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Suzuki Hungary SX4 (RW415 RW416) Service Manual – PDF DOWNLOAD
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Description
Suzuki Hungary SX4 (RW415 RW416) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Suzuki Hungary SX4 (RW415 RW416) Service Manual – PDF DOWNLOAD
Language : English
Pages : 1480
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki Hungary SX4 (RW415 RW416) Service Manual – PDF DOWNLOAD
- This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul).
- VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4).
- VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and Control Systems sections (Sections 5 – 10).
Applicable Model:
SX4 (RW415/RW416) vehicles produced at MAGYAR plant in hungarian with the following vehicle identification numbers (VINs). - The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work.
- Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
- When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others.
- Therefore, note that illustrations may differ from the vehicle being actually serviced.
- The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
Suzuki Hungary SX4 (RW415 RW416) Service Manual – PDF DOWNLOAD
START.................................................................................................................................................................................................................................... 1 IMPORTANT................................................................................................................................................................................................................................ 1 FOREWORD................................................................................................................................................................................................................................. 3 TABLE OF CONTENTS........................................................................................................................................................................................................................ 5 Precautions.............................................................................................................................................................................................................................. 7 Precautions.......................................................................................................................................................................................................................... 8 Precautions...................................................................................................................................................................................................................... 8 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System............................................................................................................................................. 8 General Precautions.......................................................................................................................................................................................................... 10 Warning for Wheel (with tire) Removal........................................................................................................................................................................................ 13 Precautions for Catalytic Converter.......................................................................................................................................................................................... 13 Precautions for Installing Mobile Communication Equipment.................................................................................................................................................................... 14 Precaution for CAN Communication System...................................................................................................................................................................................... 14 Precautions for Electrical Circuit Service................................................................................................................................................................................... 14 Air Bag Warning.............................................................................................................................................................................................................. 16 Air Bag System Service Warning............................................................................................................................................................................................... 16 Fastener Caution............................................................................................................................................................................................................. 17 Suspension Caution........................................................................................................................................................................................................... 17 Wheels and Tires Caution..................................................................................................................................................................................................... 17 Brake Caution................................................................................................................................................................................................................ 17 Repair Instructions.............................................................................................................................................................................................................. 18 Electrical Circuit Inspection Procedure...................................................................................................................................................................................... 18 Intermittent and Poor Connection Inspection.................................................................................................................................................................................. 20 General Information...................................................................................................................................................................................................................... 21 General Information.................................................................................................................................................................................................................. 22 General Description.............................................................................................................................................................................................................. 22 Abbreviations................................................................................................................................................................................................................ 22 Symbols...................................................................................................................................................................................................................... 23 Wire Color Symbols........................................................................................................................................................................................................... 23 Fasteners Information........................................................................................................................................................................................................ 24 Vehicle Lifting Points....................................................................................................................................................................................................... 26 Vehicle Identification Number................................................................................................................................................................................................ 27 Engine Identification Number................................................................................................................................................................................................. 27 Transmission Identification Number........................................................................................................................................................................................... 27 Component Location............................................................................................................................................................................................................... 28 Warning, Caution and Information Labels Location............................................................................................................................................................................. 28 Maintenance and Lubrication.......................................................................................................................................................................................................... 30 Precautions...................................................................................................................................................................................................................... 30 Precautions for Maintenance and Lubrication.................................................................................................................................................................................. 30 Scheduled Maintenance............................................................................................................................................................................................................ 30 Maintenance Schedule under Normal Driving Conditions......................................................................................................................................................................... 30 Maintenance Recommended under Severe Driving Conditions...................................................................................................................................................................... 31 Repair Instructions.............................................................................................................................................................................................................. 32 Accessory Drive Belt Inspection.............................................................................................................................................................................................. 32 Accessory Drive Belt Replacement............................................................................................................................................................................................. 32 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 32 Engine Oil and Filter Change................................................................................................................................................................................................. 33 Engine Coolant Change........................................................................................................................................................................................................ 34 Exhaust System Inspection.................................................................................................................................................................................................... 34 Spark Plug Replacement....................................................................................................................................................................................................... 34 Air Cleaner Filter Inspection................................................................................................................................................................................................ 35 Air Cleaner Filter Replacement............................................................................................................................................................................................... 35 Fuel Lines and Connections Inspection........................................................................................................................................................................................ 35 Fuel Tank Inspection......................................................................................................................................................................................................... 35 PCV Valve Inspection......................................................................................................................................................................................................... 35 Fuel Evaporative Emission Control System Inspection.......................................................................................................................................................................... 35 Brake Discs and Pads (Front) Inspection...................................................................................................................................................................................... 36 Brake Drums and Shoes (Rear) Inspection...................................................................................................................................................................................... 36 Brake Hoses and Pipes Inspection............................................................................................................................................................................................. 36 Brake Fluid Replacement...................................................................................................................................................................................................... 36 Brake Lever and Cable Inspection............................................................................................................................................................................................. 36 Clutch Fluid Inspection...................................................................................................................................................................................................... 37 Tires Inspection............................................................................................................................................................................................................. 37 Wheel Discs Inspection....................................................................................................................................................................................................... 37 Wheel Bearing Inspection..................................................................................................................................................................................................... 37 Suspension System Inspection................................................................................................................................................................................................. 38 Steering System Inspection................................................................................................................................................................................................... 38 Drive Shaft (Axle) Boots Inspection.......................................................................................................................................................................................... 38 Propeller Shaft (4WD) Inspection............................................................................................................................................................................................. 39 Manual Transaxle Oil Inspection.............................................................................................................................................................................................. 39 Manual Transaxle Oil Replacement............................................................................................................................................................................................. 39 Automatic Transaxle Fluid Level Inspection................................................................................................................................................................................... 39 Automatic Transaxle Fluid Replacement........................................................................................................................................................................................ 39 Automatic Transaxle Fluid Cooler Hose Inspection............................................................................................................................................................................. 39 Transfer Oil Inspection (4WD)................................................................................................................................................................................................ 39 Transfer Oil Replacement (4WD)............................................................................................................................................................................................... 39 Rear Deferential Oil Inspection (4WD)........................................................................................................................................................................................ 39 Rear Deferential Oil Replacement (4WD)....................................................................................................................................................................................... 39 All Latches, Hinges and Locks Inspection..................................................................................................................................................................................... 39 HVAC Air Filter (If Equipped) Inspection..................................................................................................................................................................................... 40 HVAC Air Filter (If Equipped) Replacement.................................................................................................................................................................................... 40 Final Inspection for Maintenance Service..................................................................................................................................................................................... 40 Specifications................................................................................................................................................................................................................... 41 Tightening Torque Specifications............................................................................................................................................................................................. 41 Special Tools and Equipment...................................................................................................................................................................................................... 41 Recommended Fluids and Lubricants............................................................................................................................................................................................ 41 Special Tool................................................................................................................................................................................................................. 41 Engine................................................................................................................................................................................................................................... 43 Precautions.......................................................................................................................................................................................................................... 48 Precautions...................................................................................................................................................................................................................... 48 Precautions for Engine....................................................................................................................................................................................................... 48 Engine General Information and Diagnosis............................................................................................................................................................................................. 49 Precautions...................................................................................................................................................................................................................... 49 Precautions on Engine Service................................................................................................................................................................................................ 49 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 49 Precautions for DTC Troubleshooting.......................................................................................................................................................................................... 50 Precautions of ECM Circuit Inspection........................................................................................................................................................................................ 50 Precautions of Electric Throttle Body System Calibration..................................................................................................................................................................... 50 General Description.............................................................................................................................................................................................................. 50 Statement on Cleanliness and Care............................................................................................................................................................................................ 50 Engine Diagnosis General Description......................................................................................................................................................................................... 51 On-Board Diagnostic System Description....................................................................................................................................................................................... 51 Engine and Emission Control System Description............................................................................................................................................................................... 53 CAN Communication System Description......................................................................................................................................................................................... 53 Air Intake System Description................................................................................................................................................................................................ 55 Description of Electric Throttle Body System Calibration..................................................................................................................................................................... 56 Electronic Control System Description........................................................................................................................................................................................ 56 Description of Electric Throttle Body System................................................................................................................................................................................. 57 Engine and Emission Control Input / Output Table............................................................................................................................................................................. 63 Schematic and Routing Diagram.................................................................................................................................................................................................... 64 Engine and Emission Control System Diagram................................................................................................................................................................................... 64 Component Location............................................................................................................................................................................................................... 65 Electronic Control System Components Location................................................................................................................................................................................ 65 Diagnostic Information and Procedures............................................................................................................................................................................................ 66 Engine and Emission Control System Check..................................................................................................................................................................................... 66 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 69 DTC Check.................................................................................................................................................................................................................... 70 DTC Clearance................................................................................................................................................................................................................ 70 DTC Table.................................................................................................................................................................................................................... 71 For Vehicle Equipped with A/T................................................................................................................................................................................................ 74 Fail-Safe Table.............................................................................................................................................................................................................. 75 Scan Tool Data............................................................................................................................................................................................................... 76 Visual Inspection............................................................................................................................................................................................................ 82 Engine Basic Inspection...................................................................................................................................................................................................... 83 Engine Symptom Diagnosis..................................................................................................................................................................................................... 86 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started).............................................................................................................. 92 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................................................................................................................... 94 DTC P0010: Camshaft Position Actuator Circuit (for engine with VVT system)................................................................................................................................................... 95 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / Retarded (for engine with VVT system).................................................................................................... 97 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)......................................................................................................................................................... 99 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)......................................................................................................................................................... 101 DTC P0101: Mass Air Flow Circuit Range / Performance......................................................................................................................................................................... 103 DTC P0102: Mass Air Flow Circuit Low Input................................................................................................................................................................................... 106 DTC P0103: Mass Air Flow Circuit High Input.................................................................................................................................................................................. 107 DTC P0106: Manifold Absolute Pressure Range / Performance.................................................................................................................................................................... 109 DTC P0107: Manifold Absolute Pressure Circuit Low Input...................................................................................................................................................................... 110 DTC P0108: Manifold Absolute Pressure Circuit High Input..................................................................................................................................................................... 112 DTC P0111: Intake Air Temperature Circuit Range / Performance................................................................................................................................................................ 114 DTC P0112: Intake Air Temperature Sensor Circuit Low......................................................................................................................................................................... 116 DTC P0113: Intake Air Temperature Sensor Circuit High........................................................................................................................................................................ 118 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................................................................................................ 120 DTC P0117: Engine Coolant Temperature Circuit Low............................................................................................................................................................................ 123 DTC P0118: Engine Coolant Temperature Circuit High........................................................................................................................................................................... 125 DTC P0122: Throttle Position Sensor (Main) Circuit Low....................................................................................................................................................................... 127 DTC P0123: Throttle Position Sensor (Main) Circuit High...................................................................................................................................................................... 129 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)............................................................................................................................................ 132 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)................................................................................................................................................................. 134 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1).......................................................................................................................................................... 135 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)............................................................................................................................................ 138 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2).......................................................................................................................................................... 140 DTC P0171 / P0172: Fuel System Too Lean / Rich............................................................................................................................................................................... 142 DTC P0222: Throttle Position Sensor (Sub) Circuit Low........................................................................................................................................................................ 144 DTC P0223: Throttle Position Sensor (Sub) Circuit High....................................................................................................................................................................... 146 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...................................................................................... 149 DTC P0327 / P0328: Knock Sensor Circuit Low / High........................................................................................................................................................................... 151 DTC P0335: Crankshaft Position (CKP) Sensor Circuit.......................................................................................................................................................................... 153 DTC P0340: Camshaft Position (CMP) Sensor Circuit............................................................................................................................................................................ 155 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected................................................................................................................................. 158 DTC P0403: Exhaust Gas Recirculation Control Circuit......................................................................................................................................................................... 160 DTC P0420: Catalyst System Efficiency below Threshold........................................................................................................................................................................ 162 DTC P0443: Evaporative Emission System Purge Control Valve Circuit........................................................................................................................................................... 164 DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High...................................................................................................................................................................... 166 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...................................................................................................................................................................... 167 DTC P0481: Cooling Fan 2 (A/C Condenser Fan) Control Circuit................................................................................................................................................................. 169 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction............................................................................................................................................................................ 172 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low....................................................................................................................................................................... 174 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High...................................................................................................................................................................... 176 DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance.................................................................................... 177 DTC P0616: Starter Relay Circuit Low......................................................................................................................................................................................... 178 DTC P0617: Starter Relay Circuit High........................................................................................................................................................................................ 179 DTC P1510: ECM Back-Up Power Supply Malfunction.............................................................................................................................................................................. 180 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance....................................................................................................................................................... 182 DTC P2102: Throttle Actuator Control Motor Circuit Low....................................................................................................................................................................... 184 DTC P2103: Throttle Actuator Control Motor Circuit High...................................................................................................................................................................... 185 DTC P2111: Throttle Actuator Control System - Stuck Open..................................................................................................................................................................... 186 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance....................................................................................................................................................... 187 DTC P2122: Pedal Position Sensor (Main) Circuit Low Input.................................................................................................................................................................... 189 DTC P2123: Pedal Position Sensor (Main) Circuit High Input................................................................................................................................................................... 191 DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input..................................................................................................................................................................... 193 DTC P2128: Pedal Position Sensor (Sub) Circuit High Input.................................................................................................................................................................... 195 DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation......................................................................................................................................................... 198 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation............................................................................................................................................................ 201 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction........................................................................................................................................................... 203 DTC U0073: Control Module Communication Bus Off.............................................................................................................................................................................. 205 DTC U0101: Lost Communication with TCM....................................................................................................................................................................................... 209 DTC U0121: Lost Communication with ABS / ESP‚ Control Module................................................................................................................................................................. 212 DTC U0140: Lost Communication with Body Control Module....................................................................................................................................................................... 216 Inspection of ECM and Its Circuits........................................................................................................................................................................................... 219 ECM Power and Ground Circuit Check........................................................................................................................................................................................... 241 Fuel Injector Circuit Check.................................................................................................................................................................................................. 244 Fuel Pump and Its Circuit Check.............................................................................................................................................................................................. 246 Fuel Pressure Check.......................................................................................................................................................................................................... 249 A/C Condenser Cooling Fan Control System Inspection.......................................................................................................................................................................... 250 A/C System Circuits Check.................................................................................................................................................................................................... 253 Electric Load Signal Circuit Check........................................................................................................................................................................................... 256 Radiator Cooling Fan Control System Check.................................................................................................................................................................................... 258 Repair Instructions.............................................................................................................................................................................................................. 259 Idle Speed and IAC Throttle Valve Opening Inspection......................................................................................................................................................................... 259 Special Tools and Equipment...................................................................................................................................................................................................... 260 Special Tool................................................................................................................................................................................................................. 260 Aux. Emission Control Devices........................................................................................................................................................................................................ 261 Diagnostic Information and Procedures............................................................................................................................................................................................ 261 EGR System Inspection........................................................................................................................................................................................................ 261 Repair Instructions.............................................................................................................................................................................................................. 261 EVAP Canister Purge Inspection............................................................................................................................................................................................... 261 EVAP Canister Purge Valve and Its Circuit Inspection......................................................................................................................................................................... 261 Vacuum Passage Inspection.................................................................................................................................................................................................... 262 Vacuum Hose Inspection....................................................................................................................................................................................................... 263 EVAP Canister Purge Valve Inspection......................................................................................................................................................................................... 263 EVAP Canister Inspection..................................................................................................................................................................................................... 264 EGR Valve Removal and Installation........................................................................................................................................................................................... 264 EGR Valve Inspection......................................................................................................................................................................................................... 264 PCV Hose Inspection.......................................................................................................................................................................................................... 265 PCV Valve Inspection......................................................................................................................................................................................................... 265 Special Tools and Equipment...................................................................................................................................................................................................... 265 Special Tool................................................................................................................................................................................................................. 265 Engine Electrical Devices............................................................................................................................................................................................................ 266 Repair Instructions.............................................................................................................................................................................................................. 266 Engine Control Module (ECM) Removal and Installation......................................................................................................................................................................... 266 Manifold Absolute Pressure (MAP) Sensor Inspection........................................................................................................................................................................... 266 Electric Throttle Body Assembly On-Vehicle Inspection........................................................................................................................................................................ 267 Electric Throttle Body System Calibration.................................................................................................................................................................................... 269 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection....................................................................................................................................................... 270 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation.................................................................................................................................................... 270 Accelerator Pedal Position (APP) Sensor Assembly Inspection.................................................................................................................................................................. 271 Engine Coolant Temperature (ECT) Sensor Removal and Installation............................................................................................................................................................. 271 Engine Coolant Temperature (ECT) Sensor Inspection........................................................................................................................................................................... 272 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection........................................................................................................................................................ 272 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation............................................................................................................................................................ 272 Camshaft Position (CMP) Sensor Removal and Installation...................................................................................................................................................................... 273 Camshaft Position (CMP) Sensor Inspection.................................................................................................................................................................................... 273 Crankshaft Position (CKP) Sensor Removal and Installation.................................................................................................................................................................... 274 Crankshaft Position (CKP) Sensor Inspection.................................................................................................................................................................................. 275 Knock Sensor Removal and Installation........................................................................................................................................................................................ 275 Main Relay, Fuel Pump Relay, Starting Motor Control Relay, Throttle Actuator Control Relay and Radiator Cooling Fan Relay Inspection......................................................................................... 276 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection............................................................................................................................................ 276 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation......................................................................................................................................... 277 Intake Air Temperature (IAT) Sensor Inspection............................................................................................................................................................................... 277 Specifications................................................................................................................................................................................................................... 278 Tightening Torque Specifications............................................................................................................................................................................................. 278 Engine Mechanical.................................................................................................................................................................................................................... 279 General Description.............................................................................................................................................................................................................. 279 Engine Construction Description.............................................................................................................................................................................................. 279 Camshaft Position Control (VVT Variable Valve Timing) System Description..................................................................................................................................................... 281 Diagnostic Information and Procedures............................................................................................................................................................................................ 283 Compression Check............................................................................................................................................................................................................ 283 Engine Vacuum Check.......................................................................................................................................................................................................... 284 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 285 Repair Instructions.............................................................................................................................................................................................................. 288 Air Intake System Components................................................................................................................................................................................................. 288 Air Cleaner Filter Removal and Installation.................................................................................................................................................................................. 288 Air Cleaner Filter Inspection and Cleaning................................................................................................................................................................................... 288 Air Cleaner Assembly Removal and Installation................................................................................................................................................................................ 289 Cylinder Head Cover Removal and Installation................................................................................................................................................................................. 289 Throttle Body and Intake Manifold Components................................................................................................................................................................................. 291 Throttle Body On-Vehicle Inspection.......................................................................................................................................................................................... 292 Electric Throttle Body Assembly Removal and Installation..................................................................................................................................................................... 292 Throttle Body Cleaning....................................................................................................................................................................................................... 292 Intake Manifold Removal and Installation..................................................................................................................................................................................... 293 Engine Mountings Components.................................................................................................................................................................................................. 294 Engine Assembly Removal and Installation..................................................................................................................................................................................... 295 Timing Chain Cover Components................................................................................................................................................................................................ 300 Timing Chain Cover Removal and Installation.................................................................................................................................................................................. 301 Timing Chain Cover Inspection................................................................................................................................................................................................ 303 Oil Control Valve Removal and Installation (For Engine with VVT)............................................................................................................................................................. 304 Oil Control Valve Inspection (For Engine with VVT)........................................................................................................................................................................... 304 Timing Chain and Chain Tensioner Components.................................................................................................................................................................................. 305 Timing Chain and Chain Tensioner Removal and Installation.................................................................................................................................................................... 305 Timing Chain and Chain Tensioner Inspection.................................................................................................................................................................................. 309 Camshaft, Tappet and Shim Components......................................................................................................................................................................................... 310 Camshaft, Tappet and Shim Removal and Installation........................................................................................................................................................................... 311 Camshaft, Tappet and Shim Inspection......................................................................................................................................................................................... 314 Valves and Cylinder Head Components.......................................................................................................................................................................................... 317 Valves and Cylinder Head Removal and Installation............................................................................................................................................................................ 318 Valves and Cylinder Head Disassembly and Assembly............................................................................................................................................................................ 320 Valves and Valve Guides Inspection........................................................................................................................................................................................... 323 Cylinder Head Inspection..................................................................................................................................................................................................... 325 Valve Spring Inspection...................................................................................................................................................................................................... 326 Pistons, Piston Rings, Connecting Rods and Cylinders Components.............................................................................................................................................................. 327 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation................................................................................................................................................ 327 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly................................................................................................................................................ 329 Cylinders, Pistons and Piston Rings Inspection............................................................................................................................................................................... 330 Piston Pins and Connecting Rods Inspection................................................................................................................................................................................... 332 Crank Pin and Connecting Rod Bearings Inspection............................................................................................................................................................................. 333 Main Bearings, Crankshaft and Cylinder Block Components...................................................................................................................................................................... 337 Main Bearings, Crankshaft and Cylinder Block Removal and Installation........................................................................................................................................................ 338 Crankshaft Inspection........................................................................................................................................................................................................ 341 Main Bearings Inspection..................................................................................................................................................................................................... 342 Sensor Plate Inspection...................................................................................................................................................................................................... 347 Rear Oil Seal Inspection..................................................................................................................................................................................................... 347 Flywheel Inspection.......................................................................................................................................................................................................... 347 Cylinder Block Inspection.................................................................................................................................................................................................... 347 Specifications................................................................................................................................................................................................................... 348 Tightening Torque Specifications............................................................................................................................................................................................. 348 Special Tools and Equipment...................................................................................................................................................................................................... 349 Recommended Service Material................................................................................................................................................................................................. 349 Special Tool................................................................................................................................................................................................................. 350 Engine Lubrication System............................................................................................................................................................................................................ 352 General Description.............................................................................................................................................................................................................. 352 Engine Lubrication Description............................................................................................................................................................................................... 352 Diagnostic Information and Procedures............................................................................................................................................................................................ 353 Oil Pressure Check........................................................................................................................................................................................................... 353 Repair Instructions.............................................................................................................................................................................................................. 354 Oil Pan and Oil Pump Strainer Components..................................................................................................................................................................................... 354 Oil Pan and Oil Pump Strainer Removal and Installation....................................................................................................................................................................... 355 Oil Pan and Oil Pump Strainer Cleaning....................................................................................................................................................................................... 356 Oil Pump Components.......................................................................................................................................................................................................... 357 Oil Pump Removal and Installation............................................................................................................................................................................................ 357 Oil Pump Disassembly and Reassembly.......................................................................................................................................................................................... 357 Oil Pump Inspection.......................................................................................................................................................................................................... 358 Specifications................................................................................................................................................................................................................... 360 Tightening Torque Specifications............................................................................................................................................................................................. 360 Special Tools and Equipment...................................................................................................................................................................................................... 360 Recommended Service Material................................................................................................................................................................................................. 360 Special Tool................................................................................................................................................................................................................. 360 Engine Cooling System................................................................................................................................................................................................................ 361 General Description.............................................................................................................................................................................................................. 361 Cooling System Description................................................................................................................................................................................................... 361 Coolant Description.......................................................................................................................................................................................................... 361 Schematic and Routing Diagram.................................................................................................................................................................................................... 362 Coolant Circulation.......................................................................................................................................................................................................... 362 Diagnostic Information and Procedures............................................................................................................................................................................................ 363 Engine Cooling Symptom Diagnosis............................................................................................................................................................................................. 363 Repair Instructions.............................................................................................................................................................................................................. 364 Cooling System Components.................................................................................................................................................................................................... 364 Coolant Level Check.......................................................................................................................................................................................................... 365 Engine Cooling System Inspection and Cleaning................................................................................................................................................................................ 365 Cooling System Draining...................................................................................................................................................................................................... 365 Cooling System Flush and Refill.............................................................................................................................................................................................. 366 Cooling Water Pipes or Hoses Removal and Installation........................................................................................................................................................................ 366 Thermostat Removal and Installation.......................................................................................................................................................................................... 367 Thermostat Inspection........................................................................................................................................................................................................ 367 Radiator Cooling Fan Assembly On-Vehicle Inspection.......................................................................................................................................................................... 368 Radiator Cooling Fan Relay Inspection........................................................................................................................................................................................ 368 Radiator Cooling Fan Assembly Removal and Installation....................................................................................................................................................................... 368 Radiator Cooling Fan Disassembly and Reassembly.............................................................................................................................................................................. 369 Radiator On-Vehicle Inspection and Cleaning.................................................................................................................................................................................. 369 Radiator Removal and Installation............................................................................................................................................................................................ 369 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.......................................................................................................................................................... 370 Water Pump / Generator Drive Belt Removal and Installation................................................................................................................................................................... 370 Water Pump Removal and Installation.......................................................................................................................................................................................... 371 Water Pump Inspection........................................................................................................................................................................................................ 372 Specifications................................................................................................................................................................................................................... 372 Tightening Torque Specifications............................................................................................................................................................................................. 372 Special Tools and Equipment...................................................................................................................................................................................................... 372 Recommended Service Material................................................................................................................................................................................................. 372 Fuel System.......................................................................................................................................................................................................................... 373 Precautions...................................................................................................................................................................................................................... 373 Precautions on Fuel System Service........................................................................................................................................................................................... 373 General Description.............................................................................................................................................................................................................. 374 Fuel System Description...................................................................................................................................................................................................... 374 Fuel Delivery System Description............................................................................................................................................................................................. 374 Fuel Pump Description........................................................................................................................................................................................................ 374 Schematic and Routing Diagram.................................................................................................................................................................................................... 374 Fuel Delivery System Diagram................................................................................................................................................................................................. 374 Diagnostic Information and Procedures............................................................................................................................................................................................ 375 Fuel Pressure Inspection..................................................................................................................................................................................................... 375 Fuel Cut Operation Inspection................................................................................................................................................................................................ 376 Repair Instructions.............................................................................................................................................................................................................. 376 Fuel System Components....................................................................................................................................................................................................... 376 Fuel Hose Disconnecting and Reconnecting..................................................................................................................................................................................... 377 Fuel Pressure Relief Procedure............................................................................................................................................................................................... 378 Fuel Leakage Check Procedure................................................................................................................................................................................................. 379 Fuel Lines On-Vehicle Inspection............................................................................................................................................................................................. 379 Fuel Pipe Removal and Installation........................................................................................................................................................................................... 379 Fuel Injector On-Vehicle Inspection.......................................................................................................................................................................................... 380 Fuel Injector Removal and Installation....................................................................................................................................................................................... 380 Fuel Injector Inspection..................................................................................................................................................................................................... 381 Fuel Filler Cap Inspection................................................................................................................................................................................................... 382 Fuel Tank Removal and Installation........................................................................................................................................................................................... 383 Fuel Tank Inspection......................................................................................................................................................................................................... 384 Fuel Tank Purging Procedure.................................................................................................................................................................................................. 384 Fuel Pump On-Vehicle Inspection.............................................................................................................................................................................................. 385 Fuel Pump Assembly Removal and Installation.................................................................................................................................................................................. 385 Fuel Pump Inspection......................................................................................................................................................................................................... 387 Specifications................................................................................................................................................................................................................... 388 Tightening Torque Specifications............................................................................................................................................................................................. 388 Special Tools and Equipment...................................................................................................................................................................................................... 388 Special Tool................................................................................................................................................................................................................. 388 Ignition System...................................................................................................................................................................................................................... 390 General Description.............................................................................................................................................................................................................. 390 Ignition System Construction................................................................................................................................................................................................. 390 Schematic and Routing Diagram.................................................................................................................................................................................................... 391 Ignition System Wiring Circuit Diagram....................................................................................................................................................................................... 391 Component Location............................................................................................................................................................................................................... 392 Ignition System Components Location.......................................................................................................................................................................................... 392 Diagnostic Information and Procedures............................................................................................................................................................................................ 393 Ignition System Symptom Diagnosis............................................................................................................................................................................................ 393 Reference Waveform of Ignition System........................................................................................................................................................................................ 393 Ignition System Check........................................................................................................................................................................................................ 393 Ignition Spark Test.......................................................................................................................................................................................................... 395 Repair Instructions.............................................................................................................................................................................................................. 395 High-Tension Cord Removal and Installation................................................................................................................................................................................... 395 High-Tension Cord Inspection................................................................................................................................................................................................. 396 Spark Plug Removal and Installation.......................................................................................................................................................................................... 396 Spark Plug Inspection........................................................................................................................................................................................................ 396 Ignition Coil Assembly (Including Ignitor) Removal and Installation.......................................................................................................................................................... 397 Ignition Coil Assembly (Including Ignitor) Inspection........................................................................................................................................................................ 397 Ignition Timing Inspection................................................................................................................................................................................................... 397 Specifications................................................................................................................................................................................................................... 399 Tightening Torque Specifications............................................................................................................................................................................................. 399 Special Tools and Equipment...................................................................................................................................................................................................... 399 Special Tool................................................................................................................................................................................................................. 399 Starting System...................................................................................................................................................................................................................... 400 Schematic and Routing Diagram.................................................................................................................................................................................................... 400 Cranking System Circuit Diagram.............................................................................................................................................................................................. 400 Diagnostic Information and Procedures............................................................................................................................................................................................ 400 Cranking System Symptom Diagnosis............................................................................................................................................................................................ 400 Cranking System Test......................................................................................................................................................................................................... 402 Repair Instructions.............................................................................................................................................................................................................. 403 Starting Motor Dismounting and Remounting.................................................................................................................................................................................... 403 Starting Motor Components.................................................................................................................................................................................................... 404 Starting Motor Inspection.................................................................................................................................................................................................... 406 Specifications................................................................................................................................................................................................................... 409 Cranking System Specifications............................................................................................................................................................................................... 409 Tightening Torque Specifications............................................................................................................................................................................................. 410 Special Tools and Equipment...................................................................................................................................................................................................... 410 Recommended Service Material................................................................................................................................................................................................. 410 Charging System...................................................................................................................................................................................................................... 411 General Description.............................................................................................................................................................................................................. 411 Battery Description.......................................................................................................................................................................................................... 411 Generator Description........................................................................................................................................................................................................ 412 Diagnostic Information and Procedures............................................................................................................................................................................................ 413 Battery Inspection........................................................................................................................................................................................................... 413 Generator Symptom Diagnosis.................................................................................................................................................................................................. 413 Generator Test (Undercharged Battery Check).................................................................................................................................................................................. 414 Generator Test (Overcharged Battery Check)................................................................................................................................................................................... 414 Repair Instructions.............................................................................................................................................................................................................. 415 Jump Starting in Case of Emergency........................................................................................................................................................................................... 415 Battery Dismounting and Remounting........................................................................................................................................................................................... 415 Generator Dismounting and Remounting......................................................................................................................................................................................... 416 Generator Components......................................................................................................................................................................................................... 417 Generator Inspection......................................................................................................................................................................................................... 417 Specifications................................................................................................................................................................................................................... 419 Charging System Specifications............................................................................................................................................................................................... 419 Tightening Torque Specifications............................................................................................................................................................................................. 419 Exhaust System....................................................................................................................................................................................................................... 420 General Description.............................................................................................................................................................................................................. 420 Exhaust System Description................................................................................................................................................................................................... 420 Diagnostic Information and Procedures............................................................................................................................................................................................ 420 Exhaust System Check......................................................................................................................................................................................................... 420 Repair Instructions.............................................................................................................................................................................................................. 421 Exhaust System Components.................................................................................................................................................................................................... 421 Exhaust Manifold Removal and Installation.................................................................................................................................................................................... 422 Exhaust Pipe and Muffler Removal and Installation............................................................................................................................................................................ 423 Specifications................................................................................................................................................................................................................... 424 Tightening Torque Specifications............................................................................................................................................................................................. 424 Suspension............................................................................................................................................................................................................................... 425 Precautions.......................................................................................................................................................................................................................... 427 Precautions...................................................................................................................................................................................................................... 427 Precautions on Suspension.................................................................................................................................................................................................... 427 Suspension General Diagnosis......................................................................................................................................................................................................... 428 Diagnostic Information and Procedures............................................................................................................................................................................................ 428 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................................................................................................... 428 Specifications................................................................................................................................................................................................................... 430 Wheel Alignment Specifications............................................................................................................................................................................................... 430 Front Suspension..................................................................................................................................................................................................................... 431 General Description.............................................................................................................................................................................................................. 431 Front Suspension Construction................................................................................................................................................................................................ 431 Front Wheel Alignment Construction........................................................................................................................................................................................... 432 Repair Instructions.............................................................................................................................................................................................................. 432 Front Wheel Alignment Inspection and Adjustment.............................................................................................................................................................................. 432 Front Strut Assembly Components.............................................................................................................................................................................................. 434 Front Strut Assembly Removal and Installation................................................................................................................................................................................ 435 Front Strut Assembly Disassembly and Assembly................................................................................................................................................................................ 436 Front Strut Assembly Check................................................................................................................................................................................................... 437 Front Wheel Hub and Steering Knuckle Components.............................................................................................................................................................................. 438 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation................................................................................................................................................. 438 Front Wheel Hub, Disc, Bolt and Bearing Check................................................................................................................................................................................ 442 Suspension Control Arm Assembly Removal and Installation..................................................................................................................................................................... 442 Suspension Control Arm / Bushing Disassembly and Assembly.................................................................................................................................................................... 443 Suspension Control Arm / Steering Knuckle Check.............................................................................................................................................................................. 444 Suspension Control Arm Bushing Check......................................................................................................................................................................................... 444 Suspension Control Arm Joint Check........................................................................................................................................................................................... 444 Front Suspension Frame, Stabilizer Bar and/or Bushings Components............................................................................................................................................................ 445 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation.............................................................................................................................................. 446 Front Suspension Frame Check................................................................................................................................................................................................. 449 Front Stabilizer Bar, Bushing and/or Joint Check............................................................................................................................................................................. 449 Front Suspension Fasteners Check............................................................................................................................................................................................. 449 Specifications................................................................................................................................................................................................................... 450 Tightening Torque Specifications............................................................................................................................................................................................. 450 Special Tools and Equipment...................................................................................................................................................................................................... 451 Recommended Service Material................................................................................................................................................................................................. 451 Special Tool................................................................................................................................................................................................................. 451 Rear Suspension...................................................................................................................................................................................................................... 452 Repair Instructions.............................................................................................................................................................................................................. 452 Rear Suspension Components................................................................................................................................................................................................... 452 Rear Shock Absorber Removal and Installation................................................................................................................................................................................. 453 Rear Shock Absorber Inspection............................................................................................................................................................................................... 454 Rear Shock Absorber Bush Inspection.......................................................................................................................................................................................... 454 Coil Spring Removal and Installation......................................................................................................................................................................................... 455 Spring Upper Seat / Spring Lower Seat Inspection............................................................................................................................................................................. 456 Rear Axle Removal and Installation........................................................................................................................................................................................... 456 Rear Axle and Coil Spring Inspection......................................................................................................................................................................................... 458 Rear Axle Bush Inspection.................................................................................................................................................................................................... 459 Rear Wheel Disc, Bolt and Bearing Inspection................................................................................................................................................................................. 459 Rear Wheel Hub Assembly Removal and Installation............................................................................................................................................................................. 459 Rear Suspension Fasteners Inspection......................................................................................................................................................................................... 461 Specifications................................................................................................................................................................................................................... 461 Tightening Torque Specifications............................................................................................................................................................................................. 461 Wheels and Tires..................................................................................................................................................................................................................... 462 General Description.............................................................................................................................................................................................................. 462 Tires Description............................................................................................................................................................................................................ 462 Wheels Description........................................................................................................................................................................................................... 463 Irregular and/or Premature Wear Description.................................................................................................................................................................................. 464 Wear Indicators Description.................................................................................................................................................................................................. 464 Radial Tire Waddle Description............................................................................................................................................................................................... 464 Radial Tire Lead / Pull Description.......................................................................................................................................................................................... 465 Balancing Wheels Description................................................................................................................................................................................................. 465 Repair Instructions.............................................................................................................................................................................................................. 466 General Balance Procedures................................................................................................................................................................................................... 466 Tire Rotation................................................................................................................................................................................................................ 466 Wheel Removal and Installation............................................................................................................................................................................................... 467 Tire Mounting and Dismounting................................................................................................................................................................................................ 467 Tire Repair.................................................................................................................................................................................................................. 467 Specifications................................................................................................................................................................................................................... 468 Wheels and Tires Specifications.............................................................................................................................................................................................. 468 Tightening Torque Specifications............................................................................................................................................................................................. 468 Driveline / Axle......................................................................................................................................................................................................................... 469 Precautions.......................................................................................................................................................................................................................... 471 Precautions...................................................................................................................................................................................................................... 471 Precautions on Driveline / Axle.............................................................................................................................................................................................. 471 Drive Shaft / Axle................................................................................................................................................................................................................... 472 Front............................................................................................................................................................................................................................ 472 General Description.......................................................................................................................................................................................................... 472 Front Drive Shaft Construction........................................................................................................................................................................................... 472 Component Location........................................................................................................................................................................................................... 472 Front Drive Shaft Assembly Components Location........................................................................................................................................................................... 472 Diagnostic Information and Procedures........................................................................................................................................................................................ 473 Front Drive Shaft Symptom Diagnosis...................................................................................................................................................................................... 473 Repair Instructions.......................................................................................................................................................................................................... 474 Front Drive Shaft Components............................................................................................................................................................................................. 474 Front Drive Shaft Assembly On-Vehicle Inspection......................................................................................................................................................................... 475 Front Drive Shaft Assembly Removal and Installation...................................................................................................................................................................... 475 Front Drive Shaft Disassembly and Reassembly............................................................................................................................................................................. 476 Center Shaft and Center Bearing Support Disassembly and Reassembly (If Equipped)......................................................................................................................................... 484 Specifications............................................................................................................................................................................................................... 485 Tightening Torque Specifications......................................................................................................................................................................................... 485 Special Tools and Equipment.................................................................................................................................................................................................. 486 Recommended Service Material............................................................................................................................................................................................. 486 Special Tool............................................................................................................................................................................................................. 486 Rear............................................................................................................................................................................................................................. 487 General Description.......................................................................................................................................................................................................... 487 Rear Drive Shaft Construction............................................................................................................................................................................................ 487 Repair Instructions.......................................................................................................................................................................................................... 487 Rear Drive Shaft Components.............................................................................................................................................................................................. 487 Rear Drive Shaft Assembly Removal and Installation....................................................................................................................................................................... 487 Rear Drive Shaft Disassembly and Reassembly.............................................................................................................................................................................. 488 Specifications............................................................................................................................................................................................................... 489 Tightening Torque Specifications......................................................................................................................................................................................... 489 Special Tools and Equipment.................................................................................................................................................................................................. 489 Recommended Service Material............................................................................................................................................................................................. 489 Special Tool............................................................................................................................................................................................................. 489 Differential......................................................................................................................................................................................................................... 490 Precautions...................................................................................................................................................................................................................... 490 Precaution for Rear Differential Oil Leakage................................................................................................................................................................................. 490 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 490 General Description.............................................................................................................................................................................................................. 491 Rear Differential Description................................................................................................................................................................................................ 491 Coupling Description......................................................................................................................................................................................................... 491 4WD Control System Components................................................................................................................................................................................................ 492 4WD Control System Description............................................................................................................................................................................................... 493 Function of 4WD Control System Component..................................................................................................................................................................................... 493 4WD Control System Wiring Circuit Diagram.................................................................................................................................................................................... 494 Terminal Arrangement of 4WD Control Module................................................................................................................................................................................... 494 Input / Output Signal Table of 4WD Control Module............................................................................................................................................................................ 495 On-Board Diagnostic System Description....................................................................................................................................................................................... 495 CAN Communication System Description......................................................................................................................................................................................... 496 Diagnostic Information and Procedures............................................................................................................................................................................................ 497 4WD Control System Check..................................................................................................................................................................................................... 497 4WD Position Indicator Operation Check....................................................................................................................................................................................... 499 4WD Control System Operation Inspection...................................................................................................................................................................................... 499 Visual Inspection............................................................................................................................................................................................................ 499 DTC Check.................................................................................................................................................................................................................... 500 DTC Clearance................................................................................................................................................................................................................ 500 DTC Table.................................................................................................................................................................................................................... 501 Fail-Safe Table.............................................................................................................................................................................................................. 501 Scan Tool Data............................................................................................................................................................................................................... 502 Scan Tool Data Definitions................................................................................................................................................................................................... 502 Rear Differential Symptom Diagnosis.......................................................................................................................................................................................... 503 4WD Control Symptom Diagnosis................................................................................................................................................................................................ 503 4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops............................................................................................................................................... 504 4WD Position Indicator Remains ON Steady at Ignition Switch ON............................................................................................................................................................... 505 DTC C1240: 4WD Control Module Power Supply Circuit Malfunction............................................................................................................................................................... 506 DTC C1243: Internal Circuit Malfunction of 4WD Control Module................................................................................................................................................................ 507 DTC C1250: Coupling Air Temperature Sensor Circuit Open...................................................................................................................................................................... 507 DTC C1251: Coupling Air Temperature Sensor Circuit Short..................................................................................................................................................................... 509 DTC C1252: Coupling Assembly Circuit Open.................................................................................................................................................................................... 510 DTC C1253: Coupling Assembly Circuit Short................................................................................................................................................................................... 512 DTC C1254: 2WD/4WD Switch Malfunction........................................................................................................................................................................................ 513 DTC U0073: Control Module Communication Bus Off.............................................................................................................................................................................. 515 DTC U0100: Lost Communication with ECM....................................................................................................................................................................................... 517 DTC U0121: Lost Communication with ABS / ESP‚ Control Module................................................................................................................................................................. 518 DTC U0126: Lost Communication with Steering Angle Sensor Module.............................................................................................................................................................. 518 DTC U0155: Lost Communication with Instrument Panel Cluster (IPC) Control Module............................................................................................................................................. 519 Inspection of 4WD Control Module and Its Circuits............................................................................................................................................................................ 520 Repair Instructions.............................................................................................................................................................................................................. 522 Rear Differential Oil Level Check............................................................................................................................................................................................ 522 Rear Differential Oil Change................................................................................................................................................................................................. 522 2WD/4WD Switch Removal and Installation...................................................................................................................................................................................... 523 2WD/4WD Switch Inspection.................................................................................................................................................................................................... 523 4WD Control Module Removal and Installation.................................................................................................................................................................................. 523 Coupling Air Temperature Sensor Removal and Installation..................................................................................................................................................................... 523 Coupling Air Temperature Sensor Inspection................................................................................................................................................................................... 524 Coupling Assembly Inspection................................................................................................................................................................................................. 524 Rear Differential Mountings Components....................................................................................................................................................................................... 525 Front Mounting Arm and/or Rear Mounting Bracket Assembly Removal and Installation............................................................................................................................................ 526 Rear Mounting Bracket Assembly Disassembly and Reassembly.................................................................................................................................................................... 526 Rear Differential Dismounting and Remounting................................................................................................................................................................................. 526 Rear Differential Components................................................................................................................................................................................................. 527 Rear Differential Disassembly and Reassembly................................................................................................................................................................................. 528 Rear Differential Inspection................................................................................................................................................................................................. 539 Specifications................................................................................................................................................................................................................... 539 Tightening Torque Specifications............................................................................................................................................................................................. 539 Special Tools and Equipment...................................................................................................................................................................................................... 540 Recommended Service Material................................................................................................................................................................................................. 540 Special Tool................................................................................................................................................................................................................. 540 Transfer............................................................................................................................................................................................................................. 543 General Description.............................................................................................................................................................................................................. 543 Transfer Description......................................................................................................................................................................................................... 543 Diagnostic Information and Procedures............................................................................................................................................................................................ 543 Transfer Symptom Diagnosis................................................................................................................................................................................................... 543 Repair Instructions.............................................................................................................................................................................................................. 544 Transfer Oil Level Check..................................................................................................................................................................................................... 544 Transfer Oil Change.......................................................................................................................................................................................................... 544 Transfer Dismounting and Remounting.......................................................................................................................................................................................... 545 Transfer Assembly Components................................................................................................................................................................................................. 546 Transfer Assembly Disassembly and Reassembly................................................................................................................................................................................. 547 Reduction Drive Gear Assembly Disassembly and Reassembly..................................................................................................................................................................... 549 Reduction Driven Gear Assembly Disassembly and Reassembly.................................................................................................................................................................... 549 Transfer Right Case and Left Case Disassembly and Reassembly................................................................................................................................................................. 551 Transfer Output Retainer Assembly Disassembly and Reassembly................................................................................................................................................................. 551 Transfer Assembly Inspection................................................................................................................................................................................................. 555 Bevel Gear Tooth Contact Inspection.......................................................................................................................................................................................... 555 Specifications................................................................................................................................................................................................................... 557 Tightening Torque Specifications............................................................................................................................................................................................. 557 Special Tools and Equipment...................................................................................................................................................................................................... 558 Recommended Service Material................................................................................................................................................................................................. 558 Special Tool................................................................................................................................................................................................................. 558 Propeller Shafts..................................................................................................................................................................................................................... 560 Precautions...................................................................................................................................................................................................................... 560 Propeller Shaft Caution...................................................................................................................................................................................................... 560 General Description.............................................................................................................................................................................................................. 560 Propeller Shaft Construction................................................................................................................................................................................................. 560 Diagnostic Information and Procedures............................................................................................................................................................................................ 560 Propeller Shaft Symptom Diagnosis............................................................................................................................................................................................ 560 Repair Instructions.............................................................................................................................................................................................................. 561 Propeller Shaft Joint Check.................................................................................................................................................................................................. 561 Propeller Shaft Assembly Removal and Installation............................................................................................................................................................................ 561 Propeller Shaft Inspection................................................................................................................................................................................................... 561 Specifications................................................................................................................................................................................................................... 562 Tightening Torque Specifications............................................................................................................................................................................................. 562 Brakes................................................................................................................................................................................................................................... 563 Precautions.......................................................................................................................................................................................................................... 565 Precautions...................................................................................................................................................................................................................... 565 Precautions for Brakes....................................................................................................................................................................................................... 565 Brake Control System and Diagnosis................................................................................................................................................................................................... 566 Precautions...................................................................................................................................................................................................................... 566 Precautions on Brake......................................................................................................................................................................................................... 566 General Description.............................................................................................................................................................................................................. 566 Brakes Construction.......................................................................................................................................................................................................... 566 Front Brake Hose / Pipe Construction......................................................................................................................................................................................... 567 Rear Brake Hose / Pipe Construction.......................................................................................................................................................................................... 568 Diagnostic Information and Procedures............................................................................................................................................................................................ 568 Brakes Diagnosis Note........................................................................................................................................................................................................ 568 Brakes Symptom Diagnosis..................................................................................................................................................................................................... 569 Repair Instructions.............................................................................................................................................................................................................. 571 Brake Pedal Free Height Inspection........................................................................................................................................................................................... 571 Brake Pedal Play Inspection.................................................................................................................................................................................................. 571 Excessive Pedal Travel Inspection............................................................................................................................................................................................ 571 Master Cylinder and Brake Fluid Level Inspection............................................................................................................................................................................. 572 Stop Light Switch Adjustment................................................................................................................................................................................................. 572 Air Bleeding of Brake System................................................................................................................................................................................................. 572 Front Brake Hose / Pipe Removal and Installation............................................................................................................................................................................. 573 Rear Brake Hose / Pipe Removal and Installation.............................................................................................................................................................................. 574 Brake Hose and Pipe Inspection............................................................................................................................................................................................... 574 Master Cylinder Assembly Components.......................................................................................................................................................................................... 575 Master Cylinder Reservoir Removal and Installation........................................................................................................................................................................... 575 Master Cylinder Assembly Removal and Installation............................................................................................................................................................................ 576 Master Cylinder Assembly Inspection.......................................................................................................................................................................................... 577 Brake Booster Components..................................................................................................................................................................................................... 577 Booster Operation Inspection................................................................................................................................................................................................. 578 Brake Booster Removal and Installation....................................................................................................................................................................................... 579 Brake Booster Inspection..................................................................................................................................................................................................... 580 Specifications................................................................................................................................................................................................................... 580 Tightening Torque Specifications............................................................................................................................................................................................. 580 Special Tools and Equipment...................................................................................................................................................................................................... 580 Recommended Service Material................................................................................................................................................................................................. 580 Front Brakes......................................................................................................................................................................................................................... 581 Repair Instructions.............................................................................................................................................................................................................. 581 Front Disc Brake Components.................................................................................................................................................................................................. 581 Front Disc Brake Pad On-Vehicle Inspection................................................................................................................................................................................... 582 Front Disc Brake Pad Removal and Installation................................................................................................................................................................................ 582 Front Disc Brake Pad Inspection.............................................................................................................................................................................................. 583 Front Disc Brake Caliper Removal and Installation............................................................................................................................................................................ 583 Front Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................ 584 Front Disc Brake Caliper Inspection.......................................................................................................................................................................................... 586 Front Brake Disc Removal and Installation.................................................................................................................................................................................... 586 Front Brake Disc Inspection.................................................................................................................................................................................................. 587 Specifications................................................................................................................................................................................................................... 588 Tightening Torque Specifications............................................................................................................................................................................................. 588 Special Tools and Equipment...................................................................................................................................................................................................... 588 Recommended Service Material................................................................................................................................................................................................. 588 Special Tool................................................................................................................................................................................................................. 588 Rear Brakes.......................................................................................................................................................................................................................... 589 Repair Instructions.............................................................................................................................................................................................................. 589 Rear Drum Brake Components................................................................................................................................................................................................... 589 Rear Brake Drum Removal and Installation..................................................................................................................................................................................... 590 Rear Brake Drum and Shoe Inspection.......................................................................................................................................................................................... 591 Rear Brake Shoe On-Vehicle Inspection........................................................................................................................................................................................ 592 Rear Brake Shoe Removal and Installation..................................................................................................................................................................................... 592 Rear Brake Shoe Inspection................................................................................................................................................................................................... 593 Wheel Cylinder Removal and Installation...................................................................................................................................................................................... 593 Wheel Cylinder Inspection.................................................................................................................................................................................................... 594 Brake Back Plate Removal and Installation.................................................................................................................................................................................... 594 Specifications................................................................................................................................................................................................................... 595 Tightening Torque Specifications............................................................................................................................................................................................. 595 Special Tools and Equipment...................................................................................................................................................................................................... 595 Recommended Service Material................................................................................................................................................................................................. 595 Parking Brake........................................................................................................................................................................................................................ 596 General Description.............................................................................................................................................................................................................. 596 Parking Brake Cable Construction............................................................................................................................................................................................. 596 Repair Instructions.............................................................................................................................................................................................................. 597 Parking Brake Inspection and Adjustment...................................................................................................................................................................................... 597 Parking Brake Cable Removal and Installation................................................................................................................................................................................. 598 Parking Brake Lever Removal and Installation................................................................................................................................................................................. 598 Specifications................................................................................................................................................................................................................... 599 Tightening Torque Specifications............................................................................................................................................................................................. 599 ABS.................................................................................................................................................................................................................................. 600 Precautions...................................................................................................................................................................................................................... 600 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 600 Precautions in On-Vehicle Service............................................................................................................................................................................................ 600 General Description.............................................................................................................................................................................................................. 600 ABS Description.............................................................................................................................................................................................................. 600 ABS Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................... 601 CAN Communication System Description......................................................................................................................................................................................... 601 Schematic and Routing Diagram.................................................................................................................................................................................................... 602 ABS Schematic................................................................................................................................................................................................................ 602 ABS Wiring Circuit Diagram................................................................................................................................................................................................... 604 Component Location............................................................................................................................................................................................................... 606 ABS Components Location...................................................................................................................................................................................................... 606 Diagnostic Information and Procedures............................................................................................................................................................................................ 606 ABS Check.................................................................................................................................................................................................................... 606 ABS Warning Lamp Check....................................................................................................................................................................................................... 608 EBD Warning Lamp (Brake Warning Lamp) Check.................................................................................................................................................................................. 608 DTC Check.................................................................................................................................................................................................................... 609 DTC Table.................................................................................................................................................................................................................... 609 DTC Clearance................................................................................................................................................................................................................ 609 Scan Tool Data............................................................................................................................................................................................................... 610 ABS Warning Lamp Does Not Come ON at Ignition Switch ON...................................................................................................................................................................... 610 ABS Warning Lamp Comes ON Steady............................................................................................................................................................................................. 611 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON............................................................................................................................................................ 613 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady........................................................................................................................................................................ 613 Serial Data Link Circuit Check............................................................................................................................................................................................... 614 DTC C1013: System Specifications Different from ABS Control Module Specifications............................................................................................................................................ 616 DTC C1015: G Sensor Circuit (for 4WD Vehicle)................................................................................................................................................................................ 617 DTC 1016: Stop lamp Switch Circuit........................................................................................................................................................................................... 618 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder...................................................................... 619 DTC C1033: Wheel Speed Sensor................................................................................................................................................................................................ 621 DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit.... 622 DTC C1057: Power Source Circuit.............................................................................................................................................................................................. 623 DTC C1061: ABS Pump Motor and/or Motor Driver Circuit........................................................................................................................................................................ 624 DTC C1063: Solenoid Valve Power Supply Driver Circuit........................................................................................................................................................................ 625 DTC C1071: ABS Control Module................................................................................................................................................................................................ 626 Repair Instructions.............................................................................................................................................................................................................. 627 ABS Hydraulic Unit Operation Check........................................................................................................................................................................................... 627 ABS Hydraulic Unit / Control Module Assembly Components...................................................................................................................................................................... 628 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................... 629 ABS Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................................................................................................ 629 Front Wheel Speed Sensor On-Vehicle Inspection............................................................................................................................................................................... 631 Front Wheel Speed Sensor Removal and Installation............................................................................................................................................................................ 632 Front Wheel Speed Sensor Inspection.......................................................................................................................................................................................... 632 Rear Wheel Speed Sensor On-Vehicle Inspection................................................................................................................................................................................ 632 Rear Wheel Speed Sensor Removal and Installation (for 4WD Vehicle)........................................................................................................................................................... 633 Rear Wheel Speed Sensor Removal and Installation (for 2WD Vehicle)........................................................................................................................................................... 633 Rear Wheel Speed Sensor Inspection........................................................................................................................................................................................... 633 Front Wheel Speed Sensor Encoder Inspection.................................................................................................................................................................................. 633 Front Wheel Speed Sensor Encoder Removal and Installation.................................................................................................................................................................... 633 Rear Wheel Speed Sensor Encoder Inspection................................................................................................................................................................................... 634 Rear Wheel Speed Sensor Encoder Removal and Installation..................................................................................................................................................................... 634 G Sensor Removal and Installation (For 4WD Vehicle).......................................................................................................................................................................... 634 G Sensor Inspection (For 4WD Vehicle)........................................................................................................................................................................................ 634 Specifications................................................................................................................................................................................................................... 635 Tightening Torque Specifications............................................................................................................................................................................................. 635 Special Tools and Equipment...................................................................................................................................................................................................... 635 Special Tool................................................................................................................................................................................................................. 635 Transmission / Transaxle................................................................................................................................................................................................................. 637 Precautions.......................................................................................................................................................................................................................... 640 Precautions...................................................................................................................................................................................................................... 640 Precautions on Transmission / Transaxle...................................................................................................................................................................................... 640 Automatic Transmission/Transaxle..................................................................................................................................................................................................... 641 Precautions...................................................................................................................................................................................................................... 641 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 641 Precautions for Disassembly and Reassembly................................................................................................................................................................................... 641 General Description.............................................................................................................................................................................................................. 643 A/T Description.............................................................................................................................................................................................................. 643 Clutch / Brake / Planetary Gear Function of Automatic Transaxle.............................................................................................................................................................. 646 Table of Component Operation................................................................................................................................................................................................. 646 A/T Diagnosis General Description............................................................................................................................................................................................ 647 On-Board Diagnostic System Description....................................................................................................................................................................................... 647 CAN Communication System Description......................................................................................................................................................................................... 648 Schematic and Routing Diagram.................................................................................................................................................................................................... 649 Transmission Control Module (TCM) Wiring Diagram............................................................................................................................................................................. 649 Automatic Gear Shift Table................................................................................................................................................................................................... 651 Component Location............................................................................................................................................................................................................... 652 Electronic Shift Control System Components Location.......................................................................................................................................................................... 652 Diagnostic Information and Procedures............................................................................................................................................................................................ 654 A/T System Check............................................................................................................................................................................................................. 654 Visual Inspection............................................................................................................................................................................................................ 656 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 657 DTC Table.................................................................................................................................................................................................................... 657 DTC Check.................................................................................................................................................................................................................... 659 DTC Clearance................................................................................................................................................................................................................ 659 Fail-Safe Table.............................................................................................................................................................................................................. 660 Scan Tool Data............................................................................................................................................................................................................... 662 A/T Basic Check.............................................................................................................................................................................................................. 664 Road Test.................................................................................................................................................................................................................... 665 Manual Road Test............................................................................................................................................................................................................. 667 Engine Brake Test............................................................................................................................................................................................................ 668 Stall Test................................................................................................................................................................................................................... 668 Time Lag Test................................................................................................................................................................................................................ 669 Line Pressure Test........................................................................................................................................................................................................... 670 “P” Range Test............................................................................................................................................................................................................... 671 A/T Symptom Diagnosis........................................................................................................................................................................................................ 672 No Gear Shift to 4th gear.................................................................................................................................................................................................... 679 No Lock-Up Occurs............................................................................................................................................................................................................ 680 DTC P0602: Control Module Programming Error.................................................................................................................................................................................. 681 DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input)....................................................................................................................................................... 682 DTC P0707: Transmission Range Sensor Circuit Low............................................................................................................................................................................. 684 DTC P0711: Transmission Fluid Temperature Sensor “A” Control Range / Performance............................................................................................................................................. 686 DTC P0712: Transmission Fluid Temperature Sensor Circuit Low................................................................................................................................................................. 687 DTC P0713: Transmission Fluid Temperature Sensor Circuit High................................................................................................................................................................ 688 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction.................................................................................................................................................................. 689 DTC P0722: Output Speed Sensor (VSS) Circuit No Signal....................................................................................................................................................................... 691 DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON............................................................................................................................................... 692 DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction................................................................................................................................................................ 693 DTC P0787: Shift / Timing Solenoid Control Circuit Low....................................................................................................................................................................... 695 DTC P0788: Shift / Timing Solenoid Control Circuit High...................................................................................................................................................................... 697 DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance................................................................................................................................................. 698 DTC P0962: Pressure Control Solenoid Control Circuit Low..................................................................................................................................................................... 700 DTC P0963: Pressure Control Solenoid Control Circuit High.................................................................................................................................................................... 702 DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low................................................................................................................. 704 DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High.................................................................................................................................... 706 DTC P1702: Internal Control Module Memory Check Sum Error.................................................................................................................................................................... 708 DTC P1723: Range Select Switch Malfunction................................................................................................................................................................................... 708 DTC P1878: Torque Converter Clutch Shudder................................................................................................................................................................................... 709 DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance....................................................................................................................... 710 DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High...................................................................................................................................... 712 DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low............................................................................................................................... 714 DTC U0073: Control Module Communication Bus Off.............................................................................................................................................................................. 716 DTC U0100: Lost Communication with ECM / PCM “A”............................................................................................................................................................................. 718 Inspection of TCM and Its Circuits........................................................................................................................................................................................... 720 TCM Power and Ground Circuit Check........................................................................................................................................................................................... 724 Brake Interlock System Inspection............................................................................................................................................................................................ 725 Repair Instructions.............................................................................................................................................................................................................. 726 Learning Control Initialization.............................................................................................................................................................................................. 726 A/T Fluid Level Check........................................................................................................................................................................................................ 726 A/T Fluid Change............................................................................................................................................................................................................. 727 Selector Lever Components.................................................................................................................................................................................................... 728 Select Lever Assembly Installation........................................................................................................................................................................................... 728 Select Lever Knob Installation............................................................................................................................................................................................... 728 Selector Lever Inspection.................................................................................................................................................................................................... 728 Select Cable Components...................................................................................................................................................................................................... 729 Select Cable Removal and Installation........................................................................................................................................................................................ 729 Select Cable Adjustment...................................................................................................................................................................................................... 730 Transmission Range Sensor (Shift Switch) Inspection and Adjustment........................................................................................................................................................... 730 Output Shaft Speed Sensor (VSS) Removal and Installation..................................................................................................................................................................... 731 Output Shaft Speed Sensor (VSS) Inspection................................................................................................................................................................................... 731 Input Shaft Speed Sensor Removal and Installation............................................................................................................................................................................ 732 Input Shaft Speed Sensor Inspection.......................................................................................................................................................................................... 732 Transmission Fluid Temperature Sensor Removal and Installation............................................................................................................................................................... 732 Transmission Fluid Temperature Sensor Inspection............................................................................................................................................................................. 733 “3” Position Switch Inspection............................................................................................................................................................................................... 733 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation................................................................................................................................... 734 Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection................................................................................................................................................ 735 Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation...................................................................................................... 737 Pressure Control Solenoid Valve Inspection................................................................................................................................................................................... 737 Transmission Control Module (TCM) Removal and Installation................................................................................................................................................................... 738 A/T Relay Inspection......................................................................................................................................................................................................... 739 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 739 Shift Lock Solenoid Inspection............................................................................................................................................................................................... 740 Shift Lock Solenoid Replacement.............................................................................................................................................................................................. 740 Key Interlock Cable Removal and Installation................................................................................................................................................................................. 740 A/T Fluid Cooler Hoses Replacement........................................................................................................................................................................................... 742 Automatic Transaxle Unit Components.......................................................................................................................................................................................... 743 Automatic Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................... 744 Automatic Transaxle Assembly Components...................................................................................................................................................................................... 746 Automatic Transaxle Unit Disassembly......................................................................................................................................................................................... 748 Oil Pump Assembly Components................................................................................................................................................................................................. 759 Oil Pump Assembly Disassembly and Reassembly................................................................................................................................................................................. 760 Oil Pump Assembly Inspection................................................................................................................................................................................................. 760 Direct Clutch Assembly Components............................................................................................................................................................................................ 762 Direct Clutch Assembly Preliminary Check..................................................................................................................................................................................... 763 Direct Clutch Assembly Disassembly and Reassembly............................................................................................................................................................................ 763 Direct Clutch Assembly Inspection............................................................................................................................................................................................ 765 Forward and Reverse Clutch Assembly Components............................................................................................................................................................................... 766 Forward and Reverse Clutch Assembly Preliminary Check........................................................................................................................................................................ 767 Forward and Reverse Clutch Assembly Disassembly and Reassembly............................................................................................................................................................... 767 Forward and Reverse Clutch Assembly Inspection............................................................................................................................................................................... 771 2nd Brake Piston Assembly Components......................................................................................................................................................................................... 772 2nd Brake Piston Assembly Disassembly and Reassembly......................................................................................................................................................................... 772 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components.................................................................................................................................................... 773 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly.................................................................................................................................... 773 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection.................................................................................................................................................... 775 Countershaft Assembly Components............................................................................................................................................................................................. 775 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 776 Valve Body Assembly Components............................................................................................................................................................................................... 777 Valve Body Assembly Disassembly and Reassembly............................................................................................................................................................................... 777 Differential Assembly Components............................................................................................................................................................................................. 779 Differential Assembly Disassembly and Reassembly............................................................................................................................................................................. 779 Differential Assembly Inspection............................................................................................................................................................................................. 781 Torque Converter Housing Disassembly and Reassembly.......................................................................................................................................................................... 781 Transaxle Case Disassembly and Reassembly.................................................................................................................................................................................... 784 Automatic Transaxle Unit Inspection and Adjustment........................................................................................................................................................................... 785 Automatic Transaxle Unit Assembly............................................................................................................................................................................................ 787 Specifications................................................................................................................................................................................................................... 804 Tightening Torque Specifications............................................................................................................................................................................................. 804 Special Tools and Equipment...................................................................................................................................................................................................... 805 Recommended Service Material................................................................................................................................................................................................. 805 Special Tool................................................................................................................................................................................................................. 805 Manual Transmission/Transaxle........................................................................................................................................................................................................ 808 General Description.............................................................................................................................................................................................................. 808 Manual Transaxle Construction................................................................................................................................................................................................ 808 Diagnostic Information and Procedures............................................................................................................................................................................................ 812 Manual Transaxle Symptom Diagnosis........................................................................................................................................................................................... 812 Repair Instructions.............................................................................................................................................................................................................. 812 Manual Transaxle Oil Level Check............................................................................................................................................................................................. 812 Manual Transaxle Oil Change.................................................................................................................................................................................................. 813 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 814 Gear Shift Control Lever and Cable Components................................................................................................................................................................................ 815 Gear Shift Control Lever and Cable Removal and Installation.................................................................................................................................................................. 816 Gear Select Control Cable Adjustment......................................................................................................................................................................................... 816 Back Up Lamp Switch Removal and Installation................................................................................................................................................................................. 817 Back Up Lamp Switch Inspection............................................................................................................................................................................................... 817 Manual Transaxle Unit Components............................................................................................................................................................................................. 818 Manual Transaxle Unit Dismounting and Remounting............................................................................................................................................................................. 819 Gear Shift and Select Shaft Assembly Components.............................................................................................................................................................................. 820 Gear Shift and Select Shaft Assembly Removal and Installation................................................................................................................................................................ 821 Gear Shift and Select Shaft Assembly Disassembly and Reassembly.............................................................................................................................................................. 822 Manual Transaxle Assembly Components......................................................................................................................................................................................... 823 Fifth Gear Disassembly and Reassembly........................................................................................................................................................................................ 824 Manual Transaxle Assembly Disassembly and Reassembly......................................................................................................................................................................... 826 Right Case Disassembly and Reassembly........................................................................................................................................................................................ 831 Left Case Disassembly and Reassembly......................................................................................................................................................................................... 832 Input Shaft and Countershaft Components...................................................................................................................................................................................... 833 Input Shaft Disassembly and Reassembly....................................................................................................................................................................................... 834 Countershaft Disassembly and Reassembly...................................................................................................................................................................................... 837 Gear Shift Shaft Components.................................................................................................................................................................................................. 841 5th and Reverse Gear Shift Shafts Disassembly and Reassembly................................................................................................................................................................. 841 Gear Shift Shaft and Fork Inspection......................................................................................................................................................................................... 841 Differential Components...................................................................................................................................................................................................... 842 Differential Disassembly and Reassembly...................................................................................................................................................................................... 842 Specifications................................................................................................................................................................................................................... 844 Tightening Torque Specifications............................................................................................................................................................................................. 844 Special Tools and Equipment...................................................................................................................................................................................................... 845 Recommended Service Material................................................................................................................................................................................................. 845 Special Tool................................................................................................................................................................................................................. 845 Clutch............................................................................................................................................................................................................................... 848 General Description.............................................................................................................................................................................................................. 848 Clutch (Hydraulic Type) Construction......................................................................................................................................................................................... 848 Diagnostic Information and Procedures............................................................................................................................................................................................ 849 Clutch System Symptom Diagnosis.............................................................................................................................................................................................. 849 Repair Instructions.............................................................................................................................................................................................................. 850 Clutch Pedal Inspection...................................................................................................................................................................................................... 850 Clutch Fluid Level Inspection................................................................................................................................................................................................ 850 Air Bleeding of Clutch System................................................................................................................................................................................................ 850 Clutch Fluid Pipe and Hose Location.......................................................................................................................................................................................... 851 Clutch Fluid Pipe Removal and Installation................................................................................................................................................................................... 851 Clutch Fluid Pipe Inspection................................................................................................................................................................................................. 851 Clutch Master Cylinder Removal and Installation.............................................................................................................................................................................. 852 Clutch Operating Cylinder Assembly Removal and Installation.................................................................................................................................................................. 852 Clutch Cover and Clutch Disc Components...................................................................................................................................................................................... 854 Clutch Cover and Clutch Disc Removal and Installation........................................................................................................................................................................ 855 Clutch Cover and Clutch Disc Inspection...................................................................................................................................................................................... 856 Specifications................................................................................................................................................................................................................... 856 Tightening Torque Specifications............................................................................................................................................................................................. 856 Special Tools and Equipment...................................................................................................................................................................................................... 857 Recommended Service Material................................................................................................................................................................................................. 857 Special Tool................................................................................................................................................................................................................. 857 Steering................................................................................................................................................................................................................................. 859 Precautions.......................................................................................................................................................................................................................... 861 Precautions...................................................................................................................................................................................................................... 861 Precautions on Steering...................................................................................................................................................................................................... 861 Steering General Diagnosis........................................................................................................................................................................................................... 862 Precautions...................................................................................................................................................................................................................... 862 Precautions for Steering Diagnosis........................................................................................................................................................................................... 862 Diagnostic Information and Procedures............................................................................................................................................................................................ 862 Steering Symptom Diagnosis................................................................................................................................................................................................... 862 Steering Wheel and Column............................................................................................................................................................................................................ 864 Precautions...................................................................................................................................................................................................................... 864 Service Precautions of Steering Wheel and Column............................................................................................................................................................................. 864 General Description.............................................................................................................................................................................................................. 864 Steering Wheel and Column Construction....................................................................................................................................................................................... 864 Diagnostic Information and Procedures............................................................................................................................................................................................ 865 Checking Steering Column for Accident Damage................................................................................................................................................................................. 865 Repair Instructions.............................................................................................................................................................................................................. 866 Steering Wheel and Column Construction....................................................................................................................................................................................... 866 Steering Wheel Removal and Installation...................................................................................................................................................................................... 867 Contact Coil Cable Assembly Removal and Installation......................................................................................................................................................................... 868 Centering Contact Coil Cable Assembly........................................................................................................................................................................................ 869 Contact Coil Cable Assembly Inspection....................................................................................................................................................................................... 869 Steering Angle Sensor Removal and Installation............................................................................................................................................................................... 869 Steering Angle Sensor Inspection............................................................................................................................................................................................. 870 Steering Column Removal and Installation..................................................................................................................................................................................... 870 Steering Column Inspection................................................................................................................................................................................................... 871 Ignition Switch Cylinder Assembly Removal and Installation (without Keyless Start System).................................................................................................................................... 872 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................................................................................................ 872 Steering Lower Shaft Removal and Installation................................................................................................................................................................................ 873 Specifications................................................................................................................................................................................................................... 873 Tightening Torque Specifications............................................................................................................................................................................................. 873 Special Tools and Equipment...................................................................................................................................................................................................... 874 Special Tool................................................................................................................................................................................................................. 874 Power Assisted Steering System....................................................................................................................................................................................................... 875 Precautions...................................................................................................................................................................................................................... 875 Steering System Note......................................................................................................................................................................................................... 875 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 875 General Description.............................................................................................................................................................................................................. 876 P/S System Description....................................................................................................................................................................................................... 876 EPS Diagnosis General Description............................................................................................................................................................................................ 877 On-Board Diagnostic System Description....................................................................................................................................................................................... 877 Schematic and Routing Diagram.................................................................................................................................................................................................... 878 EPS System Wiring Circuit Diagram............................................................................................................................................................................................ 878 Diagnostic Information and Procedures............................................................................................................................................................................................ 879 EPS System Check............................................................................................................................................................................................................. 879 “EPS” Warning Lamp Check..................................................................................................................................................................................................... 881 DTC Check.................................................................................................................................................................................................................... 881 DTC Clearance................................................................................................................................................................................................................ 882 DTC Table.................................................................................................................................................................................................................... 882 Visual Inspection............................................................................................................................................................................................................ 883 Scan Tool Data............................................................................................................................................................................................................... 883 P/S System Symptom Diagnosis................................................................................................................................................................................................. 885 Serial Data Link Circuit Check (No communication to P/S Control Module)...................................................................................................................................................... 886 “EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stops................................................................................................................................................... 887 “EPS” Warning Lamp Comes ON Steady and Engine Start.......................................................................................................................................................................... 888 DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure..................................................................................................................................................................... 889 DTC C1116: Torque Sensor 9 V Power Supply Circuit Failure.................................................................................................................................................................... 891 DTC C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure.............................................................................................................................................................. 892 DTC C1122: Engine Speed Signal Circuit Failure............................................................................................................................................................................... 894 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure..................................................................................................................................................................... 895 DTC C1153: P/S Control Module Power Supply Circuit Voltage Low............................................................................................................................................................... 896 DTC C1155: P/S Control Module Failure........................................................................................................................................................................................ 897 Inspection of P/S Control Module and Its Circuits............................................................................................................................................................................ 898 Steering Wheel Play Check.................................................................................................................................................................................................... 901 Steering Force Check......................................................................................................................................................................................................... 901 Repair Instructions.............................................................................................................................................................................................................. 902 Steering Gear Case Assembly Components....................................................................................................................................................................................... 902 Tie-Rod End Boot On-Vehicle Inspection....................................................................................................................................................................................... 903 Tie-Rod End Removal and Installation......................................................................................................................................................................................... 903 Tie-Rod End Inspection....................................................................................................................................................................................................... 904 Steering Shaft Joint On-Vehicle Inspection................................................................................................................................................................................... 904 Steering Gear Case Assembly Removal and Installation......................................................................................................................................................................... 904 Steering Rack Boot Inspection................................................................................................................................................................................................ 905 Tie-Rod / Rack Boot Removal and Installation................................................................................................................................................................................. 905 Steering Rack Plunger Removal and Installation............................................................................................................................................................................... 907 Steering Rack Plunger Inspection............................................................................................................................................................................................. 907 P/S Control Module Removal and Installation.................................................................................................................................................................................. 908 Torque Sensor Inspection..................................................................................................................................................................................................... 908 Motor Assembly Inspection.................................................................................................................................................................................................... 909 Specifications................................................................................................................................................................................................................... 910 Tightening Torque Specifications............................................................................................................................................................................................. 910 Special Tools and Equipment...................................................................................................................................................................................................... 910 Recommended Service Material................................................................................................................................................................................................. 910 Special Tool................................................................................................................................................................................................................. 910 HVAC..................................................................................................................................................................................................................................... 911 Precautions.......................................................................................................................................................................................................................... 914 Precautions...................................................................................................................................................................................................................... 914 Precautions on HVAC.......................................................................................................................................................................................................... 914 Heater and Ventilation............................................................................................................................................................................................................... 915 General Description.............................................................................................................................................................................................................. 915 Heater and Ventilation Construction.......................................................................................................................................................................................... 915 Schematic and Routing Diagram.................................................................................................................................................................................................... 916 Heater and Ventilation Wiring Circuit Diagram................................................................................................................................................................................ 916 Diagnostic Information and Procedures............................................................................................................................................................................................ 917 Heater and Ventilation Symptom Diagnosis..................................................................................................................................................................................... 917 Repair Instructions.............................................................................................................................................................................................................. 918 HVAC Unit Components......................................................................................................................................................................................................... 918 HVAC Unit Removal and Installation........................................................................................................................................................................................... 918 Blower Motor Removal and Installation........................................................................................................................................................................................ 918 Blower Motor Inspection...................................................................................................................................................................................................... 918 Blower Motor Resistor Removal and Installation............................................................................................................................................................................... 919 Blower Motor Resistor Inspection............................................................................................................................................................................................. 919 Blower Motor Relay Inspection................................................................................................................................................................................................ 920 HVAC Control Unit Components................................................................................................................................................................................................. 920 HVAC Control Unit Removal and Installation................................................................................................................................................................................... 921 Blower Speed Selector Inspection............................................................................................................................................................................................. 923 Air Intake Selector Inspection............................................................................................................................................................................................... 923 Air Intake Control Actuator Removal and Installation......................................................................................................................................................................... 923 Air Intake Control Actuator Inspection....................................................................................................................................................................................... 924 Center Ventilation Louver Removal and Installation........................................................................................................................................................................... 924 Side Ventilation Louver Removal and Installation............................................................................................................................................................................. 924 HVAC Air Filter (If Equipped) Removal and Installation....................................................................................................................................................................... 925 HVAC Air Filter Inspection (If Equipped)..................................................................................................................................................................................... 925 Air Conditioning System.............................................................................................................................................................................................................. 926 Manual Type...................................................................................................................................................................................................................... 926 Precautions.................................................................................................................................................................................................................. 926 A/C System Caution....................................................................................................................................................................................................... 926 Precautions on Servicing A/C System...................................................................................................................................................................................... 926 General Description.......................................................................................................................................................................................................... 928 Refrigerant Type Identification.......................................................................................................................................................................................... 928 Sub-Cool A/C System Description.......................................................................................................................................................................................... 929 Manual A/C Electronic Input Output Table................................................................................................................................................................................. 930 A/C Operation Description................................................................................................................................................................................................ 930 Schematic and Routing Diagram................................................................................................................................................................................................ 931 Major Components of A/C System........................................................................................................................................................................................... 931 A/C System Wiring Diagram................................................................................................................................................................................................ 932 Diagnostic Information and Procedures........................................................................................................................................................................................ 933 A/C System Symptom Diagnosis............................................................................................................................................................................................. 933 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................................................................................................... 935 A/C System Performance Inspection........................................................................................................................................................................................ 937 A/C System Inspection at ECM............................................................................................................................................................................................. 941 Repair Instructions.......................................................................................................................................................................................................... 942 Operation Procedure for Refrigerant Charge............................................................................................................................................................................... 942 Condenser Cooling Fan Inspection......................................................................................................................................................................................... 947 Condenser Assembly On-Vehicle Inspection................................................................................................................................................................................. 948 Condenser Assembly Removal and Installation.............................................................................................................................................................................. 948 HVAC Unit Components..................................................................................................................................................................................................... 949 HVAC Unit Removal and Installation....................................................................................................................................................................................... 950 Evaporator Inspection.................................................................................................................................................................................................... 950 Evaporator Temperature Sensor Removal and Installation................................................................................................................................................................... 951 Evaporator Temperature Sensor Inspection................................................................................................................................................................................. 951 Expansion Valve Removal and Installation................................................................................................................................................................................. 952 Expansion Valve Inspection............................................................................................................................................................................................... 952 A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................................................................................................................................... 952 A/C Refrigerant Pressure Sensor Removal and Installation................................................................................................................................................................. 952 A/C Switch Inspection.................................................................................................................................................................................................... 953 A/C System Relay Inspection.............................................................................................................................................................................................. 953 Compressor Drive Belt Inspection and Adjustment.......................................................................................................................................................................... 954 Compressor Drive Belt Removal and Installation........................................................................................................................................................................... 954 Compressor Assembly Removal and Installation............................................................................................................................................................................. 955 Compressor Assembly Components........................................................................................................................................................................................... 956 Magnet Clutch Inspection................................................................................................................................................................................................. 956 Magnet Clutch Removal and Installation................................................................................................................................................................................... 956 Thermal Switch Inspection................................................................................................................................................................................................ 958 Thermal Switch Removal and Installation.................................................................................................................................................................................. 958 Relief Valve Inspection.................................................................................................................................................................................................. 958 Relief valve Removal and Installation.................................................................................................................................................................................... 959 Specifications............................................................................................................................................................................................................... 959 Tightening Torque Specifications......................................................................................................................................................................................... 959 Special Tools and Equipment.................................................................................................................................................................................................. 960 Recommended Service Material............................................................................................................................................................................................. 960 Special Tool............................................................................................................................................................................................................. 960 Automatic Type................................................................................................................................................................................................................... 961 Precautions.................................................................................................................................................................................................................. 961 A/C System Caution....................................................................................................................................................................................................... 961 Precautions in Diagnosing Trouble........................................................................................................................................................................................ 961 Precautions on Servicing A/C System...................................................................................................................................................................................... 961 General Description.......................................................................................................................................................................................................... 961 Auto A/C System Description.............................................................................................................................................................................................. 961 HVAC Control Module Operation Description................................................................................................................................................................................ 963 Refrigerant Type Identification.......................................................................................................................................................................................... 963 Sub-Cool A/C System Description.......................................................................................................................................................................................... 963 A/C Operation Description................................................................................................................................................................................................ 963 On-Board Diagnostic System Description................................................................................................................................................................................... 964 Schematic and Routing Diagram................................................................................................................................................................................................ 964 Major Components of A/C System........................................................................................................................................................................................... 964 A/C System Wiring Diagram................................................................................................................................................................................................ 965 Diagnostic Information and Procedures........................................................................................................................................................................................ 966 A/C System Symptom Diagnosis............................................................................................................................................................................................. 966 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................................................................................................... 968 DTC Check................................................................................................................................................................................................................ 968 DTC Clearance............................................................................................................................................................................................................ 969 DTC Table................................................................................................................................................................................................................ 970 Fail-Safe Table.......................................................................................................................................................................................................... 973 Scan Tool Data........................................................................................................................................................................................................... 974 Air Conditioning System Check............................................................................................................................................................................................ 976 Visual Inspection........................................................................................................................................................................................................ 978 DTC B1502: Inside Air Temperature Sensor Circuit Malfunction............................................................................................................................................................. 978 DTC B1503: Evaporator Temperature Sensor Circuit Malfunction............................................................................................................................................................. 979 DTC B1504: Sunload Sensor Circuit Malfunction............................................................................................................................................................................ 981 DTC B1511: Temperature Control Actuator Circuit Malfunction.............................................................................................................................................................. 982 DTC B1512: Air flow Control Actuator Circuit Malfunction................................................................................................................................................................. 983 DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction................................................................................................................................................... 985 DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction...................................................................................................................................................... 987 DTC B1520 / B1521 / B1522: Temperature / Blower Speed / Air Flow Selector Malfunction.................................................................................................................................... 988 DTC B1541: Back-Up Power Supply Circuit Malfunction...................................................................................................................................................................... 989 DTC B1546: A/C Refrigerant Pressure Malfunction.......................................................................................................................................................................... 990 DTC B1551: Serial Communication Circuit Malfunction...................................................................................................................................................................... 990 DTC B1552: HVAC Control Module Check Sum Error........................................................................................................................................................................... 991 DTC B1553: CAN Communication Circuit Malfunction......................................................................................................................................................................... 992 DTC B1557: VSS Signal Failure............................................................................................................................................................................................ 992 DTC B1561: ECT Signal Failure............................................................................................................................................................................................ 993 DTC B1562: Outside Air Temperature Signal Failure........................................................................................................................................................................ 993 DTC B1563: A/C Refrigerant Pressure Signal Failure....................................................................................................................................................................... 993 DTC B1570: Engine Type Signal Failure.................................................................................................................................................................................... 994 DTC B1571: Combination Meter Spec Signal Failure......................................................................................................................................................................... 994 Inspection of HVAC Control Module and Its Circuit........................................................................................................................................................................ 995 A/C System Performance Inspection........................................................................................................................................................................................ 997 A/C System Inspection at ECM............................................................................................................................................................................................. 997 Repair Instructions.......................................................................................................................................................................................................... 997 Operation Procedure for Refrigerant Charge............................................................................................................................................................................... 997 HVAC Unit Components..................................................................................................................................................................................................... 998 HVAC Unit Removal and Installation....................................................................................................................................................................................... 999 Temperature Control Actuator Removal and Installation.................................................................................................................................................................... 999 Temperature Control Actuator Inspection.................................................................................................................................................................................. 999 Air Flow Control Actuator Removal and Installation.......................................................................................................................................................................1000 Air Flow Control Actuator Inspection.....................................................................................................................................................................................1000 Air Intake Actuator Removal and Installation.............................................................................................................................................................................1001 Air Intake Actuator Inspection...........................................................................................................................................................................................1001 Actuator Linkage Inspection..............................................................................................................................................................................................1001 Blower Motor Controller Removal and Installation.........................................................................................................................................................................1001 Blower Motor Controller Inspection.......................................................................................................................................................................................1001 HVAC Control Module Removal and Installation.............................................................................................................................................................................1001 Sunload Sensor Removal and Installation..................................................................................................................................................................................1002 Sunload Sensor Inspection................................................................................................................................................................................................1002 Outside Air Temperature Sensor Removal and Installation..................................................................................................................................................................1002 Outside Air Temperature Sensor Inspection................................................................................................................................................................................1002 Inside Air Temperature Sensor Removal and Installation...................................................................................................................................................................1002 Inside Air Temperature Sensor Inspection.................................................................................................................................................................................1003 Condenser Cooling Fan Relay Inspection...................................................................................................................................................................................1003 Condenser Cooling Fan Removal and Installation...........................................................................................................................................................................1003 Condenser Cooling Fan Inspection.........................................................................................................................................................................................1003 Condenser Assembly On-Vehicle Inspection.................................................................................................................................................................................1003 Condenser Assembly Removal and Installation..............................................................................................................................................................................1003 Evaporator Inspection....................................................................................................................................................................................................1003 Evaporator Temperature Sensor Removal and Installation...................................................................................................................................................................1003 Evaporator Temperature Sensor Inspection.................................................................................................................................................................................1003 Expansion Valve Removal and Installation.................................................................................................................................................................................1003 Expansion Valve Inspection...............................................................................................................................................................................................1003 A/C Refrigerant Pressure Sensor and Its Circuit Inspection...............................................................................................................................................................1003 A/C Refrigerant Pressure Sensor Removal and Installation.................................................................................................................................................................1003 Compressor Relay Inspection..............................................................................................................................................................................................1003 Compressor Drive Belt Inspection and Adjustment..........................................................................................................................................................................1003 Compressor Drive Belt Removal and Installation...........................................................................................................................................................................1003 Compressor Assembly Removal and Installation.............................................................................................................................................................................1003 Compressor Assembly Components...........................................................................................................................................................................................1003 Magnet Clutch Removal and Installation...................................................................................................................................................................................1003 Magnet Clutch Inspection.................................................................................................................................................................................................1004 Thermal Switch Inspection................................................................................................................................................................................................1004 Thermal Switch Removal and Installation..................................................................................................................................................................................1004 Relief Valve Inspection..................................................................................................................................................................................................1004 Special Tools and Equipment..................................................................................................................................................................................................1004 Special Tool.............................................................................................................................................................................................................1004 Restraint................................................................................................................................................................................................................................1005 Precautions..........................................................................................................................................................................................................................1007 Precautions......................................................................................................................................................................................................................1007 Precautions on Restraint.....................................................................................................................................................................................................1007 Seat Belts...........................................................................................................................................................................................................................1008 Precautions......................................................................................................................................................................................................................1008 Precautions on Service and Diagnosis of Seat Belt............................................................................................................................................................................1008 General Description..............................................................................................................................................................................................................1008 Seat Belt Construction.......................................................................................................................................................................................................1008 Diagnostic Information and Procedures............................................................................................................................................................................................1009 Repair and Inspection Required after Accident................................................................................................................................................................................1009 Repair Instructions..............................................................................................................................................................................................................1010 Front Seat Belt Components...................................................................................................................................................................................................1010 Front Seat Belt Removal and Installation.....................................................................................................................................................................................1011 Front Seat Belt Inspection...................................................................................................................................................................................................1012 Rear Seat Belt Components....................................................................................................................................................................................................1013 Rear Seat Belt Removal and Installation......................................................................................................................................................................................1014 Rear Seat Belt Inspection....................................................................................................................................................................................................1014 Specifications...................................................................................................................................................................................................................1014 Tightening Torque Specifications.............................................................................................................................................................................................1014 Air Bag System.......................................................................................................................................................................................................................1015 Precautions......................................................................................................................................................................................................................1015 Precautions on Service and Diagnosis of Air Bag System.......................................................................................................................................................................1015 Precautions on Handling and Storage of Air Bag System Components.............................................................................................................................................................1015 Precautions on Disposal of Air Bag and Seat Belt Pretensioner................................................................................................................................................................1019 General Description..............................................................................................................................................................................................................1019 Air Bag System Construction..................................................................................................................................................................................................1019 Air Bag System Input / Output Table..........................................................................................................................................................................................1020 Schematic and Routing Diagram....................................................................................................................................................................................................1021 Air Bag System Wiring Circuit Diagram........................................................................................................................................................................................1021 Component Location...............................................................................................................................................................................................................1023 Air Bag System Components, Wiring and Connectors Location....................................................................................................................................................................1023 Diagnostic Information and Procedures............................................................................................................................................................................................1024 Air Bag Diagnostic System Check..............................................................................................................................................................................................1024 Air Bag Diagnostic System Check Flow.........................................................................................................................................................................................1024 DTC Table....................................................................................................................................................................................................................1025 DTC Check....................................................................................................................................................................................................................1026 DTC Clearance................................................................................................................................................................................................................1026 Scan Tool Data...............................................................................................................................................................................................................1027 “AIR BAG” Warning Lamp Comes ON Steady.......................................................................................................................................................................................1027 “AIR BAG” Warning Lamp Does Not Come ON......................................................................................................................................................................................1029 “AIR BAG” Warning Lamp Flashes...............................................................................................................................................................................................1030 DTC B1013: SDM fault.........................................................................................................................................................................................................1031 DTC B1014: “AIR BAG” Warning Lamp Circuit Failure............................................................................................................................................................................1031 DTC B1016: Power Source Voltage High.........................................................................................................................................................................................1032 DTC B1017: Power Source Voltage Low..........................................................................................................................................................................................1033 DTC B1021: Front Air Bag Module Deployed.....................................................................................................................................................................................1035 DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed................................................................................................................................................................1036 DTC B1026: Pretensioner Activated............................................................................................................................................................................................1037 DTC B1027: Reusable Number Exceeded..........................................................................................................................................................................................1037 DTC B1031: Driver Air Bag Initiator Circuit Resistance High..................................................................................................................................................................1038 DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...................................................................................................................................................................1041 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground..................................................................................................................................................................1044 DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...........................................................................................................................................................1047 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...............................................................................................................................................................1049 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low................................................................................................................................................................1052 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...............................................................................................................................................................1054 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................................1056 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High.........................................................................................................................................1058 DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low..........................................................................................................................................1061 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.........................................................................................................................................1062 DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit..................................................................................................................................1064 DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High.........................................................................................................................................1065 DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low..........................................................................................................................................1069 DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground.........................................................................................................................................1072 DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit..................................................................................................................................1075 DTC B1071: Forward-Sensor Performance Problem................................................................................................................................................................................1077 DTC B1072: Forward-Sensor Communication Error................................................................................................................................................................................1078 DTC B1073: Forward-Sensor Circuit Short to Ground............................................................................................................................................................................1078 DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open.............................................................................................................................................................1079 DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem........................................................................................................................................................1081 DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error........................................................................................................................................................1081 DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground....................................................................................................................................................1081 DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open.....................................................................................................................................1083 DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID............................................................................................................................................................1084 DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High.................................................................................................................................1085 DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low..................................................................................................................................1088 DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground.................................................................................................................................1091 DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit..........................................................................................................................1094 Inspection of Intermittent and Poor Connections..............................................................................................................................................................................1096 Repair and Inspection Required after Accident................................................................................................................................................................................1097 Repair Instructions..............................................................................................................................................................................................................1100 Disabling Air Bag System.....................................................................................................................................................................................................1100 Enabling Air Bag System......................................................................................................................................................................................................1101 SDM Removal and Installation.................................................................................................................................................................................................1101 SDM Inspection...............................................................................................................................................................................................................1103 Driver Air Bag (Inflator) Module Removal and Installation....................................................................................................................................................................1103 Driver Air Bag (Inflator) Module Inspection..................................................................................................................................................................................1104 Passenger Air Bag (Inflator) Module Removal and Installation.................................................................................................................................................................1104 Passenger Air Bag (Inflator) Module Inspection...............................................................................................................................................................................1106 Side-Air Bag (Inflator) Module Removal and Installation......................................................................................................................................................................1107 Side-Air Bag (Inflator) Inspection...........................................................................................................................................................................................1108 Side Curtain-Air Bag (Inflator) Module Removal and Installation..............................................................................................................................................................1109 Side Curtain-Air Bag (Inflator) Module Inspection............................................................................................................................................................................1110 Forward-Sensor Removal and Installation......................................................................................................................................................................................1110 Forward-Sensor Inspection....................................................................................................................................................................................................1111 Side-Sensor Removal and Installation.........................................................................................................................................................................................1111 Side-Sensor Inspection.......................................................................................................................................................................................................1112 Passenger Air Bag (Inflator) Module Repair Harness Installation..............................................................................................................................................................1113 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal................................................................................................................................................................1114 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.............................................................................................................................................1124 Specifications...................................................................................................................................................................................................................1125 Tightening Torque Specifications.............................................................................................................................................................................................1125 Special Tools and Equipment......................................................................................................................................................................................................1125 Use of Special Tools.........................................................................................................................................................................................................1125 Recommended Service Material.................................................................................................................................................................................................1126 Special Tool.................................................................................................................................................................................................................1126 Body, Cab and Accessories................................................................................................................................................................................................................1129 Precautions..........................................................................................................................................................................................................................1134 Precautions......................................................................................................................................................................................................................1134 Precautions on Body, Cab and Accessories.....................................................................................................................................................................................1134 Precautions for Body Service.................................................................................................................................................................................................1134 Fastener Caution for Body Service............................................................................................................................................................................................1134 Wiring Systems.......................................................................................................................................................................................................................1135 Precautions......................................................................................................................................................................................................................1135 Cautions in Body Electrical System Servicing.................................................................................................................................................................................1135 Precautions for Wiring System................................................................................................................................................................................................1135 General Description..............................................................................................................................................................................................................1136 Abbreviations................................................................................................................................................................................................................1136 Wire / Connector Color Symbols...............................................................................................................................................................................................1136 Symbols and Marks............................................................................................................................................................................................................1137 How to Read Connector Layout Diagram.........................................................................................................................................................................................1138 How to Read Connector Codes and Terminal Nos.................................................................................................................................................................................1139 How to Read Ground Point.....................................................................................................................................................................................................1142 How to Read Power Supply Diagram.............................................................................................................................................................................................1143 How to Read System Circuit Diagram...........................................................................................................................................................................................1143 Harness Routing and Connector Layout Diagram.....................................................................................................................................................................................1145 Connector Layout Diagram.....................................................................................................................................................................................................1145 Engine Compartment...........................................................................................................................................................................................................1145 Instrument Panel.............................................................................................................................................................................................................1153 Door, Roof...................................................................................................................................................................................................................1158 Floor........................................................................................................................................................................................................................1161 Rear.........................................................................................................................................................................................................................1165 Ground Point.....................................................................................................................................................................................................................1166 Ground (earth) Point.........................................................................................................................................................................................................1166 Power Supply Diagram.............................................................................................................................................................................................................1167 Power Supply Diagram (Petrol)................................................................................................................................................................................................1167 Power Supply Diagram (DSL)...................................................................................................................................................................................................1168 Fuses and the Protected Parts................................................................................................................................................................................................1168 Fuses in Main Fuse Box (Petrol)..............................................................................................................................................................................................1169 Fuses in Main Fuse Box (DSL).................................................................................................................................................................................................1169 Individual Circuit Fuse Box No. 1 (Petrol)...................................................................................................................................................................................1170 Individual Circuit Fuse Box No. 1 (DSL)......................................................................................................................................................................................1171 Individual Circuit Fuse Box No. 3 (DSL)......................................................................................................................................................................................1172 Individual Circuit Fuse Box No. 2 (In J/B)...................................................................................................................................................................................1172 Junction Block (J/B) Connector / Fuse Layout.................................................................................................................................................................................1175 Junction Block Inner Circuit (Overview)......................................................................................................................................................................................1177 Junction Block Inner Circuit (Detail)........................................................................................................................................................................................1178 System Circuit Diagram...........................................................................................................................................................................................................1183 System Circuit Diagram.......................................................................................................................................................................................................1183 A-1 Cranking System Circuit Diagram (Petrol).................................................................................................................................................................................1184 A-1 Cranking System Circuit Diagram (DSL)....................................................................................................................................................................................1185 A-2 Charging System Circuit Diagram (Petrol).................................................................................................................................................................................1186 A-2 Charging System Circuit Diagram (DSL)....................................................................................................................................................................................1187 A-3 Ignition System Circuit Diagram (Petrol).................................................................................................................................................................................1188 A-4 Cooling System Circuit Diagram (Petrol)..................................................................................................................................................................................1189 A-4 Cooling System Circuit Diagram (DSL).....................................................................................................................................................................................1190 A-5 Engine and A/C Control System Circuit Diagram (Petrol)...................................................................................................................................................................1191 A-5 Engine and A/C Control System Circuit Diagram (DSL)......................................................................................................................................................................1196 A-6 A/T Control System Circuit Diagram.......................................................................................................................................................................................1201 A-7 Immobilizer System Circuit Diagram (Petrol)..............................................................................................................................................................................1203 A-7 Immobilizer System Circuit Diagram (DSL).................................................................................................................................................................................1204 A-8 Body Control System Circuit Diagram......................................................................................................................................................................................1205 A-10 4WD Control System......................................................................................................................................................................................................1209 B-1 Windshield Wiper and Washer Circuit Diagram..............................................................................................................................................................................1210 B-2 Rear Wiper and Washer Circuit Diagram....................................................................................................................................................................................1211 B-3 Rear Defogger Circuit Diagram............................................................................................................................................................................................1212 B-4 Power Window Circuit Diagram.............................................................................................................................................................................................1213 B-5 Power Door Lock Circuit Diagram..........................................................................................................................................................................................1215 B-6 Power Mirror Circuit Diagram.............................................................................................................................................................................................1217 B-7 Horn Circuit Diagram.....................................................................................................................................................................................................1218 B-8 Seat Heater Circuit Diagram..............................................................................................................................................................................................1219 B-9 Keyless Start System Circuit Diagram.....................................................................................................................................................................................1220 C-1 Combination Meter Circuit Diagram (Meter)................................................................................................................................................................................1221 C-2 Combination Meter Circuit Diagram (Indicator)............................................................................................................................................................................1222 C-3 Combination Meter Circuit Diagram (Warning Light)........................................................................................................................................................................1223 D-1 Headlight System Circuit Diagram.........................................................................................................................................................................................1225 D-2 Position, Tail and Licence Plate Light System Circuit Diagram............................................................................................................................................................1227 D-3 Front Fog Light System Circuit Diagram...................................................................................................................................................................................1228 D-4 Illumination Light System Circuit Diagram................................................................................................................................................................................1229 D-5 Interior Light System Circuit Diagram....................................................................................................................................................................................1230 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram..............................................................................................................................................................1231 D-7 Brake Light System Circuit Diagram.......................................................................................................................................................................................1233 D-8 Back-Up Light System Circuit Diagram.....................................................................................................................................................................................1234 D-9 Headlight Beam Leveling System Circuit Diagram...........................................................................................................................................................................1235 D-10 Rear Fog Light Circuit Diagram..........................................................................................................................................................................................1236 E-1 Heater System Circuit Diagram............................................................................................................................................................................................1237 E-2 Auto A/C System Circuit Diagram..........................................................................................................................................................................................1239 E-3 PTC Heater Circuit Diagram (DSL).........................................................................................................................................................................................1241 F-1 Air-Bag System Circuit Diagram...........................................................................................................................................................................................1243 F-2 Anti-Lock Brake System Circuit Diagram...................................................................................................................................................................................1245 F-3 Electronic Stability Program System Circuit Diagram......................................................................................................................................................................1247 F-4 Power Steering System Circuit Diagram....................................................................................................................................................................................1249 G-1 Audio System Circuit Diagram.............................................................................................................................................................................................1251 G-2 Multi Information Display / Accessory Socket System Circuit Diagram......................................................................................................................................................1252 G-4 Navigation System Circuit Diagram........................................................................................................................................................................................1253 List of Connectors...............................................................................................................................................................................................................1254 List of Connectors...........................................................................................................................................................................................................1254 C Connector..................................................................................................................................................................................................................1254 D Connector (DSL)............................................................................................................................................................................................................1255 E Connector..................................................................................................................................................................................................................1256 F Connector..................................................................................................................................................................................................................1258 G Connector..................................................................................................................................................................................................................1258 J Connector..................................................................................................................................................................................................................1260 K Connector..................................................................................................................................................................................................................1261 L Connector..................................................................................................................................................................................................................1262 O Connector..................................................................................................................................................................................................................1264 R Connector..................................................................................................................................................................................................................1264 Lighting Systems.....................................................................................................................................................................................................................1265 Component Location...............................................................................................................................................................................................................1265 Lighting System Components Location..........................................................................................................................................................................................1265 Interior Light System Location...............................................................................................................................................................................................1266 Diagnostic Information and Procedures............................................................................................................................................................................................1266 Headlight Symptom Diagnosis..................................................................................................................................................................................................1266 DRL System Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1266 Headlight Leveling Symptom Diagnosis.........................................................................................................................................................................................1267 Turn Signal and Hazard Warning Light Symptom Diagnosis.......................................................................................................................................................................1267 Clearance, Tail and License Plate Light Symptom Diagnosis....................................................................................................................................................................1268 Back Up Lamp Symptom Diagnosis...............................................................................................................................................................................................1268 Brake Light Symptom Diagnosis................................................................................................................................................................................................1268 Front Fog Light Symptom Diagnosis (if Equipped)..............................................................................................................................................................................1268 Rear Fog Light Symptom Diagnosis.............................................................................................................................................................................................1268 Illumination Cancel System Symptom Diagnosis.................................................................................................................................................................................1269 Interior Light Symptom Diagnosis.............................................................................................................................................................................................1269 DRL Operation Inspection (If Equipped).......................................................................................................................................................................................1269 Inspection of DRL Controller and Its Circuits (If Equipped)..................................................................................................................................................................1269 Repair Instructions..............................................................................................................................................................................................................1271 Headlight Housing Removal and Installation...................................................................................................................................................................................1271 Headlight Bulb Replacement...................................................................................................................................................................................................1271 Headlight Aiming Adjustment with Screen......................................................................................................................................................................................1272 Headlight Switch (in Lighting Switch) Removal and Installation...............................................................................................................................................................1273 Headlight Switch (in Lighting Switch) Inspection.............................................................................................................................................................................1273 Hazard Warning Switch Removal and Installation...............................................................................................................................................................................1273 Hazard Warning Switch Inspection.............................................................................................................................................................................................1274 Brake Light Switch Inspection................................................................................................................................................................................................1274 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.......................................................................................................................................................1274 Turn Signal Light Switch (in Lighting Switch) Inspection.....................................................................................................................................................................1274 Turn Signal and Hazard Warning Relay Removal and Installation................................................................................................................................................................1274 Turn Signal and Hazard Warning Relay Inspection..............................................................................................................................................................................1274 License Lamp Assembly Removal and Installation...............................................................................................................................................................................1275 Front Fog Light Assembly Removal and Installation (If Equipped)..............................................................................................................................................................1276 Front Fog Light Bulb Replacement (If Equipped)...............................................................................................................................................................................1276 Front Fog Light Switch Inspection (If Equipped)..............................................................................................................................................................................1276 Front Fog Light Relay Inspection (If Equipped)...............................................................................................................................................................................1276 Front Fog Light Aiming Adjustment with Screen (If Equipped)..................................................................................................................................................................1277 Headlight Levering Switch Inspection.........................................................................................................................................................................................1278 Headlight Leveling Actuator Inspection.......................................................................................................................................................................................1278 Rear Fog Light Switch Inspection.............................................................................................................................................................................................1278 Illumination Cancel Switch Inspection........................................................................................................................................................................................1278 Instrumentation / Driver Info. / Horn................................................................................................................................................................................................1279 Precautions......................................................................................................................................................................................................................1279 Precautions in Diagnosing Troubles for Combination Meter.....................................................................................................................................................................1279 General Description..............................................................................................................................................................................................................1279 CAN Communication System Description.........................................................................................................................................................................................1279 Schematic and Routing Diagram....................................................................................................................................................................................................1281 Combination Meter Circuit Diagram............................................................................................................................................................................................1281 Component Location...............................................................................................................................................................................................................1282 Audio System Component Location..............................................................................................................................................................................................1282 Diagnostic Information and Procedures............................................................................................................................................................................................1283 Speedometer and VSS Symptom Diagnosis........................................................................................................................................................................................1283 Tachometer Symptom Diagnosis.................................................................................................................................................................................................1283 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis.....................................................................................................................................................................1283 Fuel Meter Symptom Diagnosis.................................................................................................................................................................................................1283 Low Fuel Warning Light Symptom Diagnosis.....................................................................................................................................................................................1284 Oil Pressure Warning Light Symptom Diagnosis.................................................................................................................................................................................1284 Brake and Parking Brake Warning Light Symptom Diagnosis......................................................................................................................................................................1285 Seat Belt Reminder Light Symptom Diagnosis (If Equipped).....................................................................................................................................................................1285 Charge Warning Light Symptom Diagnosis.......................................................................................................................................................................................1285 Main Beam (High Beam) Indicator Symptom Diagnosis............................................................................................................................................................................1286 Warning Buzzer Circuit Symptom Diagnosis.....................................................................................................................................................................................1286 Cigarette Lighter Symptom Diagnosis (If Equipped)............................................................................................................................................................................1286 Horn Symptom Diagnosis.......................................................................................................................................................................................................1286 Information Display Symptom Diagnosis (If Equipped)..........................................................................................................................................................................1287 Clock System Diagnosis (If Equipped).........................................................................................................................................................................................1288 Audio System Symptom Diagnosis (If Equipped).................................................................................................................................................................................1288 Remote Audio Control Switch Symptom Diagnosis (If Equipped)..................................................................................................................................................................1289 Navigation Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1289 Repair Instructions..............................................................................................................................................................................................................1290 Ignition Switch Removal and Installation.....................................................................................................................................................................................1290 Ignition Switch Inspection...................................................................................................................................................................................................1290 Combination Meter Removal and Installation...................................................................................................................................................................................1291 Fuel Level Sensor Removal and Installation...................................................................................................................................................................................1291 Fuel Level Sensor Inspection.................................................................................................................................................................................................1291 Oil Pressure Switch Removal and Installation.................................................................................................................................................................................1291 Oil Pressure Switch Inspection...............................................................................................................................................................................................1292 Engine Coolant Temperature (ECT) Sensor Inspection...........................................................................................................................................................................1292 Brake Fluid Level Switch Inspection..........................................................................................................................................................................................1292 Parking Brake Switch Inspection..............................................................................................................................................................................................1292 Door Switch (Front / Rear Door) Inspection...................................................................................................................................................................................1293 Rear End Door Switch Inspection..............................................................................................................................................................................................1293 Outside Air Temperature Sensor Removal and Installation (If Equipped)........................................................................................................................................................1293 Outside Air Temperature Sensor Inspection (If Equipped)......................................................................................................................................................................1293 Instrument Panel Removal and Installation....................................................................................................................................................................................1294 Information Display (Clock) Removal and Installation.........................................................................................................................................................................1295 Audio Unit Removal and Installation (If Equipped)............................................................................................................................................................................1295 Front Speaker Removal and Installation (If Equipped).........................................................................................................................................................................1296 Rear Speaker Removal and Installation (If Equipped)..........................................................................................................................................................................1296 GPS Antenna Removal and Installation (If Equipped)...........................................................................................................................................................................1296 Horn Removal and Installation................................................................................................................................................................................................1296 Horn Inspection..............................................................................................................................................................................................................1297 Horn Relay Inspection........................................................................................................................................................................................................1297 Antenna Base Removal and Installation........................................................................................................................................................................................1297 Remote Audio Control Switch Removal and Installation (If Equipped)...........................................................................................................................................................1297 Remote Audio Control Switch Inspection (If Equipped).........................................................................................................................................................................1298 Specifications...................................................................................................................................................................................................................1298 Tightening Torque Specifications.............................................................................................................................................................................................1298 Wipers / Washers.....................................................................................................................................................................................................................1299 Diagnostic Information and Procedures............................................................................................................................................................................................1299 Front Wiper and Washer Symptom Diagnosis.....................................................................................................................................................................................1299 Rear Wiper and Washer Symptom Diagnosis......................................................................................................................................................................................1299 Repair Instructions..............................................................................................................................................................................................................1300 Wipers and Washers Components................................................................................................................................................................................................1300 Washer Tank and Washer Pump Removal and Installation.........................................................................................................................................................................1301 Washer Pump Inspection.......................................................................................................................................................................................................1301 Windshield Wiper Removal and Installation....................................................................................................................................................................................1301 Windshield Wiper Motor Inspection............................................................................................................................................................................................1302 Rear Wiper Removal and Installation..........................................................................................................................................................................................1304 Rear Wiper Motor Inspection..................................................................................................................................................................................................1305 Windshield Wiper and Washer Switch Removal and Installation..................................................................................................................................................................1306 Windshield Wiper and Washer Switch Inspection................................................................................................................................................................................1307 Rear Wiper and Washer Switch Removal and Installation........................................................................................................................................................................1308 Rear Wiper and Washer Switch Inspection......................................................................................................................................................................................1308 Rear Wiper Relay Removal and Installation....................................................................................................................................................................................1308 Rear Wiper Relay Inspection..................................................................................................................................................................................................1309 Specifications...................................................................................................................................................................................................................1309 Tightening Torque Specifications.............................................................................................................................................................................................1309 Glass / Windows / Mirrors............................................................................................................................................................................................................1310 General Description..............................................................................................................................................................................................................1310 Rear End Door Window Defogger System Description.............................................................................................................................................................................1310 Diagnostic Information and Procedures............................................................................................................................................................................................1310 Rear End door Window Defogger Symptom Diagnosis..............................................................................................................................................................................1310 Power Window Control System Symptom Diagnosis (If Equipped)..................................................................................................................................................................1310 Power Door Mirror Control System Symptom Diagnosis (If Equipped).............................................................................................................................................................1311 Door Mirror Heater Symptom Diagnosis (If Equipped)...........................................................................................................................................................................1311 Repair Instructions..............................................................................................................................................................................................................1312 Windshield Components........................................................................................................................................................................................................1312 Windshield Removal and Installation..........................................................................................................................................................................................1312 Front Pillar Window Components...............................................................................................................................................................................................1316 Front Pillar Window Removal and Installation.................................................................................................................................................................................1317 Rear Quarter Window Components...............................................................................................................................................................................................1317 Rear Quarter Window Removal and Installation.................................................................................................................................................................................1318 Rear End Door Window Components..............................................................................................................................................................................................1318 Rear End Door Glass Removal and Installation.................................................................................................................................................................................1319 Front Door Window Components.................................................................................................................................................................................................1320 Front Door Glass Removal and Installation....................................................................................................................................................................................1321 Front Door Window Regulator Removal and Installation.........................................................................................................................................................................1322 Front Door Window Regulator Inspection.......................................................................................................................................................................................1322 Rear Door Window Components..................................................................................................................................................................................................1323 Rear Door Glass Removal and Installation.....................................................................................................................................................................................1323 Rear Door Window Regulator Removal and Installation..........................................................................................................................................................................1325 Rear Door Window Regulator Inspection........................................................................................................................................................................................1325 Rear End Door Window Defogger Switch Inspection..............................................................................................................................................................................1325 Rear End Door Window Defogger Relay Inspection...............................................................................................................................................................................1326 Rear End Door Window Defogger Wire Inspection................................................................................................................................................................................1326 Rear End Door Window Defogger Wire Repair....................................................................................................................................................................................1327 Power Window Main Switch Inspection (If Equipped)............................................................................................................................................................................1327 Power Window Sub Switch Inspection (If Equipped).............................................................................................................................................................................1329 Door Mirror Components.......................................................................................................................................................................................................1329 Door Mirror Removal and Installation.........................................................................................................................................................................................1330 Power Door Mirror Switch Inspection (If Equipped)............................................................................................................................................................................1330 Power Door Mirror Actuator Inspection (If Equipped)..........................................................................................................................................................................1330 Door Mirror Heater Inspection (If Equipped)..................................................................................................................................................................................1330 Door Mirror Heater Switch Inspection (If Equipped)...........................................................................................................................................................................1331 Special Tools and Equipment......................................................................................................................................................................................................1331 Recommended Service Material.................................................................................................................................................................................................1331 Security and Locks...................................................................................................................................................................................................................1332 General Description..............................................................................................................................................................................................................1332 Key Coding Construction......................................................................................................................................................................................................1332 Rear End Door Opener System Description......................................................................................................................................................................................1332 Component Location...............................................................................................................................................................................................................1333 Power Door Lock and Keyless Entry System Component Location (If Equipped)....................................................................................................................................................1333 Diagnostic Information and Procedures............................................................................................................................................................................................1334 Power Door Lock System Symptom Diagnosis (If Equipped).......................................................................................................................................................................1334 Power Door Lock System Operation Inspection (If Equipped)....................................................................................................................................................................1334 Keyless Entry System Symptom Diagnosis (If Equipped).........................................................................................................................................................................1335 Keyless Entry System Operation Inspection (If Equipped)......................................................................................................................................................................1336 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...................................................................................................................................................1336 Rear End Door Opener System Symptom Diagnosis (If Equipped)..................................................................................................................................................................1336 Rear End Door Opener System Operation Inspection (If Equipped)...............................................................................................................................................................1336 Repair Instructions..............................................................................................................................................................................................................1337 Front Door Lock Assembly Components..........................................................................................................................................................................................1337 Front Door Lock Assembly Removal and Installation............................................................................................................................................................................1337 Front Door Lock Assembly Inspection..........................................................................................................................................................................................1339 Power Door Lock Switch Inspection (If Equipped)..............................................................................................................................................................................1339 Door Key Cylinder Switch Inspection (If Equipped)............................................................................................................................................................................1339 Power Door Lock Actuator Inspection (If Equipped)............................................................................................................................................................................1340 Rear Door Lock Assembly Components...........................................................................................................................................................................................1341 Rear Door Lock Assembly Removal and Installation.............................................................................................................................................................................1341 Rear Door Lock Assembly Inspection...........................................................................................................................................................................................1341 Rear End Door Lock Assembly Components.......................................................................................................................................................................................1342 Rear End Door Lock Assembly Removal and Installation.........................................................................................................................................................................1343 Rear End Door Lock Assembly Inspection.......................................................................................................................................................................................1343 Rear End Door Opener Switch Inspection (If Equipped).........................................................................................................................................................................1344 Replacement of Transmitter Battery (If Equipped).............................................................................................................................................................................1344 Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System).................................................................................................................................1345 Keyless Entry Receiver Removal and Installation (If Equipped)................................................................................................................................................................1345 Keyless Entry Receiver and Its Circuit Inspection (If Equipped)..............................................................................................................................................................1346 Specifications...................................................................................................................................................................................................................1347 Tightening Torque Specifications.............................................................................................................................................................................................1347 Special Tools and Equipment......................................................................................................................................................................................................1347 Recommended Service Material.................................................................................................................................................................................................1347 Seats................................................................................................................................................................................................................................1348 Repair Instructions..............................................................................................................................................................................................................1348 Front Seat Components........................................................................................................................................................................................................1348 Front Seat Removal and Installation..........................................................................................................................................................................................1349 Rear Seat Components.........................................................................................................................................................................................................1349 Rear Seat Removal and Installation...........................................................................................................................................................................................1350 Specifications...................................................................................................................................................................................................................1350 Tightening Torque Specifications.............................................................................................................................................................................................1350 Special Tools and Equipment......................................................................................................................................................................................................1350 Recommended Service Material.................................................................................................................................................................................................1350 Interior Trim........................................................................................................................................................................................................................1351 Repair Instructions..............................................................................................................................................................................................................1351 Floor Carpet Removal and Installation........................................................................................................................................................................................1351 Head Lining Removal and Installation.........................................................................................................................................................................................1352 Console Box Components.......................................................................................................................................................................................................1353 Specifications...................................................................................................................................................................................................................1354 Tightening Torque Specifications.............................................................................................................................................................................................1354 Hood / Fenders / Doors...............................................................................................................................................................................................................1355 Repair Instructions..............................................................................................................................................................................................................1355 Hood Removal and Installation................................................................................................................................................................................................1355 Hood Inspection and Adjustment...............................................................................................................................................................................................1355 Front Fender Components......................................................................................................................................................................................................1356 Front Fender Removal and Installation........................................................................................................................................................................................1356 Front Door Assembly Components...............................................................................................................................................................................................1357 Front Door Assembly Removal and Installation.................................................................................................................................................................................1357 Rear Door Assembly Components................................................................................................................................................................................................1359 Rear Door Assembly Removal and Installation..................................................................................................................................................................................1359 Rear End Door Assembly Components............................................................................................................................................................................................1360 Rear End Door Assembly Removal and Installation..............................................................................................................................................................................1360 Specifications...................................................................................................................................................................................................................1362 Tightening Torque Specifications.............................................................................................................................................................................................1362 Special Tools and Equipment......................................................................................................................................................................................................1362 Recommended Service Material.................................................................................................................................................................................................1362 Body Structure.......................................................................................................................................................................................................................1363 Repair Instructions..............................................................................................................................................................................................................1363 Front Bumper and Rear Bumper Components......................................................................................................................................................................................1363 Cowl Top Components..........................................................................................................................................................................................................1364 Specifications...................................................................................................................................................................................................................1365 Body Dimensions..............................................................................................................................................................................................................1365 Panel Clearance..............................................................................................................................................................................................................1372 Paint / Coatings.....................................................................................................................................................................................................................1373 General Description..............................................................................................................................................................................................................1373 Anti-Corrosion Treatment Construction........................................................................................................................................................................................1373 Plastic Parts Finishing......................................................................................................................................................................................................1373 Component Location...............................................................................................................................................................................................................1374 Sealant Application Areas....................................................................................................................................................................................................1374 Under Coating Application Areas..............................................................................................................................................................................................1381 Anti-Corrosion Compound Application Area.....................................................................................................................................................................................1383 Exterior Trim........................................................................................................................................................................................................................1385 Repair Instructions..............................................................................................................................................................................................................1385 Roof Molding Removal and Installation........................................................................................................................................................................................1385 Splash Guard Removal and Installation (If Equipped)..........................................................................................................................................................................1386 Control systems..........................................................................................................................................................................................................................1387 Precautions..........................................................................................................................................................................................................................1389 Precautions......................................................................................................................................................................................................................1389 Precautions for Control Systems..............................................................................................................................................................................................1389 Body Electrical Control System.......................................................................................................................................................................................................1390 Precautions......................................................................................................................................................................................................................1390 Precautions in Diagnosing Trouble............................................................................................................................................................................................1390 General Description..............................................................................................................................................................................................................1390 BCM General Description......................................................................................................................................................................................................1390 CAN Communication System Description.........................................................................................................................................................................................1390 Theft Deterrent Light........................................................................................................................................................................................................1391 Schematic and Routing Diagram....................................................................................................................................................................................................1391 Body Electrical Control System Wiring Circuit Diagram........................................................................................................................................................................1391 Connector Layout Diagram of BCM and Junction Block Assembly..................................................................................................................................................................1394 Component Location...............................................................................................................................................................................................................1395 BCM and Related System Component Location....................................................................................................................................................................................1395 Diagnostic Information and Procedures............................................................................................................................................................................................1396 BCM Self-Diagnosis Function..................................................................................................................................................................................................1396 Body Electrical Control System Check.........................................................................................................................................................................................1397 Scan Tool Data...............................................................................................................................................................................................................1399 DTC Table....................................................................................................................................................................................................................1400 DTC Check....................................................................................................................................................................................................................1401 DTC Clearance................................................................................................................................................................................................................1402 BCM Power Circuit and Ground Circuit Check...................................................................................................................................................................................1403 DTC B1133 (DTC No. 1133): Battery Voltage Too High...........................................................................................................................................................................1404 DTC B1141 / DTC B1142 (No. 1141 / No. 1142) Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction...............................................................................................................1405 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction..............................................................................................................................................................1406 DTC B1157 (No. 1157) Air Bag Deployment Signal Input.........................................................................................................................................................................1407 DTC B1170 (No. 1170): EEPROM Access Error....................................................................................................................................................................................1407 DTC U0073 (No. 0073): Control Module Communication Bus Off...................................................................................................................................................................1408 DTC U0100 (No. 0100): Lost Communication with ECM............................................................................................................................................................................1410 DTC U0101 (No. 0101): Lost Communication with TCM............................................................................................................................................................................1412 DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module..................................................................................................................................1413 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...................................................................................................................................................1415 Inspection of BCM and its Circuits...........................................................................................................................................................................................1416 Repair Instructions..............................................................................................................................................................................................................1424 BCM (Included in Junction Block Assembly) Removal and Installation...........................................................................................................................................................1424 Outside Air Temperature Sensor Removal and Installation......................................................................................................................................................................1424 Outside Air Temperature Sensor Inspection....................................................................................................................................................................................1424 Special Tools and Equipment......................................................................................................................................................................................................1424 Special Tool.................................................................................................................................................................................................................1424 Immobilizer Control System...........................................................................................................................................................................................................1425 Precautions......................................................................................................................................................................................................................1425 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1425 Precaution in Replacing ECM..................................................................................................................................................................................................1425 Precautions in Handling Immobilizer Control System...........................................................................................................................................................................1425 General Description..............................................................................................................................................................................................................1426 Immobilizer Control System Introduction......................................................................................................................................................................................1426 Immobilizer Control System Components Location...............................................................................................................................................................................1427 On-Board Diagnostic System Description (Self-diagnosis Function).............................................................................................................................................................1427 Schematic and Routing Diagram....................................................................................................................................................................................................1428 Immobilizer Control System Wiring Circuit Diagram............................................................................................................................................................................1428 Diagnostic Information and Procedures............................................................................................................................................................................................1429 Immobilizer Control System Check.............................................................................................................................................................................................1429 Diagnostic Trouble Code (DTC) Check..........................................................................................................................................................................................1429 Diagnostic Trouble Code (DTC) Clearance......................................................................................................................................................................................1430 Diagnostic Trouble Code (DTC) Table..........................................................................................................................................................................................1430 Scan Tool Data...............................................................................................................................................................................................................1431 Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop..........................................................................................................................................1431 Immobilizer Indicator Lamp Remains ON after Engine Start.....................................................................................................................................................................1432 DTC P1614: Transponder Response Error........................................................................................................................................................................................1433 DTC P1615: Steering Lock Unit Communication Error (for Vehicle with Keyless Start System)....................................................................................................................................1433 DTC P1616: Unregistered Keyless Start Control Module (for Vehicle with Keyless Start System).................................................................................................................................1435 DTC P1618: Keyless Start Control Module CAN Communication Error (for Vehicle with Keyless Start System)......................................................................................................................1435 DTC P1621: Immobilizer Communication Line Error..............................................................................................................................................................................1436 DTC P1622: EEPROM Reading / Writing Error....................................................................................................................................................................................1437 DTC P1623: Unregistered Transponder..........................................................................................................................................................................................1437 DTC P1625: Immobilizer Antenna Error.........................................................................................................................................................................................1438 DTC P1636: Immobilizer Information Registration Failure......................................................................................................................................................................1438 DTC P1638: Immobilizer Information Mismatched................................................................................................................................................................................1439 Inspection of Immobilizer Control Module (ICM) and Its Circuit...............................................................................................................................................................1440 Repair Instructions..............................................................................................................................................................................................................1443 Immobilizer Control Module (ICM) Removal and Installation....................................................................................................................................................................1443 Registration of the Ignition Key.............................................................................................................................................................................................1443 Procedure after ECM Replacement..............................................................................................................................................................................................1443 Special Tools and Equipment......................................................................................................................................................................................................1443 Special Tool.................................................................................................................................................................................................................1443 Keyless Start System.................................................................................................................................................................................................................1444 General Description..............................................................................................................................................................................................................1444 Keyless Start System Description.............................................................................................................................................................................................1444 Parts and Functions..........................................................................................................................................................................................................1445 Keyless Engine Start Function................................................................................................................................................................................................1446 Door Lock Function of Keyless Start System...................................................................................................................................................................................1447 Operation Area of Remote Controller..........................................................................................................................................................................................1448 Alarm Function...............................................................................................................................................................................................................1449 CAN Communication System Description.........................................................................................................................................................................................1449 Schematic and Routing Diagram....................................................................................................................................................................................................1450 Keyless Start System Electric Wiring Circuit Diagram.........................................................................................................................................................................1450 Diagnostic Information and Procedures............................................................................................................................................................................................1451 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1451 Self-Diagnosis Function......................................................................................................................................................................................................1451 Keyless Start System Diagnosis Introduction..................................................................................................................................................................................1451 Keyless Start System Check...................................................................................................................................................................................................1451 Customer Questionnaire (Example).............................................................................................................................................................................................1452 Key Indicator Lamp Check.....................................................................................................................................................................................................1453 DTC Check....................................................................................................................................................................................................................1453 DTC Table....................................................................................................................................................................................................................1454 DTC Clearance................................................................................................................................................................................................................1455 Keyless Start System Symptom Diagnosis.......................................................................................................................................................................................1455 Keyless Start System Operation Inspection....................................................................................................................................................................................1456 Door Lock Operation (Keyless Start System)...................................................................................................................................................................................1457 Inspection of Keyless Start Control Module and Its Circuits..................................................................................................................................................................1457 No DTC Detection After Performing DTC Check..................................................................................................................................................................................1461 Key Indicator Lamp Circuit Check (Key Indicator Lamp Doesn’t Light when Ignition Knob Switch is Pushed)......................................................................................................................1463 Keyless Start Control Module Power and Ground Circuit Check..................................................................................................................................................................1465 DTC No. 11: Communication Error with Steering Lock Unit......................................................................................................................................................................1466 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...........................................................................................................................1467 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM Reading Error) / (EEPROM Writing Error)..........................................................................................................1467 DTC No. 31: Lost Communication with BCM......................................................................................................................................................................................1468 DTC No. 33: Control Module Communication Bus Off.............................................................................................................................................................................1470 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure............................................................................................................................1472 Repair Instructions..............................................................................................................................................................................................................1473 Antennas and Request Switches Removal and Installation.......................................................................................................................................................................1473 Front Door (Driver and Passenger Side), Rear End Door Request Switch Inspection..............................................................................................................................................1474 Steering Lock Unit Removal and Installation..................................................................................................................................................................................1474 Steering Lock Unit Inspection................................................................................................................................................................................................1474 Front Door Lock Switch Inspection............................................................................................................................................................................................1474 Keyless Start Control Module Removal and Installation........................................................................................................................................................................1475 Remote Controller Inspection.................................................................................................................................................................................................1475 Replacement of Remote Controller Battery.....................................................................................................................................................................................1476 Registration Procedure for Remote Controller ID Code.........................................................................................................................................................................1476 COPYRIGHT................................................................................................................................................................................................................................1478
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