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Suzuki JB419 Grand Vitara Supplementary Service Manual – PDF DOWNLOAD
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Suzuki JB419 Grand Vitara Supplementary Service Manual – PDF DOWNLOAD
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Suzuki JB419 Grand Vitara Supplementary Service Manual – PDF DOWNLOAD
Language : English
Pages : 752
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Suzuki JB419 Grand Vitara Supplementary Service Manual – PDF DOWNLOAD
Top.................................................................................................................................................................................................................................................................... 0 Manual List............................................................................................................................................................................................................................................................ 0 IMPORTANT.............................................................................................................................................................................................................................................................. 1 FOREWORD............................................................................................................................................................................................................................................................... 3 TABLE OF CONTENTS...................................................................................................................................................................................................................................................... 5 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual................................................................................................................ 7 Precautions............................................................................................................................................................................................................................................................ 7 Precautions........................................................................................................................................................................................................................................................ 8 Precautions.................................................................................................................................................................................................................................................... 8 General Precautions........................................................................................................................................................................................................................................ 8 Precaution for Vehicle Equipped with ESP‚ System........................................................................................................................................................................................................... 11 Precautions for Catalytic Converter and Diesel Particulate Filter.......................................................................................................................................................................................... 11 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual............................................................................................................ 13 General Information.................................................................................................................................................................................................................................................... 13 General Information................................................................................................................................................................................................................................................ 14 General Description............................................................................................................................................................................................................................................ 14 Abbreviations.............................................................................................................................................................................................................................................. 14 Fastener Information....................................................................................................................................................................................................................................... 15 Engine Identification Number............................................................................................................................................................................................................................... 17 Transmission Identification Number......................................................................................................................................................................................................................... 17 Component Location............................................................................................................................................................................................................................................. 18 Warning, Caution and Information Label Location............................................................................................................................................................................................................ 18 Maintenance and Lubrication........................................................................................................................................................................................................................................ 20 Scheduled Maintenance.......................................................................................................................................................................................................................................... 20 MIZOGUCHI Maintenance Schedule under Normal Driving Conditions............................................................................................................................................................................................. 20 Maintenance Recommended under Severe Driving Conditions.................................................................................................................................................................................................... 21 Repair Instructions............................................................................................................................................................................................................................................ 22 Engine Accessory Drive Belt, Tensioner and Idler Replacement............................................................................................................................................................................................... 22 Camshaft Timing Belt and Tensioner Replacement............................................................................................................................................................................................................. 22 Engine Oil and Filter Change............................................................................................................................................................................................................................... 22 Engine Coolant Change...................................................................................................................................................................................................................................... 23 Exhaust system Inspection.................................................................................................................................................................................................................................. 23 Air Cleaner Filter Inspection.............................................................................................................................................................................................................................. 23 Air Cleaner Filter Replacement............................................................................................................................................................................................................................. 23 Fuel Lines and Connections Inspection...................................................................................................................................................................................................................... 24 Fuel Filter Replacement.................................................................................................................................................................................................................................... 24 Steering System Inspection................................................................................................................................................................................................................................. 24 Manual Transmission Oil Inspection......................................................................................................................................................................................................................... 24 Manual Transmission Oil Change............................................................................................................................................................................................................................. 25 Transfer Oil Inspection (If Equipped)...................................................................................................................................................................................................................... 25 Transfer (If Equipped) and Differential Oil Change......................................................................................................................................................................................................... 25 Power Steering (P/S) System Inspection..................................................................................................................................................................................................................... 25 Specifications................................................................................................................................................................................................................................................. 26 Tightening Torque Specifications........................................................................................................................................................................................................................... 26 Special Tools and Equipment.................................................................................................................................................................................................................................... 26 Recommended Fluids and Lubricants.......................................................................................................................................................................................................................... 26 Special Tool............................................................................................................................................................................................................................................... 26 Engine................................................................................................................................................................................................................................................................. 27 Precautions........................................................................................................................................................................................................................................................ 32 Precautions.................................................................................................................................................................................................................................................... 32 Precautions for Engine..................................................................................................................................................................................................................................... 32 Engine General Information and Diagnosis........................................................................................................................................................................................................................... 33 Precautions.................................................................................................................................................................................................................................................... 33 Precautions on Engine Service.............................................................................................................................................................................................................................. 33 Precautions in Diagnosing Trouble.......................................................................................................................................................................................................................... 33 Statement on Cleanliness and Care.......................................................................................................................................................................................................................... 34 General Description............................................................................................................................................................................................................................................ 34 Engine Diagnosis General Description....................................................................................................................................................................................................................... 34 On-Board Diagnostic System Description..................................................................................................................................................................................................................... 34 CAN Communication System Description....................................................................................................................................................................................................................... 36 Electronic Control System Description...................................................................................................................................................................................................................... 38 Diesel Particulate Filter Regeneration Description......................................................................................................................................................................................................... 43 Component Location............................................................................................................................................................................................................................................. 44 Electronic Control System Components Location.............................................................................................................................................................................................................. 44 Diagnostic Information and Procedures.......................................................................................................................................................................................................................... 45 Malfunction Indicator Lamp (MIL) Check..................................................................................................................................................................................................................... 45 Injection Warning Light (Gravity 1 Fault) Check............................................................................................................................................................................................................ 45 Red Stop Warning Light (Gravity 2 Fault) Check............................................................................................................................................................................................................. 45 Engine and Emission Control System Check................................................................................................................................................................................................................... 46 DTC Check.................................................................................................................................................................................................................................................. 48 DTC Clearance.............................................................................................................................................................................................................................................. 48 DTC Table.................................................................................................................................................................................................................................................. 49 Indicator lamp operation table............................................................................................................................................................................................................................. 52 Scan Tool Data............................................................................................................................................................................................................................................. 55 Visual Inspection.......................................................................................................................................................................................................................................... 57 Engine Basic Inspection.................................................................................................................................................................................................................................... 57 DTC P0016: Crankshaft Position-Camshaft Position Correlation Malfunction................................................................................................................................................................................... 58 DTC P0033: Turbo Charger Bypass Valve Control Circuit Malfunction.......................................................................................................................................................................................... 59 DTC P0089: Fuel Pressure Regulator 1 Performance Malfunction............................................................................................................................................................................................... 60 DTC P0100: Mass or Volume Air Flow Circuit Malfunction..................................................................................................................................................................................................... 64 DTC P0105: Manifold Absolute Pressure / Barometric Pressure Circuit Malfunction............................................................................................................................................................................ 66 DTC P0110: Intake Air Temperature Sensor 1 Circuit Malfunction............................................................................................................................................................................................. 66 DTC P0115: Engine Coolant Temperature Circuit Malfunction.................................................................................................................................................................................................. 68 DTC P0190: Fuel Rail Pressure Sensor Circuit Malfunction................................................................................................................................................................................................... 69 DTC P0201: Fuel Injector Circuit / Open Malfunction-Cylinder 1............................................................................................................................................................................................. 70 DTC P0202: Fuel Injector Circuit / Open Malfunction-Cylinder 2............................................................................................................................................................................................. 71 DTC P0203: Fuel Injector Circuit / Open Malfunction-Cylinder 3............................................................................................................................................................................................. 72 DTC P0204: Fuel Injector Circuit / Open Malfunction-Cylinder 4............................................................................................................................................................................................. 73 DTC P0225: Accelerator Pedal Position (APP) Sensor Assembly / Switch “C” Circuit Malfunction............................................................................................................................................................... 74 DTC P0235: Turbo / Super Charger Boost Sensor “A” Circuit Malfunction...................................................................................................................................................................................... 76 DTC P0243: Turbo / Super Charger Wastegate Solenoid “A” Malfunction........................................................................................................................................................................................ 77 DTC P0297: Vehicle Overspeed Condition Malfunction......................................................................................................................................................................................................... 79 DTC P0301: Cylinder 1 Misfire Detected Malfunction......................................................................................................................................................................................................... 80 DTC P0302: Cylinder 2 Misfire Detected Malfunction......................................................................................................................................................................................................... 80 DTC P0303: Cylinder 3 Misfire Detected Malfunction......................................................................................................................................................................................................... 81 DTC P0304: Cylinder 4 Misfire Detected Malfunction......................................................................................................................................................................................................... 81 DTC P0335: Crankshaft Position Sensor “A” Circuit Malfunction.............................................................................................................................................................................................. 82 DTC P0340: Camshaft Position Sensor “A” Circuit Malfunction................................................................................................................................................................................................ 83 DTC P0380: Glow Plug / Heater Circuit “A” Malfunction...................................................................................................................................................................................................... 84 DTC P0403: Exhaust Gas Recirculation Control Circuit Malfunction........................................................................................................................................................................................... 85 DTC P0409: Exhaust Gas Recirculation Sensor “A” Circuit Malfunction........................................................................................................................................................................................ 86 DTC P0470: Exhaust Pressure Sensor Malfunction............................................................................................................................................................................................................. 87 DTC P0480: Fan 1 Control Circuit........................................................................................................................................................................................................................... 88 DTC P0481: Fan 2 Control Circuit........................................................................................................................................................................................................................... 89 DTC P0486: Exhaust Gas Recirculation Sensor “B” Circuit Malfunction........................................................................................................................................................................................ 90 DTC P0500: Vehicle Speed Sensor “A” Malfunction............................................................................................................................................................................................................ 91 DTC P0530: A/C Refrigerant Pressure Sensor “A” Circuit Malfunction......................................................................................................................................................................................... 92 DTC P0544: Exhaust Gas Temperature Sensor Circuit Malfunction.............................................................................................................................................................................................. 93 DTC P0560: System Voltage Malfunction...................................................................................................................................................................................................................... 94 DTC P0571: Brake Switch “A” Circuit Malfunction............................................................................................................................................................................................................ 95 DTC P0575: Cruise Control Input Circuit Malfunction........................................................................................................................................................................................................ 96 DTC P0606: ECM / PCM Processor Malfunction................................................................................................................................................................................................................. 96 DTC P0611: Fuel injector Control Module Performance Malfunction............................................................................................................................................................................................ 98 DTC P0615: Starter Relay Circuit Malfunction............................................................................................................................................................................................................... 99 DTC P0627: Fuel Pump “A” Control Circuit / Open............................................................................................................................................................................................................100 DTC P0638: Throttle Actuator Control Range / Performance Malfunction.......................................................................................................................................................................................101 DTC P0641: Sensor Reference Voltage “A” Circuit / Open Malfunction.........................................................................................................................................................................................104 DTC P0645: A/C Clutch Relay Control Circuit................................................................................................................................................................................................................106 DTC P0651: Sensor Reference Voltage “B” Circuit / Open Malfunction.........................................................................................................................................................................................107 DTC P0670: Glow Plug Module Control Circuit Malfunction....................................................................................................................................................................................................109 DTC P0685: ECM / PCM Power Relay Control Circuit / Open Malfunction........................................................................................................................................................................................110 DTC P0697: Sensor Reference Voltage “C” Circuit / Open Malfunction.........................................................................................................................................................................................110 DTC P0830: Clutch Pedal Switch “A” Circuit Malfunction.....................................................................................................................................................................................................112 DTC P1431: Clogged Particulate Filter Failures Malfunction.................................................................................................................................................................................................112 DTC P1436: Regeneration Request Failures Malfunction.......................................................................................................................................................................................................113 DTC P1480: Defective Particulate Filter Inlet Pick-Off Failures Malfunction................................................................................................................................................................................114 DTC P1641: Additional Heater Relay No.1 Control Circuit....................................................................................................................................................................................................114 DTC P1642: Additional Heater Relay No.2 and 3 Control Circuit..............................................................................................................................................................................................115 DTC P2002: Particulate Trap Efficiency Below Threshold Malfunction.........................................................................................................................................................................................116 DTC P2031: Exhaust Gas Temperature Sensor Circuit Malfunction..............................................................................................................................................................................................117 DTC P2120: Throttle/Pedal Position Sensor/Switch “D” Circuit Malfunction...................................................................................................................................................................................118 DTC P2141: Exhaust Gas Recirculation Throttle Control Circuit Low Malfunction..............................................................................................................................................................................120 DTC P2142: Exhaust Gas Recirculation Throttle Control Circuit High Malfunction.............................................................................................................................................................................121 DTC P2264: Water in Fuel Sensor Circuit Malfunction........................................................................................................................................................................................................122 DTC P2413: Exhaust Gas Recirculation System Performance Malfunction........................................................................................................................................................................................123 DTC P242A: Turbine Inlet Temperature Sensor and Wake-up Sensor Failure Malfunction.........................................................................................................................................................................124 DTC P242B: Turbine Inlet Temperature Sensor Regulation Failure Malfunction.................................................................................................................................................................................125 DTC P2600: Coolant Pump Control Circuit / Open Malfunction.................................................................................................................................................................................................126 DTC P3031: Temperature Threshold Overshoot Failures During After-sales Regeneration........................................................................................................................................................................127 Fault Finding-Customer Complaints..........................................................................................................................................................................................................................127 Table 1: No dialogue with the ECM..........................................................................................................................................................................................................................128 Table 2: The Engine Does Not Start.........................................................................................................................................................................................................................128 Table 3: The Engine Starts with Difficulty.................................................................................................................................................................................................................129 Table 4: Injection Noise...................................................................................................................................................................................................................................130 Table 5: Poor Performance with Smoke.......................................................................................................................................................................................................................131 Table 6: Poor Performance without Smoke....................................................................................................................................................................................................................132 Table 7: Irregular Engine Operation........................................................................................................................................................................................................................133 Table 8: Fuel System Leaks.................................................................................................................................................................................................................................134 Table 9: Rough idle........................................................................................................................................................................................................................................135 Table 10: Oil leaks from the turbocharger..................................................................................................................................................................................................................136 Fault Finding-Tests........................................................................................................................................................................................................................................136 Test 1: Exhaust system check...............................................................................................................................................................................................................................137 Test 2: Low pressure circuit check.........................................................................................................................................................................................................................138 Test 3: Checking the turbocharged air inlet circuit........................................................................................................................................................................................................139 Test 4: MAF sensor.........................................................................................................................................................................................................................................140 Test 5: Variable geometry turbocharger control.............................................................................................................................................................................................................141 Test 6: Rotating part of a turbocharger....................................................................................................................................................................................................................142 Test 7: Exhaust gas recirculation valve....................................................................................................................................................................................................................143 Test 8: Injector malfunction...............................................................................................................................................................................................................................144 Special Tools and Equipment....................................................................................................................................................................................................................................146 Special Tool...............................................................................................................................................................................................................................................146 Aux. Emission Control Devices......................................................................................................................................................................................................................................147 Repair Instructions............................................................................................................................................................................................................................................147 EGR Valve Inspection.......................................................................................................................................................................................................................................147 Exhaust Gas Temperature Sensor 1, 2 and 3 Removal and Installation.........................................................................................................................................................................................147 Exhaust Gas Temperature Sensor 1, 2 and 3 Inspection.......................................................................................................................................................................................................149 Diesel Particulate Filter Differential Pressure Sensor Removal and Installation............................................................................................................................................................................149 Specifications.................................................................................................................................................................................................................................................149 Tightening Torque Specifications...........................................................................................................................................................................................................................149 Engine Electrical Devices..........................................................................................................................................................................................................................................150 Precautions....................................................................................................................................................................................................................................................150 Precaution in Replacing ECM................................................................................................................................................................................................................................150 General Description............................................................................................................................................................................................................................................150 ECM Registration...........................................................................................................................................................................................................................................150 Repair Instructions............................................................................................................................................................................................................................................151 Idle Speed Inspection......................................................................................................................................................................................................................................151 Engine Control Module (ECM) Removal and Installation.......................................................................................................................................................................................................151 Registration Procedure for the ECM.........................................................................................................................................................................................................................151 Registration Procedure for the Fuel Injector Calibration Code..............................................................................................................................................................................................152 EGR Valve Data Initialization..............................................................................................................................................................................................................................152 Inlet Throttle Valve Data Initialization...................................................................................................................................................................................................................153 Diesel Particulate Filter Data Initialization..............................................................................................................................................................................................................153 Diesel Particulate Filter After-sales Regeneration Procedure...............................................................................................................................................................................................153 Glow Plug Removal and Installation.........................................................................................................................................................................................................................154 Glow Plug Inspection.......................................................................................................................................................................................................................................155 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection.....................................................................................................................................................................................155 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation..................................................................................................................................................................................155 Accelerator Pedal Position (APP) Sensor Assembly Inspection................................................................................................................................................................................................156 Engine Coolant Temperature (ECT) Sensor Removal and Installation...........................................................................................................................................................................................157 Engine Coolant Temperature (ECT) Sensor Inspection.........................................................................................................................................................................................................157 Camshaft Position (CMP) Sensor Removal and Installation....................................................................................................................................................................................................158 Crankshaft Position (CKP) Sensor (Engine Speed Sensor) Removal and Installation............................................................................................................................................................................158 Crankshaft Position (CKP) (Engine Speed Sensor) Sensor Inspection..........................................................................................................................................................................................159 Boost Pressure Sensor Removal and Installation.............................................................................................................................................................................................................159 Main Relay and Fuel Heater Relay Inspection................................................................................................................................................................................................................159 Pre-Heating Unit Removal and Installation..................................................................................................................................................................................................................160 Boost Pressure Control Solenoid Valve Removal and Installation.............................................................................................................................................................................................160 Boost Pressure Control Solenoid Valve Inspection...........................................................................................................................................................................................................161 Turbocharger Electric Water Pump Removal and Installation..................................................................................................................................................................................................161 Turbocharger Electric Water Pump Inspection................................................................................................................................................................................................................161 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Removal and Installation..............................................................................................................................................................................162 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection.....................................................................................................................................................................................162 Inlet Throttle Valve Removal and Installation..............................................................................................................................................................................................................162 Inlet Throttle Valve On-Vehicle Inspection.................................................................................................................................................................................................................162 Specifications.................................................................................................................................................................................................................................................163 Tightening Torque Specifications...........................................................................................................................................................................................................................163 Special Tools and Equipment....................................................................................................................................................................................................................................163 Special Tool...............................................................................................................................................................................................................................................163 Engine Mechanical..................................................................................................................................................................................................................................................164 Diagnostic Information and Procedures..........................................................................................................................................................................................................................164 Compression Check..........................................................................................................................................................................................................................................164 Valve Lash (Clearance) Inspection..........................................................................................................................................................................................................................165 Valve Lash (Clearance) Adjustment..........................................................................................................................................................................................................................166 Repair Instructions............................................................................................................................................................................................................................................167 Air Cleaner Components.....................................................................................................................................................................................................................................167 Air Cleaner Removal and Installation.......................................................................................................................................................................................................................167 Air Cleaner Filter Removal and Installation................................................................................................................................................................................................................167 Air Cleaner Filter Inspection and Cleaning.................................................................................................................................................................................................................168 Intercooler and Air Intake Pipe Components.................................................................................................................................................................................................................168 Intercooler Removal and Installation.......................................................................................................................................................................................................................168 Air intake Pipe Removal and Installation...................................................................................................................................................................................................................169 Cylinder Head Cover Components.............................................................................................................................................................................................................................170 Cylinder Head Cover Removal and Installation...............................................................................................................................................................................................................170 Oil Separator Components...................................................................................................................................................................................................................................172 Oil Separator Removal and Installation.....................................................................................................................................................................................................................172 Vacuum Pump Removal and Installation.......................................................................................................................................................................................................................173 Vacuum Pump Inspection.....................................................................................................................................................................................................................................173 Timing Belt and Belt Tensioner Components..................................................................................................................................................................................................................174 Timing Belt and Belt Tensioner Removal and Installation....................................................................................................................................................................................................175 Timing Belt and Belt Tensioner Inspection..................................................................................................................................................................................................................180 Engine Mounting Components.................................................................................................................................................................................................................................181 Engine Assembly Removal and Installation...................................................................................................................................................................................................................182 EGR Valve Components.......................................................................................................................................................................................................................................187 EGR Valve Removal and Installation.........................................................................................................................................................................................................................188 EGR Pipe and EGR Cooler Removal and Installation...........................................................................................................................................................................................................189 Turbocharger Components....................................................................................................................................................................................................................................191 Turbocharger Assembly Removal and Installation.............................................................................................................................................................................................................191 Turbocharger Assembly Inspection...........................................................................................................................................................................................................................194 Turbocharger Assembly Adjustment...........................................................................................................................................................................................................................194 Intake Manifold and Exhaust Manifold Components............................................................................................................................................................................................................195 Intake Manifold and Exhaust Manifold Removal and Installation..............................................................................................................................................................................................196 Camshaft and Tappet Components.............................................................................................................................................................................................................................197 Camshaft and Tappet Removal and Installation...............................................................................................................................................................................................................198 Camshaft and Tappet Inspection.............................................................................................................................................................................................................................201 Valve and Cylinder Head Assembly Components................................................................................................................................................................................................................202 Valve and Cylinder Head Assembly Removal and Installation..................................................................................................................................................................................................203 Valve and Cylinder Head Assembly Inspection................................................................................................................................................................................................................205 Valve and Cylinder Head Disassembly and Reassembly.........................................................................................................................................................................................................205 Valves and Valve Guides Inspection.........................................................................................................................................................................................................................207 Cylinder Head Inspection...................................................................................................................................................................................................................................209 Valve Spring Inspection....................................................................................................................................................................................................................................210 Piston, Piston Ring, Connecting Rod and Cylinder Components................................................................................................................................................................................................211 Piston, Piston Ring and Connecting Rod Removal and Installation............................................................................................................................................................................................211 Cylinders, Pistons and Piston Rings Inspection.............................................................................................................................................................................................................214 Piston Pins and Connecting Rods Inspection.................................................................................................................................................................................................................215 Crank Pin and Connecting Rod Bearings Inspection...........................................................................................................................................................................................................216 Main Bearing, Crankshaft and Cylinder Block Component......................................................................................................................................................................................................218 Main Bearing, Crankshaft and Cylinder Block Removal and Installation.......................................................................................................................................................................................219 Crankshaft Inspection......................................................................................................................................................................................................................................224 Main Bearings Inspection...................................................................................................................................................................................................................................224 Specifications.................................................................................................................................................................................................................................................225 Tightening Torque Specifications...........................................................................................................................................................................................................................225 Special Tools and Equipment....................................................................................................................................................................................................................................227 Recommended Service Material...............................................................................................................................................................................................................................227 Special Tool...............................................................................................................................................................................................................................................227 Engine Lubrication System..........................................................................................................................................................................................................................................230 General Description............................................................................................................................................................................................................................................230 Engine Lubrication Description.............................................................................................................................................................................................................................230 Diagnostic Information and Procedures..........................................................................................................................................................................................................................230 Oil Pressure Check.........................................................................................................................................................................................................................................230 Repair Instructions............................................................................................................................................................................................................................................231 Oil Pan and Oil Pump Strainer Components...................................................................................................................................................................................................................231 Oil Pan and Oil Pump Strainer Removal and Installation.....................................................................................................................................................................................................232 Oil Pump, Oil Pump Chain and Gasket Holder Plate Component.................................................................................................................................................................................................237 Oil Pump, Oil Pump Chain and Gasket Holder Plate Removal and Installation..................................................................................................................................................................................237 Oil Pump, Oil Pump Chain and Gasket Holder Plate Inspection................................................................................................................................................................................................239 Heat Exchanger Removal and Installation....................................................................................................................................................................................................................239 Specifications.................................................................................................................................................................................................................................................240 Tightening Torque Specifications...........................................................................................................................................................................................................................240 Special Tools and Equipment....................................................................................................................................................................................................................................241 Recommended Service Material...............................................................................................................................................................................................................................241 Special Tool...............................................................................................................................................................................................................................................241 Engine Cooling System..............................................................................................................................................................................................................................................242 General Description............................................................................................................................................................................................................................................242 Cooling System Description.................................................................................................................................................................................................................................242 Coolant Description........................................................................................................................................................................................................................................242 Schematic and Routing Diagram..................................................................................................................................................................................................................................243 Coolant Circulation........................................................................................................................................................................................................................................243 Diagnostic Information and Procedures..........................................................................................................................................................................................................................244 Engine Cooling Symptom Diagnosis...........................................................................................................................................................................................................................244 Repair Instructions............................................................................................................................................................................................................................................245 Cooling System Components..................................................................................................................................................................................................................................245 Coolant Level Check........................................................................................................................................................................................................................................246 Engine Cooling System Inspection and Cleaning..............................................................................................................................................................................................................246 Cooling System Draining....................................................................................................................................................................................................................................246 Cooling System Refilling...................................................................................................................................................................................................................................247 Cooling System Flushing....................................................................................................................................................................................................................................247 Cooling Water Pipe or Hose Removal and Installation........................................................................................................................................................................................................248 Thermostat Assembly Removal and Installation...............................................................................................................................................................................................................248 Radiator Cooling Fan Motor On-Vehicle Inspection...........................................................................................................................................................................................................249 Radiator Cooling Fan Relay Inspection......................................................................................................................................................................................................................249 Radiator Cooling Fan Assembly Removal and Installation.....................................................................................................................................................................................................250 Radiator On-Vehicle Inspection and Cleaning................................................................................................................................................................................................................250 Radiator Removal and Installation..........................................................................................................................................................................................................................250 Water Pump Removal and Installation........................................................................................................................................................................................................................250 Water Pump Inspection......................................................................................................................................................................................................................................251 Specifications.................................................................................................................................................................................................................................................251 Tightening Torque Specifications...........................................................................................................................................................................................................................251 Special Tools and Equipment....................................................................................................................................................................................................................................251 Recommended Service Material...............................................................................................................................................................................................................................251 Fuel System........................................................................................................................................................................................................................................................252 Precautions....................................................................................................................................................................................................................................................252 Precautions on Fuel System Service.........................................................................................................................................................................................................................252 Fuel System Description....................................................................................................................................................................................................................................256 Repair Instructions............................................................................................................................................................................................................................................257 Fuel System Components.....................................................................................................................................................................................................................................257 Fuel Pressure Relief Procedure.............................................................................................................................................................................................................................258 Fuel Leakage Check Procedure...............................................................................................................................................................................................................................258 Water Draining of Fuel Filter..............................................................................................................................................................................................................................259 Air Bleeding of Fuel System................................................................................................................................................................................................................................259 Fuel Filter and Fuel Heater Removal and Installation.......................................................................................................................................................................................................259 Fuel Heater Inspection.....................................................................................................................................................................................................................................260 Fuel Hose Disconnecting and Reconnecting...................................................................................................................................................................................................................261 Fuel Lines Inspection......................................................................................................................................................................................................................................263 Fuel Pipe Removal and Installation.........................................................................................................................................................................................................................263 High Pressure Pipe Removal and Installation................................................................................................................................................................................................................264 Fuel Injector On-Vehicle Inspection........................................................................................................................................................................................................................267 Fuel Injector Removal and Installation.....................................................................................................................................................................................................................267 Injection Pump Components..................................................................................................................................................................................................................................268 Injection Pump Removal and Installation....................................................................................................................................................................................................................269 Fuel Flow Actuator Inspection..............................................................................................................................................................................................................................272 Fuel Flow Actuator Removal and Installation................................................................................................................................................................................................................272 Common Rail (High Pressure Fuel Injection Rail) Removal and Installation...................................................................................................................................................................................273 Fuel Rail Presser Sensor Inspection........................................................................................................................................................................................................................273 Fuel Filler Cap Inspection.................................................................................................................................................................................................................................274 Fuel Tank Removal and Installation.........................................................................................................................................................................................................................274 Fuel Tank Inspection.......................................................................................................................................................................................................................................275 Fuel Tank Purging Procedure................................................................................................................................................................................................................................276 Fuel Tank Inlet Valve Removal and Installation.............................................................................................................................................................................................................276 Fuel Tank Inlet Valve Inspection...........................................................................................................................................................................................................................277 Fuel Pump Assembly Removal and Installation................................................................................................................................................................................................................277 Fuel Pump Inspection.......................................................................................................................................................................................................................................278 Main Fuel Level Gauge Removal and Installation.............................................................................................................................................................................................................278 Main Fuel Level Gauge Inspection...........................................................................................................................................................................................................................278 Sub Fuel Level Gauge Removal and Installation..............................................................................................................................................................................................................278 Sub Fuel Level Gauge Inspection............................................................................................................................................................................................................................279 Specifications.................................................................................................................................................................................................................................................279 Tightening Torque Specifications...........................................................................................................................................................................................................................279 Special Tools and Equipment....................................................................................................................................................................................................................................280 Recommended Service Material...............................................................................................................................................................................................................................280 Special Tool...............................................................................................................................................................................................................................................280 Starting System....................................................................................................................................................................................................................................................281 General Description............................................................................................................................................................................................................................................281 Cranking Circuit Introduction..............................................................................................................................................................................................................................281 Starting Motor Circuit Description.........................................................................................................................................................................................................................281 Diagnostic Information and Procedures..........................................................................................................................................................................................................................282 Cranking System Symptom Diagnosis..........................................................................................................................................................................................................................282 Starting Motor Performance Test............................................................................................................................................................................................................................283 Repair Instructions............................................................................................................................................................................................................................................284 Starting Motor Components..................................................................................................................................................................................................................................284 Starting Motor Dismounting and Remounting..................................................................................................................................................................................................................285 Starting Motor Disassembly and Assembly....................................................................................................................................................................................................................285 Starting Motor Inspection..................................................................................................................................................................................................................................287 Specifications.................................................................................................................................................................................................................................................288 Starting Motor Specifications..............................................................................................................................................................................................................................288 Tightening Torque Specifications...........................................................................................................................................................................................................................288 Charging System....................................................................................................................................................................................................................................................289 General Description............................................................................................................................................................................................................................................289 Battery Description........................................................................................................................................................................................................................................289 Generator Description......................................................................................................................................................................................................................................290 Diagnostic Information and Procedures..........................................................................................................................................................................................................................291 Battery Inspection.........................................................................................................................................................................................................................................291 Generator Symptom Diagnosis................................................................................................................................................................................................................................292 Generator Test (Undercharged Battery Check)................................................................................................................................................................................................................292 Generator Test (Overcharged Battery Check).................................................................................................................................................................................................................293 Repair Instructions............................................................................................................................................................................................................................................294 Jump Starting in Case of Emergency.........................................................................................................................................................................................................................294 Battery Dismounting and Remounting.........................................................................................................................................................................................................................294 Generator Components.......................................................................................................................................................................................................................................295 Generator Dismounting and Remounting.......................................................................................................................................................................................................................296 Generator Disassembly and Assembly.........................................................................................................................................................................................................................296 Drive End Frame / Bearing Disassembly and Assembly.........................................................................................................................................................................................................298 Generator Inspection.......................................................................................................................................................................................................................................298 Accessory Drive Belt and Idler Pulley Removal and Installation.............................................................................................................................................................................................300 Accessory Drive Belt Inspection............................................................................................................................................................................................................................301 Accessory Drive Belt Tensioner Removal and Installation....................................................................................................................................................................................................301 Specifications.................................................................................................................................................................................................................................................301 Charging System Specifications.............................................................................................................................................................................................................................301 Tightening Torque Specifications...........................................................................................................................................................................................................................302 Special Tools and Equipment....................................................................................................................................................................................................................................302 Special Tool...............................................................................................................................................................................................................................................302 Exhaust System.....................................................................................................................................................................................................................................................303 General Description............................................................................................................................................................................................................................................303 Exhaust System Description.................................................................................................................................................................................................................................303 Diesel Particurate Filter..................................................................................................................................................................................................................................303 Diagnostic Information and Procedures..........................................................................................................................................................................................................................303 Exhaust System Check.......................................................................................................................................................................................................................................303 Repair Instructions............................................................................................................................................................................................................................................304 Exhaust System Components..................................................................................................................................................................................................................................304 Exhaust Manifold Removal and Installation..................................................................................................................................................................................................................305 Diesel Particulate Filter Removal and Installation.........................................................................................................................................................................................................305 Specifications.................................................................................................................................................................................................................................................305 Tightening Torque Specifications...........................................................................................................................................................................................................................305 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual............................................................................................................307 Driveline / Axle.......................................................................................................................................................................................................................................................307 Precautions........................................................................................................................................................................................................................................................309 Precautions....................................................................................................................................................................................................................................................309 Precautions for Driveline / Axle...........................................................................................................................................................................................................................309 Differential.......................................................................................................................................................................................................................................................310 Front..........................................................................................................................................................................................................................................................310 Repair Instructions........................................................................................................................................................................................................................................310 Front Differential Unit Components.....................................................................................................................................................................................................................310 Specifications.............................................................................................................................................................................................................................................310 Tightening Torque Specifications.......................................................................................................................................................................................................................310 Rear...........................................................................................................................................................................................................................................................311 Repair Instructions........................................................................................................................................................................................................................................311 Rear Differential Dismounting and Remounting...........................................................................................................................................................................................................311 Specifications.............................................................................................................................................................................................................................................311 Tightening Torque Specifications.......................................................................................................................................................................................................................311 Transfer...........................................................................................................................................................................................................................................................312 Precautions....................................................................................................................................................................................................................................................312 Transfer Warning...........................................................................................................................................................................................................................................312 General Description............................................................................................................................................................................................................................................313 4WD Control System Wiring Circuit Diagram..................................................................................................................................................................................................................313 Input / Output Signal Table of 4WD Control Module..........................................................................................................................................................................................................314 CAN Communication System Description.......................................................................................................................................................................................................................314 Diagnostic Information and Procedures..........................................................................................................................................................................................................................315 Visual Inspection..........................................................................................................................................................................................................................................315 DTC Table..................................................................................................................................................................................................................................................315 Scan Tool Data.............................................................................................................................................................................................................................................316 Scan Tool Data Definitions.................................................................................................................................................................................................................................317 4WD Control Symptom Diagnosis..............................................................................................................................................................................................................................318 DTC U1073: Control Module Communication Buss Off...........................................................................................................................................................................................................319 DTC U1100: Lost Communication with ECM.....................................................................................................................................................................................................................321 DTC U1121: Lost Communication with ABS / Electronic Stability Program Hydraulic Unit / Control Module......................................................................................................................................................322 Repair Instructions............................................................................................................................................................................................................................................323 Transfer Assembly Components...............................................................................................................................................................................................................................323 Transfer Assembly Disassembly and Reassembly...............................................................................................................................................................................................................324 Specifications.................................................................................................................................................................................................................................................333 Tightening Torque Specifications...........................................................................................................................................................................................................................333 Special Tools and Equipment....................................................................................................................................................................................................................................333 Recommended Service Material...............................................................................................................................................................................................................................333 Special Tool...............................................................................................................................................................................................................................................333 Propeller Shafts...................................................................................................................................................................................................................................................335 General Description............................................................................................................................................................................................................................................335 Propeller Shaft Construction...............................................................................................................................................................................................................................335 Repair Instructions............................................................................................................................................................................................................................................336 Propeller Shaft Removal and Installation...................................................................................................................................................................................................................336 Specifications.................................................................................................................................................................................................................................................337 Tightening Torque Specifications...........................................................................................................................................................................................................................337 Special Tools and Equipment....................................................................................................................................................................................................................................337 Recommended Service Material...............................................................................................................................................................................................................................337 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual............................................................................................................339 Brakes.................................................................................................................................................................................................................................................................339 ABS................................................................................................................................................................................................................................................................343 Precautions....................................................................................................................................................................................................................................................343 Precautions in Diagnosing Troubles.........................................................................................................................................................................................................................343 Precautions in On-Vehicle Service..........................................................................................................................................................................................................................343 Precautions in Hydraulic Unit Operation Check..............................................................................................................................................................................................................343 General Description............................................................................................................................................................................................................................................344 ABS Description............................................................................................................................................................................................................................................344 ABS Hydraulic Unit / Control Module Assembly Description...................................................................................................................................................................................................344 CAN Communication System Description.......................................................................................................................................................................................................................345 Schematic and Routing Diagram..................................................................................................................................................................................................................................346 ABS Schematic..............................................................................................................................................................................................................................................346 ABS Wiring Circuit Diagram.................................................................................................................................................................................................................................347 Component Location.............................................................................................................................................................................................................................................349 ABS Components Location....................................................................................................................................................................................................................................349 Diagnostic Information and Procedures..........................................................................................................................................................................................................................350 ABS Check..................................................................................................................................................................................................................................................350 ABS Warning Lamp Check.....................................................................................................................................................................................................................................352 DTC Check..................................................................................................................................................................................................................................................352 DTC Table..................................................................................................................................................................................................................................................353 Scan Tool Data.............................................................................................................................................................................................................................................353 ABS Warning Lamp Does Not Come ON at Ignition Switch ON....................................................................................................................................................................................................354 ABS Warning Lamp Comes ON Steady...........................................................................................................................................................................................................................356 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady......................................................................................................................................................................................................357 DTC C1015: G Sensor Circuit Failure (For 4WD Vehicle)......................................................................................................................................................................................................358 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder Failure............................................................................................359 DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet Solenoid Circuit Failure, Outlet Solenoid Circuit Failure, Master Cylinder Cut Solenoid Circuit Failure, Low Pressure Solenoid Circuit Failure....362 DTC C1057: ABS (EPS‚) Control Module Power Supply Circuit Failure..........................................................................................................................................................................................364 DTC C1061: Pump Motor and/or Motor Driver Circuit Failure..................................................................................................................................................................................................366 DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure..............................................................................................................................................................................................367 DTC C1071: ABS (ESP‚) Control Module Internal Defect.......................................................................................................................................................................................................369 DTC U1073: Control Module Communication Bus Off............................................................................................................................................................................................................370 DTC U1100: Lost Communication with ECM (Reception Error)...................................................................................................................................................................................................372 Repair Instructions............................................................................................................................................................................................................................................373 Hydraulic Unit Operation Check.............................................................................................................................................................................................................................373 ABS (ESP‚) Hydraulic Unit / Control Module Assembly On-Vehicle Inspection..................................................................................................................................................................................374 ABS (ESP‚) Hydraulic Unit / Control Module Assembly Removal and Installation...............................................................................................................................................................................374 Specifications.................................................................................................................................................................................................................................................376 Tightening Torque Specifications...........................................................................................................................................................................................................................376 Special Tools and Equipment....................................................................................................................................................................................................................................377 Special Tool...............................................................................................................................................................................................................................................377 Electronic Stability Program.......................................................................................................................................................................................................................................378 Precautions....................................................................................................................................................................................................................................................378 Precautions in Diagnosing Troubles.........................................................................................................................................................................................................................378 Precautions in On-Vehicle Service..........................................................................................................................................................................................................................378 Precautions in Hydraulic Unit Operation Check..............................................................................................................................................................................................................378 Precautions in Sensor Calibration..........................................................................................................................................................................................................................379 Precautions in Speedometer Test or Other Tests.............................................................................................................................................................................................................379 General Description............................................................................................................................................................................................................................................379 Electronic Stability Program Description...................................................................................................................................................................................................................379 ESP‚ Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................................................379 Warning Lamp, Indicator Lamp Description...................................................................................................................................................................................................................380 CAN Communication System Description.......................................................................................................................................................................................................................381 CAN Communication System For Electronic Stability Program Description......................................................................................................................................................................................382 Schematic and Routing Diagram..................................................................................................................................................................................................................................383 Electronic Stability Program Schematic.....................................................................................................................................................................................................................383 Electronic Stability Program Wiring Circuit Diagram........................................................................................................................................................................................................384 Component Location.............................................................................................................................................................................................................................................386 Electronic Stability Program Component Location............................................................................................................................................................................................................386 Diagnostic Information and Procedures..........................................................................................................................................................................................................................387 Electronic Stability Program Check.........................................................................................................................................................................................................................387 ESP‚ Warning lamp Check....................................................................................................................................................................................................................................389 ABS Warning Lamp Check.....................................................................................................................................................................................................................................389 EBD Warning Lamp (Brake Warning Lamp) Check................................................................................................................................................................................................................389 DTC Check..................................................................................................................................................................................................................................................390 DTC Table..................................................................................................................................................................................................................................................390 DTC Clearance..............................................................................................................................................................................................................................................394 Fail-Safe Table............................................................................................................................................................................................................................................394 Scan Tool Data.............................................................................................................................................................................................................................................397 ESP‚ Warning Lamp Does Not Come ON at Ignition Switch ON...................................................................................................................................................................................................398 ESP‚ Warning Lamp Comes ON Steady..........................................................................................................................................................................................................................399 Serial Data Link Circuit Check.............................................................................................................................................................................................................................400 DTC C1015 / C1017 / C1023: Longitudinal G Sensor / Lateral G Sensor / Yaw Rate Sensor in Yaw Rate / G Sensor Assembly Failure..............................................................................................................................402 DTC C1016: Stop Lamp Switch Circuit Failure................................................................................................................................................................................................................403 DTC C1018: Brake Fluid Level Switch Failure................................................................................................................................................................................................................404 DTC C1020: Master Cylinder Pressure Sensor Power Supply Failure............................................................................................................................................................................................405 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder Failure............................................................................................406 DTC C1024: Steering Angle Sensor Circuit Failure...........................................................................................................................................................................................................406 DTC C1027: ESP‚ OFF Switch Circuit Failure.................................................................................................................................................................................................................407 DTC C1028: Master Cylinder Pressure Sensor Circuit Failure.................................................................................................................................................................................................408 DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure...............................................................................................................................................................................................408 DTC C1037: Steering Angle Sensor Power Supply Failure......................................................................................................................................................................................................410 DTC C1038: Steering Angle Sensor Detect Rolling Counter Failure with ESP‚ Control Module...................................................................................................................................................................411 DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure...................................................................................................................................................................................................412 DTC C1040: Stability Control System Function Failure.......................................................................................................................................................................................................412 DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet Solenoid Circuit Failure, Outlet Solenoid Circuit Failure, Master Cylinder Cut Solenoid Circuit Failure, Low Pressure Solenoid Circuit Failure....413 DTC C1050: Back Switch Failure (For M/T Model).............................................................................................................................................................................................................413 DTC C1057: ESP‚ (ABS) control module power supply circuit failure..........................................................................................................................................................................................414 DTC C1061: Pump Motor and/or Motor Driver Circuit Failure..................................................................................................................................................................................................414 DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure..............................................................................................................................................................................................414 DTC C1071: ESP‚ (ABS) Control Module Internal Defect.......................................................................................................................................................................................................414 DTC C1073: Lost Communication With Yaw Rate / G Sensor Assembly............................................................................................................................................................................................415 DTC C1075 / 1076 / 1077 / 1078: Steering Angle Sensor / Master Cylinder Pressure Sensor / Longitudinal G Sensor / Lateral G Sensor in Yaw Rate / G Sensor Assembly Calibration Incomplete..................................................................416 DTC C1090: ECM Detect Rolling Counter Failure with ESP‚ Control Module.....................................................................................................................................................................................417 DTC C1091 / 1093: ECM / 4WD Control Module Data in CAN Line Failure........................................................................................................................................................................................417 DTC U1073: Control Module Communication Bus Off............................................................................................................................................................................................................417 DTC U1100: Lost Communication with ECM (Reception Error)...................................................................................................................................................................................................417 DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error).................................................................................................................................................................................418 DTC U1139: Lost Communication with 4WD Control Module (Reception Error) (If Equipped 4WD Control Module)...................................................................................................................................................420 DTC U1140: Lost Communication with BCM (Reception Error)...................................................................................................................................................................................................422 Repair Instructions............................................................................................................................................................................................................................................423 Hydraulic Unit Operation Check.............................................................................................................................................................................................................................423 Sensor Calibration.........................................................................................................................................................................................................................................423 ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................................................424 ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation.....................................................................................................................................................................................424 Front Wheel Speed Sensor On-Vehicle Inspection.............................................................................................................................................................................................................424 Front Wheel Speed Sensor Removal and Installation..........................................................................................................................................................................................................424 Front Wheel Speed Sensor Inspection........................................................................................................................................................................................................................424 Rear Wheel Speed Sensor On-Vehicle Inspection..............................................................................................................................................................................................................424 Rear Wheel Speed Sensor Removal and Installation...........................................................................................................................................................................................................424 Rear Wheel Speed Sensor Inspection.........................................................................................................................................................................................................................424 Front Wheel Encoder On-Vehicle Inspection..................................................................................................................................................................................................................424 Front Wheel Encoder Removal and Installation...............................................................................................................................................................................................................424 Rear Wheel Encoder On-Vehicle Inspection...................................................................................................................................................................................................................424 Rear Wheel Encoder Removal and Installation................................................................................................................................................................................................................424 Master Cylinder Pressure Sensor On-Vehicle Inspection......................................................................................................................................................................................................424 Yaw Rate / G Sensor Assembly On-Vehicle Inspection.........................................................................................................................................................................................................425 Yaw Rate / G Sensor Assembly Removal and Installation......................................................................................................................................................................................................427 Yaw Rate / G Sensor Inspection.............................................................................................................................................................................................................................428 Steering Angle Sensor On-Vehicle Inspection................................................................................................................................................................................................................428 Steering Angle Sensor Removal and Installation.............................................................................................................................................................................................................429 Steering Angle Sensor Inspection...........................................................................................................................................................................................................................429 ESP‚ OFF Switch Removal and Installation...................................................................................................................................................................................................................429 ESP‚ OFF Switch Inspection.................................................................................................................................................................................................................................429 Specifications.................................................................................................................................................................................................................................................430 Tightening Torque Specifications...........................................................................................................................................................................................................................430 Special Tools and Equipment....................................................................................................................................................................................................................................430 Special Tool...............................................................................................................................................................................................................................................430 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual............................................................................................................431 Transmission / Transaxle...............................................................................................................................................................................................................................................431 Precautions........................................................................................................................................................................................................................................................433 Precautions....................................................................................................................................................................................................................................................433 Precautions for Transmission / Transaxle...................................................................................................................................................................................................................433 Manual Transmission/Transaxle......................................................................................................................................................................................................................................434 General Description............................................................................................................................................................................................................................................434 Manual Transmission Construction...........................................................................................................................................................................................................................434 Diagnostic Information and Procedures..........................................................................................................................................................................................................................435 Manual Transmission Symptom Diagnosis......................................................................................................................................................................................................................435 Repair Instructions............................................................................................................................................................................................................................................436 Manual Transmission Assembly Components....................................................................................................................................................................................................................436 Gear Shift Lever Case Assembly Components..................................................................................................................................................................................................................438 Gear Shift Shaft and Fork Components.......................................................................................................................................................................................................................439 Input Shaft Assembly, Main Shaft Assembly and Countershaft Assembly Components.............................................................................................................................................................................440 Manual Transmission Oil Level Check........................................................................................................................................................................................................................441 Manual Transmission Oil Change.............................................................................................................................................................................................................................441 Transmission Shift Control Lever Removal and Installation..................................................................................................................................................................................................442 Transmission Shift Control Lever Inspection................................................................................................................................................................................................................444 Back Up Light Switch Removal and Installation..............................................................................................................................................................................................................444 Back Up Light Switch Inspection............................................................................................................................................................................................................................444 Gear Shift Lever Case Assembly Removal and Installation....................................................................................................................................................................................................445 Gear Shift Lever Case Assembly Disassembly and Reassembly..................................................................................................................................................................................................446 Gear Shift Lever Case Assembly Inspection..................................................................................................................................................................................................................446 Engine Rear Mounting Replacement...........................................................................................................................................................................................................................446 Manual Transmission Assembly Dismounting and Remounting....................................................................................................................................................................................................447 Manual Transmission Unit Disassembly.......................................................................................................................................................................................................................449 Manual Transmission Unit Reassembly........................................................................................................................................................................................................................451 Locating Spring Inspection.................................................................................................................................................................................................................................455 Input Shaft Assembly Disassembly and Reassembly............................................................................................................................................................................................................455 Input Shaft Inspection.....................................................................................................................................................................................................................................456 Main Shaft Disassembly.....................................................................................................................................................................................................................................456 Main Shaft Inspection......................................................................................................................................................................................................................................457 Main Shaft Reassembly......................................................................................................................................................................................................................................459 Countershaft Assembly Disassembly and Reassembly...........................................................................................................................................................................................................462 Reverse Idle Gear Assembly Disassembly and Reassembly......................................................................................................................................................................................................464 Countershaft and Reverse Idle Gear Inspection..............................................................................................................................................................................................................465 Manual Transmission Adapter Case Disassembly and Assembly..................................................................................................................................................................................................465 Specifications.................................................................................................................................................................................................................................................466 Tightening Torque Specifications...........................................................................................................................................................................................................................466 Special Tools and Equipment....................................................................................................................................................................................................................................467 Recommended Service Material...............................................................................................................................................................................................................................467 Special Tool...............................................................................................................................................................................................................................................467 Clutch.............................................................................................................................................................................................................................................................469 General Description............................................................................................................................................................................................................................................469 Clutch (Hydraulic Type) Construction.......................................................................................................................................................................................................................469 Component Location.............................................................................................................................................................................................................................................470 Clutch Fluid Pipe and Hose Location........................................................................................................................................................................................................................470 Diagnostic Information and Procedures..........................................................................................................................................................................................................................470 Air Bleeding of Clutch System..............................................................................................................................................................................................................................470 Repair Instructions............................................................................................................................................................................................................................................471 Clutch Master Cylinder Removal and Installation............................................................................................................................................................................................................471 Clutch Operating Cylinder Assembly Removal and Installation................................................................................................................................................................................................472 Clutch Cover, Clutch Disc and Flywheel Components..........................................................................................................................................................................................................473 Clutch Cover, Clutch Disc and Flywheel Removal and Installation............................................................................................................................................................................................473 Specifications.................................................................................................................................................................................................................................................475 Tightening Torque Specifications...........................................................................................................................................................................................................................475 Special Tools and Equipment....................................................................................................................................................................................................................................475 Recommended Service Material...............................................................................................................................................................................................................................475 Special Tool...............................................................................................................................................................................................................................................475 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual............................................................................................................477 Steering...............................................................................................................................................................................................................................................................477 Steering Wheel and Column..........................................................................................................................................................................................................................................479 General Description............................................................................................................................................................................................................................................479 Steering Wheel and Column Construction.....................................................................................................................................................................................................................479 Repair Instructions............................................................................................................................................................................................................................................481 Contact Coil Cable Assembly Removal and Installation.......................................................................................................................................................................................................481 Steering Angle Sensor Removal and Installation.............................................................................................................................................................................................................482 Steering Angle Sensor Inspection...........................................................................................................................................................................................................................482 Steering Column Assembly Removal and Installation..........................................................................................................................................................................................................483 Specifications.................................................................................................................................................................................................................................................485 Tightening Torque Specifications...........................................................................................................................................................................................................................485 Power Assisted Steering System.....................................................................................................................................................................................................................................486 General Description............................................................................................................................................................................................................................................486 P/S System Construction....................................................................................................................................................................................................................................486 Steering Gear Case Construction............................................................................................................................................................................................................................486 P/S Pump Construction......................................................................................................................................................................................................................................487 Diagnostic Information and Procedures..........................................................................................................................................................................................................................487 P/S System Symptom Diagnosis...............................................................................................................................................................................................................................487 Steering Force Check.......................................................................................................................................................................................................................................488 Hydraulic Pressure in P/S Circuit Check....................................................................................................................................................................................................................489 Repair Instructions............................................................................................................................................................................................................................................491 P/S Fluid Level Check......................................................................................................................................................................................................................................491 P/S Fluid Leakage Check....................................................................................................................................................................................................................................491 P/S Pump and A/C Compressor (If Equipped) Drive Belt Removal and Installation..............................................................................................................................................................................491 P/S Gear Case Assembly Removal and Installation............................................................................................................................................................................................................492 P/S Hose / Pipe Components.................................................................................................................................................................................................................................494 P/S Pump Removal and Installation..........................................................................................................................................................................................................................495 P/S Pump Assembly Components...............................................................................................................................................................................................................................495 P/S Pump Inspection........................................................................................................................................................................................................................................495 Specifications.................................................................................................................................................................................................................................................496 Tightening Torque Specifications...........................................................................................................................................................................................................................496 Special Tools and Equipment....................................................................................................................................................................................................................................496 Special Tool...............................................................................................................................................................................................................................................496 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual............................................................................................................497 HVAC...................................................................................................................................................................................................................................................................497 Heater and Ventilation.............................................................................................................................................................................................................................................500 General Description............................................................................................................................................................................................................................................500 Additional Heater System Description.......................................................................................................................................................................................................................500 Schematic and Routing Diagram..................................................................................................................................................................................................................................500 Electronic Control Input / Output Table (for Vehicle without A/C)..........................................................................................................................................................................................500 Additional Heater System Input / Output Table..............................................................................................................................................................................................................501 Additional Heater System Component Location................................................................................................................................................................................................................501 Diagnostic Information and Procedures..........................................................................................................................................................................................................................502 Heater and Ventilation Symptom Diagnosis...................................................................................................................................................................................................................502 Repair Instructions............................................................................................................................................................................................................................................503 Heater Core Removal and Installation.......................................................................................................................................................................................................................503 Additional Heater Relay Inspection.........................................................................................................................................................................................................................503 Additional Heater Assembly On-Vehicle Inspection...........................................................................................................................................................................................................504 Additional Heater Assembly Removal and Installation........................................................................................................................................................................................................504 Specifications.................................................................................................................................................................................................................................................505 Tightening Torque Specifications...........................................................................................................................................................................................................................505 Air Conditioning System............................................................................................................................................................................................................................................506 Precautions....................................................................................................................................................................................................................................................506 Precautions on Servicing Refrigerant Line..................................................................................................................................................................................................................506 Precautions on Replenishing Compressor Oil.................................................................................................................................................................................................................507 General Description............................................................................................................................................................................................................................................508 Auto A/C Electronic Control Input / Output Table...........................................................................................................................................................................................................508 A/C Refrigerant Type Description...........................................................................................................................................................................................................................508 Schematic and Routing Diagram..................................................................................................................................................................................................................................509 A/C System Wiring Circuit Diagram..........................................................................................................................................................................................................................509 Component Location.............................................................................................................................................................................................................................................511 A/C Control System Components Location.....................................................................................................................................................................................................................511 Diagnostic Information and Procedures..........................................................................................................................................................................................................................513 Scan Tool Data.............................................................................................................................................................................................................................................513 A/C System Performance Inspection..........................................................................................................................................................................................................................515 A/C System Symptom Diagnosis...............................................................................................................................................................................................................................519 DTC B1557: Wheel Speed Sensor and/or Its Circuit Malfunction...............................................................................................................................................................................................522 DTC B1561: Engine Coolant Temperature Sensor and/or Its Circuit Malfunction................................................................................................................................................................................523 DTC B1563: A/C Refrigerant Pressure Sensor and/or Its Circuit Malfunction..................................................................................................................................................................................523 Repair Instructions............................................................................................................................................................................................................................................524 Operation Procedure for Charging A/C with Refrigerant......................................................................................................................................................................................................524 HVAC Unit Removal and Installation.........................................................................................................................................................................................................................528 A/C Refrigerant Pressure Sensor and Its Circuit Inspection.................................................................................................................................................................................................529 A/C Refrigerant Pressure Sensor Removal and Installation...................................................................................................................................................................................................530 A/C Compressor Drive Belt Inspection.......................................................................................................................................................................................................................530 A/C Compressor Drive Belt Removal and Installation.........................................................................................................................................................................................................530 A/C Compressor Relay Inspection............................................................................................................................................................................................................................531 Compressor Assembly On-Vehicle Inspection..................................................................................................................................................................................................................531 Compressor Assembly and Compressor Bracket Components......................................................................................................................................................................................................532 Compressor Assembly Removal and Installation...............................................................................................................................................................................................................532 Magnet Clutch Components...................................................................................................................................................................................................................................533 Magnet Clutch Operating Check..............................................................................................................................................................................................................................533 Magnet Clutch Removal and Installation.....................................................................................................................................................................................................................534 Relief Valve On-Vehicle Inspection.........................................................................................................................................................................................................................536 Specifications.................................................................................................................................................................................................................................................536 Tightening Torque Specifications...........................................................................................................................................................................................................................536 Special Tools and Equipment....................................................................................................................................................................................................................................537 Recommended Service Material...............................................................................................................................................................................................................................537 Special Tool...............................................................................................................................................................................................................................................537 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual............................................................................................................539 Body, Cab and Accessories..............................................................................................................................................................................................................................................539 Wiring Systems.....................................................................................................................................................................................................................................................545 General Description............................................................................................................................................................................................................................................545 Abbreviations..............................................................................................................................................................................................................................................545 Symbols and Marks..........................................................................................................................................................................................................................................546 Harness Routing and Connector Layout Diagram...................................................................................................................................................................................................................547 Connector Layout Diagram...................................................................................................................................................................................................................................547 Engine Compartment.........................................................................................................................................................................................................................................548 Instrument Panel...........................................................................................................................................................................................................................................566 Door, Roof.................................................................................................................................................................................................................................................574 Floor......................................................................................................................................................................................................................................................578 Rear.......................................................................................................................................................................................................................................................584 Ground Point...................................................................................................................................................................................................................................................585 Ground (earth) Point.......................................................................................................................................................................................................................................585 Power Supply Diagram...........................................................................................................................................................................................................................................587 Power Supply Diagram.......................................................................................................................................................................................................................................587 Fuses and the Protected Parts..............................................................................................................................................................................................................................590 Fuses in Battery Fuse Box, Fuse Box No.1 (Petrol)..........................................................................................................................................................................................................590 Fuses in Battery Fuse Box, Fuse Box No.1 (DSL).............................................................................................................................................................................................................591 Fuse Box No.2 (In Power Integration No.1, Power Integration No.2), Relay Box (Petrol)......................................................................................................................................................................592 Fuse Box No.2 (In Power Integration No.1, Power Integration No.2), Relay Box No.1, Relay Box No.2 (DSL)....................................................................................................................................................593 Fuse Box No.3 (In J/B).....................................................................................................................................................................................................................................595 Junction Block (J/B) Connector / Fuse Layout...............................................................................................................................................................................................................597 Junction Block Inner Circuit (Overview)....................................................................................................................................................................................................................598 Junction Block Inner Circuit (Detail)......................................................................................................................................................................................................................599 System Circuit Diagram.........................................................................................................................................................................................................................................603 System Circuit Diagram.....................................................................................................................................................................................................................................603 A-1 Cranking System Circuit Diagram........................................................................................................................................................................................................................604 A-2 Charging System Circuit Diagram........................................................................................................................................................................................................................605 A-3 Ignition System Circuit Diagram (M16A).................................................................................................................................................................................................................606 A-3 Ignition System Circuit Diagram (J20A).................................................................................................................................................................................................................607 A-3 Ignition System Circuit Diagram (H27A).................................................................................................................................................................................................................608 A-4 Cooling System Circuit Diagram (Petrol)................................................................................................................................................................................................................610 A-4 Cooling System Circuit Diagram (DSL)...................................................................................................................................................................................................................611 A-5 Engine and A/C Control System Circuit Diagram (M16A)...................................................................................................................................................................................................612 A-5 Engine and A/C Control System Circuit Diagram (J20A)...................................................................................................................................................................................................617 A-5 Engine and A/C Control System Circuit Diagram (H27A)...................................................................................................................................................................................................622 A-5 Engine and A/C Control System Circuit Diagram (DSL)....................................................................................................................................................................................................627 A-6 A/T Control System Circuit Diagram.....................................................................................................................................................................................................................632 A-7 Immobilizer System Circuit Diagram.....................................................................................................................................................................................................................635 A-8 Body Control System Circuit Diagram....................................................................................................................................................................................................................636 A-10 4WD Control System Circuit Diagram....................................................................................................................................................................................................................641 B-1 Windshield Wiper and Washer Circuit Diagram............................................................................................................................................................................................................643 B-2 Rear Wiper and Washer Circuit Diagram..................................................................................................................................................................................................................644 B-3 Rear Defogger Circuit Diagram..........................................................................................................................................................................................................................645 B-4 Power Window Circuit Diagram...........................................................................................................................................................................................................................646 B-5 Power Door Lock Circuit Diagram........................................................................................................................................................................................................................648 B-6 Power Mirror Circuit Diagram...........................................................................................................................................................................................................................650 B-7 Horn Circuit Diagram...................................................................................................................................................................................................................................651 B-8 Seat Heater Circuit Diagram............................................................................................................................................................................................................................652 B-9 Smart Key System Circuit Diagram.......................................................................................................................................................................................................................653 B-10 Sliding Roof Circuit Diagram..........................................................................................................................................................................................................................654 B-11 Headlight Cleaner Circuit Diagram.....................................................................................................................................................................................................................655 C-1 Combination Meter Circuit Diagram......................................................................................................................................................................................................................656 D-1 Headlight System Circuit Diagram (One bulb type).......................................................................................................................................................................................................658 D-1 Headlight System Circuit Diagram (With Projector light)................................................................................................................................................................................................659 D-1 Headlight System Circuit Diagram (With Discharge bulb).................................................................................................................................................................................................660 D-2 Position, Tail and Licence Plate Light System Circuit Diagram..........................................................................................................................................................................................661 D-3 Front Fog Light System Circuit Diagram.................................................................................................................................................................................................................662 D-4 Illumination Light System Circuit Diagram..............................................................................................................................................................................................................663 D-5 Interior Light System Circuit Diagram..................................................................................................................................................................................................................664 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram............................................................................................................................................................................................665 D-7 Brake Light System Circuit Diagram.....................................................................................................................................................................................................................667 D-8 Back-Up Light System Circuit Diagram...................................................................................................................................................................................................................668 D-9 Headlight Beam Leveling System Circuit Diagram (Manual Leveling).......................................................................................................................................................................................669 D-9 Headlight Beam Leveling System Circuit Diagram (Auto Leveling).........................................................................................................................................................................................670 D-10 Rear Fog Light Circuit Diagram........................................................................................................................................................................................................................671 E-2 Auto A/C System Circuit Diagram........................................................................................................................................................................................................................672 F-1 Air-Bag System Circuit Diagram (4ch)...................................................................................................................................................................................................................674 F-1 Air-Bag System Circuit Diagram (8ch)...................................................................................................................................................................................................................675 F-2 Anti-Lock Brake System Circuit Diagram.................................................................................................................................................................................................................677 F-3 Electronic Stability Program System Circuit Diagram....................................................................................................................................................................................................679 G-1 Audio System Circuit Diagram...........................................................................................................................................................................................................................681 G-2 Multi Information Display / Accessory Socket System Circuit Diagram....................................................................................................................................................................................682 G-4 Navigation System Circuit Diagram......................................................................................................................................................................................................................683 List of Connectors.............................................................................................................................................................................................................................................683 List of Connectors.........................................................................................................................................................................................................................................683 B Connector................................................................................................................................................................................................................................................683 C Connector................................................................................................................................................................................................................................................684 D Connector................................................................................................................................................................................................................................................687 E Connector................................................................................................................................................................................................................................................687 F Connector................................................................................................................................................................................................................................................690 G Connector................................................................................................................................................................................................................................................690 J Connector................................................................................................................................................................................................................................................693 K Connector................................................................................................................................................................................................................................................694 L Connector................................................................................................................................................................................................................................................695 O Connector................................................................................................................................................................................................................................................697 Q Connector................................................................................................................................................................................................................................................697 R Connector................................................................................................................................................................................................................................................697 Instrumentation / Driver Info. / Horn..............................................................................................................................................................................................................................698 Precautions....................................................................................................................................................................................................................................................698 Precautions in Diagnosing Troubles for Combination Meter...................................................................................................................................................................................................698 General Description............................................................................................................................................................................................................................................698 CAN Communication Data of Combination Meter................................................................................................................................................................................................................698 Schematic and Routing Diagram..................................................................................................................................................................................................................................699 Combination Meter Circuit Diagram..........................................................................................................................................................................................................................699 Diagnostic Information and Procedures..........................................................................................................................................................................................................................700 Fuel Meter Symptom Diagnosis...............................................................................................................................................................................................................................700 Low Fuel Warning Light Symptom Diagnosis...................................................................................................................................................................................................................700 Repair Instructions............................................................................................................................................................................................................................................701 Fuel Level Sensor Inspection...............................................................................................................................................................................................................................701 Oil Pressure Switch Removal and Installation...............................................................................................................................................................................................................701 Oil Pressure Switch Inspection.............................................................................................................................................................................................................................702 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual............................................................................................................703 Control systems........................................................................................................................................................................................................................................................703 Cruise Control System..............................................................................................................................................................................................................................................705 General Description............................................................................................................................................................................................................................................705 Cruise Control System Construction.........................................................................................................................................................................................................................705 Components and Functions of Cruise Control System..........................................................................................................................................................................................................706 Cancel Conditions of Cruise Control System.................................................................................................................................................................................................................707 Input / Output Diagram.....................................................................................................................................................................................................................................707 Schematic and Routing Diagram..................................................................................................................................................................................................................................708 Cruise Control System Wiring Diagram.......................................................................................................................................................................................................................708 Diagnostic Information and Procedures..........................................................................................................................................................................................................................709 Cruise Control System Symptom Diagnosis....................................................................................................................................................................................................................709 Inspection of Cruise Control System Circuit................................................................................................................................................................................................................710 Body Electrical Control System.....................................................................................................................................................................................................................................711 Precautions....................................................................................................................................................................................................................................................711 Precautions in Diagnosing Trouble..........................................................................................................................................................................................................................711 General Description............................................................................................................................................................................................................................................711 CAN Communication for BCM..................................................................................................................................................................................................................................711 Schematic and Routing Diagram..................................................................................................................................................................................................................................713 Body Electrical Control System Wiring Circuit Diagram......................................................................................................................................................................................................713 Component Location.............................................................................................................................................................................................................................................715 BCM and Related System Component Location..................................................................................................................................................................................................................715 Diagnostic Information and Procedures..........................................................................................................................................................................................................................716 Scan Tool Data.............................................................................................................................................................................................................................................716 DTC Table..................................................................................................................................................................................................................................................718 DTC U1073 (No. 1073): Control Module Communication Bus Off.................................................................................................................................................................................................719 DTC U1100 (No. 1100): Lost Communication with ECM..........................................................................................................................................................................................................721 Inspection of BCM and its Circuits.........................................................................................................................................................................................................................723 Immobilizer Control System.........................................................................................................................................................................................................................................730 Precautions....................................................................................................................................................................................................................................................730 Precautions in Diagnosing Troubles.........................................................................................................................................................................................................................730 Precaution in Replacing Immobilizer Control Module (ICM)...................................................................................................................................................................................................730 Precautions in Handling Immobilizer Control System.........................................................................................................................................................................................................730 General Description............................................................................................................................................................................................................................................731 Immobilizer Control System Introduction....................................................................................................................................................................................................................731 Immobilizer Control System Components Location.............................................................................................................................................................................................................732 On-Board Diagnostic System Description (Self-diagnosis Function)...........................................................................................................................................................................................732 Schematic and Routing Diagram..................................................................................................................................................................................................................................733 Immobilizer Control System Wiring Circuit Diagram..........................................................................................................................................................................................................733 Diagnostic Information and Procedures..........................................................................................................................................................................................................................734 Immobilizer Control System Check...........................................................................................................................................................................................................................734 Diagnostic Trouble Code (DTC) Check........................................................................................................................................................................................................................735 Diagnostic Trouble Code (DTC) Clearance....................................................................................................................................................................................................................735 Diagnostic Trouble Code (DTC) Table........................................................................................................................................................................................................................735 Scan Tool Data.............................................................................................................................................................................................................................................736 Injection Warning Light Does Not Come ON with Ignition Switch ON and Engine Stop...........................................................................................................................................................................737 Injection Warning Light Remains ON after Engine Start......................................................................................................................................................................................................738 DTC B1701: Transponder Code Error 1/DTC B1710: Transponder Code Error 3....................................................................................................................................................................................738 DTC B1702: ECM Communication Error 1.......................................................................................................................................................................................................................738 DTC B1703: Unregistered Transponder........................................................................................................................................................................................................................740 DTC B1704: Transponder Code Error 2........................................................................................................................................................................................................................740 DTC B1705: Transponder Response Error......................................................................................................................................................................................................................741 DTC B1706: Immobilizer Antenna Error.......................................................................................................................................................................................................................741 DTC B1707: IMM EEPROM Error................................................................................................................................................................................................................................742 DTC B1708: ECM Code Error..................................................................................................................................................................................................................................742 DTC B1709: ECM Communication Error 2.......................................................................................................................................................................................................................743 DTC B1711: ECM EEPROM Error................................................................................................................................................................................................................................744 DTC B1712: Immobilizer Communication Error.................................................................................................................................................................................................................744 DTC B1713: Immobilizer Code Error..........................................................................................................................................................................................................................746 DTC B1714: Unregistered Code...............................................................................................................................................................................................................................746 Inspection of Immobilizer Control Module (ICM) and Its Circuit.............................................................................................................................................................................................747 Repair Instructions............................................................................................................................................................................................................................................749 Immobilizer Control Module (ICM) Removal and Installation..................................................................................................................................................................................................749 Registration of the Ignition Key...........................................................................................................................................................................................................................750 Procedure after ECM Replacement............................................................................................................................................................................................................................750 Procedure after Immobilizer Control Module (ICM) Replacement...............................................................................................................................................................................................750 Special Tools and Equipment....................................................................................................................................................................................................................................750 Special Tool...............................................................................................................................................................................................................................................750 COPYRIGHT..............................................................................................................................................................................................................................................................751 BOOKCOVER..............................................................................................................................................................................................................................................................752
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