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SUZUKI JA627 JA420WD GRAND VITARA XL-7 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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“Suzuki JA627 JA420WD Grand Vitara XL-7 Supplementary Service Manual” provides extra instructions for specific model maintenance, complementing the main manual for thorough care and optimal performance.
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SUZUKI JA627 JA420WD GRAND VITARA XL-7 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI JA627 JA420WD GRAND VITARA XL-7 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 1179
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI JA627 JA420WD GRAND VITARA XL-7 SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Bookcover............................................................................................................. 1 99501-52D20-01E....................................................................................................... 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............................................................................................. 9 Servicing and handling................................................................................ 10 General Precautions....................................................................................... 13 Precaution for CAN Communication System................................................................... 16 Identification Information.................................................................................... 17 Vehicle Identification Number............................................................................. 17 Engine Identification Number.............................................................................. 17 Transmission Identification Number........................................................................ 17 Warning, Caution and Information Labels....................................................................... 18 Vehicle Lifting Points........................................................................................ 20 Abbreviations May Be Used in This Manual...................................................................... 22 Metric Information............................................................................................ 24 Metric Fasteners.......................................................................................... 24 SECTION 0B........................................................................................................ 25 Maintenance Schedule.......................................................................................... 27 Maintenance Schedule under Normal Driving Conditions...................................................... 27 Maintenance Recommended under Severe Driving Conditions................................................... 30 Maintenance Service........................................................................................... 32 Engine (H27 Engine)....................................................................................... 32 Accessory drive belt (H27 Engine)..................................................................... 32 Engine oil and filter (H27 Engine).................................................................... 33 Engine coolant (H27 Engine)........................................................................... 36 Exhaust system (H27 Engine)........................................................................... 36 Ignition System (H27 Engine).............................................................................. 36 Spark plugs (H27 Engine).............................................................................. 36 Fuel System (H27 Engine).................................................................................. 37 Air cleaner filter (H27 Engine)....................................................................... 37 Fuel lines and connections (H27 Engine)............................................................... 37 Fuel filter (H27 Engine).............................................................................. 38 Fuel tank (H27 Engine)................................................................................ 38 Emission Control System (H27 Engine)...................................................................... 38 Crankcase ventilation hoses and connections (vehicle not equipped with oxygen sensor) (H27 Engine).... 38 PCV (positive crankcase ventilation) valve (H27 Engine)............................................... 38 Fuel evaporative emission control system (H27 Engine)................................................. 39 Engine (RHW Engine)....................................................................................... 39 Accessory drive belt (RHW Engine)..................................................................... 39 Camshaft timing belt (RHW Engine)..................................................................... 40 Engine oil and oil filter (RHW Engine)................................................................ 40 Engine coolant (RHW Engine)........................................................................... 42 Exhaust system (RHW Engine)........................................................................... 42 Heater (Glow) plugs (RHW Engine)...................................................................... 43 Fuel System (RHW Engine).................................................................................. 43 Air cleaner filter (RHW Engine)....................................................................... 43 Fuel lines and connections (RHW Engine)............................................................... 44 Fuel filter (RHW Engine).............................................................................. 44 Fuel tank (RHW Engine)................................................................................ 44 Chassis and Body.......................................................................................... 45 Manual transmission oil............................................................................... 45 Automatic transmission fluid.......................................................................... 45 Transfer and differential oil......................................................................... 47 Power steering (P/S) system (if equipped)............................................................. 48 Recommended Fluids and Lubricants............................................................................. 49 SECTION 1B........................................................................................................ 51 General Description........................................................................................... 54 Refrigerant Type.......................................................................................... 54 Refrigerant Flow of Air Conditioning System............................................................... 54 Major Components and Location............................................................................. 55 General Diagnosis............................................................................................. 57 General Diagnosis Table................................................................................... 57 Quickly Checking of Refrigerant Charge.................................................................... 62 Performance Diagnosis..................................................................................... 64 Performance diagnosis table........................................................................... 66 Detail diagnosis table (at ambient temperature within 30 – 35 °C (86 – 95 °F))........................ 68 Wiring Circuit............................................................................................ 70 HVAC Control Module and Its Circuits...................................................................... 75 HVAC control module voltage table..................................................................... 76 A/C Controller and Its Circuits (RHW Engine).............................................................. 86 A/C controller voltage value table.................................................................... 87 ECM (PCM) and Its Circuits (H27 Engine)................................................................... 88 HVAC Diagnosis................................................................................................ 90 Scan Tool Data............................................................................................ 90 Scan tool data definitions............................................................................ 91 Refrigerant Recovery, Evacuation and Charging................................................................. 94 Operation Procedure for Charging A/C with Refrigerant..................................................... 94 Evacuating................................................................................................ 95 Charging.................................................................................................. 96 On-Vehicle Service............................................................................................ 99 Precaution................................................................................................ 99 A/C Condenser Assembly.................................................................................... 103 A/C Condenser Fan Assembly................................................................................ 105 Receiver/Dryer............................................................................................ 107 H27 engine (Type A)................................................................................... 107 H27 engine (Type B) and RHW engine.................................................................... 107 A/C Refrigerant (Triple) Pressure Switch (H27 Engine)..................................................... 109 A/C Refrigerant (Dual) Pressure Switch (RHW engine)....................................................... 110 A/C Compressor Relay and Condenser Fan Motor Relay........................................................ 110 Rear A/C Unit (Rear A/C Evaporator)....................................................................... 111 Rear Expansion Valve...................................................................................... 113 Refrigerant Pipes and Hoses............................................................................... 113 Rear Blower Motor Assembly................................................................................ 115 Rear Blower Motor Relay................................................................................... 116 Rear A/C Main Switch...................................................................................... 116 Rear Blower Motor Resistor................................................................................ 117 Rear Blower Motor Switch.................................................................................. 118 Rear A/C No.1 and No.2 Duct............................................................................... 119 Rear A/C No.1 duct.................................................................................... 119 Rear A/C No.2 duct.................................................................................... 119 Heater and Cooling Unit................................................................................... 120 A/C Controller (RHW Engine)............................................................................... 122 A/C Signal Relay.......................................................................................... 123 Drive Belt................................................................................................ 124 Compressor Assembly....................................................................................... 125 Magnet Clutch............................................................................................. 129 H27 engine............................................................................................ 129 RHW engine............................................................................................ 132 Required Service Materials.................................................................................... 135 Tightening Torque Specification............................................................................... 135 Special Tool.................................................................................................. 135 SECTION 3A........................................................................................................ 137 General Information........................................................................................... 137 Caster.................................................................................................... 137 Side Slip (Reference)..................................................................................... 137 SECTION 3B1....................................................................................................... 139 General Description........................................................................................... 54 Power Steering (P/S) Pump................................................................................. 141 Diagnosis..................................................................................................... 142 Power Steering Fluid...................................................................................... 142 Power steering fluid level check...................................................................... 980 Power Steering Pump Drive Belt............................................................................ 143 Belt inspection....................................................................................... 143 Belt tension check.................................................................................... 143 Belt tension adjustment............................................................................... 143 Hydraulic Pressure in P/S Circuit......................................................................... 144 Hydraulic pressure check.............................................................................. 144 On-Vehicle Service............................................................................................ 146 Power Steering Gear Box Assembly.......................................................................... 146 Power Steering Pump (For H27 Engine Model: Type A)........................................................ 148 Power Steering Pump (For H27 Engine Model: Type B)........................................................ 149 Power Steering Pump (For RHW Engine Model)................................................................ 150 SECTION 3E........................................................................................................ 157 General Description........................................................................................... 158 On-Vehicle Service............................................................................................ 159 Rear Axle Shaft and Wheel Bearing......................................................................... 159 Rear Axle Shaft Inner Oil Seal............................................................................ 163 Rear Axle Housing......................................................................................... 164 Tightening Torque Specification............................................................................... 172 Required Service Material..................................................................................... 172 Special Tool.................................................................................................. 173 SECTION 3F........................................................................................................ 175 General Description........................................................................................... 176 Tires..................................................................................................... 176 Wheels.................................................................................................... 176 SECTION 4A2....................................................................................................... 177 General Description........................................................................................... 178 Diagnosis..................................................................................................... 178 Diagnosis Table........................................................................................... 178 Drive Shaft Boot and Joint Check.......................................................................... 178 On-Vehicle Service............................................................................................ 179 Drive Shaft............................................................................................... 179 Front Drive Shaft Bearing / Oil Seal Removal and Installation............................................. 187 Tightening Torque Specifications.............................................................................. 189 Required Service Material..................................................................................... 189 Special Tool.................................................................................................. 190 SECTION 4B........................................................................................................ 191 General Description........................................................................................... 192 Propeller Shaft Components................................................................................ 192 For H27 engine model.................................................................................. 192 For RHW engine model.................................................................................. 192 Diagnosis..................................................................................................... 193 Diagnosis Table........................................................................................... 193 Propeller shaft joint check........................................................................... 193 On-Vehicle Service............................................................................................ 193 Propeller Shaft........................................................................................... 193 Tightening Torque Specification............................................................................... 198 Required Service Material..................................................................................... 198 Special Tool.................................................................................................. 198 SECTION 5......................................................................................................... 199 General Description........................................................................................... 200 Brake Construction........................................................................................ 200 Diagnosis..................................................................................................... 201 Diagnosis Table........................................................................................... 201 Check and Adjustment.......................................................................................... 202 Bleeding Brakes........................................................................................... 202 SECTION 5A........................................................................................................ 205 General Description........................................................................................... 206 Master Cylinder Assembly.................................................................................. 206 On-Vehicle Service............................................................................................ 207 Front Brake Hose/Pipe..................................................................................... 207 Master Cylinder Reservoir................................................................................. 210 Master Cylinder Assembly.................................................................................. 211 Brake Booster............................................................................................. 213 Tightening Torque Specification............................................................................... 215 Special Tool.................................................................................................. 215 SECTION 5B1....................................................................................................... 217 General Description........................................................................................... 218 Disc Brake Caliper Assembly............................................................................... 218 Diagnosis..................................................................................................... 219 Check and Adjustment.......................................................................................... 219 On-Vehicle Service............................................................................................ 219 Front Disc Brake Pad...................................................................................... 219 Front Disc Brake Caliper.................................................................................. 222 Front Brake Disc.......................................................................................... 226 Tightening Torque Specification............................................................................... 227 Required Service Material..................................................................................... 227 SECTION 5C........................................................................................................ 229 General Description........................................................................................... 230 Drum Brake Assembly....................................................................................... 230 On-Vehicle Service............................................................................................ 231 Parking Brake Cable....................................................................................... 231 Brake Drum................................................................................................ 233 Brake Shoe................................................................................................ 235 Brake Back Plate.......................................................................................... 235 Tightening Torque Specification............................................................................... 236 SECTION 6-1....................................................................................................... 237 General Information........................................................................................... 240 Statement of Cleanliness and Care......................................................................... 240 Precaution................................................................................................ 240 Precaution on engine service.......................................................................... 240 Precaution on fuel system service..................................................................... 241 Fuel pressure relief procedure........................................................................ 242 Fuel leakage check procedure.......................................................................... 242 Diagnosis..................................................................................................... 243 Engine Diagnosis General Description...................................................................... 243 On-Board Diagnostic System Description (Vehicle without Diagnosis Connector).............................. 243 On-Board Diagnostic System Description (Vehicle with Diagnosis Connector)................................. 246 Precaution in Diagnosing Trouble for Engine............................................................... 247 Engine and Emission Control System Check.................................................................. 248 Customer Problem Inspection From (Example)................................................................ 249 Visual Inspection......................................................................................... 250 Engine Basic Inspection................................................................................... 251 Malfunction Indicator Lamp (MIL) Check.................................................................... 253 Diagnostic Trouble Code (DTC) Check....................................................................... 253 Diagnostic Trouble Code (DTC) Clearance................................................................... 254 Diagnostic Trouble Code (DTC) Table....................................................................... 255 For A/T system (Refer to Section 7B1 for diagnosis)................................................... 258 For immobilizer control system (Refer to Section 8G for diagnosis).................................... 259 Fail-Safe Table........................................................................................... 260 Scan Tool Data............................................................................................ 261 Scan tool data definitions............................................................................ 264 Engine Symptom Diagnosis.................................................................................. 268 Inspection of ECM (PCM) and Its Circuits.................................................................. 273 Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” or Dims at Ignition ......... 286 Table A-2 Malfunction Indicator Lamp Circuit Check – Lamp Remains “ON” after Engine Starts................ 287 Table A-3 Malfunction Indicator Lamp Check – MIL Flashes at Ignition Switch ON (Vehicle with Diag......... 288 Table A-4 Malfunction Indicator Lamp Check – MIL Does Not Flash or Just Remains ON Even with Grou......... 288 Table A-5 ECM (PCM) Power and Ground Circuit Check – MIL Doesn’t Light at Ignition Switch ON and ......... 289 DTC P0100 (DTC No.33, 34) Mass Air Flow Circuit Malfunction............................................... 291 DTC P0110 (DTC No.23, 25) Intake Air Temp. (IAT) Circuit Malfunction...................................... 293 DTC P0115 (DTC No.14, 15) Engine Coolant Temp. Circuit Malfunction........................................ 294 DTC P0120 (DTC No.21, 22) Throttle Position Circuit Malfunction........................................... 296 DTC P0121 Throttle Position Circuit Range/Performance Problem............................................. 298 DTC P0130 (DTC No.13) HO2S-1 (Bank 1) Circuit Malfunction or No Activity Detected......................... 300 DTC P0133 HO2S-1 (Bank 1) Circuit Slow Response........................................................... 302 DTC P0135 HO2S-1 (Bank 1) Heater Circuit Malfunction...................................................... 303 DTC P0136 HO2S-2 (Bank 1) Circuit Malfunction............................................................. 305 DTC P0141 HO2S-2 (Bank 1) Heater Circuit Malfunction...................................................... 307 DTC P0150 (DTC No.26) HO2S-1 (Bank 2) Circuit Malfunction or No Activity Detected......................... 309 DTC P0153 HO2S-1 (Bank 2) Circuit Slow Response........................................................... 311 DTC P0155 HO2S-1 (Bank 2) Heater Circuit Malfunction...................................................... 312 DTC P0156 HO2S-2 (Bank 2) Circuit Malfunction............................................................. 314 DTC P0161 HO2S-2 (Bank 2) Heater Circuit Malfunction...................................................... 316 DTC P0171/P0172 Fuel System Too Lean/Rich (Bank 1)........................................................ 318 DTC P0174/P0175 Fuel System Too Lean/Rich (Bank 2)........................................................ 320 DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder 1 Misfire/Cylinder 2 Misfir......... 322 DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction.................................................... 324 DTC P0335 Crankshaft Position Sensor Circuit Malfunction.................................................. 326 DTC P0340 (DTC No.42) Camshaft Position Sensor Circuit Malfunction........................................ 328 DTC P0400 Exhaust Gas Recirculation Flow Malfunction...................................................... 331 DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction....................................... 334 DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1)............................................. 336 DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2)............................................. 338 DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction..................................... 340 DTC P0460 Fuel Level Sensor Circuit High Input............................................................ 342 DTC P0500 (DTC No.24) Vehicle Speed Sensor Malfunction.................................................... 344 DTC P0505 Idle Air Control System Malfunction............................................................. 347 DTC P0601 (DTC No.71) Internal Control Module Memory Check Sum Error...................................... 349 DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction........................................... 350 DTC P1450/P1451 Barometric Pressure Sensor Circuit Malfunction/Performance Problem........................ 352 DTC P1500 Engine Starter Signal Circuit Malfunction....................................................... 354 DTC P1510 Ecm Back-Up Power Supply Malfunction............................................................ 356 Table B-1 Fuel Pump Circuit Inspection.................................................................... 358 Table B-2 Fuel Injectors and Circuit Inspection........................................................... 360 Table B-3 Fuel Pressure Inspection........................................................................ 362 Table B-4 Idle Air Control System Inspection.............................................................. 364 Table B-5 A/C Signal Circuits Inspection (If Equipped).................................................... 366 Table B-6 A/C Condenser Fan Motor Relay Low Speed Control System Inspection (If Equipped)................. 367 Table B-7 A/C Condenser Fan Motor Relay High Speed Control System Inspection (If Equipped)................ 369 Table B-8 A/C Compressor Relay Control System Inspection (If Equipped).................................... 371 Special Tool.................................................................................................. 373 SECTION 6-2....................................................................................................... 375 General Information........................................................................................... 378 Statement of Cleanliness and Care......................................................................... 378 Precaution................................................................................................ 378 Precaution on engine service.......................................................................... 378 Precaution on fuel system service..................................................................... 379 Fuel pressure relief procedure........................................................................ 380 Fuel leakage check procedure.......................................................................... 380 Diagnosis..................................................................................................... 381 Engine Diagnosis General Description...................................................................... 381 On-Board Diagnostic System Description (Vehicle without Diagnosis Connector).............................. 381 On-Board Diagnostic System Description (Vehicle with Diagnosis Connector)................................. 384 Precaution in Diagnosing Trouble for Engine............................................................... 385 Engine and Emission Control System Check.................................................................. 386 Customer Problem Inspection Form (Example)................................................................ 387 Visual Inspection......................................................................................... 388 Engine Basic Inspection................................................................................... 389 Malfunction Indicator Lamp (MIL) Check.................................................................... 391 Diagnostic Trouble Code (DTC) Check....................................................................... 391 Diagnostic Trouble Code (DTC) Clearance................................................................... 392 Diagnostic Trouble Code (DTC) Table....................................................................... 393 For vehicle with diagnosis connector.................................................................. 393 For vehicle without diagnosis connector............................................................... 394 For A/T System (Only OBD Generic Scan Tool Is Displayed on the Following DTC(s) at the Same Time)..... 397 For immobilizer control system (Refer to Section 8G for diagnosis).................................... 398 Fail-Safe Table........................................................................................... 399 For vehicle with diagnosis connector.................................................................. 399 For vehicle without diagnosis connector............................................................... 399 Scan Tool Data............................................................................................ 400 Scan tool data definitions............................................................................ 402 Engine Symptom Diagnosis.................................................................................. 406 Inspection of ECM and Its Circuits........................................................................ 412 Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” or Dims at Ignition ......... 424 Table A-2 Malfunction Indicator Lamp Circuit Check – Lamp Remains “ON” after Engine Starts................ 425 Table A-3 Malfunction Indicator Lamp Check – MIL Flashes at Ignition Switch ON (Vehicle with Diag......... 426 Table A-4 Malfunction Indicator Lamp Check – MIL Does Not Flash or Just Remains ON Even with Grou......... 426 Table A-5 ECM Power and Ground Circuit Check – MIL Doesn’t Light at Ignition Switch ON and Engine......... 427 DTC P0031/P0032 HO2S (Bank 1 Sensor-1) Heater Control Circuit Low/High.................................... 429 DTC P0037/P0038 HO2S (Bank 1 Sensor-2) Heater Control Circuit Low/High.................................... 431 DTC P0051/P0052 HO2S (Bank 2 Sensor-1) Heater Control Circuit Low/High.................................... 434 DTC P0057/P0058 HO2S (Bank 2 Sensor-2) Heater Control Circuit Low/High.................................... 436 DTC P0100 (DTC No.33, 34) Mass Air Flow Circuit Malfunction............................................... 439 DTC P0102 Mass Air Flow Circuit Low Input................................................................. 441 DTC P0103 Mass Air Flow Circuit High Input................................................................ 443 DTC P0107/P0108 Manifold Absolute Pressure Circuit Low Input/High Input................................... 445 DTC P0110 (DTC No.23, 25) Intake Air Temp. (IAT) Circuit Malfunction...................................... 447 DTC P0112 Intake Air Temperature Sensor Circuit Low....................................................... 449 DTC P0113 Intake Air Temperature Sensor Circuit High...................................................... 450 DTC P0115 (DTC No.14, 15) Engine Coolant Temp. Circuit Malfunction........................................ 452 DTC P0117 Engine Coolant Temperature Circuit Low.......................................................... 454 DTC P0118 Engine Coolant Temperature Circuit High......................................................... 456 DTC P0120 (DTC No.21, 22) Throttle Position Circuit Malfunction........................................... 458 DTC P0121 Throttle Position Circuit Range/Performance Problem............................................. 460 DTC P0122 Throttle Position Sensor Circuit Low............................................................ 462 DTC P0123 Throttle Position Sensor Circuit High........................................................... 464 DTC P0130 (DTC No.13) HO2S-1 (Bank 1) Circuit Malfunction or No Activity Detected......................... 466 DTC P0131/P0132 O2 Sensor (Bank 1 Sensor-1) Circuit Low/High Voltage...................................... 469 DTC P0133 HO2S-1 (Bank 1) Circuit Slow Response........................................................... 472 DTC P0134 O2 Sensor (Bank 1 Sensor-1) No Activity Detected................................................ 474 DTC P0135 HO2S-1 (Bank 1) Heater Circuit Malfunction...................................................... 476 DTC P0137 O2 Sensor (Bank 1 Sensor-2) Circuit Low Voltage................................................. 478 DTC P0138/P0140 O2 Sensor (Bank 1 Sensor-2) Circuit High Voltage/No Activity Detected..................... 480 DTC P0150 (DTC No.26) HO2S-1 (Bank 2) Circuit Malfunction or No Activity Detected......................... 483 DTC P0151/P0152 O2 Sensor (Bank 2 Sensor-1) Circuit Low/High Voltage...................................... 486 DTC P0153 HO2S-1 (Bank 2) Circuit Slow Response........................................................... 489 DTC P0154 O2 Sensor (Bank 2 Sensor-1) No Activity Detected................................................ 491 DTC P0155 HO2S-1 (Bank 2) Heater Circuit Malfunction...................................................... 493 DTC P0157 O2 Sensor (Bank 2 Sensor-2) Circuit Low Voltage................................................. 495 DTC P0158/P0160 O2 Sensor (Bank 2 Sensor-2) Circuit High Voltage/No Activity Detected..................... 497 DTC P0171/P0172 Fuel System Too Lean/Rich (Bank 1)........................................................ 499 DTC P0174/P0175 Fuel System Too Lean/Rich (Bank 2)........................................................ 501 DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder 1 Misfire/Cylinder 2 Misfir......... 503 DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction.................................................... 505 DTC P0327/P0328 Knock Sensor Circuit Low/High............................................................. 507 DTC P0335 Crankshaft Position Sensor Circuit Malfunction.................................................. 509 DTC P0340 (DTC No.42) Camshaft Position Sensor Circuit Malfunction........................................ 511 DTC P0401/P0402 Exhaust Gas Recirculation Flow Insufficient Detected/ Excessive Detected.................. 514 DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction....................................... 518 DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1)............................................. 520 DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2)............................................. 522 DTC P0443 (No.55) Evap Control System Purge Control Valve Circuit Malfunction............................. 524 DTC P0463 Fuel Level Sensor Circuit High.................................................................. 526 DTC P0500 (DTC No.24) Vehicle Speed Sensor Malfunction.................................................... 528 DTC P0506/P0507 Idle Air Control System RPM Lower than Expected/Higher than Expected...................... 531 DTC P0601 (DTC No.71) Internal Control Module Memory Check Sum Error...................................... 533 DTC P0616 Starter Relay Circuit Low....................................................................... 534 DTC P0617 Starter Relay Circuit High...................................................................... 536 DTC P0660 (No.57) Intake Manifold Tuning Valve Control Circuit/Open....................................... 537 DTC P1107/P1108 Manifold Absolute Pressure Circuit Performance Low/High................................... 539 DTC P1510 (No.36) ECM Back-Up Power Supply Malfunction.................................................... 541 DTC P1601 (No.37) CAN Communication Error................................................................. 543 DTC P1603 TCM Trouble Code Detected....................................................................... 547 DTC P2227/P2228/P2229 Barometric Pressure Circuit Performance/Low/High.................................... 547 Table B-1 Fuel Pump Circuit Inspection.................................................................... 549 Table B-2 Fuel Injectors and Circuit Inspection........................................................... 551 Table B-3 Fuel Pressure Inspection........................................................................ 553 Table B-4 Idle Air Control System Inspection.............................................................. 555 Table B-5 A/C Signal Circuits Inspection (If Equipped).................................................... 557 Table B-6 A/C Condenser Fan Motor Relay Low Speed Control System Inspection (If Equipped)................. 559 Table B-7 A/C Condenser Fan Motor Relay High Speed Control System Inspection (If Equipped)................ 561 Table B-8 A/C Compressor Relay Control System Inspection (If Equipped).................................... 564 Special Tool.................................................................................................. 566 SECTION 6A2....................................................................................................... 567 On-Vehicle Service............................................................................................ 569 Throttle Body and Intake Manifold......................................................................... 569 Intake Control Valve (if equipped)........................................................................ 575 Exhaust Manifold.......................................................................................... 576 Oil Pan and Oil Pump Strainer............................................................................. 580 Camshaft and Valve Lash Adjuster.......................................................................... 585 Piston, Piston Rings, Connecting Rods and Cylinders....................................................... 589 Unit Repair Overhaul.......................................................................................... 594 Engine Assembly........................................................................................... 594 Main Bearings, Crankshaft and Cylinder Block.............................................................. 598 Special Tool.................................................................................................. 611 Tightening Torque Specifications.............................................................................. 613 SECTION 6B........................................................................................................ 615 General Description........................................................................................... 616 Cooling System Component.................................................................................. 616 For type A............................................................................................ 616 For type B............................................................................................ 617 Maintenance................................................................................................... 618 Coolant................................................................................................... 618 SECTION 6B1....................................................................................................... 619 General Description........................................................................................... 620 Cooling System Component.................................................................................. 620 Cooling System Circulation................................................................................ 621 Coolant Degassing Tank.................................................................................... 622 Water Pump................................................................................................ 622 Thermostat................................................................................................ 622 Cooling Fan............................................................................................... 623 Coolant................................................................................................... 623 Anti-freeze proportioning chart:...................................................................... 623 Coolant capacity...................................................................................... 623 Diagnosis..................................................................................................... 624 Diagnosis Table........................................................................................... 624 Maintenance................................................................................................... 625 Coolant Level Check....................................................................................... 625 Cooling System Service.................................................................................... 625 Cooling System Flush...................................................................................... 626 On-Vehicle Service........................................................................................ 628 Cooling System Draining................................................................................... 628 Cooling System Refill..................................................................................... 628 Cooling Water Pipes or Hoses.............................................................................. 628 Thermostat................................................................................................ 629 Radiator.................................................................................................. 631 Radiator Fan Relay........................................................................................ 632 Water Pump................................................................................................ 632 Required Service Materials.................................................................................... 634 Tightening Torque Specifications.............................................................................. 634 Special Tool.................................................................................................. 634 SECTION 6E2....................................................................................................... 635 General Description........................................................................................... 636 Air Intake System Description............................................................................. 643 Fuel Delivery System Description.......................................................................... 644 Electronic Control System Description..................................................................... 645 Diagnosis..................................................................................................... 655 On-Vehicle Service............................................................................................ 656 Engine and Emission Control System Description............................................................ 656 Accelerator Cable Adjustment.............................................................................. 657 A/T Throttle Cable Adjustment (4 A/T Vehicle)............................................................. 657 Idle Speed/Idle Air Control (IAC) Duty Inspection......................................................... 658 Idle mixture inspection/adjustment (vehicle without heated oxygen sensor)............................. 660 Air Intake System......................................................................................... 661 Throttle body......................................................................................... 661 Idle air control valve (IAC valve).................................................................... 664 Fast idle air valve................................................................................... 664 Vacuum tank assembly of intake manifold air tuning valve (Type B only)................................ 666 Fuel Delivery System...................................................................................... 669 Fuel pressure inspection.............................................................................. 669 Fuel pump............................................................................................. 670 Fuel pressure regulator............................................................................... 671 Fuel injector......................................................................................... 672 Electronic Control System................................................................................. 677 Engine control module (ECM)/powertrain control module (PCM)........................................... 677 Mass air flow sensor (MAF sensor)..................................................................... 678 Intake air temperature (IAT) sensor................................................................... 681 Throttle position sensor (TP sensor).................................................................. 682 Engine coolant temperature sensor (ECT sensor)........................................................ 683 Heated oxygen sensor (sensor 1)....................................................................... 684 Heated oxygen sensor (sensor 2) (if equipped)......................................................... 685 Vehicle speed sensor (VSS)............................................................................ 688 Manifold absolute pressure sensor..................................................................... 688 Fuel level sensor (sender gauge)...................................................................... 690 Camshaft position sensor.............................................................................. 690 Crankshaft position sensor............................................................................ 690 Main relay............................................................................................ 691 Fuel pump relay....................................................................................... 692 A/C compressor relay and condenser fan motor relay.................................................... 692 Fuel cut operation.................................................................................... 693 Emission Control System................................................................................... 694 EGR system (if equipped).............................................................................. 694 Evap canister purge system............................................................................ 696 Vacuum passage........................................................................................ 696 Vacuum hose........................................................................................... 697 Evap canister purge valve and its circuit............................................................. 697 Evap canister purge valve............................................................................. 698 EVAP canister......................................................................................... 699 Tank pressure control valve........................................................................... 700 PCV System................................................................................................ 701 PCV hose.............................................................................................. 701 PCV valve............................................................................................. 701 Tightening Torque Specification............................................................................... 703 Required Service Material..................................................................................... 703 Special Tool.................................................................................................. 703 SECTION 6F2....................................................................................................... 705 General Description........................................................................................... 706 Components................................................................................................ 706 System Wiring............................................................................................. 707 Diagnosis..................................................................................................... 707 Diagnostic Flow Table..................................................................................... 708 On-Vehicle Service............................................................................................ 709 Ignition Spark Check...................................................................................... 709 Ignition Timing Check and Adjustment...................................................................... 709 Ignition Coil Assembly (Igniter and Ignition Coil)........................................................ 711 Spark Plug................................................................................................ 712 CMP Sensor................................................................................................ 714 Noise Suppressor.......................................................................................... 716 Tightening Torque Specification............................................................................... 717 Special Tool.................................................................................................. 717 SECTION 6K........................................................................................................ 719 General Description........................................................................................... 720 Components................................................................................................ 720 For type A............................................................................................ 720 For type B............................................................................................ 721 SECTION 6K1....................................................................................................... 723 General Description........................................................................................... 724 Exhaust System Components................................................................................. 724 Maintenance................................................................................................... 725 On-Vehicle Service............................................................................................ 726 Exhaust Manifold.......................................................................................... 726 Muffler................................................................................................... 726 Tightening Torque Specifications.............................................................................. 726 SECTION 7A2....................................................................................................... 727 General Description........................................................................................... 728 System Description........................................................................................ 728 Diagnosis..................................................................................................... 728 On-Vehicle Service............................................................................................ 729 Transmission Gear Oil..................................................................................... 729 Transmission Shift Control Lever.......................................................................... 730 Back Up Light Switch...................................................................................... 730 Engine Rear Mounting...................................................................................... 730 Dismounting of Transmission Unit.......................................................................... 730 For H27 engine model.................................................................................. 730 For RHW engine model.................................................................................. 732 Remounting of Transmission Unit........................................................................... 735 For H27 engine model.................................................................................. 735 For RHW engine model.................................................................................. 736 Unit Repair................................................................................................... 738 Tightening Torque Specifications.............................................................................. 738 SECTION 7B1....................................................................................................... 739 General Description........................................................................................... 741 Electronic Shift Control System........................................................................... 742 Automatic gear shift diagram.......................................................................... 743 Diagnosis..................................................................................................... 745 On-Board Diagnostic System (Vehicle without Monitor Connector)............................................ 745 On-Board Diagnostic System (Vehicle with Monitor Connector)............................................... 746 Precaution in Diagnosing Trouble.......................................................................... 747 Automatic Transmission Diagnostic Flow Table.............................................................. 748 Malfunction Indicator Lamp (MIL) Check.................................................................... 751 “O/D OFF” Lamp Check...................................................................................... 751 “POWER” Lamp Check........................................................................................ 751 Diagnostic Trouble Code (DTC) Check....................................................................... 751 Diagnostic Trouble Code Clearance......................................................................... 751 Diagnostic Trouble Code Table............................................................................. 751 Fail Safe Table........................................................................................... 751 Visual Inspection......................................................................................... 752 A/T Basic Check........................................................................................... 752 Trouble Diagnosis Table 1................................................................................. 753 Trouble Diagnosis Table 2................................................................................. 753 Trouble Diagnosis Table 3................................................................................. 754 Scan Tool Data............................................................................................ 755 Inspection of PCM and Its Circuit......................................................................... 755 Wire Harness and Connectors............................................................................... 755 Table A-1: No TCC Lock-Up Occurs.......................................................................... 756 Table A-2: No Gear Shift to O/D........................................................................... 758 Table B-1: “O/D OFF” Light Circuit Check (“O/D OFF” Light Does Not Light at Ignition Switch ON Bu......... 760 Table B-2: “O/D OFF” Light Circuit Check (“O/D OFF” Light Comes ON Steadily).............................. 761 Table B-3: “POWER” Light Circuit Check (“POWER” Light Does Not Light at Ignition Switch ON But En......... 762 Table B-4: “POWER” Light Circuit Check (“POWER” Light Comes ON Steadily).................................. 763 DTC P0705 (DTC NO.72) – Transmission Range Sensor (Switch) Circuit Malfunction............................ 764 DTC P0715 (DTC NO.76) – Input/Turbine Speed Sensor Circuit Malfunction.................................... 767 DTC P0720 (DTC NO.75) Output Speed Sensor Circuit Malfunction............................................. 770 DTC P0743 (DTC NO.65/66) – TCC (Lock-Up) Solenoid Electrical.............................................. 772 DTC P0753 (DTC NO.61/62) Shift Solenoid-A (#1) Electrical DTC P0758 (DTC NO.63/64) Shift Solenoid......... 774 Stall Test................................................................................................ 776 Line Pressure Test........................................................................................ 777 Road Test................................................................................................. 778 Manual Road Test.......................................................................................... 779 Time Lag Test............................................................................................. 779 Engine Brake Test......................................................................................... 780 “P” Range Test............................................................................................ 780 On-Vehicle Service............................................................................................ 781 Maintenance Service....................................................................................... 781 Fluid level........................................................................................... 781 Fluid change.......................................................................................... 782 A/T Throttle Cable........................................................................................ 783 Solenoid Valves (Shift Solenoid Valves and TCC Solenoid Valve)............................................ 783 Tightening Torque Specification............................................................................... 784 Special Tool.................................................................................................. 784 SECTION 7B2....................................................................................................... 785 General Description........................................................................................... 787 Automatic Transmission Description........................................................................ 787 Specifications............................................................................................ 789 Clutch / Brake / Planetary Gear........................................................................... 790 Functions............................................................................................. 790 Table of Component Operation.............................................................................. 791 Electronic Shift Control System........................................................................... 792 Transmission Control Module (TCM)......................................................................... 794 Operation of shift solenoid valves and TCC solenoid valve............................................. 795 Automatic Gear Shift Diagram.............................................................................. 796 Diagnosis..................................................................................................... 798 General Description....................................................................................... 798 On-Board Diagnostic System................................................................................ 798 2 driving cycle detection logic....................................................................... 799 Pending DTC........................................................................................... 799 Freeze frame data..................................................................................... 799 Precaution in Diagnosing Trouble.......................................................................... 801 Diagnostic Information and Procedures......................................................................... 802 A/T System Check.......................................................................................... 802 Malfunction Indicator Lamp (MIL) Check.................................................................... 804 “O/D OFF” Lamp Operation Check............................................................................ 804 “POWER” Lamp Operation Check.............................................................................. 805 DTC Table................................................................................................. 805 DTC Check................................................................................................. 808 Reading DTC Using SUZUKI Scan Tool.................................................................... 808 Reading DTC Using “O/D OFF” Lamp...................................................................... 809 DTC Clearance............................................................................................. 809 DTC Clearance Using SUZUKI Scan Tool.................................................................. 810 DTC Clearance Using Monitor Connector................................................................. 810 Fail Safe Table........................................................................................... 811 Scan Tool Data............................................................................................ 813 Scan Tool Data Definitions............................................................................ 816 Visual Inspection......................................................................................... 817 A/T Basic Check........................................................................................... 818 Road Test................................................................................................. 819 Manual Road Test...................................................................................... 820 Stall Test................................................................................................ 821 Time Lag Test............................................................................................. 822 Line Pressure Test........................................................................................ 824 Engine Brake Test......................................................................................... 825 “P” Range Test............................................................................................ 826 A/T Symptom Diagnosis..................................................................................... 826 Trouble diagnosis 1................................................................................... 826 Trouble diagnosis 2................................................................................... 828 Trouble diagnosis 3................................................................................... 830 No Gear Shift to O/D...................................................................................... 831 No Lock-Up Occurs......................................................................................... 832 “O/D OFF” Light Does Not Light at Ignition Switch ON...................................................... 834 “O/D OFF” Light Comes ON Steadily......................................................................... 835 “POWER” Light Does Not Light at Ignition Switch ON........................................................ 836 “POWER” Light Comes ON Steadily........................................................................... 837 DTC P0705 (No.34) Transmission Range Sensor Circuit Malfunction........................................... 839 DTC P0707 (No.34) Transmission Range Sensor Circuit Low................................................... 841 DTC P0711 (No.81) Transmission Fluid Temperature Sensor Range / Performance............................... 843 DTC P0712 (No.38) Transmission Fluid Temperature Sensor “A” Circuit Low................................... 844 DTC P0713 (No.36) Transmission Fluid Temperature Sensor “A” Circuit High.................................. 845 DTC P0717 (No.14) Input / Turbine Speed Sensor Circuit No Signal.......................................... 847 DTC P0722 (No.31) Output Speed Sensor Circuit No Signal................................................... 849 DTC P0741 / P0742 (No.78 / No.77) TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON............. 851 DTC P0751 / P0752 (No.62 / No.61) Shift Solenoid-A Performance or Stuck OFF / Shift Solenoid-A St......... 852 DTC P0756 / P0757 (No.65 / No.63) Shift Solenoid-B Performance or Stuck OFF / Shift Solenoid-B St......... 853 DTC P0771 / P0772 (No.67 / No.66) Shift Solenoid-E Performance or Stuck OFF / Shift Solenoid-E St......... 854 DTC P0781 (No.68) 1-2 Shift............................................................................... 855 DTC P0797 (No.79) Pressure Control Solenoid “C” Stuck ON.................................................. 856 DTC P0962 / P0966 / P0970 (No.41 / No.43 / No.45) Pressure Control Solenoid “A” Control Circuit L......... 858 DTC P0963 / P0967 / P0971 (No.42 / No.44 / No.46) Pressure Control Solenoid “A” Control Circuit H......... 861 DTC P0973 / P0976 / P0985 (No.22 / No.24 / No.49) Shift Solenoid “A” Control Circuit Low / Shift ......... 863 DTC P0974 / P0977 / P0986 (No.21 / No.23 / No.48) Shift Solenoid “A” Control Circuit High / Shift......... 865 DTC P1701 (No.76) CAN Communication Problem - TCM......................................................... 868 DTC P1702 (No.83) Internal Control Module Memory Check Sum Error.......................................... 872 DTC P1703 (No.86) CAN Invalid Data - TCM.................................................................. 872 DTC P1740 (No.75) Cruise Control Signal Malfunction....................................................... 872 DTC P1874 (No.15) 4WD Low Switch Circuit Malfunction (Short).............................................. 873 DTC P1875 (No.15) 4WD Low Switch Circuit Malfunction (Open)............................................... 875 DTC P2742 (No.59) Transmission Fluid Temperature Sensor “B” Circuit Low................................... 877 DTC P2743 (No.58) Transmission Fluid Temperature Sensor “B” Circuit High.................................. 878 DTC P2763 (No.26) Torque Converter Clutch (TCC) Circuit High.............................................. 880 DTC P2764 (No.25) Torque Converter Clutch (TCC) Circuit Low............................................... 882 Inspection of TCM and Its Circuits........................................................................ 884 Brake Interlock System (If Equipped) Inspection........................................................... 889 Shift Lock (Solenoid) Manual Release System Inspection.................................................... 890 On-Vehicle Service............................................................................................ 891 Maintenance............................................................................................... 891 Fluid level........................................................................................... 891 Fluid change.......................................................................................... 892 Oil Cooler Hoses.......................................................................................... 893 Manual Selector Assembly.................................................................................. 894 Select Cable.............................................................................................. 896 Transmission Range Sensor................................................................................. 897 Inspection and adjustment............................................................................. 897 O/D OFF Switch............................................................................................ 899 Power/Normal Change Switch................................................................................ 899 Input Shaft Speed Sensor.................................................................................. 899 Output Shaft Speed Sensor................................................................................. 900 Solenoid valves (Shift solenoid-A, Shift solenoid-B, Shift solenoid-E, TCC solenoid, Pressure con......... 902 Transmission Fluid Temperature Sensor..................................................................... 905 Transmission Control Module (TCM)......................................................................... 908 Learning control initialization....................................................................... 909 4WD LOW Switch............................................................................................ 909 Oil Cooler Pipes.......................................................................................... 909 Automatic Transmission Assembly (with Transfer)........................................................... 910 Dismounting........................................................................................... 910 Unit Repair................................................................................................... 915 Tightening Torque Specifications.............................................................................. 916 Required Service Material..................................................................................... 916 Special Tool.................................................................................................. 917 SECTION 7D........................................................................................................ 919 SECTION 7E........................................................................................................ 921 SECTION 7E1....................................................................................................... 923 General Description........................................................................................... 923 4WD Control System........................................................................................ 924 System circuit........................................................................................ 925 Components and functions.............................................................................. 925 Diagnosis..................................................................................................... 927 Diagnosis Table........................................................................................... 927 Differential assembly................................................................................. 927 4WD control system diagnostic flow table.............................................................. 927 4WD Control Circuit Inspection............................................................................ 929 On-Vehicle Service............................................................................................ 931 Maintenance Service....................................................................................... 931 Gear oil change....................................................................................... 931 Inspection................................................................................................ 932 Axle lock actuator and motor.......................................................................... 932 Removal and Installation.................................................................................. 933 Axle lock actuator motor.............................................................................. 933 Differential mountings................................................................................ 934 Dismounting............................................................................................... 936 Remounting................................................................................................ 938 Unit Repair................................................................................................... 939 Tightening Torque Specifications.............................................................................. 939 Required Service Material..................................................................................... 939 Special Tool.................................................................................................. 939 SECTION 7F........................................................................................................ 941 General Description........................................................................................... 942 Diagnosis..................................................................................................... 942 Diagnosis Table........................................................................................... 942 On-Vehicle Service............................................................................................ 943 Precaution for Maintenance Service........................................................................ 943 Differential Gear Oil Change.............................................................................. 943 Rear Differential Assembly................................................................................ 944 Dismounting........................................................................................... 944 Remounting............................................................................................ 944 Unit Repair................................................................................................... 945 Tightening Torque Specification............................................................................... 946 Required Service Material..................................................................................... 946 SECTION 8B........................................................................................................ 947 General Description........................................................................................... 948 Auto-On Headlights System (If Equipped)................................................................... 948 Diagnosis..................................................................................................... 948 Auto-On Headlights System (If Equipped)................................................................... 948 On-Vehicle Service............................................................................................ 949 Headlight Switch (in Lighting Switch)..................................................................... 949 Auto-On Headlight Sensor (If Equipped).................................................................... 950 SECTION 8C........................................................................................................ 951 General Description........................................................................................... 953 PCM-BCM (4 A/T Model Only) and BCM-METER Signal Circuit Construction...................................... 953 TCM-BCM (5 A/T Model Only) and BCM-METER Signal Circuit Construction...................................... 954 Combination Meter......................................................................................... 956 Combination meter internal circuits and couplers for type A........................................... 956 Combination meter internal circuits and couplers for type B........................................... 958 Combination meter internal circuits and couplers for RHW engine....................................... 960 Diagnosis..................................................................................................... 962 A/T Selector Position Indicator........................................................................... 962 O/D OFF Indicator Lamp.................................................................................... 963 POWER Indicator Lamp...................................................................................... 965 On-Vehicle Service............................................................................................ 967 PCM-BCM Signal Circuit (4 A/T model)...................................................................... 967 TCM-BCM CAN Communication Circuit (5 A/T model)........................................................... 968 BCM-METER Signal Circuit (4 A/T model).................................................................... 969 BCM-METER Signal Circuit (5 A/T model).................................................................... 970 Illumination Controller................................................................................... 971 Fuel Level Sensor (Sender Gauge) for H27 Engine........................................................... 972 Fuel Meter/Fuel Gauge Unit RHW Engine..................................................................... 973 Fuel level gauge...................................................................................... 973 Engine Coolant Temperature (ECT) Sensor for RHW Engine.................................................... 973 Oil Pressure Switch for RHW Engine........................................................................ 973 Audio System.............................................................................................. 974 Front speaker and rear speaker........................................................................ 974 SECTION 8D........................................................................................................ 977 General Description........................................................................................... 979 Windshield Wiper and Washer............................................................................... 979 Rear wiper and washer................................................................................. 979 On-vehicle Service............................................................................................ 980 Keyless Entry System...................................................................................... 980 Keyless entry receiver circuit for type A............................................................. 980 Keyless entry receiver circuit for type B and RHW engine.............................................. 981 SECTION 8E........................................................................................................ 983 General Description........................................................................................... 984 Cruise Control System..................................................................................... 984 Cruise control system circuit......................................................................... 985 Components and functions.............................................................................. 986 Cancel conditions..................................................................................... 987 Diagnosis..................................................................................................... 988 Diagnosis Table........................................................................................... 988 Note On System Circuit Inspection......................................................................... 989 “CRUISE” Indicator Lamp Circuit Check..................................................................... 990 “SET” Indicator Lamp Circuit Check........................................................................ 991 Cruise ON/OFF, SET/COAST, RES/ACC and CANCEL Switches Circuits Check...................................... 992 VSS Circuit Check......................................................................................... 993 Brake Light Switch With Pedal Position Switch Circuits Check.............................................. 994 Transmission Range Sensor (Shift Switch) Circuit Check.................................................... 54 Clutch Pedal Position Switch Circuit Check................................................................ 54 Throttle Valve Opening Signal Circuit Check............................................................... 997 Overdrive and TCC OFF Command Signal Circuit Check........................................................ 998 Cruise Control Module Power and Ground Circuits Check..................................................... 998 Cruise Control Module and Its Circuit Inspection.......................................................... 999 SECTION 8G........................................................................................................1001 General Description...........................................................................................1003 Wiring Circuit............................................................................................1003 SECTION 8H........................................................................................................1005 Component Locator.............................................................................................1006 System Wiring Circuit.........................................................................................1007 BCM Input/Output Table........................................................................................1009 Diagnostic Trouble Code (DTC) Table...........................................................................1010 DTC B1131 Illumination Control Input Circuit Open.............................................................1011 On-Vehicle Service............................................................................................1012 Inspection of BCM and Its Circuits........................................................................1012 SECTION 8H1.......................................................................................................1021 Component Locator.............................................................................................1022 System Wiring Circuit.........................................................................................1023 BCM Input/Output Table........................................................................................1027 Diagnostic Trouble Code (DTC) Table...........................................................................1028 BCM Power Circuit and Ground Circuit Check....................................................................1029 DTC B1121 – DRL Circuit Malfunction...........................................................................1030 DTC B1131 Illumination Control Input Circuit Open (H27 Engine Only)...........................................1031 DTC B1141 Outside Air Temperature (ambient temp.) Sensor Circuit Open.........................................1032 DTC B1142 Outside Air Temperature (ambient temp.) Sensor Circuit Short To Ground..............................1032 DTC B1156 CAN Communication Error (H27 Engine Only)...........................................................1034 On-Vehicle Service............................................................................................1036 Inspection of BCM and Its Circuits........................................................................1036 SECTION 9.........................................................................................................1045 Glass, Windows and Mirror.....................................................................................1047 Quarter Window............................................................................................1047 Body Structure................................................................................................1048 Front Bumper..............................................................................................1048 Under Body Dimensions.....................................................................................1050 Body Dimensions...........................................................................................1052 Engine room...........................................................................................1052 Inner body............................................................................................1054 Side body.............................................................................................1055 Rear-end Door.........................................................................................1056 Seat..........................................................................................................1057 Second Seat for Type A....................................................................................1057 Second Seat for Type B and RHW Engine.....................................................................1058 Third Seat (If Equipped)..................................................................................1059 Paint and Coatings............................................................................................1060 Sealant Application Area..................................................................................1060 Undercoating/Anti-corrosion Compound Application Area.....................................................1067 Exterior and Interior Trim....................................................................................1069 Floor Carpet..............................................................................................1069 Front floor carpet....................................................................................1069 Rear floor carpet (without third seat vehicle)........................................................1070 Head Lining...............................................................................................1070 Tightening Torque Specification...............................................................................1074 SECTION 10........................................................................................................1075 General Description...........................................................................................1076 SECTION 10A.......................................................................................................1079 On-Vehicle Service............................................................................................1080 Service Precautions.......................................................................................1080 Service and diagnosis.................................................................................1080 Disabling air bag system..............................................................................1080 Enabling air bag system...............................................................................1080 Handling and storage..................................................................................1080 Disposal..............................................................................................1080 Front Seat Belt...........................................................................................1081 Second Rear Seat Belt.....................................................................................1084 Third Rear Seat Belt (If Equipped)........................................................................1085 Tightening Torque Specification...............................................................................1086 SECTION 10B.......................................................................................................1087 General Description...........................................................................................1089 System Components and Wiring Location View and Connectors.................................................1090 System Wiring Diagram.....................................................................................1092 Diagnosis.....................................................................................................1094 Diagnostic Trouble Code (DTC).............................................................................1094 Use of Special Tool.......................................................................................1094 Intermittents and Poor Connections........................................................................1096 Air Bag Diagnostic System Check...........................................................................1097 Air Bag Diagnostic System Check Flow Table................................................................1098 DTC Check.................................................................................................1099 DTC Clearance.............................................................................................1100 DTC Table.................................................................................................1102 Scan Tool Data............................................................................................1104 Scan Tool Data Definition.................................................................................1104 “AIR BAG” Warning Lamp Circuit Trouble Diagnosis Table....................................................1105 “AIR BAG” warning lamp comes on steady................................................................1106 “AIR BAG” warning lamp does not come on...............................................................1107 “AIR BAG” warning lamp flashes........................................................................1109 “AIR BAG” warning lamp cannot indicate flashing pattern of DTC........................................1110 SDM Cannot Communicate Through the Serial Data Circuit....................................................1111 DTC B1015 – Passenger Air Bag Initiator Circuit Resistance High...........................................1113 DTC B1016 – Passenger Air Bag Initiator Circuit Resistance Low............................................1113 DTC B1018 – Passenger Air Bag Initiator Circuit Short to Ground...........................................1113 DTC B1019 – Passenger Air Bag Initiator Circuit Short to Power Circuit....................................1113 DTC B1021 – Driver Air Bag Initiator Circuit Resistance High..............................................1118 DTC B1022 – Driver Air Bag Initiator Circuit Resistance Low...............................................1118 DTC B1024 – Driver Air Bag Initiator Circuit Short to Ground..............................................1118 DTC B1025 – Driver Air Bag Initiator Circuit Short to Power Circuit.......................................1118 DTC B1031 – Power Source Voltage High.....................................................................1124 DTC B1032 – Power Source Voltage Low......................................................................1124 DTC B1035 – RH Forward Sensor Circuit Open or Short to Ground.............................................1127 DTC B1036 – RH Forward Sensor Circuit Short Between Two Wires or Short to Power Circuit...................1127 DTC B1037 – LH Forward Sensor Circuit Open or Short to Ground.............................................1127 DTC B1038 – LH Forward Sensor Circuit Short Between Two Wires or Short to Power Circuit...................1127 DTC B1041 – Driver Pretensioner Initiator Circuit Resistance High.........................................1131 DTC B1042 – Driver Pretensioner Initiator Circuit Resistance Low..........................................1131 DTC B1043 – Driver Pretensioner Initiator Circuit Short to Ground.........................................1131 DTC B1044 – Driver Pretensioner Initiator Circuit Short to Power Circuit..................................1131 DTC B1045 – Passenger Pretensioner Initiator Circuit Resistance High......................................1131 DTC B1046 – Passenger Pretensioner Initiator Circuit Resistance Low.......................................1131 DTC B1047 – Passenger Pretensioner Initiator Circuit Short to Ground......................................1131 DTC B1048 – Passenger Pretensioner Initiator Circuit Short to Power Circuit...............................1131 DTC B1051 – Frontal Crash Detected (System Activation Command Outputted)..................................1140 DTC B1061 – “AIR BAG” Warning Lamp Circuit Failure........................................................1141 DTC B1071 – Internal SDM Fault............................................................................1142 DTC B1013 – System Specifications Different from SDM Specifications.......................................1142 On-Vehicle Service............................................................................................1143 Service Precautions.......................................................................................1143 Service and diagnosis.................................................................................1143 Disabling air bag system..............................................................................1144 Enabling air bag system...............................................................................1144 Handling and storage..................................................................................1145 Repairs and Inspections Required After an Accident........................................................1150 Accident with deployment/activation – component replacement...........................................1150 Accident with or without deployment/activation - component inspections................................1151 SDM.......................................................................................................1155 Forward Sensor............................................................................................1157 Seat Belt Pretensioner....................................................................................1161 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal.................................................1162 Deployment/Activation Outside of Vehicle..................................................................1163 Deployment/Activation Inside Vehicle......................................................................1171 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal..........................1175 Tightening Torque Specification...............................................................................1176 Required Service Material.....................................................................................1176 Special Tool..................................................................................................1176 Copyright.........................................................................................................1179 Bookcover......................................................................................................... 0
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