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SUZUKI JA627 GRAND VITARA XL-7 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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“Suzuki JA627 Grand Vitara XL-7 Supplementary Service Manual” offers additional guidance for precise maintenance, complementing the main manual for comprehensive care and optimal performance.
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SUZUKI JA627 GRAND VITARA XL-7 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI JA627 GRAND VITARA XL-7 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 657
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI JA627 GRAND VITARA XL-7 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Bookcove............................................................................................................ 1 99501_52D01_01E..................................................................................................... 2 Top............................................................................................................. 0 Manual List..................................................................................................... 0 Important....................................................................................................... 2 WARNING/CAUTION/NOTE........................................................................................ 2 Foreword........................................................................................................ 3 Table of Contents............................................................................................... 5 SECTION 0A...................................................................................................... 7 Precautions................................................................................................. 8 Precaution for Vehicles Equipped with A Supplemental Restraint (Air Bag) System......................... 8 Diagnosis........................................................................................... 8 Servicing and handling.............................................................................. 9 Identification Information.................................................................................. 12 Vehicle Identification Number........................................................................... 12 Engine Identification Number............................................................................ 13 Transmission Identification Number...................................................................... 13 Warning, Caution and Information Labels..................................................................... 14 SECTION 0B...................................................................................................... 15 Maintenance Schedule........................................................................................ 16 Maintenance Schedule under Normal Driving Conditions.................................................... 16 Maintenance Recommended under Severe Driving Conditions................................................. 18 Maintenance Service......................................................................................... 19 Engine and Emission Control............................................................................. 19 Drive belt inspection and replacement............................................................... 19 Engine oil and filter replacement................................................................... 20 SECTION 1A...................................................................................................... 23 General Description......................................................................................... 24 Rear Duct............................................................................................... 25 SECTION 1B...................................................................................................... 27 General Description......................................................................................... 29 Refrigerant Type........................................................................................ 29 Refrigerant Flow of Air Conditioning System............................................................. 29 Major Components And Location........................................................................... 30 Diagnosis................................................................................................... 32 General................................................................................................. 32 Main A/C system (front A/C system).................................................................. 32 Rear A/C system..................................................................................... 34 Quickly Checking of Refrigerant Charge (If Equipped with Sight Glass)................................... 35 Performance Diagnosis................................................................................... 36 Performance diagnosis table......................................................................... 38 Detail diagnosis table (at ambient temperature within 30 - 35 °C (85 - 95 °F))...................... 39 Wiring Circuit.......................................................................................... 40 Inspection of A/C Controller and Its Circuits........................................................... 41 Voltage check....................................................................................... 41 Refrigerant Recovery, Evacuation and Charging............................................................... 45 Operation Procedure for Charging A/C with Refrigerant................................................... 45 Recovery................................................................................................ 46 Evacuating.............................................................................................. 47 Evacuating procedure................................................................................ 47 Checking system for pressure leaks.................................................................. 48 Charging................................................................................................ 48 On-Vehicle Service.......................................................................................... 51 Precaution.............................................................................................. 51 Piping.............................................................................................. 51 Handling refrigerant HFC-134a (R-134a).............................................................. 52 Refrigerant recovery................................................................................ 52 Refrigerant charge.................................................................................. 52 Replenishing compressor oil......................................................................... 53 Rear A/C Unit (Rear A/C Evaporator)..................................................................... 54 Rear Expansion Valve.................................................................................... 55 Rear A/C Evaporator Temperature Controller.............................................................. 56 Refrigerant Pipes and Hoses............................................................................. 57 Solenoid Valve.......................................................................................... 58 Rear Blower Motor Assembly.............................................................................. 59 Rear Blower Motor Relay and Solenoid Valve Relay........................................................ 60 Rear A/C Main Switch.................................................................................... 60 Rear Blower Motor Resistor.............................................................................. 61 Rear Blower Motor Switch................................................................................ 62 Rear A/C No.1 and No.2 Duct............................................................................. 63 Rear A/C No.1 duct.................................................................................. 63 Rear A/C No.2 duct.................................................................................. 63 Compressor Assembly..................................................................................... 64 Magnet Clutch........................................................................................... 67 Required Service Materials.................................................................................. 70 Tightening Torque Specification............................................................................. 70 Special Tools............................................................................................... 70 SECTION 3A...................................................................................................... 71 General Information......................................................................................... 71 Alignment Service Data (without Load)................................................................... 71 On-Vehicle Service.......................................................................................... 71 Reference Information................................................................................... 71 SECTION 3B1..................................................................................................... 73 General Description......................................................................................... 74 Power Steering (P/S) Pump............................................................................... 74 Diagnosis................................................................................................... 74 Power Steering Pump Drive Belt.......................................................................... 74 Belt inspection..................................................................................... 74 Belt tension check.................................................................................. 74 Belt tension adjustment............................................................................. 74 Hydraulic Pressure in P/S Circuit....................................................................... 75 Hydraulic pressure check............................................................................ 75 SECTION 3C1..................................................................................................... 77 General Description......................................................................................... 78 Diagnosis................................................................................................... 79 Inspection and Repair Required after Accident........................................................... 79 On-Vehicle Service.......................................................................................... 79 Service Precautions..................................................................................... 79 Diagnosis and servicing............................................................................. 79 Disabling air bag system............................................................................ 79 Enabling air bag system............................................................................. 79 Handling and storage................................................................................ 79 Disposal............................................................................................ 79 Steering Column......................................................................................... 80 Steering Upper Shaft Assembly........................................................................... 83 Steering Lower Shaft Assembly........................................................................... 85 Checking Steering Column and Steering Upper Shaft for Accident Damage................................... 87 Tightening Torque Specification............................................................................. 88 SECTION 3D...................................................................................................... 89 On-Vehicle Service.......................................................................................... 89 Suspension Control Arm/Bushings......................................................................... 89 Tightening Torque Specification............................................................................. 90 SECTION 3E...................................................................................................... 91 On-Vehicle Service.......................................................................................... 91 Rear Axle Shaft and Wheel Bearing....................................................................... 91 Rear Axle Shaft Inner Oil Seal.......................................................................... 95 Rear Axle Housing....................................................................................... 95 Tightening Torque Specification............................................................................. 96 Required Service Material................................................................................... 96 Special Tool................................................................................................ 97 SECTION 3F...................................................................................................... 99 General Description......................................................................................... 99 Tires................................................................................................... 99 Wheels.................................................................................................. 99 SECTION 4A2.....................................................................................................101 On-Vehicle Service..........................................................................................102 Drive Shaft.............................................................................................102 Required Service Material...................................................................................104 SECTION 4B......................................................................................................105 General Description.........................................................................................105 On-Vehicle Service..........................................................................................106 Propeller Shaft.........................................................................................106 Tightening Torque Specification.............................................................................106 Required Service Material...................................................................................106 SECTION 5.......................................................................................................107 Diagnosis...................................................................................................108 Diagnosis Table.........................................................................................108 SECTION 5A......................................................................................................109 General Description.........................................................................................110 Master Cylinder Assembly................................................................................110 On-Vehicle Service..........................................................................................111 Front Brake Hose/Pipe...................................................................................111 Master Cylinder Reservoir...............................................................................114 Master Cylinder Assembly................................................................................115 Brake Booster...........................................................................................116 Tightening Torque Specification.............................................................................118 Special Tool................................................................................................118 SECTION 5C......................................................................................................119 General Description.........................................................................................120 Drum Brake Assembly.....................................................................................120 On-Vehicle Service..........................................................................................121 Parking Brake Cable.....................................................................................121 Brake Drum..............................................................................................121 Wheel Cylinder..........................................................................................123 Brake Back Plate........................................................................................123 Tightening Torque Specification.............................................................................125 SECTION 5E2.....................................................................................................127 General Description.........................................................................................129 Components/Parts Location...............................................................................129 ABS Hydraulic Unit/control Module Assembly..............................................................130 Self-diagnosis function.............................................................................130 Fail-safe function..................................................................................130 Diagnosis...................................................................................................131 Precautions in Diagnosing Troubles......................................................................131 ABS Diagnostic Flow Table...............................................................................132 ABS Warning Lamp Check..................................................................................135 EBD Warning Lamp (Brake Warning Lamp) Check.............................................................135 Diagnostic Trouble Code (DTC) Check (Using ABS Warning Lamp)............................................136 Diagnostic Trouble Code (DTC) Check (Using SUZUKI Scan Tool)............................................137 Diagnostic Trouble Code (DTC) Clearance.................................................................137 Diagnostic Trouble Code (DTC) Table.....................................................................138 System Circuit..........................................................................................140 Table-A ABS Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON..................141 Table-B ABS Warning Lamp Circuit Check – Lamp Comes “ON” Steady.........................................142 Table-C ABS Warning Lamp Circuit Check – The Lamp Flashes Continuously While Ignition Switch Is ON......143 Table-D Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal Connected to Ground.............144 Table-E EBD Warning Lamp (Brake Warning Lamp) Check – Lamp Comes “ON” Steady............................145 DTC C1015 (DTC 15) – G Sensor Circuit and 4WD Lamp Circuit..............................................146 DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right-Front Wheel Speed Sensor Circuit or Sensor Ring..........148 DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left-Front Wheel Speed Sensor Circuit or Sensor Ring...........148 DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right-Rear Wheel Speed Sensor Circuit or Sensor Ring...........148 DTC C1035 (DTC 35), DTC C1036 (DTC 36) – Left-Rear Wheel Speed Sensor Circuit or Sensor Ring............148 DTC C1041 (DTC 41) – Right-Front Inlet Solenoid Circuit.................................................150 DTC C1045 (DTC 45) – Left-Front Inlet Solenoid Circuit..................................................150 DTC C1055 (DTC 55) – Rear Inlet Solenoid Circuit........................................................150 DTC C1042 (DTC 42) – Right-Front Outlet Solenoid Circuit................................................150 DTC C1046 (DTC 46) – Left-Front Outlet Solenoid Circuit.................................................150 DTC C1056 (DTC 56) – Rear Outlet Solenoid Circuit.......................................................150 DTC C1057 (DTC 57) – Power Source Circuit...............................................................151 DTC C1061 (DTC 61) – ABS Pump Motor Circuit.............................................................152 DTC C1063 (DTC 63) – ABS Fail-Safe Relay Circuit........................................................153 DTC C1071 (DTC 71) – ABS Control Module.................................................................154 On-Vehicle Service..........................................................................................155 Precautions.............................................................................................155 ABS Hydraulic Unit Operation Check (Using SUZUKI Scan Tool).............................................155 ABS Hydraulic Unit Operation Check (Not Using Suzuki Scan Tool).........................................155 ABS Hydraulic Unit/Control Module Assembly..............................................................157 Rear Sensor Rotor (Retainer Ring).......................................................................159 Tightening Torque Specification.............................................................................160 Special Tool................................................................................................160 SECTION 6-1.....................................................................................................163 General Information.........................................................................................165 Statement of Cleanliness and Care.......................................................................165 General Information on Engine Service...................................................................165 Precaution on Fuel System Service.......................................................................166 Fuel Pressure Relief Procedure..........................................................................167 Fuel Leakage Check Procedure............................................................................167 Engine Diagnosis............................................................................................168 General Description.....................................................................................168 On-Board Diagnostic System (Vehicle without Monitor Connector)..........................................168 On-Board Diagnostic System (Vehicle with Monitor Connector).............................................171 Precaution in Diagnosing Trouble........................................................................172 Engine Diagnostic Flow Table............................................................................173 Malfunction Indicator Lamp (MIL) Check..................................................................178 Diagnostic Trouble Code (DTC) Check.....................................................................178 Diagnostic Trouble Code (DTC) Clearance.................................................................179 Diagnostic Trouble Code (DTC) Table.....................................................................180 For A/T system (Refer to Section 7B1 for diagnosis).................................................183 For immobilizer control system (Refer to Section 8G for diagnosis)..................................184 Fail-Safe Table.........................................................................................185 Scan Tool Data..........................................................................................186 Scan tool data definitions..........................................................................189 Engine Diagnosis Table..................................................................................193 Inspection of PCM (ECM) and its Circuits................................................................198 Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” or Dims at Ignition .......205 Table A-2 Malfunction Indicator Lamp Circuit Check – Lamp Remains “ON” after Engine Starts..............206 Table A-3 Malfunction Indicator Lamp Check – MIL Flashes at Ignition Switch ON (Vehicle with Moni.......207 Table A-4 Malfunction Indicator Lamp Check – MIL Does Not Flash or Just Remains ON Even with Grou.......207 Table A-5 ECM (PCM) Power and Ground Circuit Check – MIL Doesn’t Light at Ignition Switch ON and .......208 DTC P0100 (DTC No.33, 34) Mass Air Flow Circuit Malfunction.............................................210 DTC P0110 (DTC No.23, 25) Intake Air Temp. (IAT) Circuit Malfunction....................................212 DTC P0115 (DTC No.14, 15) Engine Coolant Temp. Circuit Malfunction......................................214 DTC P0120 (DTC No.21, 22) Throttle Position Circuit Malfunction.........................................216 DTC P0121 Throttle Position Circuit Range/Performance Problem...........................................218 DTC P0130 (DTC No.13) HO2S-1 (Bank 1) Circuit Malfunction or No Activity Detected.......................220 DTC P0133 HO2S-1 (Bank 1) Circuit Slow Response.........................................................222 DTC P0135 HO2S-1 (Bank 1) Heater Circuit Malfunction....................................................223 DTC P0136 HO2S-2 (Bank 1) Circuit Malfunction...........................................................225 DTC P0141 HO2S-2 (Bank 1) Heater Circuit Malfunction....................................................227 DTC P0150 (DTC No.26) HO2S-1 (Bank 2) Circuit Malfunction or No Activity Detected.......................229 DTC P0153 HO2S-1 (Bank 2) Circuit Slow Response.........................................................231 DTC P0155 HO2S-1 (Bank 2) Heater Circuit Malfunction....................................................232 DTC P0156 HO2S-2 (Bank 2) Circuit Malfunction...........................................................234 DTC P0161 HO2S-2 (Bank 2) Heater Circuit Malfunction....................................................236 DTC P0171/P0172 Fuel System Too Lean/Rich (Bank 1)......................................................238 DTC P0174/P0175 Fuel System Too Lean/Rich (Bank 2)......................................................240 DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder 1 Misfire/Cylinder 2 Misfir.......242 DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction..................................................244 DTC P0335 Crankshaft Position Sensor Circuit Malfunction................................................246 DTC P0340 (DTC No.42) Camshaft Position Sensor Circuit Malfunction......................................248 DTC P0400 Exhaust Gas Recirculation Flow Malfunction....................................................251 DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction.....................................254 DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1)...........................................256 DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2)...........................................258 DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction...................................260 Evap canister purge system inspection...............................................................262 Vacuum passage inspection...........................................................................262 Vacuum hose inspection..............................................................................263 Evap canister purge valve and its circuit inspection................................................263 Evap canister purge valve inspection................................................................263 DTC P0460 Fuel Level Sensor Circuit High Input..........................................................265 DTC P0500 (DTC No.24) Vehicle Speed Sensor Malfunction..................................................267 DTC P0505 Idle Air Control System Malfunction...........................................................270 DTC P0601 (DTC No.71) Internal Control Module Memory Check Sum Error....................................272 DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction.........................................273 DTC P1450/P1451 Barometric Pressure Sensor Circuit Malfunction/Performance Problem......................275 DTC P1500 Engine Starter Signal Circuit Malfunction.....................................................276 DTC P1510 Ecm Back-Up Power Supply Malfunction..........................................................277 Table B-1 Fuel Pump Circuit Inspection..................................................................278 Table B-2 Fuel Injectors and Circuit Inspection.........................................................279 Table B-3 Fuel Pressure Inspection......................................................................281 Table B-4 Idle Air Control System Inspection............................................................283 Table B-5 A/C Signal Circuits Inspection (If Equipped)..................................................285 Table B-6 A/C Condenser Fan Motor Relay Control System Inspection (If Equipped).........................286 Special Tool................................................................................................287 SECTION 6A2.....................................................................................................289 On-Vehicle Service..........................................................................................290 Throttle Body and Intake Manifold.......................................................................290 Exhaust Manifold........................................................................................297 LH (No.1) Bank 2nd Timing Chain and Chain Tensioner.....................................................301 Camshaft and Valve Lash Adjuster........................................................................302 Valves and Cylinder Heads...............................................................................305 Piston, Piston Rings, Connecting Rods and Cylinders.....................................................309 Unit Repair Overhaul........................................................................................314 Engine Assembly.........................................................................................314 Main Bearings, Crankshaft and Cylinder Block............................................................318 Special Tool................................................................................................324 SECTION 6B......................................................................................................327 Maintenance.................................................................................................328 Coolant.................................................................................................328 SECTION 6C......................................................................................................329 General Description.........................................................................................329 Fuel System.............................................................................................329 On-Vehicle Service..........................................................................................330 Fuel Tank...............................................................................................330 Fuel Lines..............................................................................................333 SECTION 6E2.....................................................................................................335 General Description.........................................................................................336 System Flow.............................................................................................337 System Diagram..........................................................................................338 Air Intake System.......................................................................................340 Fuel Delivery System....................................................................................341 Electronic Control System...............................................................................342 Engine and Emission Control Input/Output Table..........................................................346 Diagnosis...................................................................................................346 On-Vehicle Service..........................................................................................347 General.................................................................................................347 Accelerator Cable Adjustment............................................................................348 A/T Throttle Cable Adjustment (A/T Vehicle).............................................................348 Idle Speed/Idle Air Control (IAC) Duty Inspection.......................................................349 [Using SUZUKI scan tool]............................................................................349 [Not using SUZUKI scan tool] (vehicle with monitor connector).......................................350 Idle mixture inspection/adjustment (vehicle without heated oxygen sensor)...........................351 Air Intake System.......................................................................................352 Throttle body.......................................................................................352 Idle air control valve (IAC valve)..................................................................355 Fast idle air valve.................................................................................356 Fuel Delivery System....................................................................................357 Fuel pressure inspection............................................................................357 Fuel pump...........................................................................................358 Fuel pressure regulator.............................................................................359 Fuel injector.......................................................................................360 Electronic Control System...............................................................................365 Engine control module (ECM)/powertrain control module (PCM).........................................365 Mass air flow sensor (MAF sensor)...................................................................366 Intake air temperature (IAT) sensor.................................................................368 Throttle position sensor (TP sensor)................................................................369 Engine coolant temperature sensor (ECT sensor)......................................................370 Heated oxygen sensor (sensor 1).....................................................................371 Heated oxygen sensor (sensor 2).....................................................................372 Vehicle speed sensor (VSS)..........................................................................373 Manifold absolute pressure sensor...................................................................373 Fuel level sensor (sender gauge)....................................................................375 Crankshaft position sensor..........................................................................375 Main relay..........................................................................................375 Fuel pump relay.....................................................................................376 Fuel cut operation..................................................................................377 Emission Control System.................................................................................378 EGR system (if equipped)............................................................................378 EVAP canister.......................................................................................379 Vacuum passage......................................................................................380 PCV System..............................................................................................381 PCV hose............................................................................................381 PCV valve...........................................................................................381 PCV system..........................................................................................382 Tightening Torque Specification.............................................................................382 Special Tool................................................................................................382 SECTION 6F2.....................................................................................................385 General Description.........................................................................................386 Components..............................................................................................386 System Wiring...........................................................................................387 Diagnosis...................................................................................................388 Diagnostic Flow Table...................................................................................388 Ignition Spark Check....................................................................................390 Ignition Timing Check and Adjustment....................................................................390 On-Vehicle Service..........................................................................................392 Ignition Coil Assembly (Igniter and Ignition Coil)......................................................392 Spark Plug..............................................................................................392 CMP Sensor..............................................................................................394 Noise Suppressor........................................................................................396 Special Tool................................................................................................397 SECTION 6H......................................................................................................399 General Description.........................................................................................400 Generator...............................................................................................400 Unit Repair Overhaul........................................................................................401 Generator Assembly......................................................................................401 Inspection..........................................................................................401 Specifications..............................................................................................404 Battery.................................................................................................404 Generator...............................................................................................404 Tightening Torque Specification.............................................................................404 SECTION 6K......................................................................................................405 On-Vehicle Service..........................................................................................406 Components..............................................................................................406 SECTION 7A1.....................................................................................................409 Unit Repair.................................................................................................409 SECTION 7B1.....................................................................................................411 General Description.........................................................................................413 Electronic Shift Control System.........................................................................414 Automatic gear shift diagram........................................................................415 Diagnosis...................................................................................................417 On-Board Diagnostic System (Vehicle without monitor connector)..........................................417 On-Board Diagnostic System (Vehicle with monitor connector).............................................418 Precaution in Diagnosing Trouble........................................................................419 Automatic Transmission Diagnostic Flow Table............................................................420 Malfunction Indicator Lamp (MIL) Check..................................................................423 “O/D OFF” Lamp Check....................................................................................423 “POWER” Lamp Check......................................................................................423 Diagnostic Trouble Code (DTC) Check.....................................................................423 Diagnostic Trouble Code Clearance.......................................................................423 Diagnostic Trouble Code Table...........................................................................424 Fail Safe Table.........................................................................................424 Visual Inspection.......................................................................................424 A/T Basic Check.........................................................................................424 Trouble Diagnosis Table 1...............................................................................425 Trouble Diagnosis Table 2...............................................................................425 Trouble Diagnosis Table 3...............................................................................426 Scan Tool Data..........................................................................................427 Inspection of PCM and Its Circuit.......................................................................427 Wire Harness and Connectors.............................................................................427 Table A-1 : No TCC Lock-Up Occurs.......................................................................428 Table A-2 : No Gear Shift to O/D........................................................................430 Table B-1 : “O/D OFF” Light Circuit Check (“O/D OFF” Light Doesn’t Light at Ignition Switch ON Bu.......432 Table B-2 : “O/D OFF” Light Circuit Check (“O/D OFF” Light Comes ON Steadily)...........................433 Table B-3 : “POWER” Light Circuit Check (“POWER” Light Doesn’t Light at Ignition Switch ON But En.......434 Table B-4 : “POWER” Light Circuit Check (“POWER” Light Comes ON Steadily)...............................435 DTC P0705 (DTC NO.72) - Transmission Range Sensor (Switch) Circuit Malfunction..........................436 DTC P0715 (DTC NO.76) - Input/Turbine Speed Sensor Circuit Malfunction..................................439 DTC P0720 (DTC NO.75) Output Speed Sensor Circuit Malfunction...........................................442 DTC P0743 (DTC NO.65/66) - TCC (Lock-Up) Solenoid Electrical............................................444 DTC P0753 (DTC NO.61/62) Shift Solenoid-A (#1) Electrical DTC P0758 (DTC NO.63/64) Shift Solenoid.......446 Stall Test..............................................................................................448 Line Pressure Test......................................................................................449 Road Test...............................................................................................450 Manual Road Test........................................................................................451 Time Lag Test...........................................................................................451 Engine Brake Test.......................................................................................452 “P” Range Test..........................................................................................452 On-Vehicle Service..........................................................................................453 Maintenance Service.....................................................................................453 Fluid level.........................................................................................453 Fluid change........................................................................................454 A/T Throttle Cable......................................................................................455 Solenoid Valves (Shift Solenoid Valves and TCC Solenoid Valve)..........................................455 MANUAL SELECTOR ASSEMBLY................................................................................456 SELECT CABLE............................................................................................458 Unit Repair.................................................................................................459 Sub-Assembly Repair.....................................................................................459 Overdrive (case side)...............................................................................459 Forward clutch......................................................................................460 Front upper valve body..............................................................................464 Unit Assembly...........................................................................................469 Tightening Torque Specification.............................................................................470 Special Tool................................................................................................471 SECTION 7C1.....................................................................................................473 SECTION 7E......................................................................................................475 General Description.........................................................................................476 4WD Control System......................................................................................476 System circuit......................................................................................476 Diagnosis...................................................................................................477 Differential Assembly Diagnosis Table...................................................................477 4WD Control System Diagnostic Flow Table................................................................477 Notes on system circuit inspection..................................................................477 Flow table..........................................................................................478 4WD Control System Circuit Inspection...................................................................479 Voltage check.......................................................................................479 4WD Control System Inspection...........................................................................480 On-Vehicle Service..........................................................................................481 Differential Mountings..................................................................................481 Rear Mounting for Front Differential Carrier............................................................482 Front Differential Assembly.............................................................................483 Unit Repair.................................................................................................485 Tightening Torque Specification.............................................................................485 Special Tool................................................................................................485 SECTION 7F......................................................................................................487 General Description.........................................................................................488 Diagnosis...................................................................................................488 Diagnosis Table.........................................................................................488 On-Vehicle Service..........................................................................................489 Precaution for Maintenance Service......................................................................490 Differential Gear Oil Change............................................................................490 Rear Differential Assembly..............................................................................491 Dismounting.........................................................................................491 Remounting..........................................................................................491 Unit Repair.................................................................................................492 Disassembling Unit......................................................................................492 Component Inspection....................................................................................495 Sub-Assembly Adjustment and Reassembly..................................................................495 Differential carrier................................................................................496 Differential case...................................................................................496 Differential side bearing...........................................................................498 Drive bevel pinion..................................................................................499 Assembling Unit.........................................................................................504 Tightening Torque Specification.............................................................................507 Required Service Material...................................................................................507 Special Tool................................................................................................508 SECTION 8.......................................................................................................511 General Description.........................................................................................512 SECTION 8C......................................................................................................513 General Description.........................................................................................514 Combination Meter.......................................................................................514 On-vehicle Service..........................................................................................516 Fuel Meter/Fuel Gauge Unit..............................................................................516 Fuel level sensor (sender gauge)....................................................................516 Engine Coolant Temperature (ECT) Meter and Sensor.......................................................517 Engine coolant temperature sensor...................................................................517 Oil Pressure Light......................................................................................517 Oil pressure switch.................................................................................517 Brake Warning Light.....................................................................................517 Brake fluid level switch............................................................................517 SECTION 8D......................................................................................................519 General Description.........................................................................................520 Rear Wiper and Washer (If Equipped).....................................................................520 On-Vehicle Service..........................................................................................521 Windshield Wipers.......................................................................................521 Front wiper and washer..............................................................................521 Rear Window Wiper and Washer (For Vehicle with Cruise Control System)...................................522 Rear Wiper and Washer Switch........................................................................522 Rear Window Wiper and Washer (For Vehicle without Cruise Control System)................................522 Rear Wiper Intermittent Relay...........................................................................522 SECTION 8E......................................................................................................523 General Description.........................................................................................524 Cautions in Servicing...................................................................................524 Symbols and Marks.......................................................................................524 Abbreviations...........................................................................................524 Wiring Color Symbols....................................................................................524 Joint Connector.........................................................................................524 Fuse Box and Relay......................................................................................524 Power Supply Diagram....................................................................................524 Cruise Control System...................................................................................525 Cruise control system circuit.......................................................................525 Components and functions............................................................................526 Cancel Conditions...................................................................................527 Diagnosis...................................................................................................527 Diagnosis Table.........................................................................................527 Note on System Circuit Inspection.......................................................................529 Cruise Main Switch Indicator Lamp Circuit Check.........................................................530 “Cruise” Indicator Lamp Circuit Check...................................................................531 Cruise Main Switch, Coast/Set, Resume/Accel and Cancel Switches Circuits Check..........................532 VSS Circuit Check.......................................................................................533 Stop Lamp Switch (with Pedal Position Switch) Circuits Check............................................534 Transmission Range Switch Circuit Check.................................................................535 Clutch Pedal Position Switch Circuit Check..............................................................536 Throttle Valve Opening Signal Circuit Check.............................................................537 Overdrive and TCC off Command Signal Circuit Check......................................................538 Cruise Control Module Power and Ground Circuits Check...................................................538 Cruise Control Module and Its Circuit Inspection........................................................539 Cruise Cable Play Inspection and Adjustment.............................................................541 On-Vehicle Service..........................................................................................541 Cruise Main Switch......................................................................................541 Coast/Set, Resume/Accel and Cancel Switches.............................................................542 Vehicle Speed Sensor (VSS)..............................................................................542 Transmission Range Switch...............................................................................542 Clutch Pedal Position (CPP) Switch......................................................................543 Stop Lamp Switch (with Pedal Position Switch)...........................................................544 Cruise Control Actuator Assembly (with Control Module)..................................................545 Cruise Cable............................................................................................546 SECTION 9.......................................................................................................547 Glass, Windows and Mirror...................................................................................548 Quarter Window..........................................................................................548 Body Structure..............................................................................................549 Under Body Dimensions...................................................................................549 Body Dimensions.........................................................................................550 Seat........................................................................................................554 Second Seat.............................................................................................554 Third Seat (If Equipped)................................................................................555 Paint and Coatings..........................................................................................556 Sealant Application Area................................................................................556 Undercoating/Anti-corrosion Compound Application Area...................................................563 Exterior and Interior Trim..................................................................................565 Floor Carpet............................................................................................565 Front floor carpet..................................................................................565 Rear floor carpet (without third seat vehicle)......................................................566 Head Lining.............................................................................................566 SECTION 10......................................................................................................569 General Description.........................................................................................570 SECTION 10A.....................................................................................................571 On-Vehicle Service..........................................................................................572 Service Precautions.....................................................................................572 Service and diagnosis...............................................................................572 Disabling air bag system............................................................................572 Enabling air bag system.............................................................................572 Handling and storage................................................................................572 Disposal............................................................................................572 Front Seat Belt.........................................................................................573 Second Rear Seat Belt...................................................................................576 Third Rear Seat Belt (If Equipped)......................................................................577 Tightening Torque Specification.............................................................................578 SECTION 10B.....................................................................................................579 General Description.........................................................................................581 System Components and Wiring Location View and Connectors...............................................582 System Wiring Diagram...................................................................................583 Diagnosis...................................................................................................584 Diagnostic Trouble Code (DTC)...........................................................................584 Use of Special Tool.....................................................................................584 Intermittents and Poor Connections......................................................................586 Air Bag Diagnostic System Check.........................................................................587 Air Bag Diagnostic System Check Flow Table..............................................................588 DTC Check...............................................................................................589 DTC Clearance...........................................................................................590 DTC Table...............................................................................................592 Table A - “AIR BAG” Warning Lamp Comes ON Steady........................................................594 Table B - “AIR BAG” Warning Lamp Does Not Come ON.......................................................594 Table C - “AIR BAG” Warning Lamp Flashes................................................................594 Table D - “AIR BAG” Warning Lamp Cannot Indicate Flashing Pattern of DTC................................594 Table E - SDM Cannot Communicate through The Serial Data Circuit........................................599 DTC B1015 - Passenger Air Bag Initiator Circuit Resistance High.........................................601 DTC B1016 - Passenger Air Bag Initiator Circuit Resistance Low..........................................601 DTC B1018 - Passenger Air Bag Initiator Circuit Short to Ground.........................................601 DTC B1019 - Passenger Air Bag Initiator Circuit Short to Power Circuit..................................601 DTC B1021 – Driver Air Bag Initiator Circuit Resistance High............................................606 DTC B1022 – Driver Air Bag Initiator Circuit Resistance Low.............................................606 DTC B1024 – Driver Air Bag Initiator Circuit Short to Ground............................................606 DTC B1025 – Driver Air Bag Initiator Circuit Short to Power Circuit.....................................606 DTC B1031 – Power Source Voltage High...................................................................611 DTC B1032 – Power Source Voltage Low....................................................................611 DTC B1035 – RH Forward Sensor Circuit Open or Short to Ground...........................................614 DTC B1036 – RH Forward Sensor Circuit Short Between Two Wires or Short to Power Circuit.................614 DTC B1037 – LH Forward Sensor Circuit Open or Short to Ground...........................................614 DTC B1038 – LH Forward Sensor Circuit Short Between Two Wires or Short to Power Circuit.................614 DTC B1041 – Driver Pretensioner Initiator Circuit Resistance High.......................................618 DTC B1042 – Driver Pretensioner Initiator Circuit Resistance Low........................................618 DTC B1043 – Driver Pretensioner Initiator Circuit Short to Ground.......................................618 DTC B1044 – Driver Pretensioner Initiator Circuit Short to Power Circuit................................618 DTC B1045 – Passenger Pretensioner Initiator Circuit Resistance High....................................618 DTC B1046 – Passenger Pretensioner Initiator Circuit Resistance Low.....................................618 DTC B1047 – Passenger Pretensioner Initiator Circuit Short to Ground....................................618 DTC B1048 – Passenger Pretensioner Initiator Circuit Short to Power Circuit.............................618 DTC B1051 – Frontal Crash Detected (System Activation Command Outputted)................................624 DTC B1061 – “AIR BAG” Warning Lamp Circuit Failure......................................................625 DTC B1071 – Internal SDM Fault..........................................................................626 DTC B1013 – System Specifications Different from SDM Specifications.....................................626 On-Vehicle Service..........................................................................................627 Service Precautions.....................................................................................627 Service and diagnosis...............................................................................627 Disabling air bag system............................................................................628 Enabling air bag system.............................................................................628 Handling and storage................................................................................629 Repairs and Inspections Required after an Accident......................................................634 Accident with deployment/activation - component replacement.........................................634 Accident with or without deployment/activation - component inspections..............................635 SDM.....................................................................................................638 Forward Sensor..........................................................................................640 Seat Belt Pretensioner..................................................................................642 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal...............................................643 Deployment/Activation Outside Vehicle...................................................................644 Deployment/Activation Inside Vehicle....................................................................650 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal........................654 Tightening Torque Specification.............................................................................655 Special Tool................................................................................................655 Copyright.......................................................................................................657 bookcover....................................................................................................... 0
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