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Suzuki JB416 JB420 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD
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Suzuki JB416 JB420 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD
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Description
Suzuki JB416 JB420 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD
FILE DETAILS:
Suzuki JB416 JB420 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD
Language : English
Pages : 1740
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki JB416 JB420 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD
- This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul).
- VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4).
- VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and Control Systems sections (Sections 5 – 10).
Applicable model:
GRAND VITARA (JB416/JB420) vehicles - The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work.
- Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
- When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others.
- Therefore, note that illustrations may differ from the vehicle being actually serviced.
- The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
Suzuki JB416 JB420 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD
Top...................................................................................................................................................................................................................................... 0 Manual List.............................................................................................................................................................................................................................. 0 IMPORTANT................................................................................................................................................................................................................................ 1 FOREWORD................................................................................................................................................................................................................................. 3 TABLE OF CONTENTS........................................................................................................................................................................................................................ 5 Precautions.............................................................................................................................................................................................................................. 7 Precautions.......................................................................................................................................................................................................................... 8 Precautions...................................................................................................................................................................................................................... 8 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System............................................................................................................................................. 8 General Precautions.......................................................................................................................................................................................................... 11 Precaution in Servicing Full-Time 4WD Vehicle................................................................................................................................................................................ 14 Precautions for Catalytic Converter.......................................................................................................................................................................................... 15 Precaution for CAN Communication System...................................................................................................................................................................................... 16 Precautions for Electrical Circuit Service................................................................................................................................................................................... 16 Precautions for Installing Mobile Communication Equipment.................................................................................................................................................................... 18 Air Bag Warning.............................................................................................................................................................................................................. 18 Discharge Headlight Warning.................................................................................................................................................................................................. 18 A/C System Caution........................................................................................................................................................................................................... 18 Fastener Caution............................................................................................................................................................................................................. 18 Suspension Caution........................................................................................................................................................................................................... 19 Wheels and Tires Caution..................................................................................................................................................................................................... 19 Brakes Caution and Note...................................................................................................................................................................................................... 19 Differential Gear Oil Note................................................................................................................................................................................................... 19 Repair Instructions.............................................................................................................................................................................................................. 19 Electrical Circuit Inspection Procedure...................................................................................................................................................................................... 19 Intermittent and Poor Connection Inspection.................................................................................................................................................................................. 22 General Information...................................................................................................................................................................................................................... 23 General Information.................................................................................................................................................................................................................. 24 General Description.............................................................................................................................................................................................................. 24 Abbreviations................................................................................................................................................................................................................ 24 Symbols...................................................................................................................................................................................................................... 25 Wire Color Symbols........................................................................................................................................................................................................... 26 Fastener Information......................................................................................................................................................................................................... 26 Vehicle Lifting Points....................................................................................................................................................................................................... 28 Engine Supporting Points..................................................................................................................................................................................................... 30 Vehicle Identification Number................................................................................................................................................................................................ 30 Engine Identification Number................................................................................................................................................................................................. 30 Transmission Identification Number........................................................................................................................................................................................... 30 Component Location............................................................................................................................................................................................................... 31 Warning, Caution and Information Label Location.............................................................................................................................................................................. 31 Maintenance and Lubrication.......................................................................................................................................................................................................... 33 Precautions...................................................................................................................................................................................................................... 33 Precautions for Maintenance and Lubrication.................................................................................................................................................................................. 33 Scheduled Maintenance............................................................................................................................................................................................................ 33 Maintenance Schedule under Normal Driving Conditions......................................................................................................................................................................... 33 Maintenance Recommended under Severe Driving Conditions...................................................................................................................................................................... 34 Repair Instructions.............................................................................................................................................................................................................. 36 Engine Accessory Drive Belt Inspection....................................................................................................................................................................................... 36 Engine Accessory Drive Belt Replacement...................................................................................................................................................................................... 36 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 36 Engine Oil and Filter Change................................................................................................................................................................................................. 37 Engine Coolant Change........................................................................................................................................................................................................ 38 Exhaust system Inspection.................................................................................................................................................................................................... 39 Spark Plugs Replacement...................................................................................................................................................................................................... 39 Air Cleaner Filter Inspection................................................................................................................................................................................................ 39 Air Cleaner Filter Replacement............................................................................................................................................................................................... 39 Fuel Lines and Connections Inspection........................................................................................................................................................................................ 39 Fuel Filter Replacement...................................................................................................................................................................................................... 39 Fuel Tank Inspection......................................................................................................................................................................................................... 39 Crankcase Ventilation Hoses and Connections Inspection (Vehicle without A/F Sensor).......................................................................................................................................... 39 PCV Valve Inspection......................................................................................................................................................................................................... 39 Fuel Evaporative Emission Control System Inspection.......................................................................................................................................................................... 40 Brake Discs and Pads Inspection.............................................................................................................................................................................................. 40 Brake Drums and Shoes Inspection............................................................................................................................................................................................. 40 Brake Hoses and Pipes Inspection............................................................................................................................................................................................. 40 Brake Fluid Change........................................................................................................................................................................................................... 40 Parking Brake Lever and Cable Inspection..................................................................................................................................................................................... 41 Clutch Fluid Inspection...................................................................................................................................................................................................... 41 Tire / Wheel Inspection and Rotation......................................................................................................................................................................................... 41 Wheel Discs Inspection....................................................................................................................................................................................................... 42 Wheel Bearing Inspection..................................................................................................................................................................................................... 42 Suspension System Inspection................................................................................................................................................................................................. 42 Steering System Inspection................................................................................................................................................................................................... 42 Propeller Shafts and Drive Shafts Inspection................................................................................................................................................................................. 43 Manual Transmission Oil Inspection........................................................................................................................................................................................... 43 Manual Transmission Oil Change............................................................................................................................................................................................... 43 Automatic Transmission Fluid Inspection...................................................................................................................................................................................... 43 Automatic Transmission Fluid Change.......................................................................................................................................................................................... 44 Automatic Transmission Fluid Cooler Hose Inspection.......................................................................................................................................................................... 44 Transfer Oil Inspection (If Equipped)........................................................................................................................................................................................ 44 Differential Oil Inspection.................................................................................................................................................................................................. 44 Transfer (If Equipped) and Differential Oil Change........................................................................................................................................................................... 44 Power Steering (P/S) System Inspection....................................................................................................................................................................................... 45 All Hinges, Latches and Locks Inspection..................................................................................................................................................................................... 45 HVAC Air Filter Inspection (If Equipped)..................................................................................................................................................................................... 45 HVAC Air Filter Replacement (If Equipped).................................................................................................................................................................................... 45 Final Inspection for Maintenance Service..................................................................................................................................................................................... 45 Specifications................................................................................................................................................................................................................... 47 Tightening Torque Specifications............................................................................................................................................................................................. 47 Special Tools and Equipment...................................................................................................................................................................................................... 47 Recommended Fluids and Lubricants............................................................................................................................................................................................ 47 Special Tool................................................................................................................................................................................................................. 47 Engine................................................................................................................................................................................................................................... 49 Precautions.......................................................................................................................................................................................................................... 55 Precautions...................................................................................................................................................................................................................... 55 Precautions for Engine....................................................................................................................................................................................................... 55 Engine General Information and Diagnosis............................................................................................................................................................................................. 56 Precautions...................................................................................................................................................................................................................... 56 Precautions on Engine Service................................................................................................................................................................................................ 56 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 56 Precautions For DTC Troubleshooting.......................................................................................................................................................................................... 57 Precautions of ECM Circuit Inspection........................................................................................................................................................................................ 57 Precautions of Electric Throttle Body System Calibration..................................................................................................................................................................... 57 General Description.............................................................................................................................................................................................................. 57 Statement on Cleanliness and Care............................................................................................................................................................................................ 57 Engine Diagnosis General Description......................................................................................................................................................................................... 58 On-Board Diagnostic System Description....................................................................................................................................................................................... 58 Engine and Emission Control System Description............................................................................................................................................................................... 61 CAN Communication System Description......................................................................................................................................................................................... 61 Air Intake System Description................................................................................................................................................................................................ 64 Description of Electric Throttle Body System................................................................................................................................................................................. 65 Description of Electric Throttle Body System Calibration..................................................................................................................................................................... 66 Generator Control System Description......................................................................................................................................................................................... 66 A/F Sensor Description....................................................................................................................................................................................................... 67 Electronic Control System Description........................................................................................................................................................................................ 68 Engine and Emission Control Input / Output Table............................................................................................................................................................................. 76 Schematic and Routing Diagram.................................................................................................................................................................................................... 77 Engine and Emission Control System Diagram................................................................................................................................................................................... 77 Component Location............................................................................................................................................................................................................... 78 Electronic Control System Components Location................................................................................................................................................................................ 78 Diagnostic Information and Procedures............................................................................................................................................................................................ 80 Engine and Emission Control System Check..................................................................................................................................................................................... 80 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 83 DTC Check.................................................................................................................................................................................................................... 83 DTC Clearance................................................................................................................................................................................................................ 84 DTC Table.................................................................................................................................................................................................................... 85 Fail-Safe Table.............................................................................................................................................................................................................. 91 Scan Tool Data............................................................................................................................................................................................................... 92 Visual Inspection............................................................................................................................................................................................................ 98 Engine Basic Inspection...................................................................................................................................................................................................... 99 Engine Symptom Diagnosis..................................................................................................................................................................................................... 103 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started).............................................................................................................. 112 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................................................................................................................... 114 DTC P0010: Camshaft Position Actuator Circuit (For M16 Engine)............................................................................................................................................................... 115 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (For M16 Engine)............................................................................................................... 117 DTC P0030: HO2S Heater Control Circuit (Sensor-1)............................................................................................................................................................................ 119 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)......................................................................................................................................................... 120 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)......................................................................................................................................................... 124 DTC P0101: Mass Air Flow Circuit Range / Performance......................................................................................................................................................................... 127 DTC P0102: Mass Air Flow Circuit Low Input................................................................................................................................................................................... 130 DTC P0103: Mass Air Flow Circuit High Input.................................................................................................................................................................................. 132 DTC P0106: Manifold Absolute Pressure Range / Performance.................................................................................................................................................................... 134 DTC P0107: Manifold Absolute Pressure Circuit Low Input...................................................................................................................................................................... 135 DTC P0108: Manifold Absolute Pressure Circuit High Input..................................................................................................................................................................... 137 DTC P0111: Intake Air Temperature Circuit Range / Performance................................................................................................................................................................ 139 DTC P0112: Intake Air Temperature Sensor Circuit Low......................................................................................................................................................................... 142 DTC P0113: Intake Air Temperature Sensor Circuit High........................................................................................................................................................................ 144 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................................................................................................ 146 DTC P0117: Engine Coolant Temperature Circuit Low............................................................................................................................................................................ 149 DTC P0118: Engine Coolant Temperature Circuit High........................................................................................................................................................................... 150 DTC P0122: Throttle Position Sensor (Main) Circuit Low....................................................................................................................................................................... 153 DTC P0123: Throttle Position Sensor (Main) Circuit High...................................................................................................................................................................... 156 DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1)............................................................................................................. 159 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)................................................................................................................................................................. 160 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)............................................................................................................................................ 162 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2).......................................................................................................................................................... 165 DTC P0171 / P0172 / P2195 / P2196: Fuel System Too Lean / Rich / Stuck Lean / Stuck Rich..................................................................................................................................... 166 DTC P0222: Throttle Position Sensor (Sub) Circuit Low........................................................................................................................................................................ 170 DTC P0223: Throttle Position Sensor (Sub) Circuit High....................................................................................................................................................................... 173 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...................................................................................... 176 DTC P0327 / P0328: Knock Sensor Circuit Low / High........................................................................................................................................................................... 178 DTC P0335: Crankshaft Position (CKP) Sensor Circuit (For J20 Engine)......................................................................................................................................................... 180 DTC P0335: Crankshaft Position (CKP) Sensor Circuit (For M16 Engine)......................................................................................................................................................... 182 DTC P0340: Camshaft Position (CMP) Sensor Circuit............................................................................................................................................................................ 185 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected................................................................................................................................. 188 DTC P0403: Exhaust Gas Recirculation Control Circuit......................................................................................................................................................................... 191 DTC P0420: Catalyst System Efficiency below Threshold........................................................................................................................................................................ 193 DTC P0443: Evaporative Emission System Purge Control Valve Circuit........................................................................................................................................................... 195 DTC P0462: Fuel Level Sensor Circuit Low..................................................................................................................................................................................... 197 DTC P0463: Fuel Level Sensor Circuit High.................................................................................................................................................................................... 199 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...................................................................................................................................................................... 201 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction............................................................................................................................................................................ 205 DTC P0504: Brake Switch “A”/“B” Correlation (For J20 Engine)................................................................................................................................................................. 207 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low....................................................................................................................................................................... 209 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High...................................................................................................................................................................... 211 DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance.................................................................................... 212 DTC P0616: Starter Relay Circuit Low......................................................................................................................................................................................... 213 DTC P0617: Starter Relay Circuit High........................................................................................................................................................................................ 215 DTC P0620: Generator Control Circuit......................................................................................................................................................................................... 216 DTC P0625 / P0626: Generator Field Terminal Circuit Low / High............................................................................................................................................................... 218 DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (For J20 Engine).............................................................................................................................................. 220 DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High........................................................................................................................................................... 222 DTC P1510: ECM Back-Up Power Supply Malfunction.............................................................................................................................................................................. 224 DTC P1603: TCM Trouble Code Detected (For J20 Engine)........................................................................................................................................................................ 225 DTC P1674: CAN Communication (Bus Off Error)................................................................................................................................................................................. 226 DTC P1676: CAN Communication (Reception Error for TCM (for A/T model))....................................................................................................................................................... 231 DTC P1678: CAN Communication (Reception Error for BCM)....................................................................................................................................................................... 235 DTC P1685: CAN Communication (Reception Error for ABS Control Module)........................................................................................................................................................ 239 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance....................................................................................................................................................... 242 DTC P2102: Throttle Actuator Control Motor Circuit Low....................................................................................................................................................................... 244 DTC P2103: Throttle Actuator Control Motor Circuit High...................................................................................................................................................................... 246 DTC P2111: Throttle Actuator Control System - Stuck Open..................................................................................................................................................................... 247 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance....................................................................................................................................................... 248 DTC P2122: Pedal Position Sensor (Main) Circuit Low Input.................................................................................................................................................................... 250 DTC P2123: Pedal Position Sensor (Main) Circuit High Input................................................................................................................................................................... 253 DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input..................................................................................................................................................................... 255 DTC P2128: Pedal Position Sensor (Sub) Circuit High Input.................................................................................................................................................................... 257 DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation......................................................................................................................................................... 260 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation............................................................................................................................................................ 263 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction........................................................................................................................................................... 265 Inspection of ECM and Its Circuits........................................................................................................................................................................................... 267 ECM Power and Ground Circuit Check........................................................................................................................................................................................... 289 Fuel Injector Circuit Check.................................................................................................................................................................................................. 293 Fuel Pump and Its Circuit Check.............................................................................................................................................................................................. 295 Fuel Pressure Check.......................................................................................................................................................................................................... 298 A/C System Circuits Check.................................................................................................................................................................................................... 300 Electric Load Signal Circuit Check........................................................................................................................................................................................... 303 Radiator Cooling Fan Low Speed Control System Check.......................................................................................................................................................................... 305 Radiator Cooling Fan High Speed Control System Check......................................................................................................................................................................... 308 Repair Instructions.............................................................................................................................................................................................................. 310 Idle Speed and IAC Throttle Valve Opening Inspection......................................................................................................................................................................... 310 Special Tools and Equipment...................................................................................................................................................................................................... 311 Special Tool................................................................................................................................................................................................................. 311 Aux. Emission Control Devices........................................................................................................................................................................................................ 312 Diagnostic Information and Procedures............................................................................................................................................................................................ 312 EGR System Inspection........................................................................................................................................................................................................ 312 Repair Instructions.............................................................................................................................................................................................................. 312 EVAP Canister Purge Inspection............................................................................................................................................................................................... 312 EVAP Canister Purge Valve and Its Circuit Inspection......................................................................................................................................................................... 313 Vacuum Passage Inspection.................................................................................................................................................................................................... 313 Vacuum Hose and Purge Valve Chamber Inspection............................................................................................................................................................................... 314 EVAP Canister Purge Valve Inspection......................................................................................................................................................................................... 314 EVAP Canister Inspection..................................................................................................................................................................................................... 315 EGR Valve Removal and Installation........................................................................................................................................................................................... 315 EGR Valve Inspection......................................................................................................................................................................................................... 315 PCV Hose Inspection.......................................................................................................................................................................................................... 315 PCV Valve Removal and Installation........................................................................................................................................................................................... 316 PCV Valve Inspection......................................................................................................................................................................................................... 316 Specifications................................................................................................................................................................................................................... 317 Tightening Torque Specifications............................................................................................................................................................................................. 317 Special Tools and Equipment...................................................................................................................................................................................................... 317 Recommended Service Material................................................................................................................................................................................................. 317 Special Tool................................................................................................................................................................................................................. 317 Engine Electrical Devices............................................................................................................................................................................................................ 318 Repair Instructions.............................................................................................................................................................................................................. 318 Engine Control Module (ECM) Removal and Installation......................................................................................................................................................................... 318 Manifold Absolute Pressure (MAP) Sensor Inspection........................................................................................................................................................................... 318 Electric Throttle Body Assembly On-Vehicle Inspection........................................................................................................................................................................ 319 Electric Throttle Body System Calibration.................................................................................................................................................................................... 321 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection....................................................................................................................................................... 322 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation.................................................................................................................................................... 322 Accelerator Pedal Position (APP) Sensor Assembly Inspection.................................................................................................................................................................. 323 Engine Coolant Temperature (ECT) Sensor Removal and Installation............................................................................................................................................................. 323 Engine Coolant Temperature (ECT) Sensor Inspection........................................................................................................................................................................... 324 Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection............................................................................................................................................................................ 324 Heated Oxygen Sensor (HO2S-2) Heater On- Vehicle Inspection.................................................................................................................................................................. 325 Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S-2) Removal and Installation.......................................................................................................................................... 325 Camshaft Position (CMP) Sensor Removal and Installation...................................................................................................................................................................... 325 Camshaft Position (CMP) Sensor Inspection.................................................................................................................................................................................... 326 Crankshaft Position (CKP) Sensor Removal and Installation.................................................................................................................................................................... 326 Crankshaft Position (CKP) Sensor Inspection.................................................................................................................................................................................. 327 Knock Sensor Removal and Installation........................................................................................................................................................................................ 328 Control Relay Inspection..................................................................................................................................................................................................... 329 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection............................................................................................................................................ 330 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation......................................................................................................................................... 330 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection....................................................................................................................................................... 331 Vacuum Tank Assembly Inspection (For J20 Engine)............................................................................................................................................................................. 331 Electric Load Current Sensor On-Vehicle Inspection (For J20 Engine).......................................................................................................................................................... 333 Electric Load Current Sensor Removal and Installation (For J20 Engine)....................................................................................................................................................... 333 Specifications................................................................................................................................................................................................................... 334 Tightening Torque Specifications............................................................................................................................................................................................. 334 Engine Mechanical.................................................................................................................................................................................................................... 335 For M16A Engine with VVT......................................................................................................................................................................................................... 335 General Description.......................................................................................................................................................................................................... 335 Engine Construction Description.......................................................................................................................................................................................... 335 Camshaft Position Control (VVT Variable Valve Timing) System Description................................................................................................................................................. 336 Diagnostic Information and Procedures........................................................................................................................................................................................ 338 Compression Check........................................................................................................................................................................................................ 338 Engine Vacuum Check...................................................................................................................................................................................................... 339 Valve Lash (Clearance) Inspection........................................................................................................................................................................................ 340 Repair Instructions.......................................................................................................................................................................................................... 342 Air Cleaner Filter Removal and Installation.............................................................................................................................................................................. 342 Air Cleaner Filter Inspection and Cleaning............................................................................................................................................................................... 343 Cylinder Head Cover Removal and Installation............................................................................................................................................................................. 343 Throttle Body and Intake Manifold Components............................................................................................................................................................................. 345 Throttle Body On-Vehicle Inspection...................................................................................................................................................................................... 345 Electric Throttle Body Assembly Removal and Installation................................................................................................................................................................. 346 Throttle Body Cleaning................................................................................................................................................................................................... 346 Intake Manifold Removal and Installation................................................................................................................................................................................. 347 Engine Mountings Components.............................................................................................................................................................................................. 348 Engine Assembly Removal and Installation................................................................................................................................................................................. 348 Timing Chain Cover Components............................................................................................................................................................................................ 352 Timing Chain Cover Removal and Installation.............................................................................................................................................................................. 353 Timing Chain Cover Inspection............................................................................................................................................................................................ 355 Oil Control Valve Removal and Installation............................................................................................................................................................................... 355 Oil Control Valve Inspection............................................................................................................................................................................................. 356 Timing Chain and Chain Tensioner Components.............................................................................................................................................................................. 357 Timing Chain and Chain Tensioner Removal and Installation................................................................................................................................................................ 357 Timing Chain and Chain Tensioner Inspection.............................................................................................................................................................................. 360 Camshaft, Tappet and Shim Components..................................................................................................................................................................................... 361 Camshaft, Tappet and Shim Removal and Installation....................................................................................................................................................................... 361 Camshaft, Tappet and Shim Inspection..................................................................................................................................................................................... 364 Valves and Cylinder Head Components...................................................................................................................................................................................... 367 Valves and Cylinder Head Removal and Installation........................................................................................................................................................................ 368 Valves and Cylinder Head Disassembly and Assembly........................................................................................................................................................................ 369 Valves and Valve Guides Inspection....................................................................................................................................................................................... 372 Cylinder Head Inspection................................................................................................................................................................................................. 374 Valve Spring Inspection.................................................................................................................................................................................................. 375 Pistons, Piston Rings, Connecting Rods and Cylinders Components.......................................................................................................................................................... 376 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation............................................................................................................................................ 376 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly............................................................................................................................................ 378 Cylinders, Pistons and Piston Rings Inspection........................................................................................................................................................................... 379 Piston Pins and Connecting Rods Inspection............................................................................................................................................................................... 381 Crank Pin and Connecting Rod Bearings Inspection......................................................................................................................................................................... 382 Main Bearings, Crankshaft and Cylinder Block Components.................................................................................................................................................................. 386 Main Bearings, Crankshaft and Cylinder Block Removal and Installation.................................................................................................................................................... 387 Crankshaft Inspection.................................................................................................................................................................................................... 390 Main Bearings Inspection................................................................................................................................................................................................. 391 Sensor Plate Inspection.................................................................................................................................................................................................. 395 Rear Oil Seal Inspection................................................................................................................................................................................................. 395 Flywheel Inspection...................................................................................................................................................................................................... 396 Cylinder Block Inspection................................................................................................................................................................................................ 396 Specifications............................................................................................................................................................................................................... 397 Tightening Torque Specifications......................................................................................................................................................................................... 397 Special Tools and Equipment.................................................................................................................................................................................................. 398 Recommended Service Material............................................................................................................................................................................................. 398 Special Tool............................................................................................................................................................................................................. 398 For J20 Engine................................................................................................................................................................................................................... 400 General Description.......................................................................................................................................................................................................... 400 Engine Construction Description.......................................................................................................................................................................................... 400 Air Cleaner Element Introduction......................................................................................................................................................................................... 402 IMT (Intake Manifold Tuning) System...................................................................................................................................................................................... 402 Diagnostic Information and Procedures........................................................................................................................................................................................ 404 Compression Check........................................................................................................................................................................................................ 404 Engine Vacuum Check...................................................................................................................................................................................................... 405 Valve Lash (Clearance) Inspection........................................................................................................................................................................................ 406 Repair Instructions.......................................................................................................................................................................................................... 409 Air Cleaner Assembly Removal and Installation............................................................................................................................................................................ 409 Air Cleaner Filter Removal and Installation.............................................................................................................................................................................. 409 Air Cleaner Filter Inspection and Cleaning............................................................................................................................................................................... 409 Throttle Body and Intake Manifold Components............................................................................................................................................................................. 410 Throttle Body On-Vehicle Inspection...................................................................................................................................................................................... 410 Electric Throttle Body Assembly Removal and Installation................................................................................................................................................................. 410 Throttle Body Cleaning................................................................................................................................................................................................... 411 Intake Manifold Removal and Installation................................................................................................................................................................................. 411 Cylinder Head Cover Removal and Installation............................................................................................................................................................................. 412 Engine Mountings Components.............................................................................................................................................................................................. 414 Engine Assembly Removal and Installation................................................................................................................................................................................. 415 Timing Chain Cover Components............................................................................................................................................................................................ 418 Timing Chain Cover Removal and Installation.............................................................................................................................................................................. 418 Timing Chain Cover Cleaning and Inspection............................................................................................................................................................................... 421 2nd Timing Chain and Chain Tensioner Components.......................................................................................................................................................................... 421 2nd Timing Chain and Chain Tensioner Removal and Installation............................................................................................................................................................ 422 2nd Timing Chain and Chain Tensioner Inspection.......................................................................................................................................................................... 424 1st Timing Chain and Chain Tensioner Components.......................................................................................................................................................................... 425 1st Timing Chain and Chain Tensioner Removal and Installation............................................................................................................................................................ 426 1st Timing Chain and Chain Tensioner Inspection.......................................................................................................................................................................... 428 Camshafts, Tappet and Shim Components.................................................................................................................................................................................... 429 Camshafts, Tappet and Shim Removal and Installation...................................................................................................................................................................... 429 Camshaft, Tappet and Shim Inspection..................................................................................................................................................................................... 431 Valves and Cylinder Head Components...................................................................................................................................................................................... 433 Valves and Cylinder Head Removal and Installation........................................................................................................................................................................ 433 Valves and Cylinder Head Disassembly and Assembly........................................................................................................................................................................ 435 Valves and Valve Guides Inspection....................................................................................................................................................................................... 438 Cylinder Head Inspection................................................................................................................................................................................................. 440 Valve Spring Inspection.................................................................................................................................................................................................. 441 Pistons, Piston Rings, Connecting Rods and Cylinders Components.......................................................................................................................................................... 442 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation............................................................................................................................................ 442 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly............................................................................................................................................ 443 Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning............................................................................................................................................. 446 Main Bearings, Crankshaft and Cylinder Block Components.................................................................................................................................................................. 452 Main Bearings, Crankshaft and Cylinder Block Removal and Installation.................................................................................................................................................... 453 Main Bearings, Crankshaft and Cylinder Block Inspection.................................................................................................................................................................. 456 Specifications............................................................................................................................................................................................................... 463 Tightening Torque Specifications......................................................................................................................................................................................... 463 Special Tools and Equipment.................................................................................................................................................................................................. 464 Recommended Service Material............................................................................................................................................................................................. 464 Special Tool............................................................................................................................................................................................................. 464 Engine Lubrication System............................................................................................................................................................................................................ 467 For M16A Engine with VVT......................................................................................................................................................................................................... 467 General Description.......................................................................................................................................................................................................... 467 Engine Lubrication Description........................................................................................................................................................................................... 467 Diagnostic Information and Procedures........................................................................................................................................................................................ 469 Oil Pressure Check....................................................................................................................................................................................................... 469 Repair Instructions.......................................................................................................................................................................................................... 470 Oil Pan and Oil Pump Strainer Components................................................................................................................................................................................. 470 Oil Pan and Oil Pump Strainer Removal and Installation................................................................................................................................................................... 471 Oil Pan and Oil Pump Strainer Cleaning................................................................................................................................................................................... 472 Oil Pump Components...................................................................................................................................................................................................... 473 Oil Pump Removal and Installation........................................................................................................................................................................................ 473 Oil Pump Disassembly and Reassembly...................................................................................................................................................................................... 473 Oil Pump Inspection...................................................................................................................................................................................................... 474 Specifications............................................................................................................................................................................................................... 476 Tightening Torque Specifications......................................................................................................................................................................................... 476 Special Tools and Equipment.................................................................................................................................................................................................. 476 Recommended Service Material............................................................................................................................................................................................. 476 Special Tool............................................................................................................................................................................................................. 476 For J20 Engine................................................................................................................................................................................................................... 477 General Description.......................................................................................................................................................................................................... 477 Engine Lubrication Description........................................................................................................................................................................................... 477 Diagnostic Information and Procedures........................................................................................................................................................................................ 479 Oil Pressure Check....................................................................................................................................................................................................... 479 Repair Instructions.......................................................................................................................................................................................................... 480 Oil Pan and Oil Pump Strainer Components................................................................................................................................................................................. 480 Oil Pan and Oil Pump Strainer Removal and Installation................................................................................................................................................................... 481 Oil Pan and Oil Pump Strainer Cleaning................................................................................................................................................................................... 482 Oil Pump Components...................................................................................................................................................................................................... 482 Oil Pump Removal and Installation........................................................................................................................................................................................ 483 Oil Pump Disassembly and Assembly........................................................................................................................................................................................ 483 Oil Pump Inspection...................................................................................................................................................................................................... 484 Specifications............................................................................................................................................................................................................... 485 Tightening Torque Specifications......................................................................................................................................................................................... 485 Special Tools and Equipment.................................................................................................................................................................................................. 486 Recommended Service Material............................................................................................................................................................................................. 486 Special Tool............................................................................................................................................................................................................. 486 Engine Cooling System................................................................................................................................................................................................................ 487 General Description.............................................................................................................................................................................................................. 487 Cooling System Description................................................................................................................................................................................................... 487 Coolant Description.......................................................................................................................................................................................................... 487 Schematic and Routing Diagram.................................................................................................................................................................................................... 488 Coolant Circulation.......................................................................................................................................................................................................... 488 Diagnostic Information and Procedures............................................................................................................................................................................................ 489 Engine Cooling Symptom Diagnosis............................................................................................................................................................................................. 489 Repair Instructions.............................................................................................................................................................................................................. 490 Cooling System Components.................................................................................................................................................................................................... 490 Coolant Level Check.......................................................................................................................................................................................................... 492 Engine Cooling System Inspection and Cleaning................................................................................................................................................................................ 492 Cooling System Draining...................................................................................................................................................................................................... 493 Cooling System Flush and Refill.............................................................................................................................................................................................. 493 Cooling Water Pipes or Hoses Removal and Installation........................................................................................................................................................................ 494 Thermostat Removal and Installation (For M16 Engine Model)................................................................................................................................................................... 494 Thermostat Removal and Installation (For J20 Engine Model)................................................................................................................................................................... 495 Thermostat Inspection........................................................................................................................................................................................................ 495 Radiator Cooling Fan Motor On-Vehicle Inspection............................................................................................................................................................................. 496 Radiator Cooling Fan Relay Inspection........................................................................................................................................................................................ 496 Radiator Cooling Fan Assembly Removal and Installation....................................................................................................................................................................... 497 Radiator On-Vehicle Inspection and Cleaning.................................................................................................................................................................................. 497 Radiator Removal and Installation............................................................................................................................................................................................ 498 Water Pump Removal and Installation (For M16 Engine Model)................................................................................................................................................................... 498 Water Pump Removal and Installation (For J20 Engine Model)................................................................................................................................................................... 499 Water Pump Inspection........................................................................................................................................................................................................ 500 Specifications................................................................................................................................................................................................................... 500 Tightening Torque Specifications............................................................................................................................................................................................. 500 Special Tools and Equipment...................................................................................................................................................................................................... 500 Recommended Service Material................................................................................................................................................................................................. 500 Fuel System.......................................................................................................................................................................................................................... 501 Precautions...................................................................................................................................................................................................................... 501 Precautions on Fuel System Service........................................................................................................................................................................................... 501 General Description.............................................................................................................................................................................................................. 501 Fuel System Description...................................................................................................................................................................................................... 501 Fuel Delivery System Description............................................................................................................................................................................................. 501 Fuel Pump Description........................................................................................................................................................................................................ 502 Schematic and Routing Diagram.................................................................................................................................................................................................... 502 Fuel Delivery System Diagram................................................................................................................................................................................................. 502 Diagnostic Information and Procedures............................................................................................................................................................................................ 503 Fuel Pressure Inspection..................................................................................................................................................................................................... 503 Fuel Cut Operation Inspection................................................................................................................................................................................................ 504 Repair Instructions.............................................................................................................................................................................................................. 505 Fuel System Components....................................................................................................................................................................................................... 505 Fuel Hose Disconnecting and Reconnecting..................................................................................................................................................................................... 508 Fuel Pressure Relief Procedure............................................................................................................................................................................................... 510 Fuel Leakage Check Procedure................................................................................................................................................................................................. 510 Fuel Lines On-Vehicle Inspection............................................................................................................................................................................................. 511 Fuel Pipe Removal and Installation........................................................................................................................................................................................... 511 Fuel Injector On-Vehicle Inspection.......................................................................................................................................................................................... 511 Fuel Injector Removal and Installation....................................................................................................................................................................................... 512 Fuel Injector Inspection..................................................................................................................................................................................................... 513 Fuel Pressure Regulator Removal and Installation............................................................................................................................................................................. 515 Fuel Pressure Regulator Inspection........................................................................................................................................................................................... 515 Fuel Filler Cap Inspection................................................................................................................................................................................................... 516 Fuel Tank Inlet Valve Removal and Installation............................................................................................................................................................................... 516 Fuel Tank Inlet Valve Inspection............................................................................................................................................................................................. 517 Fuel Tank Removal and Installation........................................................................................................................................................................................... 517 Fuel Tank Inspection......................................................................................................................................................................................................... 519 Fuel Tank Purging Procedure.................................................................................................................................................................................................. 519 Fuel Pump On-Vehicle Inspection.............................................................................................................................................................................................. 519 Fuel Pump Assembly Removal and Installation.................................................................................................................................................................................. 520 Main Fuel Level Sensor Removal and Installation.............................................................................................................................................................................. 521 Fuel Pump Inspection......................................................................................................................................................................................................... 521 Sub Fuel Level Sensor Removal and Installation............................................................................................................................................................................... 521 Sub Fuel Level Sensor Inspection............................................................................................................................................................................................. 522 Specifications................................................................................................................................................................................................................... 522 Tightening Torque Specifications............................................................................................................................................................................................. 522 Special Tools and Equipment...................................................................................................................................................................................................... 523 Recommended Service Material................................................................................................................................................................................................. 523 Special Tool................................................................................................................................................................................................................. 523 Ignition System...................................................................................................................................................................................................................... 524 General Description.............................................................................................................................................................................................................. 524 Ignition System Construction................................................................................................................................................................................................. 524 Schematic and Routing Diagram.................................................................................................................................................................................................... 525 Ignition System Wiring Circuit Diagram....................................................................................................................................................................................... 525 Component Location............................................................................................................................................................................................................... 526 Ignition System Components Location.......................................................................................................................................................................................... 526 Diagnostic Information and Procedures............................................................................................................................................................................................ 527 Ignition System Symptom Diagnosis............................................................................................................................................................................................ 527 Reference Waveform of Ignition System........................................................................................................................................................................................ 527 Ignition System Check........................................................................................................................................................................................................ 527 Ignition Spark Test.......................................................................................................................................................................................................... 529 Repair Instructions.............................................................................................................................................................................................................. 530 High-Tension Cord Removal and Installation (For M16 Engine).................................................................................................................................................................. 530 High-Tension Cord Inspection (For M16 Engine)................................................................................................................................................................................ 530 Spark Plug Removal and Installation.......................................................................................................................................................................................... 530 Spark Plug Inspection........................................................................................................................................................................................................ 531 Ignition Coil Assembly (Including ignitor) Removal and Installation.......................................................................................................................................................... 531 Ignition Coil Assembly (Including ignitor) Inspection........................................................................................................................................................................ 532 Ignition Timing Inspection................................................................................................................................................................................................... 532 Specifications................................................................................................................................................................................................................... 534 Tightening Torque Specifications............................................................................................................................................................................................. 534 Special Tools and Equipment...................................................................................................................................................................................................... 534 Special Tool................................................................................................................................................................................................................. 534 Starting System...................................................................................................................................................................................................................... 535 Precautions...................................................................................................................................................................................................................... 535 Cranking System Note......................................................................................................................................................................................................... 535 General Description.............................................................................................................................................................................................................. 535 Cranking Circuit Introduction................................................................................................................................................................................................ 535 Starting Motor Circuit Description........................................................................................................................................................................................... 535 Diagnostic Information and Procedures............................................................................................................................................................................................ 536 Cranking System Symptom Diagnosis............................................................................................................................................................................................ 536 Starting Motor Performance Test.............................................................................................................................................................................................. 537 Repair Instructions.............................................................................................................................................................................................................. 539 Starting Motor Dismounting and Remounting.................................................................................................................................................................................... 539 Starting Motor Components.................................................................................................................................................................................................... 540 Starting Motor Inspection.................................................................................................................................................................................................... 541 Specifications................................................................................................................................................................................................................... 544 Starting Motor Specifications................................................................................................................................................................................................ 544 Tightening Torque Specifications............................................................................................................................................................................................. 544 Special Tools and Equipment...................................................................................................................................................................................................... 544 Recommended Service Material................................................................................................................................................................................................. 544 Charging System...................................................................................................................................................................................................................... 545 General Description.............................................................................................................................................................................................................. 545 Battery Description.......................................................................................................................................................................................................... 545 Generator Description........................................................................................................................................................................................................ 546 Diagnostic Information and Procedures............................................................................................................................................................................................ 547 Battery Inspection........................................................................................................................................................................................................... 547 Generator Symptom Diagnosis.................................................................................................................................................................................................. 548 Generator Test (Undercharged Battery Check).................................................................................................................................................................................. 548 Generator Test (Overcharged Battery Check)................................................................................................................................................................................... 549 Repair Instructions.............................................................................................................................................................................................................. 550 Jump Starting in Case of Emergency........................................................................................................................................................................................... 550 Battery Dismounting and Remounting........................................................................................................................................................................................... 551 Water Pump and Generator Drive Belt Removal and Installation (For M16 Engine)................................................................................................................................................ 551 Water Pump and Generator Drive Belt Tension Inspection and Adjustment (For M16 Engine)....................................................................................................................................... 552 Water Pump and Generator Drive Belt On-Vehicle Inspection (For J20 Engine)................................................................................................................................................... 553 Water Pump and Generator Drive Belt Removal and Installation (For J20 Engine)................................................................................................................................................ 554 Generator Dismounting and Remounting......................................................................................................................................................................................... 555 Generator Components......................................................................................................................................................................................................... 556 Generator Inspection......................................................................................................................................................................................................... 557 Specifications................................................................................................................................................................................................................... 560 Charging System Specifications............................................................................................................................................................................................... 560 Tightening Torque Specifications............................................................................................................................................................................................. 560 Exhaust System....................................................................................................................................................................................................................... 561 General Description.............................................................................................................................................................................................................. 561 Exhaust System Description................................................................................................................................................................................................... 561 Diagnostic Information and Procedures............................................................................................................................................................................................ 561 Exhaust System Check......................................................................................................................................................................................................... 561 Repair Instructions.............................................................................................................................................................................................................. 561 Exhaust System Components.................................................................................................................................................................................................... 561 Exhaust Manifold Removal and Installation (For M16 Engine Model)............................................................................................................................................................. 564 Exhaust Manifold Removal and Installation (For J20 Engine Model)............................................................................................................................................................. 564 Exhaust Pipe and Muffler Removal and Installation............................................................................................................................................................................ 565 Specifications................................................................................................................................................................................................................... 566 Tightening Torque Specifications............................................................................................................................................................................................. 566 Suspension............................................................................................................................................................................................................................... 567 Precautions.......................................................................................................................................................................................................................... 569 Precautions...................................................................................................................................................................................................................... 569 Precautions on Suspension.................................................................................................................................................................................................... 569 Suspension General Diagnosis......................................................................................................................................................................................................... 570 Diagnostic Information and Procedures............................................................................................................................................................................................ 570 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................................................................................................... 570 Specifications................................................................................................................................................................................................................... 572 Wheel Alignment Specifications............................................................................................................................................................................................... 572 Front Suspension..................................................................................................................................................................................................................... 573 General Description.............................................................................................................................................................................................................. 573 Front Suspension Construction................................................................................................................................................................................................ 573 Front Wheel Alignment Construction........................................................................................................................................................................................... 574 Repair Instructions.............................................................................................................................................................................................................. 574 Front Wheel Alignment Inspection and Adjustment.............................................................................................................................................................................. 574 Front Strut Assembly Components.............................................................................................................................................................................................. 576 Front Strut Assembly Removal and Installation................................................................................................................................................................................ 577 Front Strut Assembly Disassembly and Assembly................................................................................................................................................................................ 579 Front Strut Assembly Check................................................................................................................................................................................................... 580 Front Wheel Hub Assembly and Steering Knuckle Components..................................................................................................................................................................... 581 Front Wheel Hub Assembly Removal and Installation............................................................................................................................................................................ 581 Steering Knuckle Removal and Installation.................................................................................................................................................................................... 583 Front Wheel Hub, Disc, Nut and Bearing Check................................................................................................................................................................................. 584 Suspension Control Arm Removal and Installation.............................................................................................................................................................................. 585 Suspension Control Arm / Bushing Disassembly and Assembly.................................................................................................................................................................... 587 Suspension Control Arm / Steering Knuckle Check.............................................................................................................................................................................. 588 Suspension Control Arm Bushing Check......................................................................................................................................................................................... 588 Suspension Control Arm Joint Check........................................................................................................................................................................................... 588 Front Suspension Frame, Stabilizer Bar and/or Bushings Components............................................................................................................................................................ 589 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation.............................................................................................................................................. 590 Front Suspension Frame Check................................................................................................................................................................................................. 594 Front Stabilizer Bar, Bushing and/or Joint Check............................................................................................................................................................................. 594 Front Suspension Fasteners Check............................................................................................................................................................................................. 595 Specifications................................................................................................................................................................................................................... 595 Tightening Torque Specifications............................................................................................................................................................................................. 595 Special Tools and Equipment...................................................................................................................................................................................................... 596 Recommended Service Material................................................................................................................................................................................................. 596 Special Tool................................................................................................................................................................................................................. 596 Rear Suspension...................................................................................................................................................................................................................... 597 General Description.............................................................................................................................................................................................................. 597 Rear Suspension Construction................................................................................................................................................................................................. 597 Rear Wheel Alignment Construction............................................................................................................................................................................................ 598 Repair Instructions.............................................................................................................................................................................................................. 598 Rear Wheel Alignment Inspection and Adjustment............................................................................................................................................................................... 598 Rear Shock Absorber and Rear Coil Spring Components.......................................................................................................................................................................... 600 Rear Shock Absorber Removal and Installation................................................................................................................................................................................. 601 Shock Absorber Check......................................................................................................................................................................................................... 602 Rear Coil Spring and Bump Stopper Removal and Installation................................................................................................................................................................... 602 Rear Coil Spring Check....................................................................................................................................................................................................... 604 Rod and Arm Components....................................................................................................................................................................................................... 605 Control Rod Removal and Installation......................................................................................................................................................................................... 606 Control Rod / Bushing Disassembly and Assembly............................................................................................................................................................................... 608 Control Rod Check............................................................................................................................................................................................................ 608 Trailing Rod Removal and Installation........................................................................................................................................................................................ 609 Trailing Rod / Bushing Disassembly and Assembly.............................................................................................................................................................................. 610 Trailing Rod Check........................................................................................................................................................................................................... 611 Lower Arm Removal and Installation........................................................................................................................................................................................... 611 Lower Arm / Bushing Disassembly and Assembly................................................................................................................................................................................. 612 Lower Arm Check.............................................................................................................................................................................................................. 613 Upper Arm Removal and Installation........................................................................................................................................................................................... 613 Upper Arm / Bushing Disassembly and Assembly................................................................................................................................................................................. 615 Upper Arm Check.............................................................................................................................................................................................................. 615 Rear Suspension Frame Components............................................................................................................................................................................................. 616 Rear Suspension Frame Removal and Installation............................................................................................................................................................................... 617 Rear Suspension frame / Bushing Disassembly and Assembly..................................................................................................................................................................... 619 Rear Suspension Frame, Bushing and Pad Check................................................................................................................................................................................. 620 Rear Wheel Hub Assembly and Rear Suspension Knuckle Components............................................................................................................................................................... 620 Rear Wheel Hub Assembly Removal and Installation............................................................................................................................................................................. 621 Rear Wheel Hub Assembly, Wheel Bearing and Wheel Stud Inspection............................................................................................................................................................. 623 Rear Wheel Disc, Nut and Bearing Check....................................................................................................................................................................................... 623 Rear Suspension knuckle Removal and Installation............................................................................................................................................................................. 624 Rear Suspension Knuckle Check................................................................................................................................................................................................ 627 Rear Suspension Fasteners Check.............................................................................................................................................................................................. 627 Specifications................................................................................................................................................................................................................... 628 Tightening Torque Specifications............................................................................................................................................................................................. 628 Special Tools and Equipment...................................................................................................................................................................................................... 629 Recommended Service Material................................................................................................................................................................................................. 629 Special Tool................................................................................................................................................................................................................. 629 Wheels and Tires..................................................................................................................................................................................................................... 630 General Description.............................................................................................................................................................................................................. 630 Tires Description............................................................................................................................................................................................................ 630 Wheels Description........................................................................................................................................................................................................... 631 Irregular and/or Premature Wear Description.................................................................................................................................................................................. 631 Wear Indicators Description.................................................................................................................................................................................................. 632 Radial Tire Waddle Description............................................................................................................................................................................................... 632 Radial Tire Lead / Pull Description.......................................................................................................................................................................................... 633 Balancing Wheels Description................................................................................................................................................................................................. 633 Repair Instructions.............................................................................................................................................................................................................. 634 General Balance Procedures................................................................................................................................................................................................... 634 Tire Rotation................................................................................................................................................................................................................ 634 Wheel Removal and Installation............................................................................................................................................................................................... 635 Tire Mounting and Dismounting................................................................................................................................................................................................ 635 Tire Repair.................................................................................................................................................................................................................. 635 Specifications................................................................................................................................................................................................................... 636 Wheels and Tires Specifications.............................................................................................................................................................................................. 636 Tightening Torque Specifications............................................................................................................................................................................................. 636 Driveline / Axle......................................................................................................................................................................................................................... 637 Precautions.......................................................................................................................................................................................................................... 640 Precautions...................................................................................................................................................................................................................... 640 Precautions for Driveline / Axle............................................................................................................................................................................................. 640 Drive Shaft / Axle................................................................................................................................................................................................................... 641 Front............................................................................................................................................................................................................................ 641 General Description.......................................................................................................................................................................................................... 641 Front Drive Shaft Construction........................................................................................................................................................................................... 641 Diagnostic Information and Procedures........................................................................................................................................................................................ 641 Front Drive Shaft Symptom Diagnosis...................................................................................................................................................................................... 641 Repair Instructions.......................................................................................................................................................................................................... 642 Front Drive Shaft Boot and Joint Check................................................................................................................................................................................... 642 Front Drive Shaft Components............................................................................................................................................................................................. 642 Front Drive Shaft Assembly Removal and Installation...................................................................................................................................................................... 643 Front Drive Shaft Disassembly and Assembly............................................................................................................................................................................... 643 Specifications............................................................................................................................................................................................................... 646 Tightening Torque Specifications......................................................................................................................................................................................... 646 Special Tools and Equipment.................................................................................................................................................................................................. 646 Recommended Service Material............................................................................................................................................................................................. 646 Special Tool............................................................................................................................................................................................................. 646 Rear............................................................................................................................................................................................................................. 647 General Description.......................................................................................................................................................................................................... 647 Rear Drive Shaft Construction............................................................................................................................................................................................ 647 Repair Instructions.......................................................................................................................................................................................................... 647 Rear Drive Shaft Components.............................................................................................................................................................................................. 647 Rear Drive Shaft Assembly Removal and Installation....................................................................................................................................................................... 648 Rear Drive Shaft Disassembly and Assembly................................................................................................................................................................................ 648 Specifications............................................................................................................................................................................................................... 649 Tightening Torque Specifications......................................................................................................................................................................................... 649 Special Tools and Equipment.................................................................................................................................................................................................. 649 Recommended Service Material............................................................................................................................................................................................. 649 Special Tool............................................................................................................................................................................................................. 649 Differential......................................................................................................................................................................................................................... 650 Front............................................................................................................................................................................................................................ 650 General Description.......................................................................................................................................................................................................... 650 Front Differential Construction.......................................................................................................................................................................................... 650 Diagnostic Information and Procedures........................................................................................................................................................................................ 650 Front Differential Symptom Diagnosis..................................................................................................................................................................................... 650 Repair Instructions.......................................................................................................................................................................................................... 651 Front Differential Oil Change............................................................................................................................................................................................ 651 Front Differential Unit Components....................................................................................................................................................................................... 652 Front Differential Dismounting and Remounting............................................................................................................................................................................ 652 Front Differential Components............................................................................................................................................................................................ 653 Front Differential Assembly Disassembly and Reassembly................................................................................................................................................................... 654 Front Differential Inspection............................................................................................................................................................................................ 666 Specifications............................................................................................................................................................................................................... 667 Tightening Torque Specifications......................................................................................................................................................................................... 667 Special Tools and Equipment.................................................................................................................................................................................................. 667 Recommended Service Material............................................................................................................................................................................................. 667 Special Tool............................................................................................................................................................................................................. 667 Rear............................................................................................................................................................................................................................. 670 General Description.......................................................................................................................................................................................................... 670 Rear Differential Construction........................................................................................................................................................................................... 670 Diagnostic Information and Procedures........................................................................................................................................................................................ 670 Rear Differential Symptom Diagnosis...................................................................................................................................................................................... 670 Repair Instructions.......................................................................................................................................................................................................... 670 Rear Differential Oil Change............................................................................................................................................................................................. 670 Rear Differential Unit Components........................................................................................................................................................................................ 670 Rear Differential Dismounting and Remounting............................................................................................................................................................................. 671 Rear Differential Components............................................................................................................................................................................................. 672 Rear Differential Assembly Disassembly and Reassembly.................................................................................................................................................................... 673 Rear Differential Inspection............................................................................................................................................................................................. 685 Specifications............................................................................................................................................................................................................... 685 Tightening Torque Specifications......................................................................................................................................................................................... 685 Special Tools and Equipment.................................................................................................................................................................................................. 686 Recommended Service Material............................................................................................................................................................................................. 686 Special Tool............................................................................................................................................................................................................. 686 Transfer............................................................................................................................................................................................................................. 689 Motor-Shift Type (Transfer with Shift Actuator).................................................................................................................................................................................. 689 Precautions.................................................................................................................................................................................................................. 689 Transfer Warning......................................................................................................................................................................................................... 689 Precautions in Diagnosing Trouble........................................................................................................................................................................................ 689 General Description.......................................................................................................................................................................................................... 689 Transfer Description..................................................................................................................................................................................................... 689 Transfer Shift Control System Components................................................................................................................................................................................. 690 4WD Control System Description........................................................................................................................................................................................... 691 Function of 4WD Control System Component................................................................................................................................................................................. 693 4WD Control System Operation............................................................................................................................................................................................. 693 4WD Control System Wiring Circuit Diagram................................................................................................................................................................................ 699 Terminal Arrangement of 4WD Control Module............................................................................................................................................................................... 700 Input / Output Signal Table of 4WD Control Module........................................................................................................................................................................ 700 On-Board Diagnostic System Description................................................................................................................................................................................... 700 CAN Communication System Description..................................................................................................................................................................................... 701 Diagnostic Information and Procedures........................................................................................................................................................................................ 702 4WD Control System Check................................................................................................................................................................................................. 702 Transfer Position Indicator Operation Check.............................................................................................................................................................................. 705 4WD Control System Operation Inspection.................................................................................................................................................................................. 705 Visual Inspection........................................................................................................................................................................................................ 706 DTC Check................................................................................................................................................................................................................ 707 DTC Clearance............................................................................................................................................................................................................ 708 DTC Table................................................................................................................................................................................................................ 708 Fail-Safe Table.......................................................................................................................................................................................................... 709 Scan Tool Data........................................................................................................................................................................................................... 710 Scan Tool Data Definitions............................................................................................................................................................................................... 710 4WD Control Symptom Diagnosis............................................................................................................................................................................................ 711 Transfer Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops...................................................................................................................................... 712 Transfer Position Indicator Remains ON Steady at Ignition Switch ON...................................................................................................................................................... 714 DTC C1213: Transfer Switch Circuit Open.................................................................................................................................................................................. 715 DTC C1214: Transfer Switch Circuit Short................................................................................................................................................................................. 716 DTC C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open........................................................................... 718 DTC C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short......................................................................... 720 DTC C1227: 4L/N Switch Circuit Open...................................................................................................................................................................................... 722 DTC C1228: 4L/N Switch Circuit Short..................................................................................................................................................................................... 723 DTC C1230: Transfer Actuator Circuit Malfunction......................................................................................................................................................................... 725 DTC C1237: Center Differential Lock Switch Circuit Open.................................................................................................................................................................. 726 DTC C1238: Center Differential Lock Switch Circuit Short................................................................................................................................................................. 728 DTC C1240: 4WD Control Module Power Supply Circuit Malfunction........................................................................................................................................................... 729 DTC C1243: Internal Circuit Malfunction of 4WD Control Module............................................................................................................................................................ 730 DTC C1246: Clutch Pedal Position (CPP) Switch Circuit Short.............................................................................................................................................................. 731 DTC U1073: Control Module Communication Buss Off......................................................................................................................................................................... 732 DTC U1100: Lost Communication with ECM................................................................................................................................................................................... 734 DTC U1101: Lost Communication with TCM................................................................................................................................................................................... 736 DTC U1121: Lost Communication with ABS Hydraulic Unit / Control Module................................................................................................................................................... 738 Inspection of 4WD Control Module and Its Circuits........................................................................................................................................................................ 739 Repair Instructions.......................................................................................................................................................................................................... 742 Transfer Oil Level Check................................................................................................................................................................................................. 742 Transfer Oil Change...................................................................................................................................................................................................... 742 Transfer Oil Seal Removal and Installation............................................................................................................................................................................... 743 Transfer Switch Removal and Installation................................................................................................................................................................................. 743 Transfer Switch Inspection............................................................................................................................................................................................... 744 4WD Control Module Removal and Installation.............................................................................................................................................................................. 744 Transfer Assembly Dismounting and Remounting............................................................................................................................................................................. 745 Transfer Assembly Components............................................................................................................................................................................................. 746 Transfer Assembly Disassembly and Reassembly............................................................................................................................................................................. 747 Transfer Assembly Inspection............................................................................................................................................................................................. 755 Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft Assembly Components........................................................................................................ 757 Input Gear Assembly Disassembly and Reassembly........................................................................................................................................................................... 758 Counter Gear Assembly Disassembly and Reassembly......................................................................................................................................................................... 759 Front Output Shaft Assembly Disassembly and Reassembly................................................................................................................................................................... 759 Rear Output Shaft Assembly Disassembly and Reassembly.................................................................................................................................................................... 760 Specifications............................................................................................................................................................................................................... 761 Tightening Torque Specifications......................................................................................................................................................................................... 761 Special Tools and Equipment.................................................................................................................................................................................................. 761 Recommended Service Material............................................................................................................................................................................................. 761 Special Tool............................................................................................................................................................................................................. 762 Non-Shift Type (Transfer without Shift Actuator)................................................................................................................................................................................. 763 Precautions.................................................................................................................................................................................................................. 763 Transfer Warning......................................................................................................................................................................................................... 763 General Description.......................................................................................................................................................................................................... 763 Transfer Construction.................................................................................................................................................................................................... 763 Diagnostic Information and Procedures........................................................................................................................................................................................ 764 Transfer Symptom Diagnosis............................................................................................................................................................................................... 764 Repair Instructions.......................................................................................................................................................................................................... 765 Transfer Oil Change...................................................................................................................................................................................................... 765 Transfer Oil Level Check................................................................................................................................................................................................. 765 Transfer Oil Seal Removal and Installation............................................................................................................................................................................... 765 Transfer Assembly Dismounting and Remounting............................................................................................................................................................................. 765 Transfer Assembly Components............................................................................................................................................................................................. 766 Transfer Assembly Disassembly and Reassembly............................................................................................................................................................................. 768 Input Gear Assembly Disassembly and Reassembly........................................................................................................................................................................... 774 Front Output Shaft Assembly Disassembly and Reassembly................................................................................................................................................................... 774 Rear Output Shaft Assembly Disassembly and Reassembly.................................................................................................................................................................... 774 Specifications............................................................................................................................................................................................................... 775 Tightening Torque Specifications......................................................................................................................................................................................... 775 Special Tools and Equipment.................................................................................................................................................................................................. 775 Recommended Service Material............................................................................................................................................................................................. 775 Special Tool............................................................................................................................................................................................................. 775 Propeller Shafts..................................................................................................................................................................................................................... 776 Precautions...................................................................................................................................................................................................................... 776 Propeller Shaft Caution...................................................................................................................................................................................................... 776 General Description.............................................................................................................................................................................................................. 776 Propeller Shaft Construction................................................................................................................................................................................................. 776 Diagnostic Information and Procedures............................................................................................................................................................................................ 777 Propeller Shaft Symptom Diagnosis............................................................................................................................................................................................ 777 Repair Instructions.............................................................................................................................................................................................................. 777 Propeller Shaft Joint Check.................................................................................................................................................................................................. 777 Propeller Shaft Removal and Installation..................................................................................................................................................................................... 777 Propeller Shaft Disassembly and Assembly..................................................................................................................................................................................... 778 Propeller Shaft Inspection................................................................................................................................................................................................... 780 Specifications................................................................................................................................................................................................................... 780 Tightening Torque Specifications............................................................................................................................................................................................. 780 Special Tools and Equipment...................................................................................................................................................................................................... 781 Recommended Service Material................................................................................................................................................................................................. 781 Special Tool................................................................................................................................................................................................................. 781 Brakes................................................................................................................................................................................................................................... 783 Precautions.......................................................................................................................................................................................................................... 785 Precautions...................................................................................................................................................................................................................... 785 Precautions for Brakes....................................................................................................................................................................................................... 785 Brake Control System and Diagnosis................................................................................................................................................................................................... 786 General Description.............................................................................................................................................................................................................. 786 Brakes Construction.......................................................................................................................................................................................................... 786 Front Brake Hose / Pipe Construction......................................................................................................................................................................................... 787 Rear Brake Hose / Pipe Construction.......................................................................................................................................................................................... 788 Master Cylinder Assembly Construction........................................................................................................................................................................................ 788 Booster Assembly Construction................................................................................................................................................................................................ 789 Diagnostic Information and Procedures............................................................................................................................................................................................ 789 Brake Diagnosis Note......................................................................................................................................................................................................... 789 Brakes Symptom Diagnosis..................................................................................................................................................................................................... 790 Repair Instructions.............................................................................................................................................................................................................. 792 Excessive Pedal Travel Check................................................................................................................................................................................................. 792 Brake Pedal Play Check....................................................................................................................................................................................................... 792 Brake Fluid Level Check...................................................................................................................................................................................................... 792 Air Bleeding of Brake System................................................................................................................................................................................................. 793 Brake Pedal Free Height Adjustment........................................................................................................................................................................................... 794 Brake Light Switch Adjustment................................................................................................................................................................................................ 794 Brake Flexible Hose and Pipe Check........................................................................................................................................................................................... 794 Master Cylinder Check........................................................................................................................................................................................................ 794 Flushing Brake Hydraulic System.............................................................................................................................................................................................. 795 Booster Operation Check...................................................................................................................................................................................................... 795 Front Brake Hose / Pipe Removal and Installation............................................................................................................................................................................. 796 Rear Brake Hose / Pipe Removal and Installation.............................................................................................................................................................................. 796 Master Cylinder Components................................................................................................................................................................................................... 797 Master Cylinder Reservoir Removal and Installation........................................................................................................................................................................... 798 Master Cylinder Assembly Removal and Installation............................................................................................................................................................................ 799 Master Cylinder Assembly Inspection.......................................................................................................................................................................................... 800 Brake Booster Components..................................................................................................................................................................................................... 801 Brake Booster Removal and Installation....................................................................................................................................................................................... 802 Booster Push Rod Clevis Adjustment........................................................................................................................................................................................... 802 Specifications................................................................................................................................................................................................................... 803 Tightening Torque Specifications............................................................................................................................................................................................. 803 Special Tools and Equipment...................................................................................................................................................................................................... 803 Recommended Service Material................................................................................................................................................................................................. 803 Special Tool................................................................................................................................................................................................................. 803 Front Brakes......................................................................................................................................................................................................................... 804 General Description.............................................................................................................................................................................................................. 804 Front Disc Brake Caliper Assembly Construction............................................................................................................................................................................... 804 Repair Instructions.............................................................................................................................................................................................................. 805 Front Disc Brake Components.................................................................................................................................................................................................. 805 Front Disc Brake Pad On-Vehicle Check........................................................................................................................................................................................ 806 Front Disc Brake Pad Removal and Installation................................................................................................................................................................................ 806 Front Brake Disc and Pad Inspection.......................................................................................................................................................................................... 807 Front Disc Brake Caliper Removal and Installation............................................................................................................................................................................ 808 Front Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................ 809 Front Disc Brake Caliper Inspection.......................................................................................................................................................................................... 810 Front Brake Disc Removal and Installation.................................................................................................................................................................................... 811 Front Brake Disc Inspection.................................................................................................................................................................................................. 811 Specifications................................................................................................................................................................................................................... 812 Tightening Torque Specifications............................................................................................................................................................................................. 812 Special Tools and Equipment...................................................................................................................................................................................................... 812 Recommended Service Material................................................................................................................................................................................................. 812 Rear Brakes.......................................................................................................................................................................................................................... 813 General Description.............................................................................................................................................................................................................. 813 Rear Drum Brake Assembly Construction........................................................................................................................................................................................ 813 Repair Instructions.............................................................................................................................................................................................................. 814 Rear Drum Brake Assembly Components.......................................................................................................................................................................................... 814 Rear Brake Drum Removal and Installation..................................................................................................................................................................................... 815 Rear Brake Drum and Shoe Inspection.......................................................................................................................................................................................... 816 Rear Brake Shoe On-Vehicle Check............................................................................................................................................................................................. 816 Rear Brake Shoe Removal and Installation..................................................................................................................................................................................... 817 Rear Brake Shoe Inspection................................................................................................................................................................................................... 818 Wheel Cylinder Removal and Installation...................................................................................................................................................................................... 818 Wheel Cylinder Inspection.................................................................................................................................................................................................... 819 Rear Brake Back Plate Removal and Installation............................................................................................................................................................................... 819 Specifications................................................................................................................................................................................................................... 821 Tightening Torque Specifications............................................................................................................................................................................................. 821 Special Tools and Equipment...................................................................................................................................................................................................... 821 Recommended Service Material................................................................................................................................................................................................. 821 Parking Brake........................................................................................................................................................................................................................ 822 Component Location............................................................................................................................................................................................................... 822 Parking Brake Cable Location................................................................................................................................................................................................. 822 Repair Instructions.............................................................................................................................................................................................................. 823 Parking Brake Check and Adjustment........................................................................................................................................................................................... 823 Parking Brake Lever Removal and Installation................................................................................................................................................................................. 824 Parking Brake Cable Removal and Installation................................................................................................................................................................................. 824 Specifications................................................................................................................................................................................................................... 825 Tightening Torque Specifications............................................................................................................................................................................................. 825 ABS.................................................................................................................................................................................................................................. 826 Precautions...................................................................................................................................................................................................................... 826 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 826 Precautions in On-Vehicle Service............................................................................................................................................................................................ 826 General Description.............................................................................................................................................................................................................. 826 ABS Description.............................................................................................................................................................................................................. 826 ABS Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................... 827 CAN Communication System Description......................................................................................................................................................................................... 827 Schematic and Routing Diagram.................................................................................................................................................................................................... 828 ABS Schematic................................................................................................................................................................................................................ 828 ABS Wiring Circuit Diagram................................................................................................................................................................................................... 829 Component Location............................................................................................................................................................................................................... 831 ABS Components Location...................................................................................................................................................................................................... 831 Diagnostic Information and Procedures............................................................................................................................................................................................ 832 ABS Check.................................................................................................................................................................................................................... 832 ABS Warning Lamp Check....................................................................................................................................................................................................... 834 EBD Warning Lamp (Brake Warning Lamp) Check.................................................................................................................................................................................. 834 DTC Check.................................................................................................................................................................................................................... 834 DTC Table.................................................................................................................................................................................................................... 835 DTC Clearance................................................................................................................................................................................................................ 835 Scan Tool Data............................................................................................................................................................................................................... 835 ABS Warning Lamp Does Not Come ON at Ignition Switch ON...................................................................................................................................................................... 836 ABS Warning Lamp Comes ON Steady............................................................................................................................................................................................. 838 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON............................................................................................................................................................ 840 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady........................................................................................................................................................................ 841 Serial Data Link Circuit Check............................................................................................................................................................................................... 842 DTC C1015: G Sensor Circuit.................................................................................................................................................................................................. 844 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder...................................................................... 845 DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit.... 847 DTC C1057: Power Source Circuit.............................................................................................................................................................................................. 848 DTC C1061: ABS Pump Motor and/or Motor Driver Circuit........................................................................................................................................................................ 849 DTC C1063: Solenoid Valve Power Supply Driver Circuit........................................................................................................................................................................ 850 DTC C1071: ABS Control Module................................................................................................................................................................................................ 851 DTC U1073: Control Module Communication Bus Off.............................................................................................................................................................................. 852 DTC U1100: Lost Communication with ECM (Reception Error)..................................................................................................................................................................... 854 Repair Instructions.............................................................................................................................................................................................................. 855 ABS Hydraulic Unit Operation Check........................................................................................................................................................................................... 855 ABS Hydraulic Unit / Control Module Assembly Components...................................................................................................................................................................... 856 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................... 856 ABS Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................................................................................................ 857 Front Wheel Speed Sensor On-Vehicle Inspection............................................................................................................................................................................... 859 Front Wheel Speed Sensor Removal and Installation............................................................................................................................................................................ 860 Front Wheel Speed Sensor Inspection.......................................................................................................................................................................................... 861 Rear Wheel Speed Sensor On-Vehicle Inspection................................................................................................................................................................................ 861 Rear Wheel Speed Sensor Removal and Installation............................................................................................................................................................................. 861 Rear Wheel Speed Sensor Inspection........................................................................................................................................................................................... 862 Front Wheel Encoder On-Vehicle Inspection.................................................................................................................................................................................... 862 Front Wheel Encoder Removal and Installation................................................................................................................................................................................. 862 Rear Wheel Encoder On-Vehicle Inspection..................................................................................................................................................................................... 862 Rear Wheel Encoder Removal and Installation.................................................................................................................................................................................. 862 Specifications................................................................................................................................................................................................................... 863 Tightening Torque Specifications............................................................................................................................................................................................. 863 Special Tools and Equipment...................................................................................................................................................................................................... 863 Special Tool................................................................................................................................................................................................................. 863 Transmission / Transaxle................................................................................................................................................................................................................. 865 Precautions.......................................................................................................................................................................................................................... 868 Precautions...................................................................................................................................................................................................................... 868 Precautions for Transmission / Transaxle..................................................................................................................................................................................... 868 Automatic Transmission/Transaxle..................................................................................................................................................................................................... 869 Precautions...................................................................................................................................................................................................................... 869 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 869 General Service Procedure Information........................................................................................................................................................................................ 869 Precautions for Disassembly and Reassembly................................................................................................................................................................................... 869 General Description.............................................................................................................................................................................................................. 871 Automatic Transmission Description........................................................................................................................................................................................... 871 Clutch / Brake Functions of Automatic Transmission........................................................................................................................................................................... 873 Table of A/T System Component Operation...................................................................................................................................................................................... 874 CAN Communication System Description......................................................................................................................................................................................... 875 Electronic Shift Control Input / Output Table................................................................................................................................................................................ 876 Brake Interlock System Description........................................................................................................................................................................................... 879 A/T Diagnosis General Description............................................................................................................................................................................................ 879 On-Board Diagnostic System Description....................................................................................................................................................................................... 879 Schematic and Routing Diagram.................................................................................................................................................................................................... 881 Automatic Gear Shift Table................................................................................................................................................................................................... 881 Bearing and Race Installation Diagram........................................................................................................................................................................................ 884 Component Location............................................................................................................................................................................................................... 885 Electronic Shift Control System Components Location.......................................................................................................................................................................... 885 Diagnostic Information and Procedures............................................................................................................................................................................................ 886 A/T System Check............................................................................................................................................................................................................. 886 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 888 Transmission Warning Light Operation Check (Vehicle is Equipped with Engine Diagnosis Connector)............................................................................................................................. 888 “POWER” Lamp Operation Check................................................................................................................................................................................................. 888 DTC Table.................................................................................................................................................................................................................... 889 DTC Check.................................................................................................................................................................................................................... 890 DTC Clearance................................................................................................................................................................................................................ 891 Fail Safe Table.............................................................................................................................................................................................................. 892 Scan Tool Data............................................................................................................................................................................................................... 894 Visual Inspection............................................................................................................................................................................................................ 897 A/T Basic Check.............................................................................................................................................................................................................. 897 Road Test.................................................................................................................................................................................................................... 898 Manual Road Test............................................................................................................................................................................................................. 899 Stall Test................................................................................................................................................................................................................... 900 Time Lag Test................................................................................................................................................................................................................ 901 Line Pressure Test........................................................................................................................................................................................................... 901 Engine Brake Test............................................................................................................................................................................................................ 903 “P” Range Test............................................................................................................................................................................................................... 903 A/T Symptom Diagnosis........................................................................................................................................................................................................ 904 No Gear Shift to 4th Gear.................................................................................................................................................................................................... 911 No Lock-Up Occurs............................................................................................................................................................................................................ 912 Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON (Vehicle is equipped with engine diagnosis connector).............................................................................. 913 Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON (Vehicle is equipped with engine diagnosis connector).................................................................................... 913 “POWER” Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON................................................................................................................................................. 914 DTC P0705 Transmission Range Sensor Circuit Malfunction...................................................................................................................................................................... 914 DTC P0707 Transmission Range Sensor Circuit Low.............................................................................................................................................................................. 916 DTC P0712 Transmission Fluid Temperature Sensor “A” Circuit Low.............................................................................................................................................................. 918 DTC P0713 Transmission Fluid Temperature Sensor “A” Circuit High............................................................................................................................................................. 919 DTC P0717 Input / Turbine Speed Sensor Circuit No Signal..................................................................................................................................................................... 920 DTC P0722 Output Speed Sensor Circuit No Signal.............................................................................................................................................................................. 921 DTC P0741 / P0742 TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON................................................................................................................................................ 922 DTC P0751 / P0752 Shift Solenoid-A Performance or Stuck OFF / Shift Solenoid-A Stuck ON...................................................................................................................................... 923 DTC P0756 / P0757 Shift Solenoid-B Performance or Stuck OFF / Shift Solenoid-B Stuck ON...................................................................................................................................... 924 DTC P0962 Pressure Control Solenoid “A” Control Circuit Low.................................................................................................................................................................. 925 DTC P0963 Pressure Control Solenoid “A” Control Circuit High................................................................................................................................................................. 926 DTC P0973 / P0976 Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low............................................................................................................................ 927 DTC P0974 / P0977 Shift Solenoid “A” Control Circuit High / Shift Solenoid “B” Control Circuit High.......................................................................................................................... 929 DTC P1702 Internal Control Module Memory Check Sum Error..................................................................................................................................................................... 930 DTC P1703 CAN Invalid Data - TCM............................................................................................................................................................................................. 930 DTC P1723 Range Select Switch Malfunction.................................................................................................................................................................................... 931 DTC P1774: CAN Communication Bus Off......................................................................................................................................................................................... 932 DTC P1777: TCM Lost Communication with ECM (Reception Error)................................................................................................................................................................. 934 DTC P1778: TCM Lost Communication with BCM (Reception Error)................................................................................................................................................................. 935 DTC P1874 4L Switch Circuit Malfunction (Short).............................................................................................................................................................................. 936 DTC P1875 4L Switch Circuit Malfunction (Open)............................................................................................................................................................................... 937 DTC P1878 Torque Converter Clutch Shudder.................................................................................................................................................................................... 939 DTC P2763 Torque Converter Clutch (TCC) Circuit High......................................................................................................................................................................... 939 DTC P2764 Torque Converter Clutch (TCC) Circuit Low.......................................................................................................................................................................... 941 Inspection of TCM and Its Circuits........................................................................................................................................................................................... 942 TCM Power and Ground Circuit Check........................................................................................................................................................................................... 946 Repair Instructions.............................................................................................................................................................................................................. 948 A/T Fluid Level Check........................................................................................................................................................................................................ 948 A/T Fluid Change............................................................................................................................................................................................................. 949 Manual Selector Assembly Components.......................................................................................................................................................................................... 949 Manual Selector Assembly Removal and Installation............................................................................................................................................................................ 950 Select Lever Knob Installation............................................................................................................................................................................................... 950 Manual Selector Assembly Inspection.......................................................................................................................................................................................... 950 “3” Position Switch Inspection............................................................................................................................................................................................... 950 Select Cable Component....................................................................................................................................................................................................... 951 Select Cable Adjustment...................................................................................................................................................................................................... 951 Transmission Range Sensor Removal and Installation........................................................................................................................................................................... 952 Transmission Range Sensor Inspection and Adjustment.......................................................................................................................................................................... 952 Key Interlock Cable Removal and Installation................................................................................................................................................................................. 953 Brake and key Interlock System Inspection.................................................................................................................................................................................... 955 Mode Select Switch Inspection................................................................................................................................................................................................ 956 Input Shaft Speed Sensor Removal and Installation............................................................................................................................................................................ 956 Input Shaft Speed Sensor Inspection.......................................................................................................................................................................................... 956 Output Shaft Speed Sensor Removal and Installation........................................................................................................................................................................... 957 Output Shaft Speed Sensor Inspection......................................................................................................................................................................................... 957 Oil Cooler Hose and Pipe Components.......................................................................................................................................................................................... 958 Oil Cooler Hose and Pipes Removal and Installation........................................................................................................................................................................... 958 Solenoid Valves (Shift Solenoid-A, Shift Solenoid-B, TCC Pressure Control Solenoid and Pressure Control Solenoid Removal and Installation.................................................................................... 959 Solenoid Valves (Shift Solenoid-A, Shift Solenoid-B, TCC Pressure Control Solenoid and Pressure Control Solenoid Inspection.................................................................................................. 960 Transmission Fluid Temperature Sensor Removal and Installation............................................................................................................................................................... 961 Transmission Fluid Temperature Sensor Inspection............................................................................................................................................................................. 962 Transmission Control Module (TCM) Removal and Installation................................................................................................................................................................... 963 A/T Relay Inspection......................................................................................................................................................................................................... 963 Automatic Transmission Unit Components....................................................................................................................................................................................... 964 Automatic Transmission Assembly Dismounting and Remounting................................................................................................................................................................... 965 Automatic Transmission Unit Disassembly...................................................................................................................................................................................... 966 Oil Pump Components.......................................................................................................................................................................................................... 971 Oil Pump Disassembly and Assembly............................................................................................................................................................................................ 972 Oil Pump Inspection.......................................................................................................................................................................................................... 972 Overdrive (Planetary Gear Side) Components................................................................................................................................................................................... 974 Overdrive (Planetary Gear Side) Disassembly and Assembly..................................................................................................................................................................... 974 Overdrive (Planetary Gear Side) Inspection................................................................................................................................................................................... 976 Overdrive (Case Side) Components............................................................................................................................................................................................. 977 Overdrive (Case Side) Disassembly and Assembly............................................................................................................................................................................... 978 Overdrive (Case Side) Inspection............................................................................................................................................................................................. 979 Forward Clutch Components.................................................................................................................................................................................................... 980 Forward Clutch Disassembly and Assembly...................................................................................................................................................................................... 980 Forward Clutch Inspection.................................................................................................................................................................................................... 982 Direct Clutch Components..................................................................................................................................................................................................... 983 Direct Clutch Disassembly and Assembly....................................................................................................................................................................................... 983 Direct Clutch Inspection..................................................................................................................................................................................................... 985 Center Support Components.................................................................................................................................................................................................... 986 Center Support Disassembly and Assembly...................................................................................................................................................................................... 987 Center Support Inspection.................................................................................................................................................................................................... 990 Planetary Gears and Output Shaft Components.................................................................................................................................................................................. 991 Planetary Gears and Output Shaft Disassembly and Assembly.................................................................................................................................................................... 992 Planetary Gears and Output Shaft Inspection.................................................................................................................................................................................. 993 Valve Body Assembly Components............................................................................................................................................................................................... 994 Automatic Transmission Unit Assembly......................................................................................................................................................................................... 994 Specifications...................................................................................................................................................................................................................1003 Tightening Torque Specifications.............................................................................................................................................................................................1003 Special Tools and Equipment......................................................................................................................................................................................................1004 Recommended Service Material.................................................................................................................................................................................................1004 Special Tool.................................................................................................................................................................................................................1004 Manual Transmission/Transaxle........................................................................................................................................................................................................1006 General Description..............................................................................................................................................................................................................1006 Manual Transmission Construction.............................................................................................................................................................................................1006 Diagnostic Information and Procedures............................................................................................................................................................................................1007 Manual Transmission Symptom Diagnosis........................................................................................................................................................................................1007 Repair Instructions..............................................................................................................................................................................................................1008 Manual Transmission Assembly Components......................................................................................................................................................................................1008 Gear Shift Control Lever Rear Case Assembly Components.......................................................................................................................................................................1010 Gear Shift Lever Front Case Assembly Components..............................................................................................................................................................................1011 Gear Shift Shaft and Fork Components.........................................................................................................................................................................................1012 Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components.............................................................................................................................................1013 Manual Transmission Oil Change...............................................................................................................................................................................................1014 Transmission Shift Control Lever Removal and Installation....................................................................................................................................................................1015 Transmission Shift Control Lever Inspection..................................................................................................................................................................................1015 Back Up Light Switch Removal and Installation................................................................................................................................................................................1016 Back Up Light Switch Inspection..............................................................................................................................................................................................1016 Gear Shift Control Lever Rear Case Assembly Removal and Installation.........................................................................................................................................................1016 Gear Shift Control Lever Rear Case Assembly Disassembly and Reassembly.......................................................................................................................................................1017 Gear Shift Control Lever Rear Case Assembly Inspection.......................................................................................................................................................................1017 Gear Shift Lever Front Case Assembly Removal and Installation................................................................................................................................................................1017 Gear Shift Lever Front Case Assembly Disassembly and Reassembly..............................................................................................................................................................1018 Gear Shift Lever Front Case Assembly Inspection..............................................................................................................................................................................1019 Engine Rear Mounting Replacement.............................................................................................................................................................................................1019 Manual Transmission Assembly Dismounting and Remounting......................................................................................................................................................................1019 Manual Transmission Unit Disassembly.........................................................................................................................................................................................1022 Manual Transmission Unit Reassembly..........................................................................................................................................................................................1023 Locating Spring Inspection...................................................................................................................................................................................................1026 Input Shaft Disassembly......................................................................................................................................................................................................1026 Input Shaft Inspection.......................................................................................................................................................................................................1027 Input Shaft Reassembly.......................................................................................................................................................................................................1028 Countershaft Disassembly and Assembly........................................................................................................................................................................................1030 Countershaft and Reverse Idle Gear Inspection................................................................................................................................................................................1033 Output Shaft Disassembly and Assembly........................................................................................................................................................................................1034 Output Shaft Inspection......................................................................................................................................................................................................1034 Manual Transmission Front Case Disassembly and Assembly......................................................................................................................................................................1035 Manual Transmission Adapter Case Disassembly and Assembly....................................................................................................................................................................1035 Specifications...................................................................................................................................................................................................................1036 Tightening Torque Specifications.............................................................................................................................................................................................1036 Special Tools and Equipment......................................................................................................................................................................................................1037 Recommended Service Material.................................................................................................................................................................................................1037 Special Tool.................................................................................................................................................................................................................1037 Clutch...............................................................................................................................................................................................................................1039 General Description..............................................................................................................................................................................................................1039 Clutch (Hydraulic Type) Construction.........................................................................................................................................................................................1039 Component Location...............................................................................................................................................................................................................1040 Clutch Fluid Pipe and Hose Location..........................................................................................................................................................................................1040 Diagnostic Information and Procedures............................................................................................................................................................................................1041 Clutch (Hydraulic Type) Symptom Diagnosis....................................................................................................................................................................................1041 Clutch Pedal Height Inspection...............................................................................................................................................................................................1042 Clutch Pedal Free Travel Check...............................................................................................................................................................................................1042 Clutch Fluid Inspection......................................................................................................................................................................................................1042 Air Bleeding of Clutch System................................................................................................................................................................................................1042 Repair Instructions..............................................................................................................................................................................................................1043 Clutch Pedal Position (CPP) Switch Removal and Installation..................................................................................................................................................................1043 Clutch Pedal Position (CPP) Switch Inspection and Adjustment.................................................................................................................................................................1043 Clutch Fluid Pipe and Hose Removal and Installation..........................................................................................................................................................................1043 Clutch Fluid Pipe and Hose Inspection........................................................................................................................................................................................1044 Clutch Master Cylinder Removal and Installation..............................................................................................................................................................................1045 Clutch Master Cylinder Inspection............................................................................................................................................................................................1045 Clutch Operating Cylinder Assembly Removal and Installation..................................................................................................................................................................1046 Clutch Cover, Clutch Disc and Flywheel Components............................................................................................................................................................................1047 Clutch Cover, Clutch Disc and Flywheel Removal and Installation..............................................................................................................................................................1048 Clutch Cover, Clutch Disc and Flywheel Inspection............................................................................................................................................................................1049 Specifications...................................................................................................................................................................................................................1050 Tightening Torque Specifications.............................................................................................................................................................................................1050 Special Tools and Equipment......................................................................................................................................................................................................1050 Recommended Service Material.................................................................................................................................................................................................1050 Special Tool.................................................................................................................................................................................................................1050 Steering.................................................................................................................................................................................................................................1051 Precautions..........................................................................................................................................................................................................................1053 Precautions......................................................................................................................................................................................................................1053 Precautions for Steering.....................................................................................................................................................................................................1053 Steering General Diagnosis...........................................................................................................................................................................................................1054 Diagnostic Information and Procedures............................................................................................................................................................................................1054 Steering Symptom Diagnosis...................................................................................................................................................................................................1054 Steering Wheel and Column............................................................................................................................................................................................................1055 Precautions......................................................................................................................................................................................................................1055 Service Precautions of Air Bag Steering Wheel and Column.....................................................................................................................................................................1055 Handling and Storage of Air Bag Steering Wheel and Column....................................................................................................................................................................1055 Disposal of Air Bag Steering Wheel and Column................................................................................................................................................................................1055 General Description..............................................................................................................................................................................................................1055 Steering Wheel and Column Construction.......................................................................................................................................................................................1055 Diagnostic Information and Procedures............................................................................................................................................................................................1057 Air Bag Steering Wheel and Column Symptom Diagnosis..........................................................................................................................................................................1057 Air Bag Steering Wheel and Column Inspection and Repair Required after Accident..............................................................................................................................................1057 Diagnosis and Servicing of Air Bag Steering Wheel and Column.................................................................................................................................................................1057 Repair Instructions..............................................................................................................................................................................................................1057 Checking Steering Column for Accident Damage.................................................................................................................................................................................1057 Steering Wheel Removal and Installation......................................................................................................................................................................................1058 Contact Coil Cable Assembly Removal and Installation.........................................................................................................................................................................1059 Contact Coil Cable Assembly Inspection.......................................................................................................................................................................................1061 Centering Contact Coil Cable Assembly........................................................................................................................................................................................1061 Steering Column Assembly Removal and Installation............................................................................................................................................................................1061 Steering Column Assembly Inspection..........................................................................................................................................................................................1064 Ignition Switch Cylinder Assembly Removal and Installation (Without Keyless Start System)....................................................................................................................................1064 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................................................................................................1065 Adjustable Steering Column Release Lever Inspection..........................................................................................................................................................................1065 Steering Upper Shaft Assembly Removal and Installation.......................................................................................................................................................................1065 Steering Upper Shaft Assembly Inspection.....................................................................................................................................................................................1066 Steering Lower Shaft Assembly Removal and Installation.......................................................................................................................................................................1067 Specifications...................................................................................................................................................................................................................1068 Tightening Torque Specifications.............................................................................................................................................................................................1068 Special Tools and Equipment......................................................................................................................................................................................................1068 Special Tool.................................................................................................................................................................................................................1068 Power Assisted Steering System.......................................................................................................................................................................................................1069 Precautions......................................................................................................................................................................................................................1069 P/S System Note..............................................................................................................................................................................................................1069 General Description..............................................................................................................................................................................................................1069 P/S System Construction......................................................................................................................................................................................................1069 Steering Gear Case Construction..............................................................................................................................................................................................1070 P/S Pump Construction........................................................................................................................................................................................................1070 Schematic and Routing Diagram....................................................................................................................................................................................................1071 P/S Fluid Flow Diagram.......................................................................................................................................................................................................1071 Diagnostic Information and Procedures............................................................................................................................................................................................1071 P/S System Symptom Diagnosis.................................................................................................................................................................................................1071 Steering Wheel Check.........................................................................................................................................................................................................1072 Steering Force Check.........................................................................................................................................................................................................1073 Steering Wheel Recovery Check................................................................................................................................................................................................1073 Idle Up System Check.........................................................................................................................................................................................................1073 Hydraulic Pressure in P/S Circuit Check......................................................................................................................................................................................1073 Repair Instructions..............................................................................................................................................................................................................1075 P/S Fluid Change.............................................................................................................................................................................................................1075 P/S Fluid Level Check........................................................................................................................................................................................................1075 P/S Fluid Leakage Check......................................................................................................................................................................................................1076 P/S System Air Bleeding Procedure............................................................................................................................................................................................1076 P/S Pump and A/C Compressor (If Equipped) Drive Belt Inspection and Adjustment for M16 Engine Model..........................................................................................................................1077 P/S Pump and A/C Compressor (If Equipped) Drive Belt Inspection and Adjustment for J20 Engine Model..........................................................................................................................1077 P/S Pump and A/C Compressor (If Equipped) Drive Belt Removal and Installation for M16 Engine Model...........................................................................................................................1077 P/S Pump and A/C Compressor (If Equipped) Drive Belt Removal and Installation for J20 Engine Model...........................................................................................................................1078 Steering Rack Boot Check.....................................................................................................................................................................................................1078 Tie-Rod End Boot Check.......................................................................................................................................................................................................1078 Tie-Rod End Removal and Installation.........................................................................................................................................................................................1078 Tie-Rod End Ball Joint Inspection............................................................................................................................................................................................1079 P/S Gear Case Assembly Components............................................................................................................................................................................................1080 P/S Gear Case Assembly Removal and Installation..............................................................................................................................................................................1081 Steering Gear Case Mount Bushing Removal and Installation....................................................................................................................................................................1082 Steering Gear Case Mount Bushing Inspection..................................................................................................................................................................................1082 Rack Boot / Tie-Rod Removal and Installation.................................................................................................................................................................................1083 P/S Hose / Pipe Components...................................................................................................................................................................................................1084 P/S Pump Removal and Installation for M16 Engine Model.......................................................................................................................................................................1086 P/S Pump Removal and Installation for J20 Engine Model.......................................................................................................................................................................1086 P/S Pump Components for M16 Engine Model.....................................................................................................................................................................................1087 P/S Pump Assembly Components for J20 Engine Model............................................................................................................................................................................1088 P/S Pump Disassembly and Assembly for M16 Engine Model.......................................................................................................................................................................1088 P/S Pump Inspection for M16 Engine Model.....................................................................................................................................................................................1090 P/S Pump Inspection for J20 Engine Model.....................................................................................................................................................................................1091 Specifications...................................................................................................................................................................................................................1091 Tightening Torque Specifications.............................................................................................................................................................................................1091 Special Tools and Equipment......................................................................................................................................................................................................1092 Recommended Service Material.................................................................................................................................................................................................1092 Special Tool.................................................................................................................................................................................................................1092 HVAC.....................................................................................................................................................................................................................................1093 Precautions..........................................................................................................................................................................................................................1096 Precautions......................................................................................................................................................................................................................1096 Precautions for HVAC.........................................................................................................................................................................................................1096 Heater and Ventilation...............................................................................................................................................................................................................1097 General Description..............................................................................................................................................................................................................1097 Heater and Ventilation Construction..........................................................................................................................................................................................1097 Body Ventilation Construction................................................................................................................................................................................................1098 On-Board Diagnostic System Description (for Vehicle without A/C).............................................................................................................................................................1098 HVAC Control System Description (for Vehicle without A/C)....................................................................................................................................................................1099 Schematic and Routing Diagram....................................................................................................................................................................................................1099 Heater and Ventilation Wiring Circuit Diagram................................................................................................................................................................................1099 Electronic Control Input / Output Table (for Vehicle without A/C)............................................................................................................................................................1099 Electronic Components Location for Heater (for Vehicle without A/C)..........................................................................................................................................................1100 Diagnostic Information and Procedures............................................................................................................................................................................................1101 Heater and Ventilation System Check..........................................................................................................................................................................................1101 Visual Inspection............................................................................................................................................................................................................1103 DTC Check....................................................................................................................................................................................................................1103 DTC Clearance................................................................................................................................................................................................................1103 DTC Table....................................................................................................................................................................................................................1103 Fail-Safe Table..............................................................................................................................................................................................................1103 Scan Tool Data...............................................................................................................................................................................................................1103 Heater and Ventilation Symptom Diagnosis.....................................................................................................................................................................................1104 Repair Instructions..............................................................................................................................................................................................................1105 Blower Unit and Heater Unit Components.......................................................................................................................................................................................1105 HVAC Unit Removal and Installation (for Vehicle without A/C).................................................................................................................................................................1105 HVAC Air Filter Removal and Installation (for Vehicle without A/C)...........................................................................................................................................................1105 HVAC Air Filter Inspection (for Vehicle without A/C).........................................................................................................................................................................1105 Blower Motor Removal and Installation........................................................................................................................................................................................1105 Blower Motor Inspection......................................................................................................................................................................................................1105 Blower Motor Controller Removal and Installation.............................................................................................................................................................................1106 Blower Motor Controller Inspection...........................................................................................................................................................................................1106 Blower Motor Relay Inspection................................................................................................................................................................................................1106 Heater Core Removal and Installation.........................................................................................................................................................................................1107 HVAC Control Module Removal and Installation.................................................................................................................................................................................1107 HVAC Control Module and Its Circuits Inspection (for Vehicle without A/C)....................................................................................................................................................1107 Air Flow Control Actuator Removal and Installation...........................................................................................................................................................................1107 Air Flow Control Actuator Inspection.........................................................................................................................................................................................1107 Temperature Control Actuator Removal and Installation........................................................................................................................................................................1108 Temperature Control Actuator Inspection......................................................................................................................................................................................1108 Air Intake Control Actuator Removal and Installation.........................................................................................................................................................................1109 Air Intake Control Actuator Inspection.......................................................................................................................................................................................1109 Actuator Linkage Inspection..................................................................................................................................................................................................1109 Center Ventilation Louver Removal and Installation...........................................................................................................................................................................1110 Side Ventilation Louver Removal and Installation.............................................................................................................................................................................1110 Rear Duct Components.........................................................................................................................................................................................................1111 Rear Duct Removal and Installation...........................................................................................................................................................................................1111 Air Conditioning System..............................................................................................................................................................................................................1112 Precautions......................................................................................................................................................................................................................1112 A/C System Caution...........................................................................................................................................................................................................1112 Precautions on Servicing A/C System..........................................................................................................................................................................................1112 Precautions in Diagnosing Trouble............................................................................................................................................................................................1112 Precautions on Handling Refrigerant HFC-134a (R-134a)........................................................................................................................................................................1112 Precautions on Servicing Refrigerant Line....................................................................................................................................................................................1113 Precautions on Refrigerant Recovery..........................................................................................................................................................................................1114 Precautions on Refrigerant Charge............................................................................................................................................................................................1114 Precautions on Replenishing Compressor Oil...................................................................................................................................................................................1114 Precautions on Servicing Compressor Assembly.................................................................................................................................................................................1115 General Description..............................................................................................................................................................................................................1115 AUTO A/C System Description..................................................................................................................................................................................................1115 HVAC Control System Description..............................................................................................................................................................................................1115 Auto A/C Electronic Control Input / Output Table.............................................................................................................................................................................1116 HVAC Control Module Operation Description....................................................................................................................................................................................1116 A/C Refrigerant Type Description.............................................................................................................................................................................................1116 Sub-Cool A/C System Description..............................................................................................................................................................................................1117 A/C Evaporator Temperature Sensor Description................................................................................................................................................................................1118 On-Board Diagnostic System Description.......................................................................................................................................................................................1118 Schematic and Routing Diagram....................................................................................................................................................................................................1119 A/C System Wiring Circuit Diagram............................................................................................................................................................................................1119 Component Location...............................................................................................................................................................................................................1120 Major Components of A/C System...............................................................................................................................................................................................1120 A/C Control System Components Location.......................................................................................................................................................................................1121 Diagnostic Information and Procedures............................................................................................................................................................................................1122 Air Conditioning System Check................................................................................................................................................................................................1122 DTC Check....................................................................................................................................................................................................................1124 DTC Clearance................................................................................................................................................................................................................1125 DTC Table....................................................................................................................................................................................................................1125 Fail-Safe Table..............................................................................................................................................................................................................1128 Scan Tool Data...............................................................................................................................................................................................................1129 Visual Inspection............................................................................................................................................................................................................1131 A/C System Performance Inspection............................................................................................................................................................................................1131 A/C System Symptom Diagnosis.................................................................................................................................................................................................1137 Abnormal Noise Diagnosis.....................................................................................................................................................................................................1139 Abnormal Noise Symptom Diagnosis of A/C System...............................................................................................................................................................................1139 DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction......................................................................................................................................................1141 DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction..............................................................................................................................................1142 DTC B1504: Sunload Sensor and/or Its Circuit Malfunction.....................................................................................................................................................................1144 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction.....................................................................................................................................1145 DTC B1512: Air Flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction........................................................................................................................................1148 DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction.......................................................................................................................................................1150 DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction..........................................................................................................................................................1153 DTC B1520: Temperature Selector and/or Its Circuit Malfunction...............................................................................................................................................................1155 DTC B1521: Blower Speed Selector and/or Its Circuit Malfunction..............................................................................................................................................................1156 DTC B1530: Air Intake Control Actuator (Position Sensor) and/or Its Circuit Malfunction......................................................................................................................................1156 DTC B1531: Air Intake Control Actuator and/or Its Circuit Malfunction........................................................................................................................................................1159 DTC B1546: A/C Refrigerant Pressure Malfunction..............................................................................................................................................................................1161 DTC B1551: Serial Communication Circuit Malfunction..........................................................................................................................................................................1162 DTC B1552: Serial Communication Circuit Malfunction..........................................................................................................................................................................1164 DTC B1553: CAN Communication Circuit Malfunction.............................................................................................................................................................................1164 DTC B1556: Camshaft Position (CMP) Sensor and/or Its Circuit Malfunction.....................................................................................................................................................1165 DTC B1557: Wheel Speed Sensor and/or Its Circuit Malfunction.................................................................................................................................................................1165 DTC B1561: Engine Coolant Temperature Sensor and/or Its Circuit Malfunction..................................................................................................................................................1165 DTC B1562: Outside Air Temperature Sensor and/or Its Circuit Malfunction.....................................................................................................................................................1166 DTC B1563: A/C Refrigerant Pressure Sensor and/or Its Circuit Malfunction....................................................................................................................................................1166 HVAC Control Module and Its Circuits Inspection..............................................................................................................................................................................1166 A/C System Inspection at ECM.................................................................................................................................................................................................1169 Repair Instructions..............................................................................................................................................................................................................1170 Operation Procedure for Charging A/C with Refrigerant........................................................................................................................................................................1170 A/C Condenser Assembly On-Vehicle Inspection.................................................................................................................................................................................1174 A/C Condenser Assembly Removal and Installation..............................................................................................................................................................................1174 Desiccant Removal and Installation...........................................................................................................................................................................................1175 HVAC Air Filter Removal and Installation.....................................................................................................................................................................................1176 HVAC Air Filter Inspection...................................................................................................................................................................................................1176 HVAC Unit Components.........................................................................................................................................................................................................1177 HVAC Unit Removal and Installation...........................................................................................................................................................................................1178 A/C Evaporator Removal and Installation......................................................................................................................................................................................1179 A/C Evaporator Inspection....................................................................................................................................................................................................1179 A/C Evaporator Temperature Sensor Removal and Installation...................................................................................................................................................................1179 A/C Evaporator Temperature Sensor Inspection.................................................................................................................................................................................1180 Expansion Valve On-Vehicle Inspection........................................................................................................................................................................................1180 Expansion Valve Removal and Installation.....................................................................................................................................................................................1181 A/C Refrigerant Pressure Sensor and Its Circuit Inspection...................................................................................................................................................................1181 A/C Refrigerant Pressure Sensor Removal and Installation.....................................................................................................................................................................1182 Sunload Sensor Removal and Installation......................................................................................................................................................................................1182 Sunload Sensor Inspection....................................................................................................................................................................................................1183 Inside Air Temperature Sensor Removal and Installation.......................................................................................................................................................................1183 Inside Air Temperature Sensor Inspection.....................................................................................................................................................................................1183 Outside Air Temperature Sensor Removal and Installation......................................................................................................................................................................1183 Outside Air Temperature Sensor Inspection....................................................................................................................................................................................1183 Air Flow Control Actuator Removal and Installation...........................................................................................................................................................................1183 Air Flow Control Actuator Inspection.........................................................................................................................................................................................1183 Air Intake Control Actuator Removal and Installation.........................................................................................................................................................................1184 Air Intake Control Actuator Inspection.......................................................................................................................................................................................1184 Temperature Control Actuator Removal and Installation........................................................................................................................................................................1184 Temperature Control Actuator Inspection......................................................................................................................................................................................1184 HVAC Control Module Removal and Installation.................................................................................................................................................................................1184 A/C Compressor Drive Belt Inspection and Adjustment..........................................................................................................................................................................1184 A/C Compressor Drive Belt Removal and Installation...........................................................................................................................................................................1184 A/C Compressor Relay Inspection..............................................................................................................................................................................................1184 Compressor Assembly On-Vehicle Inspection....................................................................................................................................................................................1185 Compressor Assembly Removal and Installation for M16 Engine Model............................................................................................................................................................1185 Compressor Assembly Removal and Installation for J20 Engine Model............................................................................................................................................................1186 Magnet Clutch Components for M16 Engine Model................................................................................................................................................................................1187 Magnet Clutch Components for J20 Engine Model................................................................................................................................................................................1188 Magnet Clutch Operating Check for M16 Engine Model...........................................................................................................................................................................1188 Magnet Clutch Operating Check for J20 Engine Model...........................................................................................................................................................................1188 Magnet Clutch Removal and Installation for M16 Engine Model..................................................................................................................................................................1189 Magnet Clutch Removal and Installation for J20 Engine Model..................................................................................................................................................................1191 Thermal Switch On-Vehicle Inspection for M16 Engine Model....................................................................................................................................................................1192 Thermal Switch Removal and Installation for M16 Engine Model.................................................................................................................................................................1193 Relief Valve On-Vehicle Inspection for M16 Engine Model......................................................................................................................................................................1193 Relief Valve On-Vehicle Inspection For J20 Engine Model......................................................................................................................................................................1193 Relief Valve Removal and Installation for M16 Engine Model...................................................................................................................................................................1193 Specifications...................................................................................................................................................................................................................1194 Tightening Torque Specifications.............................................................................................................................................................................................1194 Special Tools and Equipment......................................................................................................................................................................................................1195 Recommended Service Material.................................................................................................................................................................................................1195 Special Tool.................................................................................................................................................................................................................1195 Restraint................................................................................................................................................................................................................................1197 Precautions..........................................................................................................................................................................................................................1199 Precautions......................................................................................................................................................................................................................1199 Precautions on Restraint.....................................................................................................................................................................................................1199 Seat Belts...........................................................................................................................................................................................................................1200 Precautions......................................................................................................................................................................................................................1200 Precautions on Service and Diagnosis of Seat Belt............................................................................................................................................................................1200 General Description..............................................................................................................................................................................................................1200 Seat Belt Construction.......................................................................................................................................................................................................1200 Diagnostic Information and Procedures............................................................................................................................................................................................1201 Repair and Inspection Required after Accident................................................................................................................................................................................1201 Repair Instructions..............................................................................................................................................................................................................1202 Front Seat Belt Components...................................................................................................................................................................................................1202 Front Seat Belt Removal and Installation.....................................................................................................................................................................................1203 Front Seat Belt Inspection...................................................................................................................................................................................................1203 Rear Seat Belt Components....................................................................................................................................................................................................1205 Rear Seat Belt Removal and Installation......................................................................................................................................................................................1206 Rear Seat Belt Inspection....................................................................................................................................................................................................1206 Specifications...................................................................................................................................................................................................................1206 Tightening Torque Specifications.............................................................................................................................................................................................1206 Air Bag System.......................................................................................................................................................................................................................1207 Precautions......................................................................................................................................................................................................................1207 Precautions on Service and Diagnosis of Air Bag System.......................................................................................................................................................................1207 Precautions on Handling and Storage of Air Bag System Components.............................................................................................................................................................1207 Precautions on Disposal of Air Bag and Seat Belt Pretensioner................................................................................................................................................................1211 General Description..............................................................................................................................................................................................................1211 Air Bag System Construction..................................................................................................................................................................................................1211 Air Bag System Input / Output Table..........................................................................................................................................................................................1212 Schematic and Routing Diagram....................................................................................................................................................................................................1213 Air Bag System Wiring Circuit Diagram........................................................................................................................................................................................1213 Component Location...............................................................................................................................................................................................................1217 Air Bag System Components, Wiring and Connectors Location....................................................................................................................................................................1217 Diagnostic Information and Procedures............................................................................................................................................................................................1218 Air Bag Diagnostic System Check..............................................................................................................................................................................................1218 Air Bag Diagnostic System Check Flow.........................................................................................................................................................................................1218 DTC Table....................................................................................................................................................................................................................1220 DTC Check....................................................................................................................................................................................................................1222 DTC Clearance................................................................................................................................................................................................................1223 Scan Tool Data...............................................................................................................................................................................................................1224 “AIR BAG” Warning Lamp Comes ON Steady.......................................................................................................................................................................................1225 “AIR BAG” Warning Lamp Does Not Come ON......................................................................................................................................................................................1228 “AIR BAG” Warning Lamp Flashes...............................................................................................................................................................................................1229 “AIR BAG” Warning Lamp Cannot Indicate Flashing Pattern of DTC (If Equipped with “AIR BAG” Monitor Coupler)..................................................................................................................1230 DTC B1013: SDM fault.........................................................................................................................................................................................................1231 DTC B1016: Power Source Voltage High.........................................................................................................................................................................................1231 DTC B1017: Power Source Voltage Low..........................................................................................................................................................................................1233 DTC B1021: Air Bag Module Deployed...........................................................................................................................................................................................1235 DTC B1031: Driver Air Bag Initiator Circuit Resistance High..................................................................................................................................................................1236 DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...................................................................................................................................................................1240 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground..................................................................................................................................................................1243 DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...........................................................................................................................................................1246 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...............................................................................................................................................................1249 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low................................................................................................................................................................1252 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...............................................................................................................................................................1255 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................................1258 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High.........................................................................................................................................1261 DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low..........................................................................................................................................1264 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.........................................................................................................................................1267 DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit..................................................................................................................................1270 DTC B1073 / B1077: Driver / Passenger Forward-Sensor Circuit Short to Ground.................................................................................................................................................1273 DTC B1074 / B1078: Driver / Passenger Forward-Sensor Circuit Short to Power Circuit or Open..................................................................................................................................1275 DTC B1085: Wrong Side-Sensor ID..............................................................................................................................................................................................1277 DTC B1086 / B1096: Left / Right Side-Sensor Performance Problem..............................................................................................................................................................1277 DTC B1087 / B1097: Left / Right Side-Sensor Communication Error..............................................................................................................................................................1277 DTC B1321 / B1325: Left / Right Side-Air Bag Initiator Circuit Resistance High...............................................................................................................................................1279 DTC B1322 / B1326: Left / Right Side-Air Bag Initiator Circuit Resistance Low................................................................................................................................................1283 DTC B1323 / B1327: Left / Right Side-Air Bag Initiator Circuit Short to Ground...............................................................................................................................................1286 DTC B1324 / B1328: Left / Right Side-Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................1289 DTC B1331 / B1335: Left / Right Side Curtain-Air Bag Initiator Circuit Resistance High.......................................................................................................................................1291 DTC B1332 / B1336: Left / Right Side Curtain-Air Bag Initiator Circuit Resistance Low........................................................................................................................................1294 DTC B1333 / B1337: Left / Right Side Curtain-Air Bag Initiator Circuit Short to Ground.......................................................................................................................................1296 DTC B1334 / B1338: Left / Right Side Curtain-Air Bag Initiator Circuit Short to Power Circuit................................................................................................................................1298 Inspection of Intermittent and Poor Connections..............................................................................................................................................................................1299 Repair and Inspection Required after Accident................................................................................................................................................................................1300 Repair Instructions..............................................................................................................................................................................................................1303 Disabling Air Bag System.....................................................................................................................................................................................................1303 Enabling Air Bag System......................................................................................................................................................................................................1304 SDM Removal and Installation.................................................................................................................................................................................................1304 SDM Inspection...............................................................................................................................................................................................................1305 Driver Air Bag (Inflator) Module Removal and Installation....................................................................................................................................................................1306 Driver Air Bag (Inflator) Module Inspection..................................................................................................................................................................................1307 Passenger Air Bag (Inflator) Module Removal and Installation.................................................................................................................................................................1307 Passenger Air Bag (Inflator) Module Inspection...............................................................................................................................................................................1309 Side-Air Bag (Inflator) Module Removal and Installation......................................................................................................................................................................1309 Side-Air Bag (Inflator) Inspection...........................................................................................................................................................................................1311 Side Curtain-Air Bag (Inflator) Module Removal and Installation..............................................................................................................................................................1311 Side Curtain-Air Bag (Inflator) Module Inspection............................................................................................................................................................................1313 Forward-Sensor Removal and Installation......................................................................................................................................................................................1313 Forward-Sensor Inspection....................................................................................................................................................................................................1314 Side-Sensor Removal and Installation.........................................................................................................................................................................................1314 Side-Sensor Inspection.......................................................................................................................................................................................................1315 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal................................................................................................................................................................1316 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.............................................................................................................................................1326 Specifications...................................................................................................................................................................................................................1327 Tightening Torque Specifications.............................................................................................................................................................................................1327 Special Tools and Equipment......................................................................................................................................................................................................1327 Use of Special Tools.........................................................................................................................................................................................................1327 Recommended Service Material.................................................................................................................................................................................................1328 Special Tool.................................................................................................................................................................................................................1329 Body, Cab and Accessories................................................................................................................................................................................................................1331 Precautions..........................................................................................................................................................................................................................1337 Precautions......................................................................................................................................................................................................................1337 Precautions on Body, Cab and Accessories.....................................................................................................................................................................................1337 Precautions for Body Service.................................................................................................................................................................................................1337 Fastener Caution for Body Service............................................................................................................................................................................................1337 Wiring Systems.......................................................................................................................................................................................................................1338 Precautions......................................................................................................................................................................................................................1338 Cautions in Body Electrical System Servicing.................................................................................................................................................................................1338 Precautions for Wiring System................................................................................................................................................................................................1338 General Description..............................................................................................................................................................................................................1339 Abbreviations................................................................................................................................................................................................................1339 Wire / Connector Color Symbols...............................................................................................................................................................................................1339 Symbols and Marks............................................................................................................................................................................................................1340 How to Read Connector Layout Diagram.........................................................................................................................................................................................1342 How to Read Connector Codes and Terminal Nos.................................................................................................................................................................................1343 How to Read Ground Point.....................................................................................................................................................................................................1346 How to Read Power Supply Diagram.............................................................................................................................................................................................1347 How to Read System Circuit Diagram...........................................................................................................................................................................................1348 Harness Routing and Connector Layout Diagram.....................................................................................................................................................................................1350 Connector Layout Diagram.....................................................................................................................................................................................................1350 Engine Compartment...........................................................................................................................................................................................................1350 Instrument Panel.............................................................................................................................................................................................................1359 Door, Roof...................................................................................................................................................................................................................1364 Floor........................................................................................................................................................................................................................1368 Rear.........................................................................................................................................................................................................................1374 Ground Point.....................................................................................................................................................................................................................1375 Ground (earth) Point.........................................................................................................................................................................................................1375 Power Supply Diagram.............................................................................................................................................................................................................1376 Power Supply Diagram.........................................................................................................................................................................................................1376 Fuses and the Protected Parts................................................................................................................................................................................................1380 Fuses in Battery Fuse Box, Fuse Box No.1.....................................................................................................................................................................................1380 Fuse Box No.2 (In Power Integration No.1, Power Integration No.2), Relay Box.................................................................................................................................................1381 Fuse Box No.3 (In J/B).......................................................................................................................................................................................................1382 Junction Block (J/B) Connector / Fuse Layout.................................................................................................................................................................................1384 Junction Block Inner Circuit (Overview)......................................................................................................................................................................................1385 Junction Block Inner Circuit (Detail)........................................................................................................................................................................................1386 System Circuit Diagram...........................................................................................................................................................................................................1390 System Circuit Diagram.......................................................................................................................................................................................................1390 A-1 Cranking System Circuit Diagram..........................................................................................................................................................................................1391 A-2 Charging System Circuit Diagram..........................................................................................................................................................................................1392 A-3 Ignition System Circuit Diagram (M16A)...................................................................................................................................................................................1393 A-3 Ignition System Circuit Diagram (J20A)...................................................................................................................................................................................1394 A-4 Cooling System Circuit Diagram...........................................................................................................................................................................................1395 A-5 Engine and A/C Control System Circuit Diagram (M16A).....................................................................................................................................................................1396 A-5 Engine and A/C Control System Circuit Diagram (J20A).....................................................................................................................................................................1401 A-6 A/T Control System Circuit Diagram.......................................................................................................................................................................................1406 A-7 Immobilizer System Circuit Diagram.......................................................................................................................................................................................1408 A-8 Body Control System Circuit Diagram......................................................................................................................................................................................1409 A-10 4WD Control System Circuit Diagram......................................................................................................................................................................................1414 B-1 Windshield Wiper and Washer Circuit Diagram..............................................................................................................................................................................1416 B-2 Rear Wiper and Washer Circuit Diagram....................................................................................................................................................................................1417 B-3 Rear Defogger Circuit Diagram............................................................................................................................................................................................1418 B-4 Power Window Circuit Diagram.............................................................................................................................................................................................1419 B-5 Power Door Lock Circuit Diagram..........................................................................................................................................................................................1421 B-6 Power Mirror Circuit Diagram.............................................................................................................................................................................................1423 B-7 Horn Circuit Diagram.....................................................................................................................................................................................................1424 B-8 Seat Heater Circuit Diagram..............................................................................................................................................................................................1425 B-9 Smart Key System Circuit Diagram.........................................................................................................................................................................................1426 B-10 Sliding Roof Circuit Diagram............................................................................................................................................................................................1427 B-11 Headlight Cleaner Circuit Diagram.......................................................................................................................................................................................1428 C-1 Combination Meter Circuit Diagram........................................................................................................................................................................................1429 D-1 Headlight System Circuit Diagram (One bulb type).........................................................................................................................................................................1431 D-1 Headlight System Circuit Diagram (With Projector light)..................................................................................................................................................................1432 D-1 Headlight System Circuit Diagram (With Discharge bulb)...................................................................................................................................................................1433 D-2 Position, Tail and Licence Plate Light System Circuit Diagram............................................................................................................................................................1434 D-3 Front Fog Light System Circuit Diagram...................................................................................................................................................................................1435 D-4 Illumination Light System Circuit Diagram................................................................................................................................................................................1436 D-5 Interior Light System Circuit Diagram....................................................................................................................................................................................1437 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram..............................................................................................................................................................1438 D-7 Brake Light System Circuit Diagram.......................................................................................................................................................................................1440 D-8 Back-Up Light System Circuit Diagram.....................................................................................................................................................................................1441 D-9 Headlight Beam Leveling System Circuit Diagram (Manual Leveling).........................................................................................................................................................1442 D-9 Headlight Beam Leveling System Circuit Diagram (Auto Leveling)...........................................................................................................................................................1443 D-10 Rear Fog Light Circuit Diagram..........................................................................................................................................................................................1444 E-2 Auto A/C System Circuit Diagram..........................................................................................................................................................................................1445 F-1 Air-Bag System Circuit Diagram (Without side A/B and Curtain A/B)........................................................................................................................................................1447 F-1 Air-Bag System Circuit Diagram (With side A/B and Curtain A/B)...........................................................................................................................................................1448 F-2 Anti-Lock Brake System Circuit Diagram...................................................................................................................................................................................1450 G-1 Audio System Circuit Diagram.............................................................................................................................................................................................1452 G-2 Multi Information Display / Accessory Socket System Circuit Diagram......................................................................................................................................................1453 G-4 Navigation System Circuit Diagram........................................................................................................................................................................................1454 List of Connectors...............................................................................................................................................................................................................1455 List of Connectors...........................................................................................................................................................................................................1455 B Connector..................................................................................................................................................................................................................1455 C Connector..................................................................................................................................................................................................................1455 E Connector..................................................................................................................................................................................................................1457 F Connector..................................................................................................................................................................................................................1459 G Connector..................................................................................................................................................................................................................1459 J Connector..................................................................................................................................................................................................................1462 K Connector..................................................................................................................................................................................................................1463 L Connector..................................................................................................................................................................................................................1464 O Connector..................................................................................................................................................................................................................1466 Q Connector..................................................................................................................................................................................................................1466 R Connector..................................................................................................................................................................................................................1466 Lighting Systems.....................................................................................................................................................................................................................1467 Precautions......................................................................................................................................................................................................................1467 Precautions for Discharge Headlight Service (If Equipped)....................................................................................................................................................................1467 Precautions in Diagnosing Troubles (Vehicle Equipped with Auto Leveling Headlight System)....................................................................................................................................1467 General Description..............................................................................................................................................................................................................1468 Discharge Headlight Description (If Equipped)................................................................................................................................................................................1468 Auto Leveling Headlight System Description (If Equipped).....................................................................................................................................................................1469 Auto-On Headlight System Description (If Equipped)...........................................................................................................................................................................1471 D.R.L. System Description (If Equipped)......................................................................................................................................................................................1472 Schematic and Routing Diagram....................................................................................................................................................................................................1472 Headlight Auto Leveling System wiring Circuit Diagram........................................................................................................................................................................1472 Component Location...............................................................................................................................................................................................................1473 Lighting System Components Location..........................................................................................................................................................................................1473 Interior Light System Location...............................................................................................................................................................................................1474 Diagnostic Information and Procedures............................................................................................................................................................................................1474 Self-Diagnosis Function for Auto Leveling Headlight System...................................................................................................................................................................1474 Headlight Leveling Warning Light Check.......................................................................................................................................................................................1474 Headlight Symptom Diagnosis (Vehicle Equipped With Discharge Headlight)......................................................................................................................................................1475 Headlight Symptom diagnosis (Vehicle Not Equipped With Discharge Headlight)..................................................................................................................................................1475 Auto-On Headlight System Symptom Diagnosis (If Equipped).....................................................................................................................................................................1476 DRL System Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1476 Headlight Auto Leveling System Symptom Diagnosis (If Equipped)...............................................................................................................................................................1477 Headlight Manual Leveling System Symptom Diagnosis (If Equipped).............................................................................................................................................................1477 Turn Signal and Hazard Warning Light Symptom Diagnosis.......................................................................................................................................................................1477 Clearance, Tail and License Plate Light Symptom Diagnosis....................................................................................................................................................................1478 Back-Up Light Symptom Diagnosis..............................................................................................................................................................................................1478 Stop (Brake) Lamp Symptom Diagnosis..........................................................................................................................................................................................1479 Front Fog Light (If Equipped) Symptom Diagnosis..............................................................................................................................................................................1479 Rear Fog Light Symptom Diagnosis (If Equipped)...............................................................................................................................................................................1479 Illumination Cancel System Symptom Diagnosis (If Equipped)...................................................................................................................................................................1479 Interior Light Symptom Diagnosis.............................................................................................................................................................................................1480 Auto-On Headlight Operation Inspection (If Equipped).........................................................................................................................................................................1480 DRL Operation Inspection (If Equipped).......................................................................................................................................................................................1480 Inspection of Headlight Leveling Control Module and Its Circuit (Vehicle Equipped With Auto Leveling Headlight System).......................................................................................................1481 Repair Instructions..............................................................................................................................................................................................................1483 Headlight Housing Removal and Installation...................................................................................................................................................................................1483 Headlight Bulb Replacement...................................................................................................................................................................................................1483 Ballast Removal and Installation.............................................................................................................................................................................................1484 Igniter Removal and Installation.............................................................................................................................................................................................1485 Headlight Aiming Adjustment with Screen......................................................................................................................................................................................1485 Headlight Switch (in Lighting Switch) Removal and Installation...............................................................................................................................................................1487 Headlight Switch (in Lighting Switch) Inspection.............................................................................................................................................................................1487 Hazard Warning Switch Removal and Installation...............................................................................................................................................................................1488 Hazard Warning Switch Inspection.............................................................................................................................................................................................1488 Stop (Brake) Lamp Switch Inspection..........................................................................................................................................................................................1488 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.......................................................................................................................................................1489 Turn Signal Light Switch (in Lighting Switch) Inspection.....................................................................................................................................................................1489 Turn Signal and Hazard Warning Relay Removal and Installation................................................................................................................................................................1489 Turn Signal and Hazard Warning Relay Inspection..............................................................................................................................................................................1489 License Lamp Assembly Removal and Installation...............................................................................................................................................................................1490 Front Fog Light Assembly Removal and Installation (If Equipped)..............................................................................................................................................................1490 Front Fog Light Bulb Replacement (If Equipped)...............................................................................................................................................................................1490 Front Fog Light Switch Inspection (If Equipped)..............................................................................................................................................................................1491 Front Fog Light Relay Inspection (If Equipped)...............................................................................................................................................................................1491 Front Fog Light Aiming Adjustment with Screen (If Equipped)..................................................................................................................................................................1491 Headlight Manual Leveling Switch (If Equipped) Inspection....................................................................................................................................................................1492 Headlight Leveling Actuator Inspection (If Equipped).........................................................................................................................................................................1493 Rear Fog Light Switch Inspection (If Equipped)...............................................................................................................................................................................1493 Height Sensor Removal and Installation (If Equipped).........................................................................................................................................................................1494 Height Sensor and Its Circuit Inspection (If Equipped).......................................................................................................................................................................1495 Leveling Control Module Removal and Installation (If Equipped)...............................................................................................................................................................1495 Initialization of Auto Leveling Headlight System.............................................................................................................................................................................1495 Illumination Cancel Switch (If Equipped) Inspection..........................................................................................................................................................................1496 Auto-On Headlight Sensor Inspection (If Equipped)............................................................................................................................................................................1497 Specifications...................................................................................................................................................................................................................1497 Tightening Torque Specifications.............................................................................................................................................................................................1497 Instrumentation / Driver Info. / Horn................................................................................................................................................................................................1498 Precautions......................................................................................................................................................................................................................1498 Precautions in Diagnosing Troubles for Combination Meter.....................................................................................................................................................................1498 General Description..............................................................................................................................................................................................................1498 CAN Communication Data of Combination Meter..................................................................................................................................................................................1498 Schematic and Routing Diagram....................................................................................................................................................................................................1499 Combination Meter Circuit Diagram............................................................................................................................................................................................1499 Component Location...............................................................................................................................................................................................................1500 Audio System Component Location..............................................................................................................................................................................................1500 Diagnostic Information and Procedures............................................................................................................................................................................................1501 Speedometer Symptom Diagnosis................................................................................................................................................................................................1501 Tacho meter Symptom Diagnosis................................................................................................................................................................................................1501 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis.....................................................................................................................................................................1501 Fuel Meter Symptom Diagnosis.................................................................................................................................................................................................1501 Low Fuel Warning Light Symptom Diagnosis.....................................................................................................................................................................................1502 Oil Pressure Warning Light Symptom Diagnosis.................................................................................................................................................................................1502 Brake and Parking Brake Warning Light Symptom Diagnosis......................................................................................................................................................................1503 Seat Belt Reminder Light Symptom Diagnosis (If Equipped).....................................................................................................................................................................1503 Illumination Indicator Symptom Diagnosis.....................................................................................................................................................................................1504 Headlight Auto Leveling Indicator Symptom Diagnosis (If Equipped)............................................................................................................................................................1504 A/T Power Mode Indicator Symptom Diagnosis (A/T Model Only)..................................................................................................................................................................1504 A/T Shift Position Indicator (A/T Model Only) Symptom Diagnosis..............................................................................................................................................................1505 Charge Warning Light Symptom Diagnosis.......................................................................................................................................................................................1505 Main Beam (High Beam) Indicator Symptom Diagnosis............................................................................................................................................................................1505 Warning Buzzer Circuit Symptom Diagnosis.....................................................................................................................................................................................1506 Cigarette Lighter Symptom Diagnosis (If Equipped)............................................................................................................................................................................1506 Horn Symptom Diagnosis.......................................................................................................................................................................................................1506 Information Display Symptom Diagnosis (If Equipped)..........................................................................................................................................................................1507 Clock Symptom Diagnosis (If Equipped)........................................................................................................................................................................................1507 Audio System Symptom Diagnosis (If Equipped).................................................................................................................................................................................1508 Remote Audio Control Switch Symptom Diagnosis (If Equipped)..................................................................................................................................................................1509 Navigation Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1509 Repair Instructions..............................................................................................................................................................................................................1509 Ignition Switch Removal and Installation.....................................................................................................................................................................................1509 Ignition Switch Inspection...................................................................................................................................................................................................1510 Combination Meter Removal and Installation...................................................................................................................................................................................1510 Fuel Level Sensor Removal and Installation...................................................................................................................................................................................1510 Fuel Level Sensor Inspection.................................................................................................................................................................................................1511 Oil Pressure Switch Removal and Installation.................................................................................................................................................................................1511 Oil Pressure Switch Inspection...............................................................................................................................................................................................1512 Engine Coolant Temperature (ECT) Sensor Inspection...........................................................................................................................................................................1512 Brake Fluid Level Switch Inspection..........................................................................................................................................................................................1512 Parking Brake Switch Inspection..............................................................................................................................................................................................1512 Door Switch (Front / Rear / Rear End Door) Inspection........................................................................................................................................................................1513 Outside Air Temperature Sensor Removal and Installation (If Equipped)........................................................................................................................................................1513 Outside Air Temperature Sensor Inspection (If Equipped)......................................................................................................................................................................1513 Instrument Panel Removal and Installation....................................................................................................................................................................................1513 Information Display (Clock) Removal and Installation.........................................................................................................................................................................1515 Audio Unit Removal and Installation..........................................................................................................................................................................................1515 Front Speaker Removal and Installation.......................................................................................................................................................................................1516 Rear Speaker Removal and Installation (5 Door Model).........................................................................................................................................................................1516 Rear Speaker Removal and Installation (3 Door Model).........................................................................................................................................................................1516 GPS Antenna Removal and Installation (If Equipped)...........................................................................................................................................................................1517 Horn Removal and Installation................................................................................................................................................................................................1517 Horn Inspection..............................................................................................................................................................................................................1517 Horn Relay Inspection........................................................................................................................................................................................................1517 Antenna Base Removal and Installation........................................................................................................................................................................................1518 Remote Audio Control Switch Removal and Installation.........................................................................................................................................................................1518 Remote Audio Control Switch Inspection.......................................................................................................................................................................................1519 Specifications...................................................................................................................................................................................................................1519 Tightening Torque Specifications.............................................................................................................................................................................................1519 Wipers / Washers.....................................................................................................................................................................................................................1520 Diagnostic Information and Procedures............................................................................................................................................................................................1520 Front Wiper and Washer Symptom Diagnosis.....................................................................................................................................................................................1520 Rear Wiper and Washer Symptom Diagnosis (If Equipped)........................................................................................................................................................................1520 Headlight Washer Symptom Diagnosis (If Equipped).............................................................................................................................................................................1521 Headlight Washer Operation Inspection........................................................................................................................................................................................1521 Inspection of Headlight Washer Control Module and Its Circuit................................................................................................................................................................1522 Repair Instructions..............................................................................................................................................................................................................1523 Wipers and Washers Components................................................................................................................................................................................................1523 Washer Tank and Washer Pump Removal and Installation.........................................................................................................................................................................1524 Washer Pump Inspection.......................................................................................................................................................................................................1524 Windshield Wiper Removal and Installation....................................................................................................................................................................................1525 Windshield Wiper Motor Inspection............................................................................................................................................................................................1526 Rear Wiper Removal and Installation (If Equipped)............................................................................................................................................................................1527 Rear Wiper Motor Inspection (If Equipped)....................................................................................................................................................................................1528 Windshield Wiper and Washer Switch Removal and Installation..................................................................................................................................................................1529 Windshield Wiper and Washer Switch Inspection................................................................................................................................................................................1530 Rear Wiper and Washer Switch Removal and Installation........................................................................................................................................................................1531 Rear Wiper and Washer Switch Inspection......................................................................................................................................................................................1531 Rear Wiper Relay Removal and Installation....................................................................................................................................................................................1531 Rear Wiper Relay Inspection..................................................................................................................................................................................................1532 Headlight Washer Switch Inspection (If Equipped).............................................................................................................................................................................1532 Headlight Washer Pump Removal and Installation (If Equipped).................................................................................................................................................................1532 Headlight Washer Nozzle Removal and Installation (If Equipped)...............................................................................................................................................................1532 Specifications...................................................................................................................................................................................................................1533 Tightening Torque Specifications.............................................................................................................................................................................................1533 Glass / Windows / Mirrors............................................................................................................................................................................................................1534 General Description..............................................................................................................................................................................................................1534 Rear End Door Window Defogger System Description.............................................................................................................................................................................1534 Windshield Construction......................................................................................................................................................................................................1534 Rear Quarter Window Construction.............................................................................................................................................................................................1535 Diagnostic Information and Procedures............................................................................................................................................................................................1536 Rear End door Window Defogger Symptom Diagnosis..............................................................................................................................................................................1536 Power Window Control System Symptom Diagnosis................................................................................................................................................................................1537 Power Door Mirror Control System Symptom Diagnosis (If Equipped).............................................................................................................................................................1537 Door Mirror Heater Symptom Diagnosis (If Equipped)...........................................................................................................................................................................1537 Repair Instructions..............................................................................................................................................................................................................1538 Windshield Removal and Installation..........................................................................................................................................................................................1538 Rear Quarter Window Removal and Installation.................................................................................................................................................................................1541 Front Door Window Components.................................................................................................................................................................................................1546 Front Door Glass Removal and Installation....................................................................................................................................................................................1547 Front Door Window Regulator Removal and Installation.........................................................................................................................................................................1548 Front Door Window Regulator Inspection.......................................................................................................................................................................................1548 Rear Door Window Components..................................................................................................................................................................................................1549 Rear Door Glass Removal and Installation.....................................................................................................................................................................................1549 Rear Door Window Regulator Removal and Installation..........................................................................................................................................................................1550 Rear Door Window Regulator Inspection........................................................................................................................................................................................1551 Rear End Door Window Components..............................................................................................................................................................................................1551 Rear End Door Glass Removal and Installation.................................................................................................................................................................................1552 Rear End Door Window Defogger Relay Inspection...............................................................................................................................................................................1552 Rear End Door Window Defogger Wire Inspection................................................................................................................................................................................1553 Rear End Door Window Defogger Wire Repair....................................................................................................................................................................................1553 Power Window Main Switch Inspection..........................................................................................................................................................................................1553 Power Window Sub Switch Inspection...........................................................................................................................................................................................1555 Door Mirror Components.......................................................................................................................................................................................................1555 Door Mirror Removal and Installation.........................................................................................................................................................................................1556 Power Door Mirror Switch Inspection (If Equipped)............................................................................................................................................................................1556 Power Door Mirror Actuator Inspection (If Equipped)..........................................................................................................................................................................1556 Door Mirror Heater Inspection (If Equipped)..................................................................................................................................................................................1556 Door Mirror Heater Relay Inspection (If Equipped)............................................................................................................................................................................1557 Special Tools and Equipment......................................................................................................................................................................................................1557 Recommended Service Material.................................................................................................................................................................................................1557 Security and Locks...................................................................................................................................................................................................................1558 General Description..............................................................................................................................................................................................................1558 Key Coding Construction......................................................................................................................................................................................................1558 Component Location...............................................................................................................................................................................................................1558 Power Door Lock and Keyless Entry System Component Location..................................................................................................................................................................1558 Diagnostic Information and Procedures............................................................................................................................................................................................1559 Power Door Lock System Symptom Diagnosis.....................................................................................................................................................................................1559 Power Door Lock System Operation Inspection..................................................................................................................................................................................1559 Keyless Entry System Symptom Diagnosis (If Equipped).........................................................................................................................................................................1560 Keyless Entry System Operation Inspection....................................................................................................................................................................................1561 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...................................................................................................................................................1561 Repair Instructions..............................................................................................................................................................................................................1561 Front Door Lock Assembly Components..........................................................................................................................................................................................1561 Front Door Lock Assembly Removal and Installation............................................................................................................................................................................1562 Front Door Lock Assembly Inspection..........................................................................................................................................................................................1563 Power Door Lock Switch Inspection............................................................................................................................................................................................1564 Door Key Cylinder Switch Inspection..........................................................................................................................................................................................1564 Power Door Lock Actuator Inspection (If Equipped)............................................................................................................................................................................1564 Rear Door Lock Assembly Components...........................................................................................................................................................................................1566 Rear Door Lock Assembly Removal and Installation.............................................................................................................................................................................1567 Rear Door Lock Assembly Inspection...........................................................................................................................................................................................1567 Rear End Door Lock Assembly Components.......................................................................................................................................................................................1568 Rear End Door Lock Assembly Removal and Installation.........................................................................................................................................................................1568 Rear End Door Lock Assembly Inspection.......................................................................................................................................................................................1569 Replacement of Transmitter Battery...........................................................................................................................................................................................1569 Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System).................................................................................................................................1570 Keyless Entry Receiver Removal and Installation..............................................................................................................................................................................1570 Keyless Entry Receiver and Its Circuit Inspection............................................................................................................................................................................1571 Specifications...................................................................................................................................................................................................................1572 Tightening Torque Specifications.............................................................................................................................................................................................1572 Special Tools and Equipment......................................................................................................................................................................................................1572 Recommended Service Material.................................................................................................................................................................................................1572 Seats................................................................................................................................................................................................................................1573 Diagnostic Information and Procedures............................................................................................................................................................................................1573 Front Seat Heater Symptom Diagnosis (If Equipped)............................................................................................................................................................................1573 Repair Instructions..............................................................................................................................................................................................................1573 Front Seat Components........................................................................................................................................................................................................1573 Front Seat Removal and Installation..........................................................................................................................................................................................1574 Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped)................................................................................................................................................1574 Front Seat Heater Wire Inspection (If Equipped)..............................................................................................................................................................................1574 Rear Seat Components.........................................................................................................................................................................................................1575 Rear Seat Removal and Installation...........................................................................................................................................................................................1575 Specifications...................................................................................................................................................................................................................1575 Tightening Torque Specifications.............................................................................................................................................................................................1575 Interior Trim........................................................................................................................................................................................................................1576 Repair Instructions..............................................................................................................................................................................................................1576 Floor Carpet Removal and Installation........................................................................................................................................................................................1576 Head Lining Removal and Installation.........................................................................................................................................................................................1576 Console Box Components.......................................................................................................................................................................................................1579 Sun Roof / T-Top / Convertible Top...................................................................................................................................................................................................1580 General Description..............................................................................................................................................................................................................1580 Power Sliding (Sun) Roof System Description..................................................................................................................................................................................1580 Diagnostic Information and Procedures............................................................................................................................................................................................1580 Power Sliding (Sun) Roof System Symptom Diagnosis............................................................................................................................................................................1580 Repair Instructions..............................................................................................................................................................................................................1580 Sliding (Sun) Roof Glass Components..........................................................................................................................................................................................1580 Sliding (Sun) Roof Glass Removal and Installation............................................................................................................................................................................1581 Sliding (Sun) Roof Glass Adjustment..........................................................................................................................................................................................1581 Sliding (Sun) Roof Switch Inspection.........................................................................................................................................................................................1581 Sliding (Sun) Roof Motor Removal and Installation............................................................................................................................................................................1582 Sliding (Sun) Roof System Circuit and Motor Inspection.......................................................................................................................................................................1582 Sliding (Sun) Roof Assembly Components.......................................................................................................................................................................................1583 Sliding (Sun) Roof Assembly Removal and Installation.........................................................................................................................................................................1584 Sliding (Sun) Roof Assembly Disassembly and Reassembly.......................................................................................................................................................................1585 Hood / Fenders / Doors...............................................................................................................................................................................................................1586 Repair Instructions..............................................................................................................................................................................................................1586 Hood Removal and Installation................................................................................................................................................................................................1586 Hood Inspection and Adjustment...............................................................................................................................................................................................1586 Front Fender Components......................................................................................................................................................................................................1587 Front Fender Removal and Installation........................................................................................................................................................................................1587 Front Door Assembly Components...............................................................................................................................................................................................1588 Front Door Assembly Removal and Installation.................................................................................................................................................................................1589 Rear Door Assembly Components................................................................................................................................................................................................1590 Rear Door Assembly Removal and Installation..................................................................................................................................................................................1590 Rear End Door Assembly Components............................................................................................................................................................................................1591 Rear End Door Assembly Removal and Installation..............................................................................................................................................................................1592 Specifications...................................................................................................................................................................................................................1593 Tightening Torque Specifications.............................................................................................................................................................................................1593 Special Tools and Equipment......................................................................................................................................................................................................1593 Recommended Service Material.................................................................................................................................................................................................1593 Body Structure.......................................................................................................................................................................................................................1594 Repair Instructions..............................................................................................................................................................................................................1594 Front Bumper Components......................................................................................................................................................................................................1594 Rear Bumper Components.......................................................................................................................................................................................................1595 Cowl Top Components..........................................................................................................................................................................................................1596 Specifications...................................................................................................................................................................................................................1597 Body Dimensions..............................................................................................................................................................................................................1597 Panel Clearance..............................................................................................................................................................................................................1607 Paint / Coatings.....................................................................................................................................................................................................................1609 General Description..............................................................................................................................................................................................................1609 Anti-Corrosion Treatment Construction........................................................................................................................................................................................1609 Plastic Parts Finishing......................................................................................................................................................................................................1610 Component Location...............................................................................................................................................................................................................1610 Sealant Application Areas....................................................................................................................................................................................................1610 Under Coating Application Areas..............................................................................................................................................................................................1620 Anti-Corrosion Compound Application Area.....................................................................................................................................................................................1624 Exterior Trim........................................................................................................................................................................................................................1626 Repair Instructions..............................................................................................................................................................................................................1626 Roof Drip Molding Removal and Installation (If Equipped).....................................................................................................................................................................1626 Roof Rail Removal and Installation (If Equipped).............................................................................................................................................................................1627 Splash Guard Removal and Installation (If Equipped)..........................................................................................................................................................................1628 Control systems..........................................................................................................................................................................................................................1629 Precautions..........................................................................................................................................................................................................................1631 Precautions......................................................................................................................................................................................................................1631 Precautions for Control Systems..............................................................................................................................................................................................1631 Cruise Control System................................................................................................................................................................................................................1632 General Description..............................................................................................................................................................................................................1632 Cruise Control System Construction...........................................................................................................................................................................................1632 Components and Functions of Cruise Control System............................................................................................................................................................................1633 Cancel Conditions of Cruise Control System...................................................................................................................................................................................1634 Input / Output Diagram.......................................................................................................................................................................................................1634 Schematic and Routing Diagram....................................................................................................................................................................................................1635 Cruise Control System Wiring Diagram.........................................................................................................................................................................................1635 Diagnostic Information and Procedures............................................................................................................................................................................................1636 Cruise Control System Symptom Diagnosis......................................................................................................................................................................................1636 Inspection of Cruise Control System Circuit..................................................................................................................................................................................1637 Repair Instructions..............................................................................................................................................................................................................1639 Cruise Control Switch Removal and Installation...............................................................................................................................................................................1639 Cruise Control Switch Inspection.............................................................................................................................................................................................1639 CPP Switch (for Cruise Control) Removal and Installation.....................................................................................................................................................................1639 Clutch Pedal Position (CPP) Switch (for Cruise Control) Inspection and Adjustment............................................................................................................................................1640 Stop (Brake) Lamp Switch Removal and Installation............................................................................................................................................................................1640 Stop (Brake) Lamp Switch Inspection..........................................................................................................................................................................................1640 ECM Removal and Installation.................................................................................................................................................................................................1640 Specifications...................................................................................................................................................................................................................1640 Tightening Torque Specifications.............................................................................................................................................................................................1640 Body Electrical Control System.......................................................................................................................................................................................................1641 Precautions......................................................................................................................................................................................................................1641 Precautions in Diagnosing Trouble............................................................................................................................................................................................1641 General Description..............................................................................................................................................................................................................1641 BCM General Description......................................................................................................................................................................................................1641 CAN Communication for BCM....................................................................................................................................................................................................1641 Theft Deterrent Light........................................................................................................................................................................................................1642 Schematic and Routing Diagram....................................................................................................................................................................................................1642 Body Electrical Control System Wiring Circuit Diagram........................................................................................................................................................................1642 Connector Layout Diagram of BCM..............................................................................................................................................................................................1644 Component Location...............................................................................................................................................................................................................1645 BCM and Related System Component Location....................................................................................................................................................................................1645 Diagnostic Information and Procedures............................................................................................................................................................................................1646 BCM Self-Diagnosis Function..................................................................................................................................................................................................1646 Body Electrical Control System Check.........................................................................................................................................................................................1648 Scan Tool Data...............................................................................................................................................................................................................1650 DTC Table....................................................................................................................................................................................................................1651 DTC Check....................................................................................................................................................................................................................1652 DTC Clearance................................................................................................................................................................................................................1653 BCM Power Circuit and Ground Circuit Check...................................................................................................................................................................................1654 DTC B1133 (DTC No. 1133): Battery Voltage Too High...........................................................................................................................................................................1655 DTC B1141 / DTC B1142 / DTC B1143 (No. 1141 / No. 1142/ No. 1143) Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction.........................................................................................1656 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction..............................................................................................................................................................1657 DTC B1157 (No. 1157) Air Bag Deployment Signal Input.........................................................................................................................................................................1659 DTC B1170 (No. 1170): EEPROM access error....................................................................................................................................................................................1659 DTC U1073 (No. 1073): Control Module Communication Bus Off...................................................................................................................................................................1660 DTC U1100 (No. 1100): Lost Communication with ECM............................................................................................................................................................................1663 DTC U1101 (No. 1101): Lost communication with TCM............................................................................................................................................................................1665 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...................................................................................................................................................1667 Inspection of BCM and its Circuits...........................................................................................................................................................................................1669 Repair Instructions..............................................................................................................................................................................................................1675 BCM Removal and Installation.................................................................................................................................................................................................1675 Outside Air Temperature Sensor Removal and Installation......................................................................................................................................................................1675 Outside Air Temperature Sensor Inspection....................................................................................................................................................................................1676 DRL Function Setting Procedure...............................................................................................................................................................................................1676 Special Tools and Equipment......................................................................................................................................................................................................1676 Special Tool.................................................................................................................................................................................................................1676 Immobilizer Control System...........................................................................................................................................................................................................1677 Precautions......................................................................................................................................................................................................................1677 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1677 Precaution in Replacing ECM..................................................................................................................................................................................................1677 Precautions in Handling Immobilizer Control System...........................................................................................................................................................................1677 General Description..............................................................................................................................................................................................................1678 Immobilizer Control System Introduction......................................................................................................................................................................................1678 Immobilizer Control System Components Location...............................................................................................................................................................................1678 On-Board Diagnostic System Description (Self-diagnosis Function).............................................................................................................................................................1679 Schematic and Routing Diagram....................................................................................................................................................................................................1680 Immobilizer Control System Wiring Circuit Diagram............................................................................................................................................................................1680 Diagnostic Information and Procedures............................................................................................................................................................................................1681 Immobilizer Control System Check.............................................................................................................................................................................................1681 Diagnostic Trouble Code (DTC) Check..........................................................................................................................................................................................1682 Diagnostic Trouble Code (DTC) Clearance......................................................................................................................................................................................1682 Diagnostic Trouble Code (DTC) Table..........................................................................................................................................................................................1682 Scan Tool Data...............................................................................................................................................................................................................1683 Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop..........................................................................................................................................1684 Immobilizer Indicator Lamp Remains ON after Engine Start.....................................................................................................................................................................1685 DTC P1614: Transponder Response Error........................................................................................................................................................................................1685 DTC P1615: Steering Lock Unit Communication Error (for Vehicle with Keyless Start System)....................................................................................................................................1686 DTC P1616: Unregistered Keyless Start Control Module (for Vehicle with Keyless Start System).................................................................................................................................1689 DTC P1618: Keyless Start Control Module CAN Communication Error (for Vehicle with Keyless Start System)......................................................................................................................1689 DTC P1621: Immobilizer Communication Line Error..............................................................................................................................................................................1691 DTC P1622: EEPROM Error......................................................................................................................................................................................................1694 DTC P1623: Unregistered Transponder..........................................................................................................................................................................................1694 DTC P1625: Immobilizer Antenna Error.........................................................................................................................................................................................1695 DTC P1636: Immobilizer Information Registration Failure......................................................................................................................................................................1696 DTC P1638: Immobilizer Information Mismatched................................................................................................................................................................................1697 Inspection of Immobilizer Control Module (ICM) and Its Circuit...............................................................................................................................................................1698 Repair Instructions..............................................................................................................................................................................................................1700 Immobilizer Control Module (ICM) Removal and Installation....................................................................................................................................................................1700 Registration of the Ignition Key.............................................................................................................................................................................................1700 Procedure after ECM Replacement..............................................................................................................................................................................................1700 Special Tools and Equipment......................................................................................................................................................................................................1701 Special Tool.................................................................................................................................................................................................................1701 Keyless Start System.................................................................................................................................................................................................................1702 General Description..............................................................................................................................................................................................................1702 Keyless Start System Description.............................................................................................................................................................................................1702 Parts and Functions..........................................................................................................................................................................................................1703 Keyless Engine Start Function................................................................................................................................................................................................1704 Door Lock Function of Keyless Start System...................................................................................................................................................................................1705 Operation Area of Remote Controller..........................................................................................................................................................................................1706 Alarm Function...............................................................................................................................................................................................................1707 CAN Communication of Keyless Start System....................................................................................................................................................................................1707 Schematic and Routing Diagram....................................................................................................................................................................................................1708 Keyless Start System Electric Wiring Circuit Diagram.........................................................................................................................................................................1708 Diagnostic Information and Procedures............................................................................................................................................................................................1709 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1709 Self-Diagnosis Function......................................................................................................................................................................................................1709 Keyless Start System Diagnosis Introduction..................................................................................................................................................................................1709 Keyless Start System Check...................................................................................................................................................................................................1709 Customer questionnaire (example).............................................................................................................................................................................................1710 Key Indicator Lamp Check.....................................................................................................................................................................................................1711 DTC Check....................................................................................................................................................................................................................1711 DTC Table....................................................................................................................................................................................................................1712 DTC Clearance................................................................................................................................................................................................................1713 Keyless Start System Symptom Diagnosis.......................................................................................................................................................................................1713 Keyless Start System Operation Inspection....................................................................................................................................................................................1714 Door Lock Operation (Keyless Start System)...................................................................................................................................................................................1715 Inspection of Keyless Start Control Module and Its Circuits..................................................................................................................................................................1715 No DTC Detection After Performing DTC Check..................................................................................................................................................................................1720 Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.).....................................................................................................................1722 Keyless Start Control Module Power and Ground Circuit Check..................................................................................................................................................................1723 DTC No. 11: Communication Error with Steering Lock Unit......................................................................................................................................................................1724 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...........................................................................................................................1726 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)..........................................................................................................1726 DTC No. 31: Lost Communication with BCM......................................................................................................................................................................................1727 DTC No. 33: Control Module Communication Bus Off.............................................................................................................................................................................1729 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure............................................................................................................................1731 Repair Instructions..............................................................................................................................................................................................................1733 Antennas and Request Switches Removal and Installation.......................................................................................................................................................................1733 Front Door (Driver and Passenger Side) Rear End Door Request Switch Inspection...............................................................................................................................................1734 Steering Lock Unit Removal and Installation..................................................................................................................................................................................1734 Steering Lock Unit Inspection................................................................................................................................................................................................1734 Front Door Lock Switch Inspection............................................................................................................................................................................................1734 Keyless start control module Removal and Installation........................................................................................................................................................................1735 Remote Controller Inspection.................................................................................................................................................................................................1735 Replacement of Remote Controller Battery.....................................................................................................................................................................................1735 Registration Procedure for Remote Controller ID Code.........................................................................................................................................................................1736 COPYRIGHT................................................................................................................................................................................................................................1738 BOOKCOVER_VOL1...........................................................................................................................................................................................................................1739 BOOKCOVER_VOL2...........................................................................................................................................................................................................................1740
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