYSTEM.........................................................................................................................................................2876 Terminal Layout.........................................................................................................................................................2876 Physical Values.........................................................................................................................................................2876 BCM (BODY CONTROL MODULE)...................................................................................................................................................2877 Reference Value.........................................................................................................................................................2877 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................2877 Terminal Layout.........................................................................................................................................................2880 Physical Values.........................................................................................................................................................2880 Fail Safe...............................................................................................................................................................2885 Fail-safe index.....................................................................................................................................................2885 DTC Inspection Priority Chart...........................................................................................................................................2885 DTC Index...............................................................................................................................................................2886 WIRING DIAGRAM..................................................................................................................................................................2888 POWER WINDOW SYSTEM.........................................................................................................................................................2888 Wiring Diagram..........................................................................................................................................................2888 SYMPTOM DIAGNOSIS...............................................................................................................................................................2895 NONE OF THE POWER WINDOWS CAN BE OPERATED USING ANY SWITCH..................................................................................................................2895 Diagnosis Procedure.....................................................................................................................................................2895 DRIVER SIDE POWER WINDOW ALONE DOES NOT OPERATE.............................................................................................................................2896 Diagnosis Procedure.....................................................................................................................................................2896 FRONT PASSENGER SIDE POWER WINDOW ALONE DOES NOT OPERATE....................................................................................................................2897 Diagnosis Procedure.....................................................................................................................................................2897 REAR LH SIDE POWER WINDOW ALONE DOES NOT OPERATE............................................................................................................................2898 Diagnosis Procedure.....................................................................................................................................................2898 REAR RH SIDE POWER WINDOW ALONE DOES NOT OPERATE............................................................................................................................2899 Diagnosis Procedure.....................................................................................................................................................2899 AUTO OPERATION DOES NOT OPERATE BUT MANUAL OPERATES NORMALLY (DRIVER SIDE)..................................................................................................2900 Diagnosis Procedure.....................................................................................................................................................2900 POWER WINDOW RETAINED POWER OPERATION DOES NOT OPERATE PROPERLY.............................................................................................................2901 Diagnosis Procedure.....................................................................................................................................................2901 POWER WINDOW LOCK SWITCH DOES NOT FUNCTION..................................................................................................................................2902 Diagnosis Procedure.....................................................................................................................................................2902 PRECAUTION......................................................................................................................................................................2903 PRECAUTIONS.................................................................................................................................................................2903 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2903 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2903 Precaution for Work.....................................................................................................................................................2903 PREPARATION.....................................................................................................................................................................2904 PREPARATION.................................................................................................................................................................2904 Special Service Tool....................................................................................................................................................2904 REMOVAL AND INSTALLATION........................................................................................................................................................2905 POWER WINDOW MAIN SWITCH....................................................................................................................................................2905 Removal and Installation................................................................................................................................................2905 REMOVAL.............................................................................................................................................................2905 INSTALLATION........................................................................................................................................................2905 FRONT POWER WINDOW SWITCH ..................................................................................................................................................2906 Removal and Installation................................................................................................................................................2906 REMOVAL.............................................................................................................................................................2906 INSTALLATION........................................................................................................................................................2906 REAR POWER WINDOW SWITCH ...................................................................................................................................................2907 Removal and Installation - Rear Door Switch.............................................................................................................................2907 REMOVAL.............................................................................................................................................................2907 INSTALLATION........................................................................................................................................................2907 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 PWO.....................................................................................................................................................................................2908 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2908 PRECAUTION......................................................................................................................................................................2909 PRECAUTIONS.................................................................................................................................................................2909 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2909 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2909 PREPARATION.....................................................................................................................................................................2910 PREPARATION.................................................................................................................................................................2910 Special Service Tool....................................................................................................................................................2910 WIRING DIAGRAM..................................................................................................................................................................2911 POWER SOCKET................................................................................................................................................................2911 Wiring Diagram..........................................................................................................................................................2911 REMOVAL AND INSTALLATION........................................................................................................................................................2915 POWER SOCKET................................................................................................................................................................2915 Front, Console, or Rear Cargo Power Socket..............................................................................................................................2915 POWER SOCKET........................................................................................................................................................2915 Removal.........................................................................................................................................................2915 Installation....................................................................................................................................................2915 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 RAX.....................................................................................................................................................................................2916 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2916 C200............................................................................................................................................................................2918 PRECAUTION..................................................................................................................................................................2918 PRECAUTIONS.............................................................................................................................................................2918 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................2918 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................2918 Precaution..........................................................................................................................................................2918 PREPARATION.................................................................................................................................................................2919 PREPARATION.............................................................................................................................................................2919 Special Service Tool................................................................................................................................................2919 Commercial Service Tool.............................................................................................................................................2919 SYMPTOM DIAGNOSIS...........................................................................................................................................................2921 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING....................................................................................................................2921 NVH Troubleshooting Chart...........................................................................................................................................2921 REMOVAL AND INSTALLATION....................................................................................................................................................2922 ON-VEHICLE SERVICE......................................................................................................................................................2922 Rear Axle Parts.....................................................................................................................................................2922 Rear Axle Bearing...................................................................................................................................................2922 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................2923 AXLE SHAFT..............................................................................................................................................................2923 Removal and Installation............................................................................................................................................2923 REMOVAL.........................................................................................................................................................2924 INSPECTION AFTER REMOVAL........................................................................................................................................2925 Axle Shaft..................................................................................................................................................2925 Axle Case...................................................................................................................................................2925 INSTALLATION....................................................................................................................................................2925 AXLE BEARING............................................................................................................................................................2928 Removal and Installation............................................................................................................................................2928 AXLE OIL SEAL...........................................................................................................................................................2929 Removal and Installation............................................................................................................................................2929 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2930 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................2930 Axle Specification..................................................................................................................................................2930 Shim Washers........................................................................................................................................................2930 M226............................................................................................................................................................................2931 PRECAUTION..................................................................................................................................................................2931 PRECAUTIONS.............................................................................................................................................................2931 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................2931 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................2931 Precaution..........................................................................................................................................................2931 PREPARATION.................................................................................................................................................................2932 PREPARATION.............................................................................................................................................................2932 Special Service Tool................................................................................................................................................2932 Commercial Service Tool.............................................................................................................................................2932 SYMPTOM DIAGNOSIS...........................................................................................................................................................2933 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING....................................................................................................................2933 NVH Troubleshooting Chart...........................................................................................................................................2933 REMOVAL AND INSTALLATION....................................................................................................................................................2934 ON-VEHICLE SERVICE......................................................................................................................................................2934 Rear Axle Parts.....................................................................................................................................................2934 Rear Axle Bearing...................................................................................................................................................2934 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................2935 AXLE SHAFT..............................................................................................................................................................2935 Removal and Installation............................................................................................................................................2935 REMOVAL.........................................................................................................................................................2936 INSPECTION AFTER REMOVAL........................................................................................................................................2937 Axle Shaft..................................................................................................................................................2937 Axle Shaft Bearing and Cup..................................................................................................................................2937 Axle Shaft Bearing Cage.....................................................................................................................................2937 Axle Shaft Housing..........................................................................................................................................2937 INSTALLATION....................................................................................................................................................2937 AXLE BEARING............................................................................................................................................................2939 Removal and Installation............................................................................................................................................2939 AXLE OIL SEAL...........................................................................................................................................................2940 Removal and Installation............................................................................................................................................2940 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2941 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................2941 Axle Bearing........................................................................................................................................................2941 RSU.....................................................................................................................................................................................2942 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2942 PRECAUTION......................................................................................................................................................................2943 PRECAUTIONS.................................................................................................................................................................2943 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2943 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2943 Precaution for Rear Suspension..........................................................................................................................................2943 PREPARATION.....................................................................................................................................................................2944 PREPARATION.................................................................................................................................................................2944 Commercial Service Tool.................................................................................................................................................2944 SYMPTOM DIAGNOSIS...............................................................................................................................................................2945 NOISE VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.........................................................................................................................2945 NVH Troubleshooting Chart...............................................................................................................................................2945 PERIODIC MAINTENANCE............................................................................................................................................................2946 REAR SUSPENSION ASSEMBLY....................................................................................................................................................2946 On-Vehicle Inspection and Service.......................................................................................................................................2946 STABILIZER BAR..............................................................................................................................................................2947 Inspection..............................................................................................................................................................2947 REMOVAL AND INSTALLATION........................................................................................................................................................2948 REAR SUSPENSION ASSEMBLY....................................................................................................................................................2948 Component...............................................................................................................................................................2948 UNIT REMOVAL AND INSTALLATION...................................................................................................................................................2950 SHOCK ABSORBER..............................................................................................................................................................2950 Removal and Installation................................................................................................................................................2950 REMOVAL.............................................................................................................................................................2950 INSPECTION AFTER REMOVAL............................................................................................................................................2950 INSTALLATION........................................................................................................................................................2950 Disposal................................................................................................................................................................2950 LEAF SPRING.................................................................................................................................................................2951 Removal and Installation................................................................................................................................................2951 REMOVAL.............................................................................................................................................................2952 INSPECTION AFTER REMOVAL............................................................................................................................................2952 INSTALLATION........................................................................................................................................................2952 STABILIZER BAR..............................................................................................................................................................2955 Removal and Installation................................................................................................................................................2955 REMOVAL.............................................................................................................................................................2955 INSTALLATION........................................................................................................................................................2955 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................2957 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................2957 General Specification (Rear)............................................................................................................................................2957 Wheelarch Height (Unladen*1)............................................................................................................................................2957 SB......................................................................................................................................................................................2958 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2958 BASIC INSPECTION................................................................................................................................................................2959 COMPONENT INSPECTION........................................................................................................................................................2959 Inspection..............................................................................................................................................................2959 AFTER A COLLISION...................................................................................................................................................2959 PRELIMINARY CHECKS..................................................................................................................................................2959 SEAT BELT RETRACTOR ON-VEHICLE CHECK................................................................................................................................2960 Emergency Locking Retractors (ELR) and Automatic Locking Retractors (ALR).......................................................................................2960 ELR Function Stationary Check...................................................................................................................................2960 ALR Function Stationary Check...................................................................................................................................2960 ELR Function Moving Check.......................................................................................................................................2960 FRONT SEAT BELT RETRACTOR OFF-VEHICLE CHECK.........................................................................................................................2960 REAR SEAT BELT RETRACTOR OFF-VEHICLE CHECK..........................................................................................................................2960 REAR SEAT BELT CENTER RETRACTOR OFF-VEHICLE CHECK...................................................................................................................2961 PRECAUTION......................................................................................................................................................................2962 PRECAUTIONS.................................................................................................................................................................2962 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2962 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2962 Precaution for Seat Belt Service........................................................................................................................................2962 REMOVAL AND INSTALLATION........................................................................................................................................................2963 SEAT BELTS..................................................................................................................................................................2963 Removal and Installation of Front Seat Belt.............................................................................................................................2963 REMOVAL OF SEAT BELT RETRACTOR .....................................................................................................................................2963 INSTALLATION OF SEAT BELT RETRACTOR.................................................................................................................................2964 REMOVAL OF SEAT BELT BUCKLE.........................................................................................................................................2964 INSTALLATION OF SEAT BELT BUCKLE....................................................................................................................................2964 Removal and Installation of Rear Seat Belt..............................................................................................................................2965 REMOVAL OF SEAT BELT RETRACTOR - OUTBOARD...........................................................................................................................2966 INSTALLATION OF SEAT BELT RETRACTOR - OUTBOARD......................................................................................................................2966 REMOVAL OF SEAT BELT RETRACTOR - CENTER.............................................................................................................................2966 INSTALLATION OF SEAT BELT RETRACTOR - CENTER........................................................................................................................2967 REMOVAL OF SEAT BELT BUCKLE.........................................................................................................................................2967 INSTALLATION OF SEAT BELT BUCKLE....................................................................................................................................2967 LATCH (LOWER ANCHORS AND TETHER FOR CHILDREN) SYSTEM........................................................................................................................2968 Removal and Installation................................................................................................................................................2968 TOP TETHER STRAP CHILD RESTRAINT............................................................................................................................................2969 Removal and Installation................................................................................................................................................2969 SE......................................................................................................................................................................................2970 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................2970 SERVICE INFORMATION.............................................................................................................................................................2971 SQUEAK AND RATTLE TROUBLE DIAGNOSES.........................................................................................................................................2971 Work Flow...............................................................................................................................................................2971 CUSTOMER INTERVIEW..................................................................................................................................................2971 DUPLICATE THE NOISE AND TEST DRIVE..................................................................................................................................2971 CHECK RELATED SERVICE BULLETINS.....................................................................................................................................2972 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE........................................................................................................................2972 REPAIR THE CAUSE ...................................................................................................................................................2972 CONFIRM THE REPAIR..................................................................................................................................................2973 Generic Squeak and Rattle Troubleshooting...............................................................................................................................2973 INSTRUMENT PANEL....................................................................................................................................................2973 CENTER CONSOLE......................................................................................................................................................2973 DOORS...............................................................................................................................................................2973 TRUNK...............................................................................................................................................................2973 SUNROOF/HEADLINING..................................................................................................................................................2974 OVERHEAD CONSOLE (FRONT AND REAR)...................................................................................................................................2974 SEATS...............................................................................................................................................................2974 UNDERHOOD...........................................................................................................................................................2974 Diagnostic Worksheet....................................................................................................................................................2975 PRECAUTION......................................................................................................................................................................2977 PRECAUTIONS.................................................................................................................................................................2977 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................2977 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................2977 Precaution for Work.....................................................................................................................................................2977 PREPARATION.....................................................................................................................................................................2978 PREPARATION.................................................................................................................................................................2978 Special Service Tool....................................................................................................................................................2978 Commercial Service Tool.................................................................................................................................................2978 CLIP LIST...................................................................................................................................................................2979 Descriptions for Clips..................................................................................................................................................2979 REMOVAL AND INSTALLATION........................................................................................................................................................2983 FRONT SEAT..................................................................................................................................................................2983 Exploded View...........................................................................................................................................................2983 Removal and Installation................................................................................................................................................2986 SEAT ASSEMBLY.......................................................................................................................................................2986 Removal.........................................................................................................................................................2986 Installation....................................................................................................................................................2986 SEATBACK ASSEMBLY - DRIVER’S SEAT...................................................................................................................................2986 Removal.........................................................................................................................................................2986 Installation....................................................................................................................................................2987 SEATBACK ASSEMBLY - PASSENGER’S SEAT, WITH SOFT SEATBACK............................................................................................................2987 Removal.........................................................................................................................................................2987 Installation....................................................................................................................................................2988 SEATBACK ASSEMBLY - PASSENGER’S SEAT, WITH HARD SEATBACK............................................................................................................2988 Removal.........................................................................................................................................................2988 Installation....................................................................................................................................................2989 SEATBACK ASSEMBLY - PASSENGER’S FOLD FLAT SEAT......................................................................................................................2989 Removal.........................................................................................................................................................2989 Installation....................................................................................................................................................2990 SEAT CUSHION ASSEMBLY...............................................................................................................................................2990 Removal.........................................................................................................................................................2990 Installation....................................................................................................................................................2991 REAR SEAT...................................................................................................................................................................2992 Removal and Installation................................................................................................................................................2992 SEAT CUSHION ASSEMBLY...............................................................................................................................................2992 Removal.........................................................................................................................................................2992 Installation....................................................................................................................................................2992 SEATBACK ASSEMBLY...................................................................................................................................................2992 Removal.........................................................................................................................................................2992 Installation....................................................................................................................................................2992 UNIT DISASSEMBLY AND ASSEMBLY...................................................................................................................................................2993 FRONT SEAT..................................................................................................................................................................2993 Exploded View...........................................................................................................................................................2993 Disassembly and Assembly................................................................................................................................................2996 SEATBACK ...........................................................................................................................................................2996 Disassembly.....................................................................................................................................................2996 Assembly........................................................................................................................................................2996 SEAT CUSHION TRIM AND PAD...........................................................................................................................................2996 Disassembly.....................................................................................................................................................2996 Assembly........................................................................................................................................................2996 PASSENGER SEATBACK BOARD - SOFT SEATBACK............................................................................................................................2997 Removal.........................................................................................................................................................2997 Installation....................................................................................................................................................2997 PASSENGER SEATBACK BOARD - HARD SEATBACK............................................................................................................................2997 Removal.........................................................................................................................................................2997 Installation....................................................................................................................................................2998 REAR SEAT...................................................................................................................................................................2999 Disassembly and Assembly................................................................................................................................................2999 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 SEC.....................................................................................................................................................................................3003 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3003 BASIC INSPECTION................................................................................................................................................................3005 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................3005 Work Flow...............................................................................................................................................................3005 OVERALL SEQUENCE....................................................................................................................................................3005 DETAILED FLOW.......................................................................................................................................................3005 PRE-INSPECTION FOR DIAGNOSTIC...............................................................................................................................................3008 Basic Inspection........................................................................................................................................................3008 INSPECTION AND ADJUSTMENT...................................................................................................................................................3009 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT..........................................................................................................................3009 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Requirement.........................................................................................3009 ECM RE-COMMUNICATING FUNCTION...........................................................................................................................................3009 ECM RE-COMMUNICATING FUNCTION : Description.........................................................................................................................3009 ECM RE-COMMUNICATING FUNCTION : Special Repair Requirement..........................................................................................................3009 SYSTEM DESCRIPTION..............................................................................................................................................................3010 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM-NATS)...............................................................................................................................3010 System Diagram..........................................................................................................................................................3010 System Description......................................................................................................................................................3010 INPUT/OUTPUT SIGNAL CHART...........................................................................................................................................3010 BCM.............................................................................................................................................................3010 SYSTEM DESCRIPTION..................................................................................................................................................3010 PRECAUTIONS FOR KEY REGISTRATION....................................................................................................................................3011 SECURITY INDICATOR..................................................................................................................................................3011 MAINTENANCE INFORMATION.............................................................................................................................................3011 Component Parts Location................................................................................................................................................3011 Component Description...................................................................................................................................................3012 VEHICLE SECURITY SYSTEM.....................................................................................................................................................3013 System Diagram..........................................................................................................................................................3013 System Description......................................................................................................................................................3013 DESCRIPTION.........................................................................................................................................................3013 OPERATION FLOW......................................................................................................................................................3013 Disarmed Phase..................................................................................................................................................3013 Pre-Armed Phase And Armed Phase.................................................................................................................................3013 Condition of Activating The System..............................................................................................................................3013 Condition of Deactivating The System............................................................................................................................3014 Component Parts Location................................................................................................................................................3014 Component Description...................................................................................................................................................3014 DIAGNOSIS SYSTEM (BCM)......................................................................................................................................................3016 COMMON ITEM.............................................................................................................................................................3016 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM)..................................................................................................................3016 APPLICATION ITEM................................................................................................................................................3016 SYSTEM APPLICATION..............................................................................................................................................3016 IMMU....................................................................................................................................................................3016 IMMU : CONSULT Function (BCM - IMMU)................................................................................................................................3017 SELF DIAGNOSTIC RESULT..........................................................................................................................................3017 DATA MONITOR....................................................................................................................................................3017 ACTIVE TEST.....................................................................................................................................................3017 THEFT ALM...............................................................................................................................................................3017 THEFT ALM : CONSULT Function (BCM - THEFT ALM)......................................................................................................................3017 DATA MONITOR....................................................................................................................................................3017 ACTIVE TEST.....................................................................................................................................................3017 WORK SUPPORT....................................................................................................................................................3017 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................3018 U1000 CAN COMM CIRCUIT......................................................................................................................................................3018 Description.............................................................................................................................................................3018 DTC Logic...............................................................................................................................................................3018 DTC DETECTION LOGIC.................................................................................................................................................3018 Diagnosis Procedure.....................................................................................................................................................3018 U1010 CONTROL UNIT (CAN)....................................................................................................................................................3019 Description.............................................................................................................................................................3019 DTC Logic...............................................................................................................................................................3019 DTC DETECTION LOGIC.................................................................................................................................................3019 Diagnosis Procedure.....................................................................................................................................................3019 Special Repair Requirement..............................................................................................................................................3019 B2190, P1614 NATS ANTENNA AMP...............................................................................................................................................3020 Description.............................................................................................................................................................3020 DTC Logic...............................................................................................................................................................3020 DTC DETECTION LOGIC.................................................................................................................................................3020 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3020 Diagnosis Procedure.....................................................................................................................................................3020 B2191, P1615 DIFFERENCE OF KEY..............................................................................................................................................3023 Description.............................................................................................................................................................3023 DTC Logic...............................................................................................................................................................3023 DTC DETECTION LOGIC.................................................................................................................................................3023 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3023 Diagnosis Procedure.....................................................................................................................................................3023 B2192, P1611 ID DISCORD, IMMU-ECM...........................................................................................................................................3024 Description.............................................................................................................................................................3024 DTC Logic...............................................................................................................................................................3024 DTC DETECTION LOGIC.................................................................................................................................................3024 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3024 Diagnosis Procedure.....................................................................................................................................................3024 B2193, P1612 CHAIN OF ECM-IMMU..............................................................................................................................................3026 Description.............................................................................................................................................................3026 DTC Logic...............................................................................................................................................................3026 DTC DETECTION LOGIC.................................................................................................................................................3026 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3026 Diagnosis Procedure.....................................................................................................................................................3026 P1610 LOCK MODE.............................................................................................................................................................3027 Description.............................................................................................................................................................3027 DTC Logic...............................................................................................................................................................3027 DTC DETECTION LOGIC.................................................................................................................................................3027 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3027 Diagnosis Procedure.....................................................................................................................................................3027 POWER SUPPLY AND GROUND CIRCUIT.............................................................................................................................................3028 BCM.....................................................................................................................................................................3028 BCM : Diagnosis Procedure...........................................................................................................................................3028 KEY CYLINDER SWITCH.........................................................................................................................................................3030 DRIVER SIDE.............................................................................................................................................................3030 DRIVER SIDE : Description...........................................................................................................................................3030 DRIVER SIDE : Component Function Check..............................................................................................................................3030 DRIVER SIDE : Diagnosis Procedure...................................................................................................................................3030 BACK DOOR...............................................................................................................................................................3032 BACK DOOR : Description.............................................................................................................................................3032 BACK DOOR : Component Function Check................................................................................................................................3032 BACK DOOR : Diagnosis Procedure.....................................................................................................................................3032 HORN FUNCTION...............................................................................................................................................................3035 Symptom Table...........................................................................................................................................................3035 HAZARD AND HORN REMINDER FUNCTION MALFUNCTION.......................................................................................................................3035 Conditions of Vehicle (Operating Conditions)....................................................................................................................3035 VEHICLE SECURITY INDICATOR..................................................................................................................................................3036 Description.............................................................................................................................................................3036 Component Function Check................................................................................................................................................3036 Diagnosis Procedure.....................................................................................................................................................3036 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................3038 BCM (BODY CONTROL MODULE)...................................................................................................................................................3038 Reference Value.........................................................................................................................................................3038 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................3038 Terminal Layout.........................................................................................................................................................3041 Physical Values.........................................................................................................................................................3041 Fail Safe...............................................................................................................................................................3046 Fail-safe index.....................................................................................................................................................3046 DTC Inspection Priority Chart...........................................................................................................................................3046 DTC Index...............................................................................................................................................................3047 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)................................................................................................................3049 Reference Value.........................................................................................................................................................3049 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................3049 Terminal Layout.........................................................................................................................................................3050 Physical Values.........................................................................................................................................................3050 PHYSICAL VALUES.....................................................................................................................................................3050 Fail Safe...............................................................................................................................................................3054 CAN COMMUNICATION CONTROL...........................................................................................................................................3054 If No CAN Communication Is Available With ECM...................................................................................................................3054 If No CAN Communication Is Available With BCM...................................................................................................................3054 IGNITION RELAY MALFUNCTION DETECTION FUNCTION.......................................................................................................................3054 FRONT WIPER CONTROL.................................................................................................................................................3054 STARTER MOTOR PROTECTION FUNCTION...................................................................................................................................3054 DTC Index...............................................................................................................................................................3055 WIRING DIAGRAM..................................................................................................................................................................3056 VEHICLE SECURITY SYSTEM.....................................................................................................................................................3056 Wiring Diagram..........................................................................................................................................................3056 NVIS........................................................................................................................................................................3067 Wiring Diagram..........................................................................................................................................................3067 SYMPTOM DIAGNOSIS...............................................................................................................................................................3071 VEHICLE SECURITY SYSTEM SYMPTOMS............................................................................................................................................3071 Symptom Table...........................................................................................................................................................3071 NISSAN VEHICLE IMMOBILIZER SYSTEM-NATS SYMPTOMS.............................................................................................................................3072 Symptom Table...........................................................................................................................................................3072 CONDITIONS OF VEHICLE (OPERATING CONDITIONS)........................................................................................................................3072 PRECAUTION......................................................................................................................................................................3073 PRECAUTIONS.................................................................................................................................................................3073 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3073 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3073 REMOVAL AND INSTALLATION........................................................................................................................................................3074 NATS ANTENNA AMP............................................................................................................................................................3074 Removal and Installation................................................................................................................................................3074 REMOVAL.............................................................................................................................................................3074 INSTALLATION........................................................................................................................................................3074 REMOTE KEYLESS ENTRY RECEIVER...............................................................................................................................................3075 Removal and Installation................................................................................................................................................3075 REMOVAL.............................................................................................................................................................3075 INSTALLATION........................................................................................................................................................3075 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 SR......................................................................................................................................................................................3076 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3076 BASIC INSPECTION................................................................................................................................................................3077 COLLISION DIAGNOSIS.........................................................................................................................................................3077 For Frontal Collision...................................................................................................................................................3077 FOR FRONTAL COLLISION: When SRS is activated in a collision.........................................................................................................3077 WORK PROCEDURE..................................................................................................................................................3077 SRS INSPECTION (FOR FRONTAL COLLISION)..............................................................................................................................3077 FOR FRONTAL COLLISION: When SRS is not activated in a collision.....................................................................................................3078 WORK PROCEDURE..................................................................................................................................................3078 SRS INSPECTION (FOR FRONTAL COLLISION)..............................................................................................................................3078 For Side and Rollover Collision.........................................................................................................................................3079 FOR SIDE AND ROLLOVER COLLISION: When SRS is activated in a collision...............................................................................................3079 WORK PROCEDURE..................................................................................................................................................3079 SRS INSPECTION (FOR SIDE AND ROLLOVER COLLISION)....................................................................................................................3080 FOR SIDE AND ROLLOVER COLLISION: When SRS is not activated in a collision...........................................................................................3080 WORK PROCEDURE..................................................................................................................................................3080 SRS INSPECTION (FOR SIDE AND ROLLOVER COLLISION)....................................................................................................................3081 PRECAUTION......................................................................................................................................................................3084 PRECAUTIONS.................................................................................................................................................................3084 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3084 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3084 Service.................................................................................................................................................................3084 Occupant Classification System Precaution...............................................................................................................................3084 PREPARATION.....................................................................................................................................................................3085 PREPARATION.................................................................................................................................................................3085 Special Service Tool....................................................................................................................................................3085 REMOVAL AND INSTALLATION........................................................................................................................................................3086 DRIVER AIR BAG MODULE.......................................................................................................................................................3086 Removal and Installation................................................................................................................................................3086 REMOVAL.............................................................................................................................................................3086 INSTALLATION........................................................................................................................................................3087 SPIRAL CABLE................................................................................................................................................................3088 Removal and Installation................................................................................................................................................3088 REMOVAL.............................................................................................................................................................3088 INSTALLATION........................................................................................................................................................3089 FRONT PASSENGER AIR BAG MODULE..............................................................................................................................................3090 Removal and Installation................................................................................................................................................3090 REMOVAL.............................................................................................................................................................3090 INSTALLATION........................................................................................................................................................3091 Original Passenger Air Bag Module...............................................................................................................................3091 Service Replacement Passenger Air Bag Module....................................................................................................................3091 WIRING HARNESS MODIFICATION.........................................................................................................................................3091 SIDE CURTAIN AIR BAG MODULE.................................................................................................................................................3093 Removal and Installation................................................................................................................................................3093 REMOVAL.............................................................................................................................................................3093 INSTALLATION........................................................................................................................................................3093 SIDE AIR BAG MODULE.........................................................................................................................................................3094 Removal and Installation................................................................................................................................................3094 CRASH ZONE SENSOR...........................................................................................................................................................3095 Removal and Installation................................................................................................................................................3095 REMOVAL.............................................................................................................................................................3095 INSTALLATION........................................................................................................................................................3095 SIDE AIR BAG (SATELLITE) SENSOR.............................................................................................................................................3096 Removal and Installation................................................................................................................................................3096 REMOVAL.............................................................................................................................................................3096 INSTALLATION........................................................................................................................................................3096 FRONT SEAT BELT PRE-TENSIONER...............................................................................................................................................3097 Removal and Installation................................................................................................................................................3097 DIAGNOSIS SENSOR UNIT.......................................................................................................................................................3098 Removal and Installation................................................................................................................................................3098 REMOVAL.............................................................................................................................................................3098 INSTALLATION........................................................................................................................................................3098 OCCUPANT CLASSIFICATION SYSTEM CONTROL UNIT.................................................................................................................................3100 Removal and Installation................................................................................................................................................3100 SRC.....................................................................................................................................................................................3101 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3101 BASIC INSPECTION................................................................................................................................................................3103 DIAGNOSIS AND REPAIR WORK FLOW..............................................................................................................................................3103 Work Flow...............................................................................................................................................................3103 OVERALL SEQUENCE....................................................................................................................................................3103 DETAILED WORK FLOW..................................................................................................................................................3103 INTERMITTENTS INCIDENT......................................................................................................................................................3105 Inspection Procedure....................................................................................................................................................3105 INTERMITTENT TROUBLE................................................................................................................................................3105 Trouble Diagnosis with CONSULT..........................................................................................................................................3105 DIAGNOSTIC PROCEDURE 4..............................................................................................................................................3105 Check SRS Repair History........................................................................................................................................3105 SYSTEM DESCRIPTION..............................................................................................................................................................3106 SRS AIR BAG SYSTEM..........................................................................................................................................................3106 SRS Configuration.......................................................................................................................................................3106 SRS Component Parts Location............................................................................................................................................3107 Driver Air Bag Module...................................................................................................................................................3107 Front Passenger Air Bag Module..........................................................................................................................................3108 Front Side Air Bag......................................................................................................................................................3108 Side Curtain Air Bag....................................................................................................................................................3108 Front Seat Belt Pre-tensioner with Load Limiter.........................................................................................................................3108 Direct-connect SRS Component Connectors.................................................................................................................................3109 OCCUPANT CLASSIFICATION SYSTEM..............................................................................................................................................3110 System Diagram..........................................................................................................................................................3110 Occupant Classification System (OCS)....................................................................................................................................3110 PASSENGER SEAT BELT WARNING SYSTEM..........................................................................................................................................3112 System Diagram..........................................................................................................................................................3112 System Description......................................................................................................................................................3112 Component Parts Location................................................................................................................................................3112 ON BOARD DIAGNOSTIC (OBD) SYSTEM............................................................................................................................................3113 Trouble Diagnosis Introduction..........................................................................................................................................3113 DIAGNOSIS FUNCTION..................................................................................................................................................3113 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR......................................................................................................3113 Information From Customer.......................................................................................................................................3113 Preliminary Check...............................................................................................................................................3113 SRS Operation Check.....................................................................................................................................................3113 DIAGNOSTIC PROCEDURE 1..............................................................................................................................................3113 Checking SRS Operation Using “AIR BAG” Warning Lamp-User Mode...................................................................................................3113 DIAGNOSTIC PROCEDURE 2..............................................................................................................................................3114 Trouble Diagnosis without CONSULT.......................................................................................................................................3115 DIAGNOSTIC PROCEDURE 6..............................................................................................................................................3115 Inspect SRS Malfunction Using "AIR BAG" Warning Lamp-Diagnosis Mode.............................................................................................3115 CONSULT Function (AIR BAG)..............................................................................................................................................3115 Self-Diagnosis Function (Without CONSULT)...............................................................................................................................3115 HOW TO CHANGE SELF-DIAGNOSIS MODE ..................................................................................................................................3116 DIAGNOSTIC PROCEDURE 3..............................................................................................................................................3116 Final Check of SRS Using CONSULT-Diagnosis Mode.................................................................................................................3116 DIAGNOSTIC PROCEDURE 4..............................................................................................................................................3116 Check SRS Repair History........................................................................................................................................3116 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................3117 B1049 - B1052, B1054 - B1057 DRIVER AIRBAG MODULE...........................................................................................................................3117 Description.............................................................................................................................................................3117 DTC B1049 - B1052, B1054 - B1057 DRIVER AIRBAG MODULE...............................................................................................................3117 PART LOCATION.......................................................................................................................................................3117 DTC Logic...............................................................................................................................................................3117 DTC DETECTION LOGIC ................................................................................................................................................3117 With CONSULT....................................................................................................................................................3117 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3117 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3118 Diagnosis Procedure.....................................................................................................................................................3118 B1065 - B1068, B1070 - B1073 PASSENGER AIRBAG MODULE........................................................................................................................3120 Description.............................................................................................................................................................3120 DTC B1065 - B1068, B1070 - B1073 PASSENGER AIR BAG MODULE...........................................................................................................3120 PART LOCATION.......................................................................................................................................................3120 DTC Logic...............................................................................................................................................................3120 DTC DETECTION LOGIC ................................................................................................................................................3120 With CONSULT....................................................................................................................................................3120 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3120 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3120 Diagnosis Procedure.....................................................................................................................................................3121 B1134 - B1137 SIDE AIRBAG MODULE LH.........................................................................................................................................3123 Description.............................................................................................................................................................3123 DTC B1134 - B1137 FRONT LH SIDE AIR BAG MODULE......................................................................................................................3123 PART LOCATION.......................................................................................................................................................3123 DTC Logic...............................................................................................................................................................3123 DTC DETECTION LOGIC ................................................................................................................................................3123 With CONSULT....................................................................................................................................................3123 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3123 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3123 Diagnosis Procedure.....................................................................................................................................................3123 B1129 - B1132 SIDE AIRBAG MODULE RH.........................................................................................................................................3126 Description.............................................................................................................................................................3126 DTC B1129 - B1132 FRONT RH SIDE AIR BAG MODULE......................................................................................................................3126 PART LOCATION.......................................................................................................................................................3126 DTC Logic...............................................................................................................................................................3126 DTC DETECTION LOGIC ................................................................................................................................................3126 With CONSULT....................................................................................................................................................3126 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3126 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3126 Diagnosis Procedure.....................................................................................................................................................3126 B1150 - B1153 SIDE CURTAIN AIR BAG MODULE LH................................................................................................................................3129 Description.............................................................................................................................................................3129 DTC B1150 - B1153 LH SIDE CURTAIN AIR BAG MODULE....................................................................................................................3129 PART LOCATION.......................................................................................................................................................3129 DTC Logic...............................................................................................................................................................3129 DTC DETECTION LOGIC ................................................................................................................................................3129 With CONSULT....................................................................................................................................................3129 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3129 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3129 Diagnosis Procedure.....................................................................................................................................................3129 B1145 - B1148 SIDE CURTAIN AIR BAG MODULE RH................................................................................................................................3132 Description.............................................................................................................................................................3132 DTC B1145 - B1148 RH SIDE CURTAIN AIR BAG MODULE....................................................................................................................3132 PART LOCATION.......................................................................................................................................................3132 DTC Logic...............................................................................................................................................................3132 DTC DETECTION LOGIC ................................................................................................................................................3132 With CONSULT....................................................................................................................................................3132 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3132 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3132 Diagnosis Procedure.....................................................................................................................................................3132 B1086 - B1089 SEAT BELT PRE-TENSIONER LH....................................................................................................................................3135 Description.............................................................................................................................................................3135 DTC B1086 - B1089 SEAT BELT PRE-TENSIONER LH........................................................................................................................3135 PART LOCATION.......................................................................................................................................................3135 DTC Logic...............................................................................................................................................................3135 DTC DETECTION LOGIC ................................................................................................................................................3135 With CONSULT....................................................................................................................................................3135 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3135 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3135 Diagnosis Procedure.....................................................................................................................................................3135 B1081 - B1084 SEAT BELT PRE-TENSIONER RH....................................................................................................................................3138 Description.............................................................................................................................................................3138 DTC B1081 - B1084 SEAT BELT PRE-TENSIONER RH........................................................................................................................3138 PART LOCATION.......................................................................................................................................................3138 DTC Logic...............................................................................................................................................................3138 DTC DETECTION LOGIC ................................................................................................................................................3138 With CONSULT....................................................................................................................................................3138 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3138 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3138 Diagnosis Procedure.....................................................................................................................................................3138 B1033 - B1035 CRASH ZONE SENSOR.............................................................................................................................................3141 Description.............................................................................................................................................................3141 DTC B1033 - B1035 CRASH ZONE SENSOR.................................................................................................................................3141 PART LOCATION.......................................................................................................................................................3141 DTC Logic...............................................................................................................................................................3141 DTC DETECTION LOGIC ................................................................................................................................................3141 With CONSULT....................................................................................................................................................3141 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3141 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3141 Diagnosis Procedure.....................................................................................................................................................3141 B1118 - B1120 SATELLITE SENSOR LH...........................................................................................................................................3143 Description.............................................................................................................................................................3143 DTC B1118 - B1120 SATELLITE SENSOR LH...............................................................................................................................3143 PART LOCATION.......................................................................................................................................................3143 DTC Logic...............................................................................................................................................................3143 DTC DETECTION LOGIC ................................................................................................................................................3143 With CONSULT....................................................................................................................................................3143 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3143 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3143 Diagnosis Procedure.....................................................................................................................................................3143 B1113 - B1115 SATELLITE SENSOR RH...........................................................................................................................................3145 Description.............................................................................................................................................................3145 DTC B1113 - B1115 SATELLITE SENSOR RH...............................................................................................................................3145 PART LOCATION.......................................................................................................................................................3145 DTC Logic...............................................................................................................................................................3145 DTC DETECTION LOGIC ................................................................................................................................................3145 With CONSULT....................................................................................................................................................3145 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3145 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3145 Diagnosis Procedure.....................................................................................................................................................3145 B1XXX AIR BAG DIAGNOSIS SENSOR UNIT.........................................................................................................................................3147 Description.............................................................................................................................................................3147 DTC B1XXX AIR BAG DIAGNOSIS SENSOR UNIT.............................................................................................................................3147 PART LOCATION.......................................................................................................................................................3147 DTC Logic...............................................................................................................................................................3147 DTC DETECTION LOGIC ................................................................................................................................................3147 With CONSULT....................................................................................................................................................3147 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3147 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3147 Diagnosis Procedure.....................................................................................................................................................3147 B1023 PASSENGER AIR BAG OFF INDICATOR.......................................................................................................................................3149 Description.............................................................................................................................................................3149 DTC B1023 FRONT PASSENGER AIR BAG OFF INDICATOR.....................................................................................................................3149 PART LOCATION.......................................................................................................................................................3149 DTC Logic...............................................................................................................................................................3149 DTC DETECTION LOGIC ................................................................................................................................................3149 With CONSULT....................................................................................................................................................3149 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3149 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3149 Diagnosis Procedure.....................................................................................................................................................3149 B1017 - B1022 OCCUPANT CLASSIFICATION SYSTEM................................................................................................................................3151 Description.............................................................................................................................................................3151 DTC B1017 - B1022 OCCUPANT CLASSIFICATION SYSTEM (OCS)..............................................................................................................3151 PART LOCATION.......................................................................................................................................................3151 DTC Logic...............................................................................................................................................................3151 DTC DETECTION LOGIC ................................................................................................................................................3151 With CONSULT....................................................................................................................................................3151 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3151 DTC CONFIRMATION PROCEDURE (Without CONSULT)........................................................................................................................3152 Diagnosis Procedure.....................................................................................................................................................3152 B1209 - B1211 COLLISION DETECTION...........................................................................................................................................3154 Description.............................................................................................................................................................3154 DTC B1209 - B1211 COLLISION DETECTION...............................................................................................................................3154 PART LOCATION.......................................................................................................................................................3154 DTC Logic...............................................................................................................................................................3154 DTC DETECTION LOGIC ................................................................................................................................................3154 With CONSULT....................................................................................................................................................3154 DTC CONFIRMATION PROCEDURE (With CONSULT)...........................................................................................................................3154 Diagnosis Procedure.....................................................................................................................................................3154 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................3155 DIAGNOSIS SENSOR UNIT.......................................................................................................................................................3155 Trouble Diagnosis with CONSULT..........................................................................................................................................3155 DIAGNOSTIC CODE CHART...............................................................................................................................................3155 Trouble Diagnosis without CONSULT.......................................................................................................................................3157 WARNING LAMP FLASH CODE CHART.......................................................................................................................................3157 WIRING DIAGRAM..................................................................................................................................................................3161 SRS AIR BAG CONTROL SYSTEM..................................................................................................................................................3161 Wiring Diagram..........................................................................................................................................................3161 SYMPTOM DIAGNOSIS...............................................................................................................................................................3170 SRS AIR BAG SYSTEM..........................................................................................................................................................3170 "AIR BAG" Warning Lamp Does Not Turn Off................................................................................................................................3170 DIAGNOSTIC PROCEDURE ...............................................................................................................................................3170 "AIR BAG" Warning Lamp Does Not Turn On.................................................................................................................................3170 DIAGNOSTIC PROCEDURE ...............................................................................................................................................3170 PASSENGER SEAT BELT WARNING SYSTEM..........................................................................................................................................3172 Seat Belt Warning System Does Not Function..............................................................................................................................3172 PRECAUTION......................................................................................................................................................................3173 PRECAUTIONS.................................................................................................................................................................3173 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3173 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3173 Precaution for SRS "AIR BAG" and "SEAT BELT PRE-TENSIONER" Service......................................................................................................3173 Occupant Classification System Precaution...............................................................................................................................3173 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 ST......................................................................................................................................................................................3174 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3174 PRECAUTION......................................................................................................................................................................3175 PRECAUTIONS.................................................................................................................................................................3175 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3175 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3175 Precaution for Steering System..........................................................................................................................................3175 PREPARATION.....................................................................................................................................................................3176 PREPARATION.................................................................................................................................................................3176 Special Service Tool....................................................................................................................................................3176 Commercial Service Tool.................................................................................................................................................3177 SYMPTOM DIAGNOSIS...............................................................................................................................................................3178 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING........................................................................................................................3178 NVH Troubleshooting Chart...............................................................................................................................................3178 PERIODIC MAINTENANCE............................................................................................................................................................3179 POWER STEERING FLUID........................................................................................................................................................3179 Checking Fluid Level....................................................................................................................................................3179 Checking Fluid Leakage..................................................................................................................................................3179 Air Bleeding Hydraulic System...........................................................................................................................................3179 STEERING WHEEL..............................................................................................................................................................3181 On-Vehicle Inspection and Service.......................................................................................................................................3181 CHECKING CONDITION OF INSTALLATION..................................................................................................................................3181 CHECKING STEERING WHEEL PLAY........................................................................................................................................3181 CHECKING NEUTRAL POSITION ON STEERING WHEEL.........................................................................................................................3181 CHECKING STEERING WHEEL TURNING FORCE...............................................................................................................................3181 CHECKING FRONT WHEEL TURNING ANGLE .................................................................................................................................3182 POWER STEERING OIL PUMP.....................................................................................................................................................3183 On-Vehicle Inspection and Service.......................................................................................................................................3183 CHECKING RELIEF OIL PRESSURE........................................................................................................................................3183 REMOVAL AND INSTALLATION........................................................................................................................................................3184 STEERING WHEEL..............................................................................................................................................................3184 Removal and Installation................................................................................................................................................3184 REMOVAL.............................................................................................................................................................3184 INSTALLATION........................................................................................................................................................3184 STEERING COLUMN.............................................................................................................................................................3185 Removal and Installation................................................................................................................................................3185 REMOVAL.............................................................................................................................................................3185 INSPECTION AFTER REMOVAL............................................................................................................................................3186 INSTALLATION........................................................................................................................................................3186 INSPECTION AFTER INSTALLATION.......................................................................................................................................3187 POWER STEERING GEAR AND LINKAGE.............................................................................................................................................3188 Removal and Installation................................................................................................................................................3188 REMOVAL.............................................................................................................................................................3188 INSTALLATION........................................................................................................................................................3189 INSPECTION AFTER INSTALLATION.......................................................................................................................................3189 POWER STEERING OIL PUMP.....................................................................................................................................................3190 Component...............................................................................................................................................................3190 Removal and Installation................................................................................................................................................3190 REMOVAL.............................................................................................................................................................3190 INSTALLATION........................................................................................................................................................3190 POWER STEERING OIL PUMP BRACKET.....................................................................................................................................3191 Removal.........................................................................................................................................................3191 Installation....................................................................................................................................................3191 HYDRAULIC LINE..............................................................................................................................................................3192 Removal and Installation................................................................................................................................................3192 UNIT DISASSEMBLY AND ASSEMBLY...................................................................................................................................................3194 STEERING COLUMN.............................................................................................................................................................3194 Disassembly and Assembly................................................................................................................................................3194 DISASSEMBLY.........................................................................................................................................................3194 ASSEMBLY............................................................................................................................................................3194 INSPECTION AFTER ASSEMBLY...........................................................................................................................................3195 POWER STEERING OIL PUMP.....................................................................................................................................................3196 Disassembly and Assembly................................................................................................................................................3196 INSPECTION BEFORE DISASSEMBLY.......................................................................................................................................3196 DISASSEMBLY.........................................................................................................................................................3196 INSPECTION AFTER DISASSEMBLY........................................................................................................................................3196 Body Assembly Inspection........................................................................................................................................3196 ASSEMBLY............................................................................................................................................................3196 STEERING GEAR AND LINKAGE...................................................................................................................................................3198 Disassembly and Assembly................................................................................................................................................3198 DISASSEMBLY.........................................................................................................................................................3198 INSPECTION AFTER DISASSEMBLY........................................................................................................................................3198 Boot............................................................................................................................................................3198 Gear Housing Assembly...........................................................................................................................................3199 Outer Socket and Inner Socket...................................................................................................................................3199 ASSEMBLY............................................................................................................................................................3199 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................3201 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................3201 Steering Wheel..........................................................................................................................................................3201 Steering Column.........................................................................................................................................................3201 Tie-rod.................................................................................................................................................................3201 Steering Gear...........................................................................................................................................................3202 Oil Pump................................................................................................................................................................3202 Steering Fluid..........................................................................................................................................................3202 STR.....................................................................................................................................................................................3203 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3203 BASIC INSPECTION................................................................................................................................................................3205 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................3205 Work Flow (With GR8-1200 NI)............................................................................................................................................3205 STARTING SYSTEM DIAGNOSIS WITH GR8-1200 NI..........................................................................................................................3205 OVERALL SEQUENCE....................................................................................................................................................3206 DETAILED FLOW.......................................................................................................................................................3206 Work Flow (Without GR8-1200 NI).........................................................................................................................................3209 OVERALL SEQUENCE....................................................................................................................................................3209 DETAILED FLOW.......................................................................................................................................................3209 SYSTEM DESCRIPTION..............................................................................................................................................................3211 STARTING SYSTEM.............................................................................................................................................................3211 A/T.....................................................................................................................................................................3211 A/T : System Diagram................................................................................................................................................3211 A/T : System Description............................................................................................................................................3211 A/T : Component Parts Location......................................................................................................................................3211 A/T : Component Description.........................................................................................................................................3212 M/T WITH CLUTCH INTERLOCK CANCEL SYSTEM.................................................................................................................................3212 M/T WITH CLUTCH INTERLOCK CANCEL SYSTEM : System Diagram............................................................................................................3212 M/T WITH CLUTCH INTERLOCK CANCEL SYSTEM : System Description........................................................................................................3212 M/T WITH CLUTCH INTERLOCK CANCEL SYSTEM : Component Parts Location..................................................................................................3213 M/T WITH CLUTCH INTERLOCK CANCEL SYSTEM : Component Description.....................................................................................................3213 M/T WITHOUT CLUTCH INTERLOCK CANCEL SYSTEM..............................................................................................................................3213 M/T WITHOUT CLUTCH INTERLOCK CANCEL SYSTEM : System Diagram.........................................................................................................3214 M/T WITHOUT CLUTCH INTERLOCK CANCEL SYSTEM : System Description.....................................................................................................3214 M/T WITHOUT CLUTCH INTERLOCK CANCEL SYSTEM : Component Parts Location...............................................................................................3214 M/T WITHOUT CLUTCH INTERLOCK CANCEL SYSTEM : Component Description..................................................................................................3215 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................3216 B TERMINAL CIRCUIT..........................................................................................................................................................3216 Description.............................................................................................................................................................3216 Diagnosis Procedure.....................................................................................................................................................3216 1. CHECK TERMINAL 2 POWER SUPPLY VOLTAGE............................................................................................................................3216 1. CHECK TERMINAL 2 POWER SUPPLY VOLTAGE............................................................................................................................3216 S CONNECTOR CIRCUIT.........................................................................................................................................................3218 Description.............................................................................................................................................................3218 Diagnosis Procedure.....................................................................................................................................................3218 1. CHECK STARTER MOTOR MAGNETIC SWITCH CIRCUIT......................................................................................................................3218 1. CHECK STARTER MOTOR MAGNETIC SWITCH CIRCUIT......................................................................................................................3218 WIRING DIAGRAM..................................................................................................................................................................3220 STARTING SYSTEM.............................................................................................................................................................3220 Wiring Diagram - With Clutch Interlock Cancel System....................................................................................................................3220 Wiring Diagram - Without Clutch Interlock Cancel System.................................................................................................................3226 SYMPTOM DIAGNOSIS...............................................................................................................................................................3230 STARTING SYSTEM.............................................................................................................................................................3230 Symptom Table...........................................................................................................................................................3230 PRECAUTION......................................................................................................................................................................3231 PRECAUTIONS.................................................................................................................................................................3231 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3231 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3231 Precaution for Power Generation Variable Voltage Control System.........................................................................................................3231 PREPARATION.....................................................................................................................................................................3232 PREPARATION.................................................................................................................................................................3232 Special Service Tool....................................................................................................................................................3232 Commercial Service Tool.................................................................................................................................................3232 REMOVAL AND INSTALLATION........................................................................................................................................................3233 STARTER MOTOR...............................................................................................................................................................3233 Exploded View...........................................................................................................................................................3233 Removal and Installation................................................................................................................................................3233 REMOVAL.............................................................................................................................................................3233 INSTALLATION........................................................................................................................................................3233 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................3235 STARTER MOTOR...............................................................................................................................................................3235 Starter.................................................................................................................................................................3235 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 TM......................................................................................................................................................................................3236 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3236 6MT: FS6R31A....................................................................................................................................................................3241 SYMPTOM DIAGNOSIS...........................................................................................................................................................3241 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING....................................................................................................................3241 NVH Troubleshooting Chart...........................................................................................................................................3241 DESCRIPTION.............................................................................................................................................................3242 Cross-Sectional View................................................................................................................................................3242 DOUBLE-CONE SYNCHRONIZER........................................................................................................................................3242 TRIPLE-CONE SYNCHRONIZER .......................................................................................................................................3242 PRECAUTION..................................................................................................................................................................3244 PRECAUTIONS.............................................................................................................................................................3244 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................3244 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................3244 Service Notice or Precaution........................................................................................................................................3244 Precaution for Work.................................................................................................................................................3244 PREPARATION.................................................................................................................................................................3246 PREPARATION.............................................................................................................................................................3246 Special Service Tool................................................................................................................................................3246 Commercial Service Tool.............................................................................................................................................3248 PERIODIC MAINTENANCE........................................................................................................................................................3250 M/T OIL.................................................................................................................................................................3250 Changing............................................................................................................................................................3250 DRAINING........................................................................................................................................................3250 FILLING.........................................................................................................................................................3250 Checking............................................................................................................................................................3250 OIL LEAKAGE AND OIL LEVEL.......................................................................................................................................3250 REMOVAL AND INSTALLATION....................................................................................................................................................3251 REAR OIL SEAL...........................................................................................................................................................3251 Removal and Installation............................................................................................................................................3251 REMOVAL.........................................................................................................................................................3251 INSTALLATION....................................................................................................................................................3251 . Check the transmission oil level after installation. Refer to TM-15, "Checking"...........................................................................3251 POSITION SWITCH.........................................................................................................................................................3252 Checking............................................................................................................................................................3252 BACK-UP LAMP SWITCH.............................................................................................................................................3252 PARK/NEUTRAL POSITION SWITCH....................................................................................................................................3252 SHIFT CONTROL...........................................................................................................................................................3253 Removal and Installation............................................................................................................................................3253 COMPONENTS......................................................................................................................................................3253 REMOVAL.........................................................................................................................................................3253 INSTALLATION....................................................................................................................................................3253 INSPECTION AFTER INSTALLATION...................................................................................................................................3254 AIR BREATHER HOSE.......................................................................................................................................................3255 Removal and Installation............................................................................................................................................3255 COMPONENTS......................................................................................................................................................3255 REMOVAL.........................................................................................................................................................3255 INSTALLATION....................................................................................................................................................3255 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................3256 TRANSMISSION ASSEMBLY...................................................................................................................................................3256 Removal and Installation from Vehicle ..............................................................................................................................3256 COMPONENTS......................................................................................................................................................3256 REMOVAL.........................................................................................................................................................3257 INSTALLATION....................................................................................................................................................3257 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................3259 TRANSMISSION ASSEMBLY...................................................................................................................................................3259 Overhaul............................................................................................................................................................3259 COMPONENTS......................................................................................................................................................3259 Case Components.............................................................................................................................................3259 Gear Components.............................................................................................................................................3260 Shift Control Components....................................................................................................................................3262 CASE COMPONENTS.........................................................................................................................................................3265 Disassembly.........................................................................................................................................................3265 CASE COMPONENTS.................................................................................................................................................3265 Assembly............................................................................................................................................................3268 CASE COMPONENTS.................................................................................................................................................3268 SHIFT CONTROL COMPONENTS................................................................................................................................................3275 Disassembly.........................................................................................................................................................3275 SHIFT CONTROL COMPONENTS........................................................................................................................................3275 Inspection..........................................................................................................................................................3278 SHIFT CONTROL COMPONENTS........................................................................................................................................3278 Assembly............................................................................................................................................................3278 SHIFT CONTROL COMPONENTS........................................................................................................................................3278 GEAR COMPONENTS.........................................................................................................................................................3283 Disassembly.........................................................................................................................................................3283 GEAR COMPONENTS.................................................................................................................................................3283 Inspection..........................................................................................................................................................3289 GEAR AND SHAFT..................................................................................................................................................3289 SYNCHRONIZERS...................................................................................................................................................3289 BAULK RING CLEARENCE............................................................................................................................................3290 BEARINGS........................................................................................................................................................3292 Assembly............................................................................................................................................................3292 GEAR COMPONENTS.................................................................................................................................................3292 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................3306 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................3306 General Specification...............................................................................................................................................3306 Gear End Play.......................................................................................................................................................3307 Snap Rings..........................................................................................................................................................3307 Baulk Ring Clearance................................................................................................................................................3307 5AT: RE5R05A....................................................................................................................................................................3309 BASIC INSPECTION............................................................................................................................................................3309 DIAGNOSIS AND REPAIR WORKFLOW...........................................................................................................................................3309 How to Perform Trouble Diagnosis for Quick and Accurate Repair......................................................................................................3309 INTRODUCTION....................................................................................................................................................3309 DETAILED FLOW...................................................................................................................................................3309 Diagnostic Work Sheet...............................................................................................................................................3310 INFORMATION FROM CUSTOMER.......................................................................................................................................3310 DIAGNOSTIC WORK SHEET...........................................................................................................................................3311 SYSTEM DESCRIPTION..........................................................................................................................................................3312 A/T CONTROL SYSTEM......................................................................................................................................................3312 Cross-Sectional View................................................................................................................................................3312 Shift Mechanism.....................................................................................................................................................3313 CONSTRUCTION ...................................................................................................................................................3313 FUNCTION OF CLUTCH AND BRAKE ...................................................................................................................................3314 CLUTCH AND BAND CHART ..........................................................................................................................................3314 POWER TRANSMISSION .............................................................................................................................................3315 “N” Position................................................................................................................................................3315 “P” Position................................................................................................................................................3315 "D1", “31" and “21” Positions ..............................................................................................................................3316 "11" Position...............................................................................................................................................3317 "D2" and “32” Positions.....................................................................................................................................3318 "22" and “12” Positions.....................................................................................................................................3319 "D3" and “33” Positions.....................................................................................................................................3320 "D4" Position ..............................................................................................................................................3321 "D5" Position ..............................................................................................................................................3322 “R” Position................................................................................................................................................3323 TCM Function........................................................................................................................................................3324 CONTROL SYSTEM OUTLINE..........................................................................................................................................3324 CONTROL SYSTEM DIAGRAM .........................................................................................................................................3325 CAN Communication...................................................................................................................................................3325 SYSTEM DESCRIPTION..............................................................................................................................................3325 Input/Output Signal of TCM..........................................................................................................................................3326 Line Pressure Control...............................................................................................................................................3326 LINE PRESSURE CONTROL IS BASED ON THE TCM LINE PRESSURE CHARACTERISTIC PATTERN .................................................................................3327 Normal Control..............................................................................................................................................3327 Back-up Control (Engine Brake)..............................................................................................................................3327 During Shift Change.........................................................................................................................................3327 At Low Fluid Temperature....................................................................................................................................3328 Shift Control.......................................................................................................................................................3328 SHIFT CHANGE ...................................................................................................................................................3328 Shift Change System Diagram.................................................................................................................................3328 Lock-up Control.....................................................................................................................................................3329 TORQUE CONVERTER CLUTCH CONTROL VALVE CONTROL ..................................................................................................................3329 Lock-up Control System Diagram..............................................................................................................................3329 Lock-up Released ...........................................................................................................................................3329 Lock-up Applied.............................................................................................................................................3329 SMOOTH LOCK-UP CONTROL .........................................................................................................................................3329 Half-clutched State.........................................................................................................................................3330 Slip Lock-up Control........................................................................................................................................3330 Engine Brake Control................................................................................................................................................3330 Control Valve.......................................................................................................................................................3330 FUNCTION OF CONTROL VALVE ......................................................................................................................................3330 FUNCTION OF PRESSURE SWITCH ....................................................................................................................................3331 A/T Electrical Parts Location.......................................................................................................................................3332 A/T SHIFT LOCK SYSTEM...................................................................................................................................................3334 System Description..................................................................................................................................................3334 Component Parts Location............................................................................................................................................3334 ON BOARD DIAGNOSTIC (OBD) SYSTEM........................................................................................................................................3335 Introduction........................................................................................................................................................3335 OBD-II Function for A/T System......................................................................................................................................3335 One or Two Trip Detection Logic of OBD-II...........................................................................................................................3335 ONE TRIP DETECTION LOGIC........................................................................................................................................3335 TWO TRIP DETECTION LOGIC........................................................................................................................................3335 OBD-II Diagnostic Trouble Code (DTC)................................................................................................................................3335 HOW TO READ DTC AND 1ST TRIP DTC................................................................................................................................3335 Freeze Frame Data and 1st Trip Freeze Frame Data............................................................................................................3335 HOW TO ERASE DTC................................................................................................................................................3336 <GRAPHIC> HOW TO ERASE DTC (WITH CONSULT).......................................................................................................................3336 <GRAPHIC> HOW TO ERASE DTC (WITH GST)...........................................................................................................................3336 <GRAPHIC> HOW TO ERASE DTC (NO TOOLS)...........................................................................................................................3336 Malfunction Indicator Lamp (MIL)....................................................................................................................................3336 DESCRIPTION ....................................................................................................................................................3336 DIAGNOSIS SYSTEM (TCM)..................................................................................................................................................3337 CONSULT Function (TRANSMISSION).....................................................................................................................................3337 FUNCTION........................................................................................................................................................3337 SELF-DIAGNOSTIC RESULT MODE.....................................................................................................................................3337 Display Items List..........................................................................................................................................3337 DATA MONITOR MODE...............................................................................................................................................3339 Display Items List..........................................................................................................................................3339 DTC WORK SUPPORT................................................................................................................................................3342 Display Items List..........................................................................................................................................3342 Diagnosis Procedure without CONSULT.................................................................................................................................3342 <GRAPHIC> OBD-II SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)...........................................................................................................3342 <GRAPHIC> TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS)..............................................................................................................3342 Description.................................................................................................................................................3342 Diagnostic Procedure........................................................................................................................................3343 Judgment Self-diagnosis Code................................................................................................................................3343 Erase Self-diagnosis........................................................................................................................................3344 DTC/CIRCUIT DIAGNOSIS.......................................................................................................................................................3345 U0100 LOST COMMUNICATION (ECM A)........................................................................................................................................3345 Description.........................................................................................................................................................3345 On Board Diagnosis Logic............................................................................................................................................3345 Possible Cause......................................................................................................................................................3345 DTC Confirmation Procedure..........................................................................................................................................3345 <GRAPHIC> WITH CONSULT..........................................................................................................................................3345 <GRAPHIC> WITH GST..............................................................................................................................................3345 Diagnosis Procedure.................................................................................................................................................3345 U1000 CAN COMM CIRCUIT..................................................................................................................................................3346 Description.........................................................................................................................................................3346 On Board Diagnosis Logic............................................................................................................................................3346 Possible Cause......................................................................................................................................................3346 DTC Confirmation Procedure..........................................................................................................................................3346 <GRAPHIC> WITH CONSULT..........................................................................................................................................3346 <GRAPHIC> WITH GST..............................................................................................................................................3346 Diagnosis Procedure.................................................................................................................................................3346 P0615 STARTER RELAY.....................................................................................................................................................3347 Description.........................................................................................................................................................3347 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3347 On Board Diagnosis Logic............................................................................................................................................3347 Possible Cause......................................................................................................................................................3347 DTC Confirmation Procedure..........................................................................................................................................3347 <GRAPHIC> WITH CONSULT..........................................................................................................................................3347 Diagnosis Procedure.................................................................................................................................................3347 P0700 TRANSMISSION CONTROL..............................................................................................................................................3349 Description.........................................................................................................................................................3349 On Board Diagnosis Logic............................................................................................................................................3349 Possible Cause......................................................................................................................................................3349 DTC Confirmation Procedure..........................................................................................................................................3349 <GRAPHIC> WITH CONSULT..........................................................................................................................................3349 <GRAPHIC> WITH GST..............................................................................................................................................3349 Diagnosis Procedure.................................................................................................................................................3349 P0705 TRANSMISSION RANGE SENSOR A.......................................................................................................................................3350 Description.........................................................................................................................................................3350 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3350 On Board Diagnosis Logic............................................................................................................................................3350 Possible Cause......................................................................................................................................................3350 DTC Confirmation Procedure..........................................................................................................................................3350 <GRAPHIC> WITH CONSULT..........................................................................................................................................3350 <GRAPHIC> WITH GST..............................................................................................................................................3350 Diagnosis Procedure.................................................................................................................................................3350 P0717 INPUT SPEED SENSOR A..............................................................................................................................................3352 Description.........................................................................................................................................................3352 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3352 On Board Diagnosis Logic............................................................................................................................................3352 Possible Cause......................................................................................................................................................3352 DTC Confirmation Procedure..........................................................................................................................................3352 <GRAPHIC> WITH CONSULT..........................................................................................................................................3352 <GRAPHIC> WITH GST..............................................................................................................................................3352 Diagnosis Procedure.................................................................................................................................................3352 P0720 OUTPUT SPEED SENSOR...............................................................................................................................................3354 Description.........................................................................................................................................................3354 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3354 On Board Diagnosis Logic............................................................................................................................................3354 Possible Cause......................................................................................................................................................3354 DTC Confirmation Procedure..........................................................................................................................................3354 <GRAPHIC> WITH CONSULT..........................................................................................................................................3354 <GRAPHIC> WITH GST..............................................................................................................................................3355 Diagnosis Procedure.................................................................................................................................................3355 P0725 ENGINE SPEED......................................................................................................................................................3357 Description.........................................................................................................................................................3357 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3357 On Board Diagnosis Logic............................................................................................................................................3357 Possible Cause......................................................................................................................................................3357 DTC Confirmation Procedure..........................................................................................................................................3357 <GRAPHIC> WITH CONSULT..........................................................................................................................................3357 Diagnosis Procedure.................................................................................................................................................3357 P0731 1GR INCORRECT RATIO...............................................................................................................................................3359 Description.........................................................................................................................................................3359 On Board Diagnosis Logic............................................................................................................................................3359 Possible Cause......................................................................................................................................................3359 DTC Confirmation Procedure..........................................................................................................................................3359 <GRAPHIC> WITH CONSULT..........................................................................................................................................3359 <GRAPHIC> WITH GST..............................................................................................................................................3359 Diagnosis Procedure.................................................................................................................................................3360 P0732 2GR INCORRECT RATIO...............................................................................................................................................3361 Description.........................................................................................................................................................3361 On Board Diagnosis Logic............................................................................................................................................3361 Possible Cause......................................................................................................................................................3361 DTC Confirmation Procedure..........................................................................................................................................3361 <GRAPHIC> WITH CONSULT..........................................................................................................................................3361 <GRAPHIC> WITH GST..............................................................................................................................................3361 Diagnosis Procedure.................................................................................................................................................3362 P0733 3GR INCORRECT RATIO...............................................................................................................................................3363 Description.........................................................................................................................................................3363 On Board Diagnosis Logic............................................................................................................................................3363 Possible Cause......................................................................................................................................................3363 DTC Confirmation Procedure..........................................................................................................................................3363 <GRAPHIC> WITH CONSULT..........................................................................................................................................3363 <GRAPHIC> WITH GST..............................................................................................................................................3363 Diagnosis Procedure.................................................................................................................................................3364 P0734 4GR INCORRECT RATIO...............................................................................................................................................3365 Description.........................................................................................................................................................3365 On Board Diagnosis Logic............................................................................................................................................3365 Possible Cause......................................................................................................................................................3365 DTC Confirmation Procedure..........................................................................................................................................3365 <GRAPHIC> WITH CONSULT..........................................................................................................................................3365 <GRAPHIC> WITH GST..............................................................................................................................................3365 Diagnosis Procedure.................................................................................................................................................3366 P0735 5GR INCORRECT RATIO...............................................................................................................................................3367 Description.........................................................................................................................................................3367 On Board Diagnosis Logic............................................................................................................................................3367 Possible Cause......................................................................................................................................................3367 DTC Confirmation Procedure..........................................................................................................................................3367 <GRAPHIC> WITH CONSULT..........................................................................................................................................3367 <GRAPHIC> WITH GST..............................................................................................................................................3367 Diagnosis Procedure.................................................................................................................................................3368 P0740 TORQUE CONVERTER..................................................................................................................................................3369 Description.........................................................................................................................................................3369 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3369 On Board Diagnosis Logic............................................................................................................................................3369 Possible Cause......................................................................................................................................................3369 DTC Confirmation Procedure..........................................................................................................................................3369 <GRAPHIC> WITH CONSULT..........................................................................................................................................3369 <GRAPHIC> WITH GST..............................................................................................................................................3369 Diagnosis Procedure.................................................................................................................................................3369 P0744 TORQUE CONVERTER..................................................................................................................................................3371 Description.........................................................................................................................................................3371 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3371 On Board Diagnosis Logic............................................................................................................................................3371 Possible Cause......................................................................................................................................................3371 DTC Confirmation Procedure..........................................................................................................................................3371 <GRAPHIC> WITH CONSULT..........................................................................................................................................3371 <GRAPHIC> WITH GST..............................................................................................................................................3371 Diagnosis Procedure.................................................................................................................................................3371 P0745 PRESSURE CONTROL SOLENOID A.......................................................................................................................................3373 Description.........................................................................................................................................................3373 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3373 On Board Diagnosis Logic............................................................................................................................................3373 Possible Cause......................................................................................................................................................3373 DTC Confirmation Procedure..........................................................................................................................................3373 <GRAPHIC> WITH CONSULT..........................................................................................................................................3373 <GRAPHIC> WITH GST..............................................................................................................................................3373 Diagnosis Procedure.................................................................................................................................................3373 P1705 TP SENSOR.........................................................................................................................................................3375 Description.........................................................................................................................................................3375 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3375 On Board Diagnosis Logic............................................................................................................................................3375 Possible Cause......................................................................................................................................................3375 DTC Confirmation Procedure..........................................................................................................................................3375 <GRAPHIC> WITH CONSULT..........................................................................................................................................3375 Diagnosis Procedure.................................................................................................................................................3375 P1710 TRANSMISSION FLUID TEMPERATURE SENSOR.............................................................................................................................3377 Description.........................................................................................................................................................3377 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3377 On Board Diagnosis Logic............................................................................................................................................3377 Possible Cause......................................................................................................................................................3377 DTC Confirmation Procedure..........................................................................................................................................3377 <GRAPHIC> WITH CONSULT..........................................................................................................................................3377 <GRAPHIC> WITH GST..............................................................................................................................................3377 Diagnosis Procedure.................................................................................................................................................3377 Component Inspection................................................................................................................................................3378 A/T FLUID TEMPERATURE SENSOR....................................................................................................................................3378 P1721 VEHICLE SPEED SIGNAL..............................................................................................................................................3379 Description.........................................................................................................................................................3379 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3379 On Board Diagnosis Logic............................................................................................................................................3379 Possible Cause......................................................................................................................................................3379 DTC Confirmation Procedure..........................................................................................................................................3379 <GRAPHIC> WITH CONSULT..........................................................................................................................................3379 Diagnosis Procedure.................................................................................................................................................3379 P1730 INTERLOCK.........................................................................................................................................................3381 Description.........................................................................................................................................................3381 On Board Diagnosis Logic............................................................................................................................................3381 Possible Cause......................................................................................................................................................3381 DTC Confirmation Procedure..........................................................................................................................................3381 <GRAPHIC> WITH CONSULT..........................................................................................................................................3381 <GRAPHIC> WITH GST..............................................................................................................................................3381 Judgment of Interlock...............................................................................................................................................3381 Diagnosis Procedure.................................................................................................................................................3381 P1731 1ST ENGINE BRAKING................................................................................................................................................3383 Description.........................................................................................................................................................3383 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3383 On Board Diagnosis Logic............................................................................................................................................3383 Possible Cause......................................................................................................................................................3383 DTC Confirmation Procedure..........................................................................................................................................3383 <GRAPHIC> WITH CONSULT..........................................................................................................................................3383 Diagnosis Procedure.................................................................................................................................................3383 P1752 INPUT CLUTCH SOLENOID.............................................................................................................................................3385 Description.........................................................................................................................................................3385 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3385 On Board Diagnosis Logic............................................................................................................................................3385 Possible Cause......................................................................................................................................................3385 DTC Confirmation Procedure..........................................................................................................................................3385 <GRAPHIC> WITH CONSULT..........................................................................................................................................3385 <GRAPHIC> WITH GST..............................................................................................................................................3385 Diagnosis Procedure.................................................................................................................................................3385 P1757 FRONT BRAKE SOLENOID..............................................................................................................................................3387 Description.........................................................................................................................................................3387 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3387 On Board Diagnosis Logic............................................................................................................................................3387 Possible Cause......................................................................................................................................................3387 DTC Confirmation Procedure..........................................................................................................................................3387 <GRAPHIC> WITH CONSULT..........................................................................................................................................3387 <GRAPHIC> WITH GST..............................................................................................................................................3387 Diagnosis Procedure.................................................................................................................................................3387 P1762 DIRECT CLUTCH SOLENOID............................................................................................................................................3389 Description.........................................................................................................................................................3389 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3389 On Board Diagnosis Logic............................................................................................................................................3389 Possible Cause......................................................................................................................................................3389 DTC Confirmation Procedure..........................................................................................................................................3389 <GRAPHIC> WITH CONSULT..........................................................................................................................................3389 <GRAPHIC> WITH GST..............................................................................................................................................3389 Diagnosis Procedure.................................................................................................................................................3389 P1767 HIGH AND LOW REVERSE CLUTCH SOLENOID..............................................................................................................................3391 Description.........................................................................................................................................................3391 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3391 On Board Diagnosis Logic............................................................................................................................................3391 Possible Cause......................................................................................................................................................3391 DTC Confirmation Procedure..........................................................................................................................................3391 <GRAPHIC> WITH CONSULT..........................................................................................................................................3391 <GRAPHIC> WITH GST..............................................................................................................................................3391 Diagnosis Procedure.................................................................................................................................................3391 P1772 LOW COAST BRAKE SOLENOID..........................................................................................................................................3393 Description.........................................................................................................................................................3393 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3393 On Board Diagnosis Logic............................................................................................................................................3393 Possible Cause......................................................................................................................................................3393 DTC Confirmation Procedure..........................................................................................................................................3393 <GRAPHIC> WITH CONSULT..........................................................................................................................................3393 <GRAPHIC> WITH GST..............................................................................................................................................3393 Diagnosis Procedure.................................................................................................................................................3393 P1774 LOW COAST BRAKE SOLENOID..........................................................................................................................................3395 Description.........................................................................................................................................................3395 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3395 On Board Diagnosis Logic............................................................................................................................................3395 Possible Cause......................................................................................................................................................3395 DTC Confirmation Procedure..........................................................................................................................................3395 <GRAPHIC> WITH CONSULT..........................................................................................................................................3395 <GRAPHIC> WITH GST..............................................................................................................................................3395 Diagnosis Procedure.................................................................................................................................................3396 MAIN POWER SUPPLY AND GROUND CIRCUIT....................................................................................................................................3397 Diagnosis Procedure.................................................................................................................................................3397 CLOSED THROTTLE POSITION AND WIDE OPEN THROTTLE POSITION CIRCUIT........................................................................................................3399 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3399 Diagnosis Procedure.................................................................................................................................................3399 BRAKE SIGNAL CIRCUIT....................................................................................................................................................3400 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3400 Diagnosis Procedure.................................................................................................................................................3400 A/T SHIFT LOCK SYSTEM...................................................................................................................................................3401 Description.........................................................................................................................................................3401 Diagnosis Procedure.................................................................................................................................................3401 OVERDRIVE CONTROL SWITCH................................................................................................................................................3403 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3403 Diagnosis Procedure.................................................................................................................................................3403 1ST POSITION SWITCH.....................................................................................................................................................3405 CONSULT Reference Value in Data Monitor Mode........................................................................................................................3405 Diagnosis Procedure.................................................................................................................................................3405 ECU DIAGNOSIS INFORMATION...................................................................................................................................................3407 TCM.....................................................................................................................................................................3407 Reference Value.....................................................................................................................................................3407 VALUES ON THE DIAGNOSIS TOOL....................................................................................................................................3407 TERMINAL LAYOUT.................................................................................................................................................3408 PHYSICAL VALUES.................................................................................................................................................3408 Fail-Safe...........................................................................................................................................................3409 FAIL-SAFE FUNCTION .............................................................................................................................................3409 Output Speed Sensor.........................................................................................................................................3409 Accelerator Pedal Position Sensor...........................................................................................................................3409 Throttle Position Sensor....................................................................................................................................3409 Transmission Range Switch...................................................................................................................................3409 Starter Relay...............................................................................................................................................3409 Interlock...................................................................................................................................................3409 1st Engine Braking..........................................................................................................................................3409 Line Pressure Solenoid......................................................................................................................................3409 Torque Converter Clutch Solenoid............................................................................................................................3409 Low Coast Brake Solenoid....................................................................................................................................3409 Input Clutch Solenoid.......................................................................................................................................3410 Direct Clutch Solenoid......................................................................................................................................3410 Front Brake Solenoid........................................................................................................................................3410 High and Low Reverse Clutch Solenoid........................................................................................................................3410 Input Speed Sensor 1 or 2...................................................................................................................................3410 DTC Inspection Priority Chart.......................................................................................................................................3410 DTC No. Index.......................................................................................................................................................3410 WIRING DIAGRAM..............................................................................................................................................................3412 A/T CONTROL SYSTEM......................................................................................................................................................3412 Wiring Diagram......................................................................................................................................................3412 A/T SHIFT LOCK SYSTEM...................................................................................................................................................3419 Wiring Diagram......................................................................................................................................................3419 SYMPTOM DIAGNOSIS...........................................................................................................................................................3421 SYSTEM SYMPTOM..........................................................................................................................................................3421 Symptom Chart.......................................................................................................................................................3421 PRECAUTION..................................................................................................................................................................3443 PRECAUTIONS.............................................................................................................................................................3443 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..........................................................................3443 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS................................................................................................3443 Precaution for Work.................................................................................................................................................3443 Precaution for On Board Diagnosis (OBD) System of A/T and Engine....................................................................................................3443 Precaution..........................................................................................................................................................3444 Service Notice or Precaution........................................................................................................................................3445 ATF COOLER SERVICE..............................................................................................................................................3445 OBD-II SELF-DIAGNOSIS...........................................................................................................................................3445 PREPARATION.................................................................................................................................................................3446 PREPARATION.............................................................................................................................................................3446 Special Service Tool................................................................................................................................................3446 Commercial Service Tool.............................................................................................................................................3447 PERIODIC MAINTENANCE........................................................................................................................................................3448 A/T FLUID...............................................................................................................................................................3448 Checking the A/T Fluid (ATF)........................................................................................................................................3448 Changing the A/T Fluid (ATF)........................................................................................................................................3450 A/T Fluid Cooler Cleaning...........................................................................................................................................3451 A/T FLUID COOLER CLEANING PROCEDURE.............................................................................................................................3451 A/T FLUID COOLER DIAGNOSIS PROCEDURE............................................................................................................................3452 A/T FLUID COOLER INSPECTION PROCEDURE...........................................................................................................................3453 A/T FLUID COOLER FINAL INSPECTION...............................................................................................................................3453 INSPECTIONS BEFORE TROUBLE DIAGNOSIS....................................................................................................................................3454 Fluid Condition Check...............................................................................................................................................3454 A/T FLUID CHECK.................................................................................................................................................3454 Fluid Leakage and Fluid Level Check ........................................................................................................................3454 Fluid Condition Check.......................................................................................................................................3454 Stall Test..........................................................................................................................................................3454 STALL TEST......................................................................................................................................................3454 Stall Test Procedure........................................................................................................................................3454 Judgment of Stall Test......................................................................................................................................3455 Line Pressure Test..................................................................................................................................................3455 LINE PRESSURE TEST..............................................................................................................................................3455 Line Pressure Test Port.....................................................................................................................................3455 Line Pressure Test Procedure................................................................................................................................3455 Line Pressure...............................................................................................................................................3456 Judgment of Line Pressure Test..............................................................................................................................3456 ROAD TEST...............................................................................................................................................................3458 Description.........................................................................................................................................................3458 ROAD TEST ......................................................................................................................................................3458 Check Before Engine Is Started......................................................................................................................................3458 Check at Idle.......................................................................................................................................................3458 Cruise Test - Part 1................................................................................................................................................3459 Cruise Test - Part 2................................................................................................................................................3461 Cruise Test - Part 3................................................................................................................................................3461 REMOVAL AND INSTALLATION....................................................................................................................................................3463 SHIFT CONTROL SYSTEM....................................................................................................................................................3463 Exploded view.......................................................................................................................................................3463 Removal and Installation............................................................................................................................................3463 REMOVAL.........................................................................................................................................................3463 INSTALLATION....................................................................................................................................................3464 Inspection and Adjustment...........................................................................................................................................3464 INSPECTION......................................................................................................................................................3464 ADJUSTMENT......................................................................................................................................................3464 OIL PAN.................................................................................................................................................................3465 Removal and Installation............................................................................................................................................3465 REMOVAL AND INSTALLATION........................................................................................................................................3465 Removal.....................................................................................................................................................3465 Installation................................................................................................................................................3465 CONTROL VALVE WITH TCM..................................................................................................................................................3467 Removal and Installation............................................................................................................................................3467 COMPONENTS......................................................................................................................................................3467 REMOVAL.........................................................................................................................................................3467 INSTALLATION....................................................................................................................................................3470 REAR OIL SEAL...........................................................................................................................................................3475 Removal and Installation............................................................................................................................................3475 REMOVAL.........................................................................................................................................................3475 INSTALLATION....................................................................................................................................................3475 KEY INTERLOCK CABLE.....................................................................................................................................................3477 Component...........................................................................................................................................................3477 Removal and Installation............................................................................................................................................3477 REMOVAL.........................................................................................................................................................3477 INSTALLATION....................................................................................................................................................3478 AIR BREATHER HOSE.......................................................................................................................................................3480 Removal and Installation............................................................................................................................................3480 COMPONENTS (2WD MODELS).........................................................................................................................................3480 REMOVAL (2WD MODELS)............................................................................................................................................3480 INSTALLATION (2WD MODELS).......................................................................................................................................3480 COMPONENTS (4WD MODELS).........................................................................................................................................3480 REMOVAL (4WD MODELS)............................................................................................................................................3481 INSTALLATION (4WD MODELS).......................................................................................................................................3481 A/T FLUID COOLER........................................................................................................................................................3482 Removal and Installation............................................................................................................................................3482 COMPONENTS......................................................................................................................................................3482 REMOVAL.........................................................................................................................................................3482 INSTALLATION....................................................................................................................................................3482 UNIT REMOVAL AND INSTALLATION...............................................................................................................................................3483 TRANSMISSION ASSEMBLY...................................................................................................................................................3483 Removal and Installation (2WD)......................................................................................................................................3483 COMPONENTS......................................................................................................................................................3483 REMOVAL.........................................................................................................................................................3483 INSPECTION......................................................................................................................................................3484 Installation and Inspection of Torque Converter.............................................................................................................3484 INSTALLATION....................................................................................................................................................3485 Removal and Installation (4WD)......................................................................................................................................3485 COMPONENTS......................................................................................................................................................3485 REMOVAL.........................................................................................................................................................3486 INSPECTION......................................................................................................................................................3487 Installation and Inspection of Torque Converter.............................................................................................................3487 INSTALLATION....................................................................................................................................................3488 UNIT DISASSEMBLY AND ASSEMBLY...............................................................................................................................................3489 OVERHAUL................................................................................................................................................................3489 Exploded View.......................................................................................................................................................3489 Oil Channel.........................................................................................................................................................3496 2WD models......................................................................................................................................................3496 4WD models......................................................................................................................................................3497 Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.........................................................................................3498 2WD models......................................................................................................................................................3498 4WD models......................................................................................................................................................3499 DISASSEMBLY.............................................................................................................................................................3500 Disassembly.........................................................................................................................................................3500 OIL PUMP................................................................................................................................................................3518 Exploded View.......................................................................................................................................................3518 Oil Pump........................................................................................................................................................3518 Disassembly and Assembly............................................................................................................................................3518 DISASSEMBLY.....................................................................................................................................................3518 ASSEMBLY........................................................................................................................................................3519 FRONT SUN GEAR, 3RD ONE-WAY CLUTCH......................................................................................................................................3521 Exploded View.......................................................................................................................................................3521 Disassembly and Assembly............................................................................................................................................3521 DISASSEMBLY.....................................................................................................................................................3521 INSPECTION......................................................................................................................................................3521 3rd One-way Clutch..........................................................................................................................................3521 Front Sun Gear Snap Ring....................................................................................................................................3522 Front Sun Gear..............................................................................................................................................3522 ASSEMBLY........................................................................................................................................................3522 FRONT CARRIER, INPUT CLUTCH, REAR INTERNAL GEAR.........................................................................................................................3523 Exploded View.......................................................................................................................................................3523 Disassembly and Assembly............................................................................................................................................3523 DISASSEMBLY.....................................................................................................................................................3523 INSPECTION......................................................................................................................................................3525 Front Carrier Snap Ring.....................................................................................................................................3525 Input Clutch Snap Ring......................................................................................................................................3525 Input Clutch Drum...........................................................................................................................................3525 Input Clutch Drive Plates...................................................................................................................................3525 Input Clutch Retaining Plate and Driven Plates..............................................................................................................3525 Front Carrier...............................................................................................................................................3525 Rear Internal Gear..........................................................................................................................................3525 ASSEMBLY........................................................................................................................................................3525 MID SUN GEAR, REAR SUN GEAR, HIGH AND LOW REVERSE CLUTCH HUB............................................................................................................3528 Exploded View.......................................................................................................................................................3528 VQ40DE models...................................................................................................................................................3528 Disassembly and Assembly............................................................................................................................................3528 DISASSEMBLY.....................................................................................................................................................3528 INSPECTION......................................................................................................................................................3530 High and Low Reverse Clutch Hub Snap Ring, Rear Sun Gear Snap Ring..........................................................................................3530 1st One-way Clutch..........................................................................................................................................3530 Mid Sun Gear................................................................................................................................................3530 Rear Sun Gear...............................................................................................................................................3530 High and Low Reverse Clutch Hub.............................................................................................................................3530 ASSEMBLY........................................................................................................................................................3530 HIGH AND LOW REVERSE CLUTCH.............................................................................................................................................3533 Exploded View.......................................................................................................................................................3533 Disassembly and Assembly............................................................................................................................................3533 DISASSEMBLY.....................................................................................................................................................3533 INSPECTION......................................................................................................................................................3533 High and Low Reverse Clutch Snap Ring.......................................................................................................................3533 High and Low Reverse Clutch Drive Plates....................................................................................................................3533 High and Low Reverse Clutch Retaining Plate and Driven Plates...............................................................................................3534 ASSEMBLY........................................................................................................................................................3534 DIRECT CLUTCH...........................................................................................................................................................3535 Exploded View.......................................................................................................................................................3535 Disassembly and Assembly............................................................................................................................................3535 DISASSEMBLY.....................................................................................................................................................3535 INSPECTION......................................................................................................................................................3535 Direct Clutch Snap Ring.....................................................................................................................................3535 Direct Clutch Drive Plates..................................................................................................................................3535 Direct Clutch Retaining Plate and Driven Plates.............................................................................................................3535 Direct Clutch Dish Plate....................................................................................................................................3535 ASSEMBLY........................................................................................................................................................3535 ASSEMBLY................................................................................................................................................................3537 Assembly (1)........................................................................................................................................................3537 Adjustment..........................................................................................................................................................3550 TOTAL END PLAY..................................................................................................................................................3550 Assembly (2)........................................................................................................................................................3552 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................3559 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................................................................................................3559 General Specification...............................................................................................................................................3559 Vehicle Speed at Which Gear Shifting Occurs.........................................................................................................................3559 2WD MODELS......................................................................................................................................................3559 4WD MODELS......................................................................................................................................................3559 Vehicle Speed at Which Lock-up Occurs/Releases......................................................................................................................3559 2WD MODELS......................................................................................................................................................3559 4WD MODELS......................................................................................................................................................3560 Stall Speed.........................................................................................................................................................3560 Line Pressure.......................................................................................................................................................3560 A/T Fluid Temperature Sensor........................................................................................................................................3560 Input Speed Sensor..................................................................................................................................................3560 Output Speed Sensor.................................................................................................................................................3560 Reverse brake.......................................................................................................................................................3561 Total End Play......................................................................................................................................................3561 BEARING RACE FOR ADJUSTING TOTAL END PLAY.......................................................................................................................3561 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 VTL.....................................................................................................................................................................................3562 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3562 PRECAUTION......................................................................................................................................................................3563 PRECAUTIONS.................................................................................................................................................................3563 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3563 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3563 Precaution for Working with HFC-134a (R-134a)...........................................................................................................................3563 Precaution for Work.....................................................................................................................................................3564 PREPARATION.....................................................................................................................................................................3565 PREPARATION.................................................................................................................................................................3565 Special Service Tool....................................................................................................................................................3565 Commercial Service Tool.................................................................................................................................................3565 SYSTEM DESCRIPTION..............................................................................................................................................................3566 IN-CABIN MICROFILTER........................................................................................................................................................3566 Description.............................................................................................................................................................3566 FUNCTION............................................................................................................................................................3566 REPLACEMENT TIMING..................................................................................................................................................3566 PERIODIC MAINTENANCE............................................................................................................................................................3567 IN-CABIN MICROFILTER........................................................................................................................................................3567 Removal and Installation................................................................................................................................................3567 REPLACEMENT PROCEDURE...............................................................................................................................................3567 REMOVAL AND INSTALLATION........................................................................................................................................................3568 CONTROL UNIT................................................................................................................................................................3568 Removal and Installation................................................................................................................................................3568 FRONT AIR CONTROL...................................................................................................................................................3568 Removal.........................................................................................................................................................3568 Installation....................................................................................................................................................3568 INTAKE SENSOR...............................................................................................................................................................3569 Removal and Installation................................................................................................................................................3569 REMOVAL.............................................................................................................................................................3569 INSTALLATION........................................................................................................................................................3569 BLOWER MOTOR................................................................................................................................................................3570 Component...............................................................................................................................................................3570 Removal and Installation................................................................................................................................................3570 FRONT BLOWER MOTOR..................................................................................................................................................3570 Removal.........................................................................................................................................................3570 Installation....................................................................................................................................................3570 VARIABLE BLOWER CONTROL.....................................................................................................................................................3571 Removal and Installation................................................................................................................................................3571 REMOVAL.............................................................................................................................................................3571 INSTALLATION........................................................................................................................................................3571 FRONT BLOWER MOTOR RESISTOR.................................................................................................................................................3572 Removal and Installation................................................................................................................................................3572 REMOVAL.............................................................................................................................................................3572 INSTALLATION........................................................................................................................................................3572 HEATER & COOLING UNIT ASSEMBLY..............................................................................................................................................3573 Component...............................................................................................................................................................3573 Removal and Installation................................................................................................................................................3573 HEATER AND COOLING UNIT ASSEMBLY....................................................................................................................................3573 Removal.........................................................................................................................................................3573 Installation....................................................................................................................................................3574 EVAPORATOR..................................................................................................................................................................3575 Removal and Installation................................................................................................................................................3575 REMOVAL.............................................................................................................................................................3576 INSTALLATION........................................................................................................................................................3576 EXPANSION VALVE.............................................................................................................................................................3577 Removal and Installation................................................................................................................................................3577 REMOVAL AND INSTALLATION............................................................................................................................................3577 HEATER CORE.................................................................................................................................................................3578 Component...............................................................................................................................................................3578 Removal and Installation................................................................................................................................................3578 HEATER CORE.........................................................................................................................................................3578 Removal.........................................................................................................................................................3578 Installation....................................................................................................................................................3578 INTAKE DOOR MOTOR...........................................................................................................................................................3579 Removal and Installation................................................................................................................................................3579 REMOVAL.............................................................................................................................................................3579 INSTALLATION........................................................................................................................................................3579 MODE DOOR MOTOR.............................................................................................................................................................3580 Removal and Installation................................................................................................................................................3580 REMOVAL.............................................................................................................................................................3580 INSTALLATION........................................................................................................................................................3580 AIR MIX DOOR MOTOR..........................................................................................................................................................3581 Removal and Installation................................................................................................................................................3581 REMOVAL.............................................................................................................................................................3581 INSTALLATION........................................................................................................................................................3581 DUCTS AND GRILLES...........................................................................................................................................................3582 Component...............................................................................................................................................................3582 Removal and Installation................................................................................................................................................3583 DEFROSTER NOZZLE....................................................................................................................................................3583 Removal.........................................................................................................................................................3583 Installation....................................................................................................................................................3583 RH AND LH SIDE DEMISTER DUCT........................................................................................................................................3583 Removal.........................................................................................................................................................3583 Installation....................................................................................................................................................3584 RH AND LH VENTILATOR DUCT...........................................................................................................................................3584 Removal.........................................................................................................................................................3584 Installation....................................................................................................................................................3584 CENTER VENTILATOR DUCT..............................................................................................................................................3584 Removal.........................................................................................................................................................3584 Installation....................................................................................................................................................3584 FLOOR CONNECTOR DUCT................................................................................................................................................3584 Removal.........................................................................................................................................................3584 Installation....................................................................................................................................................3584 FRONT AND REAR FLOOR DUCTS..........................................................................................................................................3584 Removal.........................................................................................................................................................3584 Installation....................................................................................................................................................3584 GRILLES.............................................................................................................................................................3584 Removal.........................................................................................................................................................3584 Installation....................................................................................................................................................3584 WCS.....................................................................................................................................................................................3585 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3585 BASIC INSPECTION................................................................................................................................................................3587 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................3587 Work Flow...............................................................................................................................................................3587 DETAILED FLOW.......................................................................................................................................................3587 SYSTEM DESCRIPTION..............................................................................................................................................................3588 WARNING CHIME SYSTEM........................................................................................................................................................3588 WARNING CHIME SYSTEM....................................................................................................................................................3588 WARNING CHIME SYSTEM : System Diagram...............................................................................................................................3588 WARNING CHIME SYSTEM : System Description...........................................................................................................................3588 COMBINATION METER...............................................................................................................................................3588 BCM.............................................................................................................................................................3588 WARNING CHIME SYSTEM : Component Parts Location.....................................................................................................................3589 WARNING CHIME SYSTEM : Component Description........................................................................................................................3589 LIGHT REMINDER WARNING CHIME............................................................................................................................................3589 LIGHT REMINDER WARNING CHIME : System Diagram.......................................................................................................................3590 LIGHT REMINDER WARNING CHIME : System Description...................................................................................................................3590 DESCRIPTION.....................................................................................................................................................3590 WARNING OPERATION CONDITIONS....................................................................................................................................3590 WARNING CANCEL CONDITIONS.......................................................................................................................................3590 LIGHT REMINDER WARNING CHIME : Component Parts Location.............................................................................................................3591 LIGHT REMINDER WARNING CHIME : Component Description................................................................................................................3591 SEAT BELT WARNING CHIME.................................................................................................................................................3591 SEAT BELT WARNING CHIME : System Diagram............................................................................................................................3591 SEAT BELT WARNING CHIME : System Description........................................................................................................................3592 DESCRIPTION.....................................................................................................................................................3592 WARNING OPERATION CONDITIONS....................................................................................................................................3592 WARNING CANCEL CONDITIONS.......................................................................................................................................3592 SEAT BELT WARNING CHIME : Component Parts Location..................................................................................................................3592 SEAT BELT WARNING CHIME : Component Description.....................................................................................................................3593 KEY WARNING CHIME.......................................................................................................................................................3593 KEY WARNING CHIME : System Diagram..................................................................................................................................3593 KEY WARNING CHIME : System Description..............................................................................................................................3593 KEY WARNING CHIME : Component Parts Location........................................................................................................................3594 KEY WARNING CHIME : Component Description...........................................................................................................................3594 DIAGNOSIS SYSTEM (METER)....................................................................................................................................................3595 Diagnosis Description...................................................................................................................................................3595 SELF-DIAGNOSIS MODE.................................................................................................................................................3595 OPERATION PROCEDURE.................................................................................................................................................3595 COMBINATION METER SELF-DIAGNOSIS MODE FUNCTIONS.....................................................................................................................3595 CONSULT Function (METER/M&A)............................................................................................................................................3596 SELF-DIAG RESULTS...................................................................................................................................................3597 Display Item List...............................................................................................................................................3597 DATA MONITOR........................................................................................................................................................3597 Display Item List...............................................................................................................................................3597 DIAGNOSIS SYSTEM (BCM)......................................................................................................................................................3599 BUZZER..................................................................................................................................................................3599 BUZZER : CONSULT Function (BCM - BUZZER)............................................................................................................................3599 DATA MONITOR....................................................................................................................................................3599 ACTIVE TEST.....................................................................................................................................................3599 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................3600 POWER SUPPLY AND GROUND CIRCUIT.............................................................................................................................................3600 COMBINATION METER.......................................................................................................................................................3600 COMBINATION METER : Diagnosis Procedure.............................................................................................................................3600 BCM (BODY CONTROL MODULE)...............................................................................................................................................3600 BCM (BODY CONTROL MODULE) : Diagnosis Procedure.....................................................................................................................3601 METER BUZZER CIRCUIT........................................................................................................................................................3602 Description.............................................................................................................................................................3602 Component Function Check................................................................................................................................................3602 Diagnosis Procedure.....................................................................................................................................................3602 SEAT BELT BUCKLE SWITCH SIGNAL CIRCUIT......................................................................................................................................3603 Description.............................................................................................................................................................3603 Component Function Check................................................................................................................................................3603 Diagnosis Procedure.....................................................................................................................................................3603 Component Inspection....................................................................................................................................................3604 KEY SWITCH SIGNAL CIRCUIT...................................................................................................................................................3605 Description.............................................................................................................................................................3605 Component Function Check................................................................................................................................................3605 Diagnosis Procedure.....................................................................................................................................................3605 Component Inspection....................................................................................................................................................3606 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................3607 COMBINATION METER...........................................................................................................................................................3607 Reference Value.........................................................................................................................................................3607 TERMINAL LAYOUT.....................................................................................................................................................3607 PHYSICAL VALUES.....................................................................................................................................................3607 Fail Safe...............................................................................................................................................................3608 DTC Index...............................................................................................................................................................3609 BCM (BODY CONTROL MODULE)...................................................................................................................................................3610 Reference Value.........................................................................................................................................................3610 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................3610 Terminal Layout.........................................................................................................................................................3613 Physical Values.........................................................................................................................................................3613 Fail Safe...............................................................................................................................................................3618 Fail-safe index.....................................................................................................................................................3618 DTC Inspection Priority Chart...........................................................................................................................................3618 DTC Index...............................................................................................................................................................3619 WIRING DIAGRAM..................................................................................................................................................................3621 WARNING CHIME SYSTEM........................................................................................................................................................3621 Wiring Diagram..........................................................................................................................................................3621 SYMPTOM DIAGNOSIS...............................................................................................................................................................3626 THE LIGHT REMINDER WARNING DOES NOT SOUND...................................................................................................................................3626 Description.............................................................................................................................................................3626 Diagnosis Procedure.....................................................................................................................................................3626 THE SEAT BELT WARNING CONTINUES SOUNDING, OR DOES NOT SOUND.................................................................................................................3627 Description.............................................................................................................................................................3627 Diagnosis Procedure.....................................................................................................................................................3627 THE KEY WARNING DOES NOT SOUND..............................................................................................................................................3628 Description.............................................................................................................................................................3628 Diagnosis Procedure.....................................................................................................................................................3628 PRECAUTION......................................................................................................................................................................3629 PRECAUTIONS.................................................................................................................................................................3629 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3629 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3629 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 WT......................................................................................................................................................................................3630 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3630 BASIC INSPECTION................................................................................................................................................................3632 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................3632 Repair Work Flow........................................................................................................................................................3632 WORK FLOW...........................................................................................................................................................3632 DETAILED FLOW.......................................................................................................................................................3632 INSPECTION AND ADJUSTMENT...................................................................................................................................................3634 Preliminary Check.......................................................................................................................................................3634 Transmitter Wake Up Operation...........................................................................................................................................3634 ID Registration Procedure...............................................................................................................................................3635 ID REGISTRATION WITH TRANSMITTER ACTIVATION TOOL....................................................................................................................3635 ID REGISTRATION WITHOUT TRANSMITTER ACTIVATION TOOL.................................................................................................................3636 SYSTEM DESCRIPTION..............................................................................................................................................................3637 TPMS........................................................................................................................................................................3637 System Diagram..........................................................................................................................................................3637 System Description......................................................................................................................................................3637 DESCRIPTION.........................................................................................................................................................3637 FUNCTION............................................................................................................................................................3637 BODY CONTROL MODULE (BCM)...........................................................................................................................................3637 TRANSMITTER.........................................................................................................................................................3637 REMOTE KEYLESS ENTRY RECEIVER.......................................................................................................................................3638 COMBINATION METER...................................................................................................................................................3638 TIRE PRESSURE WARNING CHECK CONNECTOR...............................................................................................................................3638 System Component........................................................................................................................................................3639 DIAGNOSIS SYSTEM (BCM)......................................................................................................................................................3640 CONSULT Function (BCM - COMMON ITEM)....................................................................................................................................3640 APPLICATION ITEM....................................................................................................................................................3640 SYSTEM APPLICATION..................................................................................................................................................3640 CONSULT Function (BCM - AIR PRESSURE MONITOR)...........................................................................................................................3641 SELF DIAGNOSTIC RESULT..............................................................................................................................................3641 DATA MONITOR........................................................................................................................................................3641 ACTIVE TEST.........................................................................................................................................................3641 WORK SUPPORT........................................................................................................................................................3641 Self-Diagnosis (Without CONSULT)........................................................................................................................................3641 SELF DIAGNOSTIC PROCEDURE (WITHOUT CONSULT).........................................................................................................................3642 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................3643 C1708 - C1711 DATA FROM TRANSMITTER NOT BEING RECEIVED......................................................................................................................3643 Description.............................................................................................................................................................3643 DTC Logic...............................................................................................................................................................3643 DTC DETECTION LOGIC.................................................................................................................................................3643 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3643 Diagnosis Procedure.....................................................................................................................................................3643 MALFUNCTION CODE NO. 21, 22, 23 OR 24 (DTC C1708, C1709, C1710 OR C1711)............................................................................................3643 Special Repair Requirement..............................................................................................................................................3644 C1712 - C1715, C1720 - C1723, C1724 - C1727 TRANSMITTER MALFUNCTION.........................................................................................................3645 Description.............................................................................................................................................................3645 DTC Logic...............................................................................................................................................................3645 DTC DETECTION LOGIC.................................................................................................................................................3645 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3645 Diagnosis Procedure.....................................................................................................................................................3645 MALFUNCTION CODE NO. 31, 32, 33, 34, 41, 42, 43, 44, 45, 46, 47 OR 48 (DTC C1712, C1713, C1714, C1715, C1720, C1721, C1722, C1723, C1724, C1725, C1726 OR C1727)....3645 Special Repair Requirement..............................................................................................................................................3646 C1716 - C1719 TRANSMITTER PRESSURE MALFUNCTION..............................................................................................................................3647 Description.............................................................................................................................................................3647 DTC Logic...............................................................................................................................................................3647 DTC DETECTION LOGIC.................................................................................................................................................3647 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3647 Diagnosis Procedure.....................................................................................................................................................3647 MALFUNCTION CODE NO. 35, 36, 37 OR 38 (DTC C1716, C1717, C1718 OR C1719)............................................................................................3647 Special Repair Requirement..............................................................................................................................................3648 C1729 VEHICLE SPEED SIGNAL..................................................................................................................................................3649 Description.............................................................................................................................................................3649 DTC Logic...............................................................................................................................................................3649 DTC DETECTION LOGIC.................................................................................................................................................3649 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3649 Diagnosis Procedure.....................................................................................................................................................3649 MALFUNCTION CODE NO. 52 (DTC C1729).................................................................................................................................3649 Special Repair Requirement..............................................................................................................................................3649 C1735 IGNITION SIGNAL.......................................................................................................................................................3650 Description.............................................................................................................................................................3650 DTC Logic...............................................................................................................................................................3650 DTC DETECTION LOGIC.................................................................................................................................................3650 DTC CONFIRMATION PROCEDURE..........................................................................................................................................3650 Diagnosis Procedure.....................................................................................................................................................3650 MALFUNCTION CODE NO. 54 (DTC C1735).................................................................................................................................3650 Special Repair Requirement..............................................................................................................................................3651 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................3652 BCM (BODY CONTROL MODULE)...................................................................................................................................................3652 Reference Value.........................................................................................................................................................3652 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................3652 Terminal Layout.........................................................................................................................................................3655 Physical Values.........................................................................................................................................................3655 Self-Diagnosis (With CONSULT)...........................................................................................................................................3660 FUNCTION............................................................................................................................................................3660 Self-Diagnostic Results Mode....................................................................................................................................3660 Self-Diagnosis (Without CONSULT)........................................................................................................................................3661 SELF DIAGNOSTIC PROCEDURE (WITHOUT CONSULT).........................................................................................................................3661 WIRING DIAGRAM..................................................................................................................................................................3663 TIRE PRESSURE MONITORING SYSTEM.............................................................................................................................................3663 Wiring Diagram..........................................................................................................................................................3663 SYMPTOM DIAGNOSIS...............................................................................................................................................................3666 TPMS........................................................................................................................................................................3666 Symptom Table...........................................................................................................................................................3666 LOW TIRE PRESSURE WARNING LAMP DOES NOT TURN ON.............................................................................................................................3667 Low Tire Pressure Warning Lamp Does Not Come On When Ignition Switch Is Turned On.......................................................................................3667 LOW TIRE PRESSURE WARNING LAMP STAYS ON.....................................................................................................................................3668 Low Tire Pressure Warning Lamp Stays On When Ignition Switch Is Turned On...............................................................................................3668 LOW TIRE PRESSURE WARNING LAMP BLINKS.......................................................................................................................................3669 Low Tire Pressure Warning Lamp Flashes When Ignition Switch Is Turned On................................................................................................3669 HAZARD WARNING LAMPS FLASH..................................................................................................................................................3670 Hazard Warning Lamps Flash When Ignition Switch Is Turned On............................................................................................................3670 ID REGISTRATION CANNOT BE COMPLETED.........................................................................................................................................3671 ID Registration Cannot Be Completed.....................................................................................................................................3671 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING........................................................................................................................3672 NVH Troubleshooting Chart...............................................................................................................................................3672 PRECAUTION......................................................................................................................................................................3673 PRECAUTIONS.................................................................................................................................................................3673 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3673 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3673 Precaution for Road Wheel...............................................................................................................................................3673 PREPARATION.....................................................................................................................................................................3674 PREPARATION.................................................................................................................................................................3674 Special Service Tool....................................................................................................................................................3674 Commercial Service Tool.................................................................................................................................................3674 PERIODIC MAINTENANCE............................................................................................................................................................3675 WHEEL.......................................................................................................................................................................3675 Inspection..............................................................................................................................................................3675 ALUMINUM WHEEL......................................................................................................................................................3675 STEEL WHEEL.........................................................................................................................................................3675 WHEEL AND TIRE ASSEMBLY.....................................................................................................................................................3676 Adjustment..............................................................................................................................................................3676 BALANCING WHEELS (ADHESIVE WEIGHT TYPE).............................................................................................................................3676 Preparation Before Adjustment...................................................................................................................................3676 Wheel Balance Adjustment........................................................................................................................................3676 TIRE ROTATION.......................................................................................................................................................3677 UNIT REMOVAL AND INSTALLATION...................................................................................................................................................3678 REMOVAL AND INSTALLATION....................................................................................................................................................3678 Exploded View...........................................................................................................................................................3678 Transmitter (Pressure Sensor)...........................................................................................................................................3678 REMOVAL.............................................................................................................................................................3678 INSTALLATION........................................................................................................................................................3679 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................3681 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................3681 Road Wheel..............................................................................................................................................................3681 Tire....................................................................................................................................................................3681 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70 WW......................................................................................................................................................................................3682 QUICK REFERENCE INDEX............................................................................................................................................................... 0 Table of Contents...................................................................................................................................................................3682 BASIC INSPECTION................................................................................................................................................................3684 DIAGNOSIS AND REPAIR WORKFLOW...............................................................................................................................................3684 Work Flow...............................................................................................................................................................3684 DETAILED FLOW.......................................................................................................................................................3684 SYSTEM DESCRIPTION..............................................................................................................................................................3685 FRONT WIPER AND WASHER SYSTEM...............................................................................................................................................3685 System Diagram..........................................................................................................................................................3685 System Description......................................................................................................................................................3685 OUTLINE.............................................................................................................................................................3685 FRONT WIPER BASIC OPERATION.........................................................................................................................................3685 FRONT WIPER LO OPERATION............................................................................................................................................3685 FRONT WIPER HI OPERATION............................................................................................................................................3685 FRONT WIPER INT OPERATION (LINKED WITH VEHICLE SPEED)...............................................................................................................3685 FRONT WIPER AUTO STOP OPERATION.....................................................................................................................................3686 FRONT WIPER OPERATION LINKED WITH WASHER............................................................................................................................3687 FRONT WIPER DROP WIPE OPERATION.....................................................................................................................................3687 FRONT WIPER FAIL-SAFE OPERATION.....................................................................................................................................3687 Component Parts Location................................................................................................................................................3688 Component Description...................................................................................................................................................3688 REAR WIPER AND WASHER SYSTEM................................................................................................................................................3689 System Diagram..........................................................................................................................................................3689 System Description......................................................................................................................................................3689 OUTLINE.............................................................................................................................................................3689 REAR WIPER BASIC OPERATION..........................................................................................................................................3689 REAR WIPER ON OPERATION.............................................................................................................................................3689 REAR WIPER INT OPERATION............................................................................................................................................3689 REAR WIPER AUTO STOP OPERATION......................................................................................................................................3689 REAR WIPER OPERATION LINKED WITH WASHER ............................................................................................................................3690 REAR WIPER DROP WIPE OPERATION......................................................................................................................................3690 REAR WIPER FAIL-SAFE OPERATION......................................................................................................................................3690 Component Parts Location................................................................................................................................................3691 Component Description...................................................................................................................................................3691 DIAGNOSIS SYSTEM (BCM)......................................................................................................................................................3692 COMMON ITEM.............................................................................................................................................................3692 COMMON ITEM : CONSULT Function (BCM - COMMON ITEM)..................................................................................................................3692 APPLICATION ITEM................................................................................................................................................3692 SYSTEM APPLICATION..............................................................................................................................................3692 WIPER...................................................................................................................................................................3692 WIPER : CONSULT Function (BCM - WIPER)..............................................................................................................................3693 DATA MONITOR....................................................................................................................................................3693 ACTIVE TEST.....................................................................................................................................................3693 WORK SUPPORT....................................................................................................................................................3693 DIAGNOSIS SYSTEM (IPDM E/R).................................................................................................................................................3694 Diagnosis Description...................................................................................................................................................3694 AUTO ACTIVE TEST....................................................................................................................................................3694 Description.....................................................................................................................................................3694 Operation Procedure.............................................................................................................................................3694 Inspection in Auto Active Test Mode.............................................................................................................................3694 Concept of auto active test.....................................................................................................................................3695 Diagnosis chart in auto active test mode........................................................................................................................3695 CONSULT Function (IPDM E/R).............................................................................................................................................3696 APPLICATION ITEM....................................................................................................................................................3696 SELF DIAGNOSTIC RESULT..............................................................................................................................................3696 DATA MONITOR........................................................................................................................................................3696 ACTIVE TEST.........................................................................................................................................................3697 DTC/CIRCUIT DIAGNOSIS...........................................................................................................................................................3698 WIPER AND WASHER FUSE.......................................................................................................................................................3698 Description.............................................................................................................................................................3698 Diagnosis Procedure.....................................................................................................................................................3698 FRONT WIPER MOTOR LO CIRCUIT................................................................................................................................................3699 Component Function Check................................................................................................................................................3699 Diagnosis Procedure.....................................................................................................................................................3699 FRONT WIPER MOTOR HI CIRCUIT................................................................................................................................................3701 Component Function Check................................................................................................................................................3701 Diagnosis Procedure.....................................................................................................................................................3701 FRONT WIPER AUTO STOP SIGNAL CIRCUIT........................................................................................................................................3703 Component Function Check................................................................................................................................................3703 Diagnosis Procedure.....................................................................................................................................................3703 FRONT WIPER MOTOR GROUND CIRCUIT............................................................................................................................................3705 Diagnosis Procedure.....................................................................................................................................................3705 WASHER SWITCH...............................................................................................................................................................3706 Description.............................................................................................................................................................3706 Component Inspection....................................................................................................................................................3706 WASHER MOTOR CIRCUIT........................................................................................................................................................3708 Diagnosis Procedure.....................................................................................................................................................3708 REAR WIPER MOTOR CIRCUIT....................................................................................................................................................3710 Component Function Check................................................................................................................................................3710 Diagnosis Procedure.....................................................................................................................................................3710 REAR WIPER AUTO STOP SIGNAL CIRCUIT.........................................................................................................................................3712 Component Function Check................................................................................................................................................3712 Diagnosis Procedure.....................................................................................................................................................3712 ECU DIAGNOSIS INFORMATION.......................................................................................................................................................3713 BCM (BODY CONTROL MODULE)...................................................................................................................................................3713 Reference Value.........................................................................................................................................................3713 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................3713 Terminal Layout.........................................................................................................................................................3716 Physical Values.........................................................................................................................................................3716 Fail Safe...............................................................................................................................................................3721 Fail-safe index.....................................................................................................................................................3721 DTC Inspection Priority Chart...........................................................................................................................................3721 DTC Index...............................................................................................................................................................3722 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)................................................................................................................3724 Reference Value.........................................................................................................................................................3724 VALUES ON THE DIAGNOSIS TOOL........................................................................................................................................3724 Terminal Layout.........................................................................................................................................................3725 Physical Values.........................................................................................................................................................3725 PHYSICAL VALUES.....................................................................................................................................................3725 Fail Safe...............................................................................................................................................................3729 CAN COMMUNICATION CONTROL...........................................................................................................................................3729 If No CAN Communication Is Available With ECM...................................................................................................................3729 If No CAN Communication Is Available With BCM...................................................................................................................3729 IGNITION RELAY MALFUNCTION DETECTION FUNCTION.......................................................................................................................3729 FRONT WIPER CONTROL.................................................................................................................................................3729 STARTER MOTOR PROTECTION FUNCTION...................................................................................................................................3729 DTC Index...............................................................................................................................................................3730 WIRING DIAGRAM..................................................................................................................................................................3731 FRONT WIPER AND WASHER SYSTEM...............................................................................................................................................3731 Wiring Diagram..........................................................................................................................................................3731 REAR WIPER AND WASHER SYSTEM................................................................................................................................................3736 Wiring Diagram..........................................................................................................................................................3736 SYMPTOM DIAGNOSIS...............................................................................................................................................................3741 WIPER AND WASHER SYSTEM SYMPTOMS............................................................................................................................................3741 Symptom Table...........................................................................................................................................................3741 NORMAL OPERATING CONDITION..................................................................................................................................................3744 Description.............................................................................................................................................................3744 FRONT WIPER MOTOR PROTECTION FUNCTION...............................................................................................................................3744 REAR WIPER MOTOR PROTECTION FUNCTION................................................................................................................................3744 FRONT WIPER DOES NOT OPERATE................................................................................................................................................3745 Description.............................................................................................................................................................3745 Diagnosis Procedure.....................................................................................................................................................3745 PRECAUTION......................................................................................................................................................................3747 PRECAUTION..................................................................................................................................................................3747 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"..............................................................................3747 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS....................................................................................................3747 Precaution for Procedure without Cowl Top Cover.........................................................................................................................3747 REMOVAL AND INSTALLATION........................................................................................................................................................3748 FRONT WIPER ARM.............................................................................................................................................................3748 Removal and Installation................................................................................................................................................3748 REMOVAL.............................................................................................................................................................3748 INSTALLATION........................................................................................................................................................3748 FRONT WIPER ARM ADJUSTMENT..........................................................................................................................................3748 FRONT WIPER DRIVE ASSEMBLY..................................................................................................................................................3749 Removal and Installation................................................................................................................................................3749 REMOVAL.............................................................................................................................................................3749 INSTALLATION........................................................................................................................................................3749 FRONT WASHER TUBE...........................................................................................................................................................3750 Washer Tube Layout......................................................................................................................................................3750 FRONT WASHER NOZZLE.........................................................................................................................................................3751 Removal and Installation................................................................................................................................................3751 REMOVAL.............................................................................................................................................................3751 INSTALLATION........................................................................................................................................................3751 Washer Nozzle Adjustment................................................................................................................................................3751 REAR WIPER ARM..............................................................................................................................................................3752 Removal and Installation................................................................................................................................................3752 REAR WIPER ARM......................................................................................................................................................3752 Removal.........................................................................................................................................................3752 Installation....................................................................................................................................................3752 REAR WIPER ARM ADJUSTMENT...........................................................................................................................................3753 REAR WIPER MOTOR............................................................................................................................................................3754 Removal and Installation................................................................................................................................................3754 REMOVAL.............................................................................................................................................................3754 INSTALLATION........................................................................................................................................................3754 REAR WASHER TUBE............................................................................................................................................................3756 Removal and Installation................................................................................................................................................3756 REAR WASHER HOSE LAYOUT.............................................................................................................................................3756 REAR WASHER NOZZLE..........................................................................................................................................................3757 Removal and Installation................................................................................................................................................3757 REMOVAL.............................................................................................................................................................3757 INSTALLATION........................................................................................................................................................3757 Rear Washer Nozzle Adjustment...........................................................................................................................................3757 WASHER TANK.................................................................................................................................................................3758 Removal and Installation................................................................................................................................................3758 REMOVAL.............................................................................................................................................................3758 INSTALLATION........................................................................................................................................................3758 WASHER PUMP.................................................................................................................................................................3759 Removal and Installation................................................................................................................................................3759 REMOVAL.............................................................................................................................................................3759 INSTALLATION........................................................................................................................................................3759 WIPER & WASHER SWITCH.......................................................................................................................................................3760 Removal and Installation................................................................................................................................................3760 REMOVAL.............................................................................................................................................................3760 INSTALLATION........................................................................................................................................................3760 WASHER LEVEL SWITCH.........................................................................................................................................................3761 Removal and Installation................................................................................................................................................3761 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................................................................................3762 SERVICE DATA AND SPECIFICATIONS (SDS).......................................................................................................................................3762 Specifications..........................................................................................................................................................3762 Windshield Washer Fluid.............................................................................................................................................3762 POWER SUPPLY ROUTING CIRCUIT........................................................................................................................................................ 7 FUSE BLOCK- JUNCTION BOX (J/B)...................................................................................................................................................... 67 FUSE AND FUSIBLE LINK BOX........................................................................................................................................................... 68 FUSE AND RELAY BOX.................................................................................................................................................................. 69 IPDM E\R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)........................................................................................................................ 70
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